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P3400 Operator Manual.book

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2. Figure 3 9 Air Blast Tubes Round Label Air Blast Tubes Square Label For square labels the objective is to place the label down in a single flat manner The center tubes are used to first place the center of the label down The remaining jets are used to smooth out the sides towards the front and the back refer Figure 3 10 on page 3 11 3 10 LPA Controls Rev AA P3400 Operator Manual QOOQOQOQOQOQOQOQOQOQOQOQOQOQOQ QOOQOQOQOQOQOQOQOQOQOQOQOQOQOOQ QOOQOGQQOQQOQOQQOQQOQOQQOQOQQO JzZE O0000000000000000000000000000 QOQOQOQOQOQOQOQOQOQOQOQGOQGQOQQO QOQOQOQOQOQOQOQOQOQOQOQOQOQQO QOQOQOQOQOQOQOQOQOQOQOQGOQGQQQO 0 0 0 0 0 0 0 00 0 000 00 0 00 0 00 0 00 0 00 0 0 QOQOQOQOQOQOQOQOQOQOQOQOQOQOQ 5 ill QQ0000000000000000000000000000 5 QOOQOQOQOQOQOQOQOQOQOQOQOQOQOQ QOQOQOQOQOQOQOQOQOQOQOQOQOQOQ QOOQOQOQOQOQOQOQOQOQOQOQOQOQOQ QOOQOQOQOQOQOQOQOQOQOQOQOQOQOQ OOOOQQ0000000000000000000000QOQ begs OOOO000000000000000000000000QO OOOQOGOQQGOGNOQGOQQOQOQQOQOOQO OOQOQOO ONOOQOQOQOQOQOQOO 10 00 0070 07 COL SOL Label feed Label feed For triangular labels the objective is to place the label down
3. jeqe1 apo 21529 jonpoug 19q27 due epon 215 9 jonpoJg jeqe1 9pON 2iseg Jado spon eunBjuo nue N enBijuo 4 uoneJedo apoy pue edA ajnpoyy uoneoiddy 9819S 4 11 Setting Up the Machine Rev AA P3400 Operator Manual Configuring the LPA Settings To configure each module associated with the LPA follow the instructions provided under each application type Blow Setup The only difference between blow and blow and print is that the next label feed starts at the beginning of the blow cycle instead of at the end This will reduce the overall cycle time However it should be used with caution and only with short blow periods To set up the blow module proceed as follows 10 11 12 13 In the Configure menu select Mode of Operation Set Basic Mode to Blow Set Alternate Mode to Normal and set all other sensors to Disabled Save the configuration and press Exit when prompted In the Top Level menu set the Blow Time to 100ms This can be shortened later to optimize performance Set the Blow Flight Time to 20 ms This can be adjusted later to optimize flight time compensation if activated Set the Line Speed to the actual conveyor speed for example 1000 mm s Set the Product Sensor Distance equal to Blow Flight Time x Line Speed that is 0 020 X 1
4. Code Language Availability see 06 Japanese 07 Russian 08 Italian 09 Dutch 10 Chinese Simplified 11 Arabic 12 Korean 13 Thai 14 Icelandic 15 Norwegian 16 Finnish 17 Swedish 18 Danish 19 Greek 20 Hebrew 21 English UK 23 Polish Table 1 1 List of Language Codes Note Initial availability of the Operator s Guide is indicated by an asterisk Availability of the Service Manual is indicated by a plus sign Availability of the Illustrated Parts Breakdown 15 indicated by the number sign For more information consult your Videojet distributor or subsidiary Hazard Information This section contains important hazard notices You must read these notices before using the printer The hazard information is prioritized into typographically distinct warning and caution notices as follows 1 4 Hazard Information Rev AA P3400 Operator Manual fANNaming WARNING NOTICES Warning notices denote a potential hazard to the health and safety of the users of the printer These notices clearly state the nature of the hazard and the means by which it can be avoided Warning notices together with the warning symbol shown on the left appear in full in this chapter and at their points of application in the manual They are presented in the typographical style of this notice N Caution CAUTION NOTICES Cautionary notices denote a potential
5. 1 Pneumatic Module 4 Adjustable Tamp Stop Rod 2 Tamp Pad Adapter Plate 5 Tamp Guide Rod Bearing Box and Guide Rods 3 Tamp Pad Flexible Coupling 6 Tamp Air Cylinder Figure 2 8 Tamp Jet Application Module Tamp jet works on the same principle as the tamp module except that a blast of air blows the label onto the product before the tamp pad touches the product The tamp jet can be used as a regular tamp because the jet can be used to enhance the label tack and its release from the pad The flexible tamp pad coupler Figure 2 9 on page 2 13 allows the tamp pad to conform to product misalignments of up to 20 in a fixed position or a combination of two adjacent axes This allows the pad to be in full contact with the product The tamp jet module can accommodate tamp pads of sizes ranging from 100 mm in length by 60 mm in width to 210 mm in length by 185 mm in width by simply changing the position of the flexible coupling on the tamp pad adapter plate 2 12 Introduction to the Printer Assembly Rev AA P3400 Operator Manual 1 Tamp Pad Adapter Plate 2 Flexible Tamp Pad Coupling Illustration only 3 Tamp Pad Illustration only Figure 2 9 Tamp Pad Coupler Heavy Duty Long Stroke Tamp Application Module The heavy duty long stroke HDLS tamp application module Figure 2 10 on page 2 14 comprises the following components Long stroke tamp cylinder rod guide rods support bearing and tamp pad adapter plate assembly
6. Pour la Client le du Canada Le present appareil numerique n emet pas de bruits radioelectriques depassant les limites applicales aux appareils numerique de las class A prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada Cet quipement est certifi CSA For Customers in the European Union This equipment displays the CE mark to indicate conformance to the following legislation Applicable safety standards EN 60950 2001 60127 EN 60950 1 2001 Rev AA P3400 Operator Manual Support and Training Rev AA Contact Information If you have any questions or need assistance please contact Videojet Technologies Inc at 1 800 843 3610 for all customers within the United States Outside the U S customers should contact their Videojet Technologies Inc distributor or subsidiary for assistance Videojet Technologies Inc 1500 Mittel Boulevard Wood Dale IL 60191 1073 U S A Phone 1 800 843 3610 Fax 1 800 582 1343 International Fax 630 616 3629 Web www videojet com Service Program About Total Source Commitment Total Source TOTAL SERVICE PLUS RELIABILITY is the Videojet Technologies Inc commitment to provide you our customer the complete service you deserve The Total Source Commitment The Videojet Total Source Service Program is an integral part of our business in providing marks codes and images where when and how oft
7. 2767 seconds Default setting 100 ms Rewind The time during which rewind motor runs after the label Overrun feed ends Used to ensure there is no slack liner between the peel tip and rewind Adjustable from 0 to 3 2767 seconds Default setting Error Reset Resets any latched error conditions Save Saves parameters from the menu into memory directories from 1 to 8 Recall Recalls parameters saved previously Restore Restores a default set of parameters Defaults Configure Goes to the machine configuration menu Table 4 1 Control Panel Parameters Continued Rev AA Setting Up the Machine 4 9 P3400 Operator Manual Q UOISI9A 059 xeuiejeq adA Configuration Menu 01 UOISI9A ssald 029 LINI 0 piomssed 195 dis eunBijuo pa40jses sseJd amp 13534 LINI 21492 edAL1 ed sjndjno Jeubig sjndu jonpoug uonesueduio eur 14 uoneJedo 8pon eanByuo 5 195 eanByuo 2 9175 3euJeju eanByuo 2 3nejeg aojsoy eanByuo5 eanByuo5 sod eanByuo 5 jeybiq eanByuo 2 jejibiq
8. Air Blast Tubes Oval Label on Moving Product 3 12 LPA Controls P3400 Operator Manual Q Q Q Q Figure 3 13 Air Blast Tubes Oval Label on Moving Product Print Engine Controls The control panel of the print engine contains controls to monitor and operate the print engine The position of the controls may vary depending upon the type of print engine fitted It comprises a keypad LCD display and LED indicators Using these three together the operator configures monitors and operates the print engine The print engine may also be configured and operated remotely from a controlling computer Rev AA The status indicators located on the print engine s control panel indicate the following machine operation fault conditions whenever they glow Power On indicates that the machine is switched on Label Media indicates when the label web has run out If the indicator glows when the label has not run out check the label threading that passes through the sensor The sensor may not have detected the label because it was not threaded correctly Ribbon indicates when the ribbon has run out If the indicator glows when the ribbon has not run out check the ribbon threading that passes above the sensor inside the print engine Error indicates when a print engine error has occurred This is combined with an error message dis
9. Mounting plate and adjuster blocks stop adjuster assembly Flexible tamp pad coupler Pneumatic module Rev AA Introduction to the Printer Assembly 2 13 P3400 Operator Manual M MERE RIRE ARRETE 4 E Ld N S amp d IN N N Sal 1 Flexible Pad Coupling 2 Long Stroke Tamp Cylinder and Tamp Pad Adapter Plate 3 Tamp Stop Adjuster Rod 4 Mounting Plate and Adjuster Blocks 5 Pneumatic Module Figure 2 10 HDLS Tamp Application Module The HDLS tamp module is the same in operation and function as any other linear tamp except that is a heavier duty version uses a 32 mm diameter bore air cylinder and possesses the ability to travel up to 800 mm in distance As in the tamp jet module the HDLS tamp module is fitted with a flexible tamp pad coupler The flexible tamp pad coupler allows the tamp pad to conform to product misalignments of up to 20 in a fixed position or ina combination of two adjacent axes which allows the pad to be in complete contact with the product The HDLS tamp can accommodate tamp pads of sizes ranging from 100 mm in length by 60 mm in width to 210mm in length by 185 mm in width This is done by changing the fixing position of the bearing block and adding or subtracting spacer blocks between the mounting plate and the bearing block as required 2 14 Introduction to the Printer Assembly Rev AA Rev P34
10. QQ QQ QQ QQ QQ QQ QQ OO QQ QQ QQ QQ QQ QQ QQ QQ QQ Q QOOOOO0O0O0O000000000000000000 Label feed Label feed manner The center based tubes are first used to place the center of the label down The remaining jets are used to smooth out the sides refer For oval labels the objective is to place the label down in a single flat Figure 3 8 Figure 3 7 Air Blast Tubes Rectangular Label Air Blast Tubes Oval Label 329 LPA Controls Figure 3 8 Air Blast Tubes Oval Label Rev AA P3400 Operator Manual Air Blast Tubes Round Label For round labels the objective is to place the label down in a single flat manner The center based tubes are used to first place the center of the label down The remaining jets are used to smooth out the sides refer Figure 3 9 Label feed Prod Direction 07 2010000 00000000000000000000000000 SET
11. VIDEOJET VIDEO ET P3400 LABEL PRINTER APPLICATOR Operator Manual P N 361561 01 Revision AA March 2005 Copyright 2004 Videojet Technologies Inc herein referred to as Videojet All rights reserved This document is the property of Videojet Technologies Inc and contains confidential and proprietary information owned by Videojet Any unauthorized copying use or disclosure of it without the prior written permission of Videojet is strictly prohibited Videojet Technologies Inc 1500 Mittel Boulevard Phone 1 800 843 3610 Wood Dale IL Fax 1 800 582 1343 60191 1073 USA Intl Fax 630 616 3629 www videojet com Offices USA Atlanta Chicago Intl Canada France Germany Ireland Japan Spain Singapore The Netherlands and The United Kingdom Distributors Worldwide Compliance Information For Customers in the U S A This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference 2 This device must accept any interference received including interference that may cause undesired operation N warning Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed t
12. also You can reconfigure these settings whenever necessary Low Label Sensor Setup When the low label sensor is fitted and enabled it will trigger an alarm if the supply roll falls below approximately 5 of its full capacity To set up the low label sensor proceed as follows In the Configure menu select Mode of Operation 2 SetLow LabelSignal to Enabled 3 Select Digital Inputs and select Digital Input 6 4 Setinput 6 Naming to Smart Tamp 5 Set input 6 to Digital 1 or Digital 0 depending upon the type of sensor used 6 Setinput 6 Latching to Latched 7 Setinput 6 Machine Control to None 8 Inthe Configure menu save the configuration and press Exit when prompted Note Once the settings are saved it can be used for other print jobs also You can reconfigure these settings whenever necessary 4 20 Configuring the LPA Settings Rev AA P3400 Operator Manual Starting Production Rev AA After the printer settings are finalized and the machine starts running minimal supervision is required to keep the production going The machine is fully automatic and is equipped to indicate clearly any minor defect trouble that arises during production If a detailed troubleshooting is necessary contact your service technician Starting Production 4 21 This appendix contains the following topics Preventive Maintenance General maintenance of the P3400 Maintenance of the Sato print engine M
13. in a single flat manner The center based tubes are first used to place the center of the label down The remaining jets are used to smooth out the sides refer Figure 3 11 Figure 3 10 Air Blast Tubes Square Label Air Blast Tubes Triangular Label 3 11 LPA Controls Figure 3 11 Air Blast Tubes Triangular Label Rev AA objective is to place the label down in a progressive manner The leading tubes are used to place the front of the label down first and the product movement will smooth out the remaining part of the label refer Figure 3 For long labels whose indexed length is longer than its width the 12 Air Blast Tubes Long Label P3400 Operator Manual 5 o followed by wiping action as the product Rev AA Figure 3 12 Air Blast Tubes Long Label flip over Otherwise it may cause a ripple The amount of bias towards the front of the label will depend upon the speed of the production line and the distance of the applicator from the product Adjustment of the air For moving label applications the purpose of positioning the air blast tube pressure can also enhance the label delivery refer Figure 3 13 is to apply the front end first continues to move away from the labeler Ensure that the label does not
14. is the controlling factor for the tamp jet However adjustment of the main system air pressure also alters the jet flow rate that blows the label onto the product refer Figure 3 5 on page 3 7 3 6 Controls Rev AA Rev P3400 Operator Manual 7 H P 5 CR G D one 1 Vacuum Flow Control Jet with Vacuum Control Module 2 Air Assist Flow Control on Tamp Jet with Vacuum Control Module 3 Tamp Jet Valve Figure 3 5 Tamp Jet Vacuum Box Control The vacuum box Figure 3 6 has the following components Note The vacuum box components can be adjusted depending upon the label size Adjustable baffle It is a perforated disk that is used to change the vacuum level at the vacuum grid As the baffle is rotated the holes in the vacuum box can be opened to decrease the vacuum level in the vacuum box or closed to increase it Note Large labels may require a lower vacuum level than small labels Air blast tubes These are used to route the high pressure air to blast the labels onto the product They are placed in different positions patterns on the vacuum grid depending upon the label size and shape All the air blast tubes may not be needed Unused tubes must be stored in the manifold LPA Controls 3 7 P3400 Operator Manual 3 8 LPA Controls 1 Adjustable Baffle 2 Vacuum Grid 3 Blast Tubes Figure 3 6 Vacuum Bo
15. loaded to absorb the change in tension of the label web during its movement through the machine It controls the unwind brake Idler rollers The idler rollers are free spinning rollers that support and guide the label web through the machine The position of the rollers is set for optimum feeding of the label web both in and out of the print engine ensuring a high speed of label printing and application Label web guides These spring energized plastic rings are positioned on the idler rollers to guide the label web into the print engine One is set on the inside edge of the label web and the other on the outside edge Rewind reel The spindle stores the label backing after the labels have been printed and applied It is motor driven and has a slipping clutch to prevent run on and a dancer arm to even out variations in the label rewind speeds This keeps the used label web taut and secure at all times Introduction to the Printer Assembly Rev AA P3400 Operator Manual 1 Idler Rollers 5 Unwind Dancer Arm 2 Label Web Guides 6 Unwind Reel 3 Rewind Dancer Arm 7 Rewind Reel 4 Unwind Flange with Twist Locking Collar Figure 2 4 Label Web Path Rev AA Introduction to the Printer Assembly 2 7 P3400 Operator Manual Application Modules The Videojet P3400 LPA is configured to accommodate seven different types of application modules Blow module module Tamp jet module Heavy duty long st
16. on the Control Panel 4 6 Configuration Menu 4 10 Configuring the Settings 4 12 Blow Setup aides dux iot ee 4 12 Setup STD FLEX AND HDLS 4 13 Jet Sepe eus s pos gore POELE ee Mas 4 14 Swing Arm Tamp Setup Adjustable and Fixed 4 15 Dual Label Two Panel Setup 4 16 Corner Wrap E UN Rex es 4 17 Tamp Return Sensor 4 18 lamp Extended Sensor 4 19 Smart Tamp Sensor Set p OE perd EET DI DER Fa 4 19 Low Label Sensor Setup 4 20 Starting e ERAS 4 21 General Maintenance A 1 Maintenance of the Sato Print Engine A 2 Maintenance of the Zebra Print Engine 4 Glossary 1 2 Rev AA Introduction This chapter contains the following topics Brief description about the printer Description about the manual the audience for whom it is intended and how it is organized Description of other manuals associated with this printer Hazard information List of abbreviations Conventions used for figures and tables Equipment Description The Videojet P3400 Label P
17. reconfigure these settings whenever necessary Smart Tamp Sensor Setup When the smart tamp sensor is fitted and enabled it triggers the tamp to return when the sensor detects the product This sensor enables products of differing heights to be labeled without crushing the taller ones Additionally an alarm will be triggered if the smart tamp signal is not received within the expected time period Tamp Flight Time This could be an early warning of falling air pressure a tamp malfunction or an indication that the sensor cannot see the product To set up the smart tamp sensor proceed as follows 1 Inthe Configure menu select Mode of Operation 2 Set Smart Tamp to Enabled 3 Select Digital Inputs and select Digital Input 5 4 Set Input 5 Naming to Smart Tamp Configuring the Settings 4 19 P3400 Operator Manual 5 Set Input 5 to Digital 1 or Digital 0 depending upon the type of sensor used 6 Set Input 5 Latching to Unlatched 7 Set Input 5 Machine Control to None 8 Save the configuration and press Exit when prompted 9 In the Top Level menu set the Tamp Overrun to a value that would ensure that the tamp comes in contact with the product but does not crush it Note A value of 1000 100ms is ideal as it will allow 50 mm traveling distance after the sensor sees the product 10 Save the setting in one of the memory directories 1 through 8 Note Once the settings are saved it can be used for other print jobs
18. to the Printer Assembly The P3400 LPA comprises the following main components Base module Print engine Label web path Application modules Accessories Base Module The base module includes the faceplate and contains the following parts Electronics module Unwind assembly Air assist assembly Rewind assembly Low label sensor Figure 2 1 on page 2 2 shows the base module of the P3400 LPA Rev AA Introduction to the Printer Assembly 2 1 P3400 Operator Manual 1 Control Panel 2 Air Assist Assembly 3 Rewind Assembly 4 Unwind Assembly 5 Low Label Sensor Figure 2 1 LPA Parts Assembly Electronics Module The electronics module including the Operator Control Panel OCP controls various data inputs outputs and produces the precise sequence of events resulting in the application of a printed label onto a product For more information on the electronics module refer Setting Up the Machine on page 4 5 Unwind Assembly The unwind assembly removes labels from the label roll in a controlled manner to suit the printer s label feed demand It has a built in braking mechanism that progressively releases the label roll during label feed and then reduces the speed of release when the label demand is reduced or stopped The unwind assembly is available for roll diameters of two different sizes 400 mm 16 for an outer wound label roll configuration 350 mm 13 75 f
19. 00 Operator Manual Adjustable Swing Arm Tamp Application Module The adjustable swing arm tamp application module Figure 2 11 on page 2 15 comprises the following components Rotary cylinder and adjustable tamp arm assembly Mounting plate and support arm Tamp stop adjuster assembly Tamp stop buffer assembly Flexible tamp pad coupler Pneumatic module 1 Mounting Plate Supporting 2 Long Stroke Tamp Cylinder and Tamp Pad Adapter Plate 3 Tamp Stop Buffer Assembly 4 Tamp Stop Adjuster Rod Assembly 5 Flexible Tamp Pad Coupling 6 Pneumatic Module Figure 2 11 Adjustable Swing Arm Tamp Application Module The adjustable swing arm tamp uses the principle similar to that of the tamp module As in the tamp module the tamp pad is fitted on an adjustable length arm and is swung out to the side to about a 40 mm bore diameter equivalent to a rotary cylinder It can also be supplied with a choice of dampers that enable controlled operation at low speeds and at high speeds The adjustable swing arm tamp module can accommodate tamp pads of sizes ranging from 100 mm in length by 60 mm in width to 210 mm in Introduction to the Printer Assembly 2 15 P3400 Operator Manual 2 16 length by 185 mm in width This is done by changing the position of the adjustable arm by adding or removing spacer discs and adjusting the length of the adjustable arm in out of the fixing recess The swing distance in an
20. 000 20 mm This is the minimum distance for the blow module with the conveyor running at 1000 mm s Note Product Sensor Distance is the distance between the product at the labeling position and its position when the product sensor first notices it Set Air Assist Delay to zero Set Rewind Overrun to 500 ms Save the settings in one of the memories 1 through 8 Note Once the settings are saved they can be used for other print jobs also You can reconfigure these settings whenever necessary Download a number of labels to the print engine One label should feed onto the blow grid provided the air assist and blow box vacuum have been set correctly Cycle the machine by triggering the product detector The label will blow off the grid and another label will feed onto the blow grid 4 12 Configuring the LPA Settings Rev AA Rev P3400 Operator Manual Blow time can be adjusted based on the frequency of the label being blown onto the product This will reduce the overall air consumption during normal operation Tamp Setup STD FLEX AND HDLS To set up the tamp module proceed as follows 1 2 3 10 11 12 13 In the Configure menu select Mode of Operation Set the Basic Mode to Tamp Set the Alternate Mode to Normal and set all other sensors to Disabled Save the configuration and press Exit when prompted In the Top Level menu set the Tamp Flight Time Tamp stroke length 500 that is for a 160 m
21. 5 sindino sndno jey6ig syndul jey6ig uonesueduio dwo9 poid uonesuedujo duo 1 346114 1 uoneJedo 4edo jo spou 0 piomssed AVN 8487 do 4 7 Setting Up the Machine Rev AA P3400 Operator Manual Table 4 1 provides a list of printer parameters Parameter Description Line Speed The conveyor line speed in mm s Not used if encoder or twin sensor compensation is enabled Adjustable from 0 to 3 2767 m s Default setting 250 mm s Product Distance between the product at the labeling position Sensor and the point where the sensor detects the product Distance Adjustable from 0 to 3 2767 Default setting 100 mm Tamp Flight Time taken by the tamp to move from its home position Time to its fully extended position Normal tamp linear speed is 500 mm s Adjustable from 0 to 3 2767 seconds Default setting 20 ms Blow Flight Time from start of blow signal to when the label adheres Time to the product Used in the calculation of flight time compensation Adjustable from 0 to 3 2767 seconds Default setting Blow Time The actual duration of time during which the bl
22. Clean with canned air only Note Do not use high pressure shop air Reflective media Clean with canned air After every roll of media when printing in direct thermal mode After every roll of ribbon when printing in thermal transfer mode sensor only Note Do not use high pressure shop air Belts Visual inspection for wear Every six months 500 rolls Ribbon feeding Visual inspection Once every three months Printhead open Clean with canned air Every six months sensor only Note Do not use high pressure shop air Peel bar Clean with 70 isopropyl After every roll of media alcohol Table A 3 Maintenance Schedule for the Zebra Print Engine A 4 Maintenance of the Zebra Print Engine Rev AA P3400 Operator Manual Rev AA Maintenance of the Zebra Print Engine 5 Glossary Adjustable Swing Arm Tamp Application Module The adjustable swing arm tamp uses a similar principle as tamp However the tamp pad fitted on an adjustable length arm is swung out to the side about a 40 mm bore diameter equivalent to a rotary cylinder to apply labels to the product in a similar manner to the tamp It can be equipped with a choice of dampers allowing controlled operation at low speeds and as well as at higher speeds Air Assist Tube This tube is located under the peel tip and works along with the label feed to assist in transferring and positioning the label from the peel edge to th
23. Cycle the machine by triggering the product detector and adjust the air cylinder flow controls until the cylinder extends to its full stroke blows the label off and returns to its home position just in time for the next label to feed onto the pad smoothly This procedure will set the cylinder linear speed to 500 mm s because it is considered to be the optimal speed for most tamp applications Faster or 4 14 Configuring the LPA Settings Rev AA Rev P3400 Operator Manual slower speeds can be set by recalculating the Tamp Flight Time and Tamp Return Time based on a different linear speed and by following the same procedure Blow time can be reduced until it is just long enough to blow the label onto the product This will reduce the overall air consumption during normal operation Swing Arm Tamp Setup Adjustable and Fixed To set up the swing arm tamp proceed as follows 1 2 3 4 5 In the Configure menu select Mode of Operation Set Basic Mode to Swing Arm Tamp Set Alternate Mode to Normal and set all other sensors to Disabled Save the configuration and press Exit when prompted In the Top Level menu set the Swing Arm Time equal to the time it takes for the Swing arm to fully extend typically about 950ms for a 300 mm reach module Set Swing Return to the same value Set the Line Speed to the actual conveyor speed for example 300 mm s Set the Product Sensor Distance equal to Tamp Flight Time x Line
24. E 12PIN DIN DATAMAX Introduction to the Printer Assembly 2 25 P3400 Operator Manual 40348394 ASSY CABLE INTERFACE 12PIN DIN DPM 1 Print Engine Power Cord 2 Printer Interface Cable 3 Print Engine Figure 2 21 Print Engine Interface Cables Smart Tamp Sensor smart tamp sensor Figure 2 22 on page 2 27 is a divergent beam type that is fitted to a tamp pad and is used to detect the presence of a product before the tamp pad makes physical contact with the product When the sensor detects the product it generates a signal to adjust the tamp setting creating an additional time period before the tamp cylinder returns home The adjustment of the overrun setting allows finer control over the gap between the product and the tamp pad Once the overrun time expires the tamp jet function actuates at the same time as the tamp is directed back to the home position 2 26 Introduction to the Printer Assembly Rev AA P3400 Operator Manual 1 Smart Tamp Sensor Electrical Components 2 Smart Tamp Sensor 3 Smart Tamp Sensor Fixing Components 4 Example Tamp Pad Assembly 5 Smart Tamp Sensor Figure 2 22 Smart Tamp Sensor Remote Controlling Computer A remote IBM compatible computer is required to program the LPA As several variants are available the technical manual for the computer should be used to obtain the required technical information Rev AA Introduction to the Prin
25. PA Controls Note Adjusting the pressure control will also affect the air assist flow rate In general the air pressure is set at 5 5 bar 80 psi System Air Pressure Note The filter regulator shown is for the purpose of illustration only and may vary from the one supplied with the pneumatic module The system air pressure refer Figure 3 1 on page 3 3 is increased by turning the adjuster knob in the indicated direction until the desired pressure is reached on the pressure gauge To decrease the pressure turn the adjuster knob in the opposite direction The recommended operating pressure is 5 5 bar 80 psi for most applications Note Cylinder speed should NOT be adjusted using the main system pressure Instead use the flow restrictors fitted to the air cylinders Rev AA P3400 Operator Manual 6 7 1 Adjuster Knob 7 Filter Bowl Cover 2 Pressure Gauge 8 Fixing Screw 3 Regulator Bracket with Screws and Locking Nut 9 Plastic Insert Separator 4 Regulator Assembly with Pressure Gauge 10 Plastic Vortex Element 5 Sintered Filter Element 11 O Ring 6 Clear Filter Bowl with Drain Valve 12 Push In Tube Air Fitting Figure 3 1 System Air Pressure Control Air Assist Regulation Controls The air assist regulator refer Figure 3 2 on page 3 4 controls the flow rate to the air assist jet which directs the dispensed label up to the vacuum grid or the tamp pad The setting of the control is dependant on the size of
26. Speed that is 0 950 X 300 285 mm This is the minimum distance for a 300 mm swing arm tamp with the conveyor running at 300 mm s Note Product Sensor Distance is the distance between the product at the labeling position and its position when the product sensor first notices it 9 10 11 12 13 Set Air Assist Delay to zero Set Rewind Overrun to 500ms Save the settings in one of the memories 1 through 8 Note Once the settings are saved it can be used for other print jobs also You can reconfigure these settings whenever necessary Download a number of labels to the print engine One label should feed onto the tamp pad provided the air assist and vacuum have been set correctly Cycle the machine by triggering the product detector and adjust the air cylinder flow controls until the cylinder just extends to its full stroke and returns to its home position just in time for the next label to feed onto the pad smoothly Configuring the Settings 4 15 P3400 Operator Manual Dual Label Two Panel Tamp Setup To set up a dual label tamp fitted with a 100 mm stroke tamp and a 300 mm reach swing arm tamp proceed as follows 1 2 3 4 In the Configure menu select Mode of Operation Set Basic Mode to Swing Arm Tamp Set Alternate Mode to Normal and set all other sensors to Disabled In the Configure menu save the configuration and press Exit when prompted In the Top Level menu set the Tamp Flight Ti
27. adjustable swing arm tamp can be adjusted from 300 mm up to 600 mm The swing distance is measured between the underside of the LPA and the farthest tip of the tamp pad in the swing out position The tamp pad size should be specified at the time of placing the order Swing Arm Tamp Application Module The adjustable swing arm tamp application module Figure 2 12 comprises the following Swing arm tamp assembly Swing front spacer block Pneumatic module Introduction to the Printer Assembly Rev AA Rev P3400 Operator Manual 1 Swing Arm Tamp Module 2 Swing Front Spacer Block 3 Pneumatic Module Figure 2 12 Swing Arm Tamp Application Module The swing arm tamp is a fixed swing tamp module and uses the principle similar to that of the tamp module As in the tamp module the tamp pad is fitted on a fixed length arm that is swung out to the side or the front on a fixed pivot point to apply labels to the product on either the leading or the trailing face It is also equipped with a damper that allows controlled return operation at all speeds The swing arm tamp module is not fitted with the flexible tamp pad coupling However it uses the standard range of tamp pads whose size must be specified at the time of placing an order Two Panel Tamp Application Module The two panel tamp application module Figure 2 13 comprises the following components Swing arm tamp assembly combined with the linear tam
28. ains a description of the equipment information about this manual hazard information and the abbreviations used Main parts of the LPA contains a description of the LPA s main parts Main controls of the printer provides an overview of the controls of the LPA Getting started provides complete instructions to get you started with printing labels and applying them onto the products Preventive Maintenance describes the maintenance schedules required for the printer Glossary contains a glossary of technical terms used in this manual Related Documents Rev AA The following document s are available for reference Videojet P3400 Service Manual P N 361562 01 This manual is supplied to the service technicians after they are trained by Videojet Technologies Inc Installation Instruction sheets for the Videojet P3400 printer Language Codes When ordering for manuals ensure that you add the 2 digit language code to the end of the part number For example the part number for the Spanish version of this manual would be 361561 04 Table 1 1 provides the list of language codes that are used to identify the translated versions of this manual Code Language Availability see note 01 English US 02 03 German 04 Spanish 05 Portuguese Table 1 1 List of Language Codes About the Operator Manual 1 3 P3400 Operator Manual
29. aintenance of the Zebra print engine General Maintenance Table A 1 provides a schedule of general maintenance for the Videojet P3400 LPA Note Harsh or dirty environments may require shorter intervals between preventive maintenance routines Maintenance Item Examine the rollers the tamp pad and the vacuum grid for adhesive build up or excessive dust Maintenance Method Clean with 7096 isopropyl alcohol to remove dust and adhesive build up Carefully remove the labels that have adhered to the web path components Maintenance Interval After every two to three rolls of labels or more often if required Examine the air supply and all the connections for leaks Visual inspection Weekly once Clean external Clean with low pressure Monthly once or as product sensor soft cloth surfaces air or wipe with a soft required cloth Examine the Clean the lens with a Weekly once Table A 1 General Maintenance Schedule General Maintenance A 1 P3400 Operator Manual Maintenance Item Examine the dancer Maintenance Method Adjust if necessary Maintenance Interval Monthly once or as arm tension required Inspect the Visual inspection Monthly once or as electrical required connections Inspect for loose Screws guides covers and other hardware Visual inspection Monthly once or as required Clean dust and debris from internal componen
30. ally through a connecting block to the tamp pad They ensure true vertical movement of the tamp mechanism Heavy Duty Long Stroke Tamp Application Module The HDLS tamp is the same in operation and function as any other linear tamp except that is of a heavier duty uses a 32 mm diameter bore air cylinder and has the ability to travel up to 800 mm in distance Idler Roller These are the rollers that guide the label liner along its thread path Label Printer Applicator Any device designed to print information on a label and later apply the label to an object Label Guide Collar These devices are attached to the idler rollers to facilitate proper tracking of the label liner Label Length This is the overall length of the label from leading edge to trailing edge Label Liner Web This is the silicon coated material to which the pressure sensitive label is adhered Label Peel Plate Peel Tip This plate tip is designed and positioned to separate labels peel off from the label liner when the label liner is pulled around it Labels can be applied only after they are peeled Label peel plate tip is a part of the print engine This part is also known as peeler plate peel tip peel edge peeler bar and demand plate Label Repeat This is the distance from the leading edge of one label to the leading edge of the next label on the label liner Label Rewind This is the subsystem that rewinds the spent label liner Label Rewind Dance
31. ased on a different linear speed and by following the same procedure Tamp Jet Setup To set up the tamp jet module proceed as follows 1 2 3 4 5 10 11 12 13 14 In the Configure menu select Mode of Operation Set Basic Mode to Tamp Jet Set Alternate Mode to Normal and set all other sensors to Disabled Save the configuration and press Exit when prompted In the Top Level menu set the Tamp Flight Time Tamp stroke length 500 that is for a 160 mm stroke tamp 160 500 0 320 seconds Set Tamp Return to the same time Set the Blow Time to 100ms This can be shortened later to optimize performance Set Line Speed to the actual conveyor speed for example 300 mm s Set the Product Sensor Distance equal to Tamp Flight Time x Line Speed that is 0 320 X 300 96 mm This is the minimum distance for a 160 mm tamp with the conveyor running at 300 mm s Note Product Sensor Distance is the distance between the product at the labeling position and its position when the product sensor first notices it Set Air Assist Delay to zero Set Rewind Overrun to 500ms Save the settings in one of the memory directories 1 through 8 Note Once the settings are saved it can be used for other print jobs also You can reconfigure these settings whenever necessary Download a number of labels to the print engine One label should feed onto the tamp pad provided the air assist and vacuum have been set correctly
32. blast tubes release air with force and apply the label to the product 2 10 Introduction to the Printer Assembly Rev AA Rev P3400 Operator Manual Tamp Application Module The tamp application module Figure 2 7 on page 2 11 comprises the following components Tamp cylinder Tamp guide rod bearing block and guide rods Tamp pad adapter plate assembly Pneumatic module 1 Pneumatic Module 2 Tamp Guide Rod Bearing Box and Guide Rods 3 Tamp Pad Adapter Plate Assembly 4 Tamp Air Cylinder Figure 2 7 Tamp Application Module The standard tamp module is fitted with a 25 mm diameter bore air cylinder and adjustable air cushioning controls During label printing the label is transferred to the underside of the tamp pad guided by the air assist assembly The vacuum created by the pneumatics module holds the label in position until the product is detected by the product detector When the product moves under the tamp pad the tamp extends and applies the label onto the product Introduction to the Printer Assembly 2 11 P3400 Operator Manual Tamp Jet Application Module The tamp jet application module Figure 2 8 on page 2 12 comprises the following components Tamp cylinder guide rod bearing block and tamp guide rods Tamp pad adapter plate assembly Flexible tamp pad coupler Tamp stop adjuster assembly Pneumatic module VAN Et G x V Wc ws V7
33. d an alarm warning to the system about the low label condition The signal is interpreted as a Low Label message on the OCP and or an amber light glows on the optional lamp stack beacon Print Engine The print engine Figure 2 3 is mounted on the lower front of the machine Secure the print engine hanger pin Item 1 in Figure 2 3 into the print engine and then hang the print engine from the pin to ease the assembly of the print engine fixing screws Item 2 Note Not suitable for use within Datamax print engine 1 Print Engine Hanger Pin 2 Print Engine Fixing Screws Figure 2 3 Print Engine The print engine comprises the following components 2 4 Introduction to the Printer Assembly Rev AA Rev P3400 Operator Manual Thermal printhead Electronic circuitry Ribbon drive and tensioning device Peeler bar Thermal Printhead The printhead is equipped with a series of very small densely clustered heating elements dots mounted on a ceramic substrate When electrical current is supplied to the dots they get heated rapidly and melt the ink on the ribbon The ink deposits on the label and quickly dries after the label leaves the printhead Electronic Circuitry The electronic circuitry comprises the following components Microprocessors that manage the print engine and control printing Non volatile memory that holds the print engine s operating system It is used for label creation and p
34. e applicator Air Cylinder This is a pneumatic device with an internal piston The piston has a connecting rod to the tamp pad which is coupled mechanically through a connecting block When air is applied to the air cylinder it applies pressure to the piston and extends the tamp mechanism towards the product to be labeled Assist Delay Adjusts the time from beginning of label dispense to the time the air assist is activated Blow Application Module Blow application module is an Air jet device containing an extraction fan that is used to create a vacuum within a vacuum box The vacuum inside the box holds the label to the vacuum grid The vacuum level is adjusted by a baffle located on the side of the vacuum box Air tubes blast air from the pneumatic source to apply the label to the product The air blast tubes can be moved on the vacuum grid to apply labels of different shapes or sizes to the product Dancer Arm Spring This spring provides tension for the dancer arm Drive Roller The roller provides the force for advancing the label liner It is a part of the print engine and is electronically controlled by the control card inside the back cover Faceplate This is the metal place that supports all the machine components required to unwind the label roll peel the labels apply them to the product and rewind the label liner Rev AA Glossary 1 P3400 Operator Manual Glossary 2 Guide Rods These rods are coupled mechanic
35. e label on the grid The grid should return to its home position just in time for the next label to feed onto the pad smoothly Note The tamp flight time needs to be long enough for the grid to swing into position to be ready for the approaching product and for the roller to roll the full length of the label Once this has been achieved the grid should return within the 0 5 second tamp return time Tamp Return Sensor Setup When the tamp return sensor is fitted and enabled it triggers the printer to feed the next label as soon as the tamp returns to its home position This shortens the total cycle time for tamps fitted with the smart tamp option An alarm will also be triggered if the tamp return signal is not received within the expected time period Tamp Return Time This could be an early warning of falling air pressure or a malfunction of the tamp To set up the tamp return sensor proceed as follows 1 2 3 4 5 10 In the Configure menu select Mode of Operation Set Tamp Home Signal to Enabled Select Digital Inputs and select Digital Input 3 Set Input 3 Naming to Tamp Return Set Input 3 to Digital 1 or Digital 0 depending upon the type of sensor used Set Input 3 Latching to Unlatched Set Input 3 Machine Control to None Save the configuration and press Exit when prompted In the Top Level menu set the Tamp Return Time to slightly longer than required An increase of 20 on the original value
36. eanByuo 5 duo poid oinByuo duos 346114 eanByuo 2 1980 spon eanByuo 2 220 59 4 adh Jejuug 19 0 piomssed AVI nue N 8497 do Rev AA 4 10 Setting Up the Machine P3400 Operator Manual Big yews pelqesiq Big yews Big pews 4 40 10 apo Josues dwe pews jqes q Josues due uoivan ifuo 24n311 Bis due Bis Spo peiqesiq peiqesiq 615 due BIS 3x3 Bis 1980 10 apo Bis 3x3 Jedo 10 apo epo N 232019 4 40 10 apo Josues enpon uoneoriddy pepuejxe Jo aigesiq JO JEWJON 129JeS A UO 21529 ejo o y BuIms jno oiseg jonpoJg jeqe1 jeng enpon 21529 uoneoiddy jaqe7 jenq 8 Jo Hejs 9poy ye 21529 yonpold jeqe1 apo
37. en customers specify for packages products or printed materials Our commitment includes Applications support Installation services Maintenance training Customer response center Technical support Field service Extended hours phone assistance Parts and supplies Repair service it P3400 Operator Manual Customer Training If you wish to perform your own service and maintenance on the printer Videojet Technologies Inc highly recommends that you to complete a Customer Training Course on the printer Note The manuals are intended to be supplements to and not replacements for Videojet Technologies Inc Customer Training Rev AA Table of Contents Compliance Information FOP Customers inthe LES us se VC an i For Customers Caunes ERN cen o bate ede es i Pour la Client le du Canada 23 i eet er e reco nec il For Customers the European ii Support and Training Contact Information S oe Se D pae tendon SI oett iii do DO IS cad Maths ie ac pM DUM Msc A LE a iii Customer TTAN E i erari aiat Sie EINER PESE A I iv Chapter 1 Introduction Equipment Descriptomnaa es sure ee OTORGA E 1 1 Base Mod le 1 1 1 2 Application Module 1 2 About the Operator 1 3 Related Documents sites en desi er met e aepo br reden 1 3 Language C
38. hazard to the physical integrity of equipment software without a danger to the personnel These notices clearly state the nature of the hazard and the means by which it can be avoided Cautionary notices appear in full in this chapter and at their points of application in the manual They are presented in the typographical style of this notice General Warning Notices The following warnings supplement the specific warnings that appear elsewhere in the manual These are general warnings which must be read completely understood and applied by all the personnel involved in the operation and or the maintenance of the machine PERSONAL INJURY Before disconnecting any air component ensure that the machine is switched off and all air pressure is exhausted fANNaming PERSONAL INJURY Before beginning any maintenance work or working close to the tamp application module ensure that the machine is switched off and the air pressure is exhausted Rev AA Hazard Information 1 5 P3400 Operator Manual PERSONAL INJURY While doing maintenance work or working closely with moving parts avoid wearing loose clothing Do not wear ear or finger rings while working with the machine ANNarning PERSONAL INJURY Protect your eyes to prevent cleaning solvents from entering them fNNaming PERSONAL INJURY Do not place your fingers under the printhead when the printer is operating LETHAL HAZARD When perfo
39. id to settle ready for the next label Use the cylinder flow restrictors to provide smooth and controlled movement 7 Set the Line Speed to the actual conveyor speed for example 300 mm s 8 Set the Product Sensor Distance equal to 0 5 seconds x Line Speed that is 0 5 X 300 150 mm This is the minimum distance for a 0 5 second out time for the grid to swing out in time for the grid to be in position for the approaching product with the conveyor running at 300 mm s Note Product Sensor Distance is the distance between the product at the labeling position and its position when the product sensor first notices it 9 Initially set Air Assist Delay to zero This time can be increased if label flapping or snaking is seen in the latter stages of feeding the label onto the grid 10 Set Rewind Overrun to 500ms 11 Save the settings in one of the memory directories 1 through 8 Note Once the settings are saved it can be used for other print jobs also You can reconfigure these settings whenever necessary Rev AA Configuring the LPA Settings 4 17 P3400 Operator Manual 12 13 Download number of labels to the print engine One label should feed onto the vacuum grid provided the air assist and vacuum have been set correctly Cycle the machine by triggering the product detector and adjust the air cylinder flow controls until the cylinder extends to its full stroke in a smooth and controlled manner not disturbing th
40. lacement or shape 2 8 Introduction to the Printer Assembly Rev AA P3400 Operator Manual 1 Flexible Coupling 2 Grid with Vacuum Chamber 3 Pad 4 Vacuum Hole 5 Fixing Hole Figure 2 5 Tamp Pad Assembly Blow Application Module The blow application module Figure 2 6 on page 2 10 comprises the following components Extraction fan Adjustable baffle Blast tubes Vacuum grid Pneumatic module Rev AA Introduction to the Printer Assembly 2 9 P3400 Operator Manual 1 Adjustable Baffle 2 Vacuum Grid 3 Blast Tubes not all tubes are shown 4 Fan 5 Pneumatic Module Figure 2 6 Blow Application Module Blow application module is an Air jet device that consists of an extraction fan that is used to create vacuum within a vacuum box The vacuum created inside the box holds the label to the vacuum grid The vacuum level is adjusted by a baffle located on the side of the vacuum box Air tubes blast air from the pneumatic source to apply the label onto the product The position of the air blast tubes on the vacuum grid can be adjusted to apply labels of different shapes or sizes to the product During label printing the label is transferred to the underside of the vacuum grid guided by the air assist assembly The vacuum created within the vacuum box holds the label in position until the product is detected by the product detector When the product moves under the vacuum box the air
41. ll the tamp modules 1 7 pin Din Connector 2 Laser Height Sensor 3 Sensor Lead Figure 2 17 Laser Height Sensor Beacon Assembly The beacon assembly comprises three colors Red e Amber Orange Green Table 2 1 lists the order of the lights on the beacon stack Color Position Red At the top Amber Orange In the middle Green At the base Table 2 1 Beacon Assembly Colors The beacon assembly Figure 2 18 on page 2 23 is used to indicate the status of the Videojet P3400 LPA and the print engine One light or a combination of lights glow to indicate a fault condition for instance a low label condition or a print engine fault The beacon assembly can be 2 22 Introduction to the Printer Assembly Rev AA P3400 Operator Manual fastened to any suitable structure on the supplied base or it can be used along with the universal beacon bracket assembly 1 Tri color Lampstack 2 Bracket Assembly 3 Green 4 Amber 5 Red Figure 2 18 Tri color Lampstack and Bracket Assembly Rev AA Introduction to the Printer Assembly 2 23 P3400 Operator Manual Bracket Assembly The bracket assembly is used with both the beacon assembly and the remote control box assembly Figure 2 19 shows the bracket being attached to the U arm You can position the beacon or the control box in almost any orientation to suit the installed LPA 1 Thumb Screw 2 OCP Fixing Screws 3 Clamp or Mo
42. m stroke tamp 160 500 0 320 seconds Set Tamp Return to the same time as that of Tamp Flight Time Set the Line Speed to the actual conveyor speed for example 300 mm s Set Product Sensor Distance equal to Tamp Flight Time x Line Speed that is 0 320 X 300 96 mm This is the minimum distance for a 160 mm tamp with the conveyor running at 300 mm s Note Product Sensor Distance is the distance between the product at the labeling position and its position when the product sensor first notices it Set Air Assist Delay to zero Set Rewind Overrun to 500ms Save the settings in one of the memory directories 1 through 8 Note Once the settings are saved it can be used for other print jobs also You can reconfigure these settings whenever necessary Download a number of labels to the print engine and one label should feed onto the tamp pad provided the air assist and vacuum have been set correctly Cycle the machine by triggering the product detector and adjust the air cylinder flow controls until the cylinder just extends to its full stroke and returns to its home position just in time for the next label to feed onto the pad smoothly This procedure will set the cylinder linear speed to 500 mm s which is considered to be the optimal speed for most tamp applications Faster or Configuring the LPA Settings 4 13 P3400 Operator Manual slower speeds can be set by recalculating the Tamp Flight Time and Tamp Return times b
43. mation 1 7 P3400 Operator Manual Caution SERIOUS EQUIPMENT DAMAGE Use the printer for its intended purpose only Abbreviations Used Table 1 2 provides a list of abbreviations used in this manual Abbreviation Expansion Bar Barometric CPU Central Processing Unit DC Direct Current IBM International Business Machines Input Output kg Kilograms LCD Liquid Crystal Display LED Light Emitting Diode m Meters mm Millimeters mm s Millimeters per second ms Milliseconds m s Meters per second No Number OCP Operator Control Panel PC Personal Computer PEC Photoelectric Cell PLC Programmable Logic Controller psi Pounds per Square Inch LPA Label Printer Applicator Table 1 2 List of Abbreviations 1 8 Abbreviations Used Rev AA P3400 Operator Manual Conventions for Figures and Tables The illustrations given in the manual are numbered based on the section in which they appear For example the caption Figure 1 3 represents the third figure in Chapter 1 Tables are also numbered in a similar manner For example the table title Table 1 1 represents the first table in Chapter 1 Rev AA Conventions for Figures and Tables 1 9 Main Parts of the Printer This chapter contains an introduction to the Videojet P3400 Label Printer Applicator and its assembly along with a description of the main parts Introduction
44. me Tamp stroke length 500 that is for a 100 mm stroke tamp 100 500 0 200 seconds Set Tamp Return to the same value Set the Swing Arm Time equal to the time it takes for the swing arm to fully extend typically about 950 ms for a 300 mm reach module Set Swing Return to the same value 9 Set the Line Speed to the actual conveyor speed for example 300 10 11 12 13 14 15 16 mm s Set the Product Sensor Distance equal to Tamp Flight Time x Line Speed that is 0 950 X 300 285 mm This is the minimum distance for a 300 mm reach swing arm tamp with the conveyor running at 300 mm s Note Product Sensor Distance is the distance between the product at the labeling position and its position when the product sensor first detects it Set Swing Arm Delay to Zero This will start the swing arm cycle as soon as the label is on the tamp pad Set Air Assist Delay to zero Set Rewind Overrun to 500ms Save the settings in one of the memory directories 1 through 8 Note Once the settings are saved it can be used for other print jobs also You can reconfigure these settings whenever necessary Download a number of labels to the print engine One label should feed onto the tamp pad provided the air assist and vacuum have been set correctly Cycle the machine by triggering the product detector and adjust the air cylinder flow controls until the cylinder just extends to its full stroke and returns to its home p
45. mine the presence of an approaching product Two product detectors can be used to determine the presence and the speed of the product respectively Once the product has passed by in front of the second detector the product detector generates signal to the to initiate a pre programmed delay to start the operation cycle 1 Electrical Connector 2 Retro reflective Sensor Figure 2 16 Product Detectors Height Sensor The height sensor Figure 2 17 is a laser operated device A Warning PERSONAL INJURY The precautions procedures and control outlines in regulatory documents must be strictly observed Failure to do so may result in dangerous radiation exposure Laser energy either direct or reflected is extremely hazardous to your eyes and skin Take thorough precaution to ensure that such exposure does not occur Laser equipment also potentially generates the hazards of fire high voltages and pollution You must provide adequate protective measures against these potential dangers Observe the safety precautions and procedures outlined in this manual Failure to do so can result in extensive damage to property and substantial personal injury Introduction to the Printer Assembly 2 21 P3400 Operator Manual The height sensor is used along with the height compensation function of the machine and is intended to position the labels accurately and repeatedly on the product The height compensation function can be used with a
46. n sensor Clean with 70 isopropyl With every ribbon change alcohol and or clean with canned air Note Do not use high pressure shop air Paper end switch Clean with 70 isopropyl When the end switch alcohol roller shows that debris or adhesive is present Belts Visual inspection for wear Every six months 500 rolls Door open switch Clean with canned air only As required Note Do not use high pressure shop air Peel plate Clean with 7096 isopropyl With every label roll alcohol change Table A 2 Maintenance Schedule for the Sato Print Engine Continued Rev AA Maintenance of the Sato Print Engine A 3 P3400 Operator Manual Maintenance of the Zebra Print Engine Figure A 3 provides the maintenance schedule for the Zebra print engine Note Harsh or dirty environments may require shorter intervals between preventive maintenance routines Maintenance Item Maintenance Method Printhead Clean with 70 isopropyl alcohol Platen roller Clean with 70 isopropyl alcohol Transmissive media Clean with canned air Maintenance Interval After every roll of media when printing in Direct thermal mode sensor only After every roll of ribbon Note Do not use high when printing in thermal pressure shop air transfer mode Media path Clean with 70 isopropyl alcohol Ribbon sensor Clean with canned air only Note Do not use high pressure shop air Door open sensor
47. n the product conveyor provides the sequence start signal upon detecting an approaching product on the conveyor The detector is positioned relative to the label peel tip for correct application This position is determined by the speed of the conveyor length of the product to be labeled and the desired position of the label on the product The detector should be carefully positioned to operate the applicator at maximum speed Product Sensor It receives input from the product detector Rewind Lock Pin This is the U shaped pin that is used to retain the spent label web on the rewind roll mandrel Rewind Roll This is the mandrel provided to store the spent label web Glossary 3 P3400 Operator Manual Shaft Encoder A shaft encoder kit is available to synchronize the dispense speed of the label with the line speed of the product Tamp Application Module This is a label applicator that uses an air cylinder that extends to apply the label on to the object and retracts to its home position The label is dispensed onto a tamp pad through the air assist mechanism and is held in place by vacuum created within the tamp by the pneumatic module When the product moves under the tamp the tamp assembly extends and applies the label to the product Immediately the tamp retracts and is ready for another extension Tamp Pad Tamp pad is a part of the tamp applicator that holds the label during the application process There are holes in the
48. o provide responsible protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference In such cases the users will be required to correct the interference at their own expense Shielded cables must be used with this unit to ensure compliance with Class A FCC limits The user may find the following booklet prepared by the Federal Communications Commission helpful How to Identify and Resolve Radio TV Interference Problems This booklet is available from the U S Government Printing Office Washington DC 20402 Stock No 004 00 00345 4 This equipment has been tested and certified for compliance with U S regulations regarding safety and electrical emissions by TUV Rheinland of North America Inc For Customers in Canada This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications Rev AA i P3400 Operator Manual This equipment has been tested and certified for compliance with Canadian regulations regarding safety and electrical emissions by TUV Rheinland of North America Inc
49. odes 45e whee Si 1 3 Hazard Intormatiorn Eee ee E RM EN EE EP EA RM 1 4 General Warning Notices exui Exe a er wa ode 1 5 General Caution Notices iier e ea edat C CR as 1 6 Abbreviations Used onic ews ee teed ee CP RN 1 8 Conventions for Figures and Tables 1 9 Chapter 2 Main Parts of the Printer Introduction to the Printer Assembly 2 1 Base Modules sao Veo a et 2 1 Print Bue cii eddie eh ott qur a emo I p Dn b d 2 4 Label W b Pathi tiere etae Vene ved ur eto bone ER 2 6 Application Modules 2 8 JNGCEBSSOTIOS P Ces vor koe EU uei d 2 19 Chapter 3 Main Controls of the LPA v vx ee t ev aat em UA 3 1 Pneumatic Pressure and Flow Control 3 1 PrintEngine Controls reen eer EE HC e aee dee 3 13 Zebra Control 1 3 14 SATO Control Panel 3 14 Interface 5 5 8 3 15 Rev AA 1 1 P3400 Operator Manual Chapter 4 Getting Started Loading a Ribbon into the Print Engine 4 1 Loading a Label Boll ous ues koe ERE CURE SE eed ex Ne tines 4 2 Switching the Machine 4 4 Setting Up the 4 5 Setting Parameters
50. ojet P3400 LPA is designed to operate using all or some of the following accessories Shaft encoder Product detector sensor Second product sensor Height sensor Beacon lamp stack assembly Bracket assembly Rev AA Introduction to the Printer Assembly 2 19 P3400 Operator Manual Remote OCP Print engine data cable Smart tamp sensor Machine stand assembly Remote computer Shaft Encoder A shaft encoder Figure 2 15 on page 2 20 is used when the speed of the product line is variable The shaft encoder translates the linear movement of the product line into generated drive pulses that are fed to the LPA As the varying rate of pulses is proportional to the product line speed the LPA is able to determine various delays and timing sequences This ensures that the machine operates precisely even when the product line speed is variable To choose the shaft encoder consider the following criteria 1 00 15 00 PPmm 2500 or 5000 PPR when fitted with 400 mm circumference 5 013 dia contact wheel Single or Dual Quadrature output which must rotate clockwise because the readings can be generated only in that direction 1 Shaft Encoder 2 Shaft Encoder Contact Wheel 3 Conveyor Belt Figure 2 15 Shaft Encoder 2 20 Introduction to the Printer Assembly Rev AA Rev P3400 Operator Manual Product Detector s The product detector Figure 2 16 is used to deter
51. or an inner wound label roll configuration 2 2 Introduction to the Printer Assembly Rev AA P3400 Operator Manual The unwind assembly has a twist lock type of removable flange assembly that eases the loading or replacing of label rolls Air Assist Assembly The air assist assembly Figure 2 2 contains a non stick air assist tube and an air supply tube When the label passes from the peeler bar to the application module the air assist jet directs air onto the label causing it to deform This process aids the placement of the label on to the application module b Label continues to feed out a Label starts to feed from the toward the vacuum grid print engine C Air assist blows and the label sticks to the vacuum grid 1 Blow Box with Vacuum Grid 3 Peeler Bar on Print Engine 2 Label 4 Air Assist Tube Figure 2 2 Air Assist Assembly Rev AA Introduction to the Printer Assembly 2 3 P3400 Operator Manual Rewind Assembly The rewind assembly is used to rewind or take up the used label liner after the printing and dispensing of a label The rewind assembly is fitted with a slipping clutch to accommodate the increase in diameter of the rewind waste roll as well as to accommodate different label printing speeds Low Label Sensor The low label sensor detects a reduction in the diameter of the roll of labels when it reaches a level of 5 of its total capacity The sensor then signals the LPA to sen
52. osition just in time for the next label to feed onto the pad smoothly 4 16 Configuring the LPA Settings Rev AA P3400 Operator Manual Corner Wrap Setup The corner wrap module functions from the same signals that the tamp module uses and is in the same set up except for the following In the tamp the label feeds out to the vacuum grid awaiting a product detect signal Once the signal is received the grid advances out When the previous product clears the grid path the grid stays out waiting for the next product As the product passes past the corner wrap module a roller stacks the label to the product and rolls the label down on to the leading face and then the adjacent face of the product while displacing the vacuum grid Once the roller has rolled over the trailing end of the label the unit times out and returns home ready for the next label feed To set up the corner wrap module proceed as follows 1 Inthe Configure menu select Mode of Operation 2 Set the Basic Mode to Tamp this is the same as corner wrap 3 Set Alternate Mode to Normal and set all other sensors to Disabled 4 Save the configuration and press Exit when prompted 5 In the Top Level menu initially set the Tamp Flight Time equal to the maximum 3 20 seconds this time can be reduced to ensure that the grid returns and the label loads in time for the next product 6 Set Tamp Return to approximately 0 50 seconds this time period should allow the gr
53. ow valve is energized Adjustable from 0 to 3 2767 seconds Default setting Swing Arm Delay Delay before air is shut off to swing arm tamp Used when swing arm tamp is configured as a swing arm wrap Adjustable from 0 to 3 2767 seconds Default setting Swing Arm The time swing arm tamp takes to move from its home Time position to its fully extended position Adjustable from 0 to 3 2767 seconds Default setting Tamp The time during which the tamp over travels after the Overrun smart sensor detects the product Time added at the end of tamp flight time Used to optimize tamp flight time compensation Adjustable from 0 to 3 2767 seconds Default setting 100 ms at 500 mm s which is equal to 50 mm over travel Table 4 1 Control Panel Parameters 4 8 Setting Up the Machine Rev AA P3400 Operator Manual Parameter Description Tamp Return Time allowed for tamp to return to the home position before the next label is ready Normal tamp linear speed is 500 mm s Adjustable from 0 to 3 2767 seconds Default setting is 100 ms Swing Return Time allowed for swing arm tamp to return to home position before the next label is ready Adjustable from 0 to 3 2767 seconds Default setting Air Assist Delay Delays the start of air assist Used to ensure that the label goes on to the tamp pad blow grid and is not blown away while it is between the print engine and the application module Adjustable from 0 to 3
54. p Pneumatic module Introduction to the Printer Assembly 2 17 P3400 Operator Manual 1 Two Panel Tamp Pneumatics Module 2 Two Panel Tamp Module Figure 2 13 Two Panel Tamp Application Module The purpose of the two panel tamp module is to apply a label each to the leading face and the adjacent face of a product Alternatively it is also used to apply a label each to the adjacent face and the trailing face The module is constructed from two main elements the swing arm unit and the tamp unit The swing arm unit is fastened to the tamp unit Corner Wrap Application Module The corner wrap module Figure 2 14 applies the same label to the leading face and the adjacent face of a product It comprises the following components Corner wrap module Pneumatics module 2 18 Introduction to the Printer Assembly Rev AA P3400 Operator Manual 1 Tamp Pneumatics Module 2 Corner Wrap Application Figure 2 14 Corner Wrap Application Module When a corner wrap operation is initiated it feeds out a label onto the dispense pad Due to the product movement and its associated forces the label is tacked to the initial leading face of the product by a roller The label is then applied progressively from the lead face onto the adjacent face of the product while the dispense pad and the roller are repositioned around a pivot point and are fixed to the machine Accessories The Vide
55. pad through which the air is sucked creating vacuum inside the tamp The vacuum helps the tamp to hold the label till the air cylinder extends the tamp and affixes the label on to the object Each tamp pad is manufactured for a specific label size and should not be used for a label size that does not match Tamp Jet Application Module Tamp jet works on the same principle as a tamp except that a blast of air blows the label onto the product prior to the tamp pad not shown touching the product The tamp jet can also be used as a regular tamp as the jet can be used to enhance the label tack and release from the pad Swing Arm Tamp Application Module The Swing arm tamp is a fixed swing tamp module and uses a similar principle as tamp However the tamp pad fitted on a fixed length arm is swung out to the side or the front about a fixed pivot point to apply labels to the product in a similar manner to the tamp It is equipped with a damper allowing controlled return operation at all speeds Glossary 4 Rev AA
56. played at the control panel for example printhead cover open On Line indicates when the print engine is on and ready to print Print Engine Controls 3 13 P3400 Operator Manual Pause indicates that the print engine is paused Press it again to put the printer back online Data indicates that the print engine is communicating with the remote computer Note Refer the print engine user manual for information on the other print engine functions such as status lights buttons operating systems instructions and configuration Print Contrast controls the adjustment of the print contrast located near the LCD Power Switch controls the power to the print engine Zebra Control Panel Figure 3 14 shows the zebra control panel Figure 3 14 Zebra Control Panel with one hinge removed for clarity SATO Control Panel Figure 3 15 shows the SATO control panel Figure 3 15 SATO Control Panel 3 14 Print Engine Controls Rev AA P3400 Operator Manual Interface Specifications There are a number of interface types depending upon the print engine chosen and its configuration For selection and configuration refer the print engine manual The interfaces are located at the rear of the print engine Figure 3 16 shows a typical representation of the interface location 1 Communications Interface Card Parallel Note The other options are Ethernet and Serial 2 LPA Inte
57. r This device controls the tension applied to the rewind roll It helps to absorb the variation in liner waste take up that occurs as a normal function of the incremental label advancing system Label Sensor This infra red thru beam detector senses the opacity of the label liner before the label is removed In doing so it also senses the spaces between Rev AA Rev P3400 Operator Manual the labels and provides label stop control The sensitivity of this sensor is adjustable and the stopping position of the label which is relative to the peel edge is adjusted electronically Label Size This is the dimension of the label width x length Label Unwind This is the subsystem that unwinds the label supply roll to facilitate label application Label Unwind Dancer This device controls the tension applied to the unwind roll It helps to absorb the shock that occurs as a normal function of the incremental label advancing system Label Unwind Flange These disks hold and retain the label supply roll Label Unwind Spindle This shaft holds the label flanges that contain the label roll Pressure Sensitive Label A material cut toa predetermined size with adhesive sensitive to contact applied on its one side These are usually supplied in rolls or fan fold Power Indicator When the power indicator is lit it indicates that power is on and supplied to all circuits Product Detector The product detector normally located o
58. rface Card Zebra 15 Pin D Sato 14 Pin Centronics Datamax 15 Pin DPM 15 Pin D Figure 3 16 Interface Specifications Rev AA Print Engine Controls 3 15 Getting Started This chapter describes the procedures to get started with using the LPA Loading a ribbon into the print engine Loading a label roll Switching on the machine Setting up the machine Configuring printer applicator settings Starting production Loading a Ribbon into the Print Engine To load a new ribbon into the print engine proceed as follows 1 Remove the new ribbon from its packaging 2 Unwind approximately 300 mm of ribbon from the reel an initial length of the ribbon is ink free and is termed leader 3 Fit the new ribbon to the unwind spindle and ensure the following The reel is pushed fully onto the spindle The dull ink side of the ribbon must face downwards as it travels through the printhead assembly 4 Lift the printhead lever and make space to slide the ribbon on the printhead 5 Thread the ribbon around the rollers and over the printhead and extend the threading to the empty rewind reel by following the threading diagram attached to the print engine 6 Secure the ribbon to the reel with an adhesive tape to prevent from slipping 7 Wind excess ribbon onto the rewind reel ensuring that the ribbon is not torn or wrinkled Rev AA Loading a Ribbon into the Print Engine 4 1 P3400 Operator Man
59. rint engine configuration Volatile memory that holds the label data ready to be printed Battery backed memory for label storage is optional Internal power supply that converts the AC mains power into the DC voltage when required by the print engine The I O interface that connects the print engine to the controlling computer and the label applicator Ribbon Drive and Tensioning Device The ribbon drive consists of two spools on which the ribbon reels are fitted The ribbon unwind reel stores unused ribbon and is free spooling under friction control The ribbon rewind reel is driven by a motor and is used to take up the used ribbon as it emerges from between the printhead and the platen Peeler Bar The peeler bar consists of a metal plate and the label is routed over its edge As the label web moves over the peeler bar the label is separated from the label backing and is positioned onto the label application module Note For specific information regarding your printer refer the printer manual Introduction to the Printer Assembly 2 5 P3400 Operator Manual 2 6 Label Web Path The label web Figure 2 4 on page 2 7 is routed into the print engine along the label web path The label web path comprises the following components Unwind reel The shaft is tightened to ensure correct label web tension and to stop any run out A twist lock collar is used to retain the roll Unwind dancer arm The dancer arm is spring
60. rinter Applicator LPA is a self contained unit which requires a signal from an external sensor to indicate the product that is to be labeled The machine is capable of printing labels and applying them to the product The Videojet P3400 LPA comprises the following modules Base module Print engine Application module Base Module The base module of the Videojet P3400 LPA comprises the following components Electronic module connector panel assembly Unwind assembly Air assist assembly Rewind assembly Low label sensor Rev AA Equipment Description 1 1 P3400 Operator Manual Print Engine The print engine transfers the image data from the external data source onto the label Application Module The application module comprises the pneumatic module and the applicator It is used to transfer the label from the print engine onto the product 1 P3400 RH Wide Base Module with Print Engine _ 5 Heavy Duty Long Stroke Module Fitted 6 Adjustable Swing Arm Tamp Module 2 Blow Airjet Module 7 STD Swing Arm Tamp Module 3 STD Tamp Module 8 Two Panel Tamp Module 4 STD Tamp Jet Module with Flex Coupling 9 Corner Wrap Module Figure 1 1 Label Printer Applicator Modules 1 2 Equipment Description Rev AA P3400 Operator Manual About the Operator Manual The operator manual is intended for the everyday users of the LPA It contains the following chapters Introduction cont
61. rming maintenance work switch off the printer s main isolator unless it is necessary to perform machine movements ANNarning ELECTRICAL HAZARD When working on the electrical equipment observe all statutory electrical safety codes and practices General Caution Notices The following caution statements supplement the specific cautions that appear elsewhere in the manual These are general cautions which must be read completely understood and applied by all the personnel involved with the operation and or the maintenance of the machine 1 6 Hazard Information Rev AA Rev P3400 Operator Manual Caution EQUIPMENT DAMAGE Use brushes and lint free clothes for cleaning Do not use high pressure air or cotton waste AN Caution EQUIPMENT DAMAGE Turn off the mains power when adjusting or repairing the machine Do not force the machine motions manually N Caution EQUIPMENT DAMAGE Do not unplug any connector on the printer when the mains power is on A Caution EQUIPMENT DAMAGE Print ribbons should be stored at a temperature range of 25 C to 30 C and at a non condensing humidity range of 20 to 80 AN Caution SERIOUS EQUIPMENT DAMAGE Do not apply excessive force to the printhead while cleaning as this can cause damage to the printhead and can void the warranty N Caution SERIOUS EQUIPMENT DAMAGE Do not run the printer with the air pressure supply above the recommended level Hazard Infor
62. roke tamp module Adjustable swing arm tamp module and swing arm tamp module Two panel tamp module Corner wrap module Note Each tamp based application module requires a tamp pad Tamp Pads Tamp pads Figure 2 5 on page 2 9 are used in all the application modules that tamp the label onto the product When a label is fed from the printer onto the tamp application module it passes under the tamp pad The tamp pad retains the label in position with the help of vacuum until the time it is to be applied onto the product Tamp pads are specifically manufactured to suit the size of the labels being applied and the style of the product Typically the tamp pad details are specified at the time of placing an order for the LPA or the application module The details can also be specified at a later date so that the tamp pad can be used in the same machine for different sizes of the label Tamp pads comprise two major parts a pad and a grid In some cases they are also fitted with a flexible coupling The pad has a series of holes through its body that allows air to be drawn in by vacuum to enable the label to stick to it The grid contains a vacuum chamber to allow uniform distribution of vacuum over the tamp pad It also contains a series of fixing holes to allow it to be fastened to the application module The flexible coupling allows tamp pads to conform to angular irregularities generated by variable product p
63. s per the standards 2 Connect the printer interface cable Figure 4 2 between the printer and the electronics module and connect the power cord to the print engine 1 Print Engine Power Cord 2 Printer Interface Cable 3 Printer Interface Cable for Zebra Datamax and DPM Print Engines 4 Printer Interface Cable for Sato Print Engine with 14 Pin Centronics Plug Figure 4 2 Switching On the Printer 3 Connect the power cord to the side of the electronics module Figure 4 3 on page 4 5 and plug it into the mains power Turn on the power switch located at the rear of the connector panel 4 4 Switching On the Machine Rev AA P3400 Operator Manual External Power Cord Figure 4 3 External Power Cord Connection 4 Turn the print engine on and wait for the print engine to cycle through its power up procedure 5 Ensure that the ribbon and the label are loaded and are threaded as per the instructions Setting Up the Machine The control panel of the Videojet P3400 LPA contains four buttons as shown in Figure 4 4 on page 4 6 Rev AA Setting Up the Machine 4 5 P3400 Operator Manual P3400 Label Printer Applicator Menu 80066 MVineoser P3400 Use of buttons The four buttons on the control panel are allocated to the following functions Move upward in the menu or increase the value of a variable Move downward in the menu or decrease the value of a variable Select a menu item or execute that i
64. tem Exit Next item or menu level or select the next element of a multiple element variable Basis of operation of the menu system The two line display is used to implement the menu system In this system the user scrolls through choices and selects the one to change or the sub menu to view Figure 4 4 Control Panel Buttons The basic operation of the two line display is to support the menu system where the user scrolls through different options and selects one to perform an action or to view the item Setting Parameters on the Control Panel Set the following parameters on the control panel as required based on the description provided The configuration flow details for each parameter are shown in Figure 4 5 on page 4 7 4 6 Setting Up the Machine Rev AA s J 10440 G p 21814 5 0 UOISI9A ssaid 1959 S 029 LINI einfyuos a 0 195 piomssed 195 A dis 4115 8 3euJeju jeuJeju s jnejaq a10 say jnejeg e1o1ses O L UoISISA 55 ANIHOVIW 13534 ones 029 LINI 14 7 odAL ed A eunBiuo5 edA 1ejuug 19
65. ter Assembly 2 27 Main Controls of the LPA This chapter contains the following topics A description of the controls A description of the print engine controls LPA Controls Rev AA The LPA controls are used to control the air flow and pressure of the pneumatic functions of the machine Pneumatic Pressure and Flow Control The pneumatic controls comprise the following System air pressure controlled via the filter regulator assembly Air assist air flow controlled via a thumbscrew adjusted air flow fitting on the pneumatic module Tamp cylinder speed control airflow controlled via a thumbscrew operated flow control fittings attached to the air cylinder Tamp pad vacuum controlled via a thumbscrew operated flow control valve fitted to the air module that regulates the air flow into a vacuum generator venturi Tamp jet control Vacuum box vacuum is controlled via an adjustable baffle on the side of the vacuum box Note The above controls will need to be adjusted to suit the application module fitted The pressure control complete with pressure gauge controls the overall pressure in the machine including the pressure in the air blast tubes in case of blow or air jet modules The setting of the control for blow or air jet modules depends upon the size of the label the speed and distance at which the product passes the applicator LPA Controls 3 1 P3400 Operator Manual 3 2 L
66. the label and the speed at which the label is dispensed Rev AA LPA Controls 3 3 P3400 Operator Manual Air Assist Flow Control Figure 3 2 Typical Position of the Air Assist Flow Control Tamp Swing Arm Tamp Cylinder Speed Control The tamp cylinder speed control Figure 3 3 on page 3 5 regulates the flow rate out of the tamp SWAT air cylinder Adjustment of these controls alters the speed at which the tamp extends and retracts or rotates The controls are fitted to the air cylinder that is in use 3 4 LPA Controls Rev P3400 Operator Manual 1 Typical Position of Tamp Cylinder Speed Flow Control 2 Tamp Speed Control Valves Figure 3 3 Speed Control Valves on Different Tamp Modules Tamp Pad Vacuum The vacuum air flow control restricts the air flow to the vacuum generator and this in turn controls the vacuum flow rate to the tamp pad Adjustment of vacuum air flow control varies the suction intensity between the label and the pad The control is fitted to the pneumatic module refer Figure 3 4 on page 3 6 Rev AA LPA Controls 3 5 P3400 Operator Manual Vacuum Flow Control Figure 3 4 Typical Position of the Vacuum Flow Control Tamp Jet Control The tamp jet function is electrically controlled and it determines the jet duration flowing to the tamp pad Typically the valve duration
67. ts Clean with canned air only DO NOT USE HIGH PRESSURE SHOP AIR As required Clean and lubricate the tamp cylinder guide rods Clean with 7096 isopropyl alcohol Lubricate with lightweight oil Monthly once Verify if all modules and accessories are fastened securely Visual inspection Monthly once Check the filter regulator for water or oil collection Visual inspection Drain if necessary Eliminate the source of contamination Weekly once Table A 1 General Maintenance Schedule Continued Maintenance of the Sato Print Engine Table A 2 provides the maintenance schedule for the Sato print engine Note Harsh or dirty environments may require shorter intervals between preventive maintenance routines Maintenance Item Maintenance Method Maintenance Interval Printhead Clean with 70 isopropyl alcohol With every ribbon change Table A 2 Maintenance Schedule for the Sato Print Engine A 2 Maintenance of the Sato Print Engine Rev AA P3400 Operator Manual Maintenance item Maintenance Method Maintenance Interval Platen roller feed Clean with 70 isopropyl With every ribbon rollers and alcohol change or when dust pressure rollers adhesive is present Upper label sensor Clean with 70 isopropyl Every two rolls of labels and lower label alcohol sensor window Media path Clean with 70 isopropyl Every two rolls of labels alcohol Ribbo
68. ual N Caution EQUIPMENT DAMAGE Turn the rewind reel only to tension the ribbon 8 Once the ribbon is loaded lower the printhead lever to the closed position and close the print engine cover Note Run a print test to check the print quality each time you load a new ribbon Loading a Label Roll To load a new label roll proceed as follows 1 Fitthe label roll Figure 4 1 on page 4 3 to the unwind reel and secure it with the quick release locking collar Ensure that the direction of the unwind reel is the same as that seen on the threading diagram 4 2 Loading a Label Roll Rev AA P3400 Operator Manual am 1 Idler Rollers 5 Unwind Flange with Twist Locking Collar 2 Label Web Guides 6 Unwind Dancer Arm 3 Rewind Dancer Arm 7 Unwind Reel 4 Rewind Reel Figure 4 1 Label Roll 2 Ensure that the print engine cover is open and the printhead lever is in the open position raised 3 Thread the label web as shown in Figure 4 1 and ensure that the web goes through the label position sensor of the print engine 4 Wind the label web around the rewind reel two or three times and secure it with the locking pin 5 Close the printhead lever and the print engine cover Rev AA Loading a Label Roll 4 3 P3400 Operator Manual Switching On the Machine To switch on the machine proceed as follows 1 Ensure that the pneumatic equipment is accurately connected and the air pressure is set a
69. unt for Lampstack and OCP 4 Mounting Post 5 Set or Grub Screw Figure 2 19 Bracket Assembly 2 24 Introduction to the Printer Assembly 6 U arm Fixing Bracket 7 Spacer 8 Typical U arm Assembly 9 Assembly Remote OCP P3400 LPA 10 Assembly Bracket Beacon OCP MNT P340 Rev AA Rev P3400 Operator Manual Remote OCP The remote OCP Figure 2 20 is used to control the electronics module of the Videojet P3400 LPA alternative to the control panel fitted to the front of the machine The remote OCP is supplied with a 2 m long cable and a bracket assembly which allows the beacon lampstack to be mounted onto the U arm and oriented in the preferred position 1 P3400 LPA Remote OCP Assembly 2 Fixing Screws Supplied with Bracket Assembly 3 Bracket Assembly Figure 2 20 Remote OCP and the Bracket Assembly There are plastic snap rivets installed on the side of the remote OCP that enables alternative positioning of the bracket with respect to the OCP Print Engine Interface Cables Each print engine has to be coordinated with the Videojet P3400 LPA with its respective data cable connected to the print engine and the LPA electronics module The LPA will not function correctly if the cable is missing The available print engine interface cables Figure 2 21 on page 2 26 are 40348391 ASSY CABLE INTERFACE 12PIN DIN SATO 40348392 ASSY CABLE INTERFACE 12PIN DIN ZEBRA 40348393 ASSY CABLE INTERFAC
70. would be an ideal figure Save the settings in one of the memory directories 1 through 8 Note Once the settings are saved it can be used for other print jobs also You can reconfigure these settings whenever necessary 4 18 Configuring the LPA Settings Rev AA Rev P3400 Operator Manual Tamp Extended Sensor Setup When the tamp extended sensor is fitted and enabled it triggers the tamp to return This can shorten the total cycle time Additionally an alarm will be triggered if the tamp extended signal is not received within the expected time period Tamp Flight Time This could also be an early warning of falling air pressure or a tamp malfunction To set up the tamp extended sensor proceed as follows In the Configure menu select Mode of Operation Set Tamp Extended to Enabled Select Digital Inputs and select Digital Input 4 Set Input 4 Naming to Tamp Extended a A N Set Input 4 to Digital 1 or Digital 0 depending upon the type of sensor used Set Input 4 Latching to Unlatched Set Input 4 Machine Control to None Save the configuration and press Exit when prompted ON OQO In the Top Level menu set the Flight Time to a slightly longer duration than required An increase of 20 of the original time would be good figure 10 Save the setting in one of the memory directories 1 through 8 Note Once the settings are saved it can be used for other print jobs also You can
71. x Components AN Warning PERSONAL INJURY Before altering the position of the blast tubes ensure that the machine is switched off and all air pressure is exhausted The following section provides information on generalized settings for the initial setup of the vacuum box The air tubes may be required to be moved to optimize the label positioning A blanking plate grid mask can be fitted to the vacuum grid when small labels are used This increases the effective vacuum around the area of the label Note The pattern of the air blast tubes on the vacuum grid does not need to be symmetrical to produce the most efficient label application Often a pattern configured to bend the label during application can yield acceptable results It is not necessary to use all the air blast tubes if the label is not a large one Start by using the tubes suggested in the following figures and adjust as required to gain optimum performance Air Blast Tubes Rectangular Label For rectangular labels the objective is to place the label down in a single flat manner The center based tubes are used to first place the center of the label down The remaining jets are used to smooth out the sides refer Figure 3 7 on page 3 9 Rev AA P3400 Operator Manual OO B88 OQOQOQOOOQOQOOQOOOOOOOOO

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