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Advanced Poly-Packaging Ti-1000, Operation Manual

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Advanced Poly-Packaging Ti-1000 Operation Manual Download Page 47

Chapter 6, Preventive Maintenance &

 

Trouble-Shooting 

_____________________________________________________________ 
 

Key Maintenance Data 
Recommended Tools / Accessories 
Equipment Cleaning / Cleanliness of Materials 
Print Head Cleaning 
Roller Cleaning  
Preventative Maintenance Checklist 
Scheduled Maintenance Chart 
Preventative Maintenance (PM) Performed (Additional) 
Maintenance Record (Other Maintenance Performed) 

Summary of Contents for Ti-1000

Page 1: ...ron OH 44306 330 785 4000 Fax 330 785 4010 www advancedpoly com sales advancedpoly com U K Advanced Poly Packaging UK Ltd Over Causeway Over Glouchester GL2 8DB 44 1452 332400 Fax 44 1452 332500 www advancedpoly com salesuk advancedpoly com ...

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Page 3: ...Ti 1000 Inline Thermal Transfer Printer ______________________________________________________________________________ Operation Guide Ver 1 Setup and Operation guide ...

Page 4: ...very In any event APPI s liability for defective components is limited to repairing or replacing the components This warranty is contingent upon proper use of equipment by Purchaser and does not cover expendable component parts such as print heads rollers bushings or if damage is due to accident unusual physical electrical or mechanical stress neglect misuse failure of electrical power improper en...

Page 5: ...ications 1 7 Print Specifications 1 8 Ribbon Specifications 1 9 System Integration 1 10 Using This Manual Topographical Conventions Chapter 2 Getting Started 2 1 Installation Procedures 2 2 Assembly Instructions 2 3 Air Power Hookup 2 4 Auxiliary Port Connection 2 5 Remote Panel Connection 2 6 Main Power 2 7 Film Bag Threading 2 8 Printer Ribbon Threading 2 9 Print Registration and Alignment 2 10 ...

Page 6: ... Power Supply Components Identification 3 8 CPU PC Board Component Identification 3 9 Interface Board 3 10 Ribbon Roll Shaft Detail 3 11 Drive Assembly Detail 3 12 Harness Description and Location 3 13 Recommended Spare Parts List 203 DPI Printer 3 14 Recommended Spare Parts List 305 DPI Printer Chapter 4 Operation 4 1 Sequence of Operation 4 2 Test Printing 4 3 Signalling Between Bagger Printer t...

Page 7: ...ever Arm Adjustment 5 9 Head Down Sensor 5 10 Inserting the Optional Flash Memory Card Chapter 6 Preventative Maintenance Trouble Shooting 6 1 Key Maintenance Data 6 2 Recommended Tools Accessories 6 3 Equipment Cleaning Cleanliness of Materials 6 4 Print Head Cleaning 6 5 Roller Cleaning 6 6 Preventative Maintenance Checklist 6 7 Scheduled Maintenance Chart 6 8 Preventative Maintenance PM Perform...

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Page 9: ...RMATION This section must be completed and returned to Advance Poly Packaging Inc to register the RAP 1400 for Warranty Protection See warranty contained in this manual for specific warranty information Company Name Address Contact Name s Title s Phone Number ________________________________ ________________________________ ________________________________ _________________________________________...

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Page 11: ...______ Chapter 1 Introduction Welcome Overview Capabilities and Performance Options and Accessories Printer Specifications Electronics Specifications Print Specifications Ribbon Specifications System Integration Using This Manual Typographical Conentions ...

Page 12: ...de with optional 305 dpi 5 head and up to 35 inches long HIGH QUALITY PRINT Printing at speeds of 10 inches per second with high resolution 203 dots per inch or optional 305 dpi head is now possible allowing you to take advantage of the fastest autobagger T 1000 Advanced Poly BaggerTM automatic L Sealer of FFS machine The high dot density produces clear clean print required for perfect scannabilit...

Page 13: ...or quality control of the finished product PC S LAPTOP IBM or other major brand laptop computers specifically designed for manufacturing environments with the latest performance specifications at exceptional values All major computers come pre loaded with the latest Windows version and label software so you simply plug in and download PRINTER CONTROLLERS Instead of having a PC on the shop floor we...

Page 14: ...ensation Print head 203 2 dots per inch or optional 305 dots per inch Print method Thermal transfer Print speeds 3 inch sec 6 inch sec 10 inch sec Optional head 3 6 8 inches sec Maximum print width 4 09 inches or optional 5 inches Dispensive modes Batch continuous tear off Message display 16 characters 1 line NOTE Specifications may change without notice 1 6 Electronics Specifications 1 CPU PD7023...

Page 15: ...r Gothic med 14 3 pt 9 Prestige Elite med 10 5 pt 10 Prestige Elite bold 15 pt 11 Courier med 15 pt 12 Courier bold 18 pt 13 OCR A B 12 pt 14 Outline font Helvetica bold 15 Writable characters 40 types 224 char types MAGNIFICATION OF BAR CODE UPC EAN JAN CODE 93 128 Up to 4 modules can be automatically calculated using 1 module width designation 1to 15 dots Dots Module Bar Code 2 3 4 5 6 7 8 UPC A...

Page 16: ...spaces can be optionally changes in a range of 1 to 99 dots MAGNIFICATION OF CHARACTERS 1 Regular font 0 5 9 5 times magnified by 0 5 times in each direction 2 Outline font 2 0 85 0mm magnified by 0 1mm in each direction CHARACTER ROTATION 0 90 120 270 degrees TYPE OF LINE 1 Horizontal 2 Vertical 3 Slant line 4 Square MAGNIFICATION OF LINES 2 to 8 dots in units of 1mm 1 8 Ribbon Specifications ...

Page 17: ...kaging baggers but will integrate to packaging equipment vertical or horizontal FFS machines other brand baggers and other packaging equipment Please contact APPI technicians and sales staff for assistance in integrating the Ti 1000 printer to your equipment FREE CONSULTATION AND PRODUCT EVALUATION We invite you to discuss your packaging requirements and our free product packaging analysis 1 10 Us...

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Page 19: ..._______________________________________________________________ Installation Procedures Assembly Instructions Air Power Hookup Auxiliary Port Connection Remote Panel Connection Main Power Film Bag Threading Printer Ribbon Threading Print Registration and Alignment Notes on Adjustments of the Ti 1000 ...

Page 20: ...rinter is mounted to a bagger remove the outer wrapping and ensure the cables are plugged in securely Operating Environment The Ti 1000 should be placed in an area free of excessive heat moisture dirt and dust Operating room temperature should range from 41 to 104 degrees Fahrenheit at 25 to 85 relative humidity with no condensation Power Requirements Provisions must be made for 110 120V 10 60 Hz ...

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Page 22: ...ord into a 110 120 VAC 60 Hz grounded power outlet If shipped with the T 1000 the printer will be connected to the power outlet located on the left rear panel of the T 1000 2 4 Auxiliary Port Connection The Ti 1000 connects to baggers via a 9 pin I O port military connector If integrated to the T 1000 connect the I O aux port to the Aux 3 port located on the rear left panel of the T 1000 Fig 2 1 N...

Page 23: ...ing the roll of bags along with the chucks to the desired location Ensure the chuck pins remain in the core plug holes when siding left or right Rollers Pull the bags over the roller immediately above the dancer assembly then down between the roll of bags and the outer dancer roller Pull the bags around the outer dancer roller over the rear guide roller on the Ti 1000 Before threading the bags ben...

Page 24: ... or the roller guides may require readjustment or realignment after the first few feet of bags are fed If web is not tracking properly moving more than 1 8 see Chapter 4 4 of T 1000 Manual Tracking Alignment Adjustments 2 8 Printer Ribbon Threading The Ti 1000 Printer heat transfers the ink of thermal ribbon to the surface of the bag The ink is wound to outside of the ribbon First remove the smoke...

Page 25: ...print head shaft clamps may be added to secure the print head assembly in position Top to Bottom Print Position To initially align the print close to the position desired simply press the alignment roller assembly downward to lift upward moving the desired print position immediately beneath the print head When the bagger is cycled slightly lower or raise the alignment roller moving the print to th...

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Page 27: ...e Back Panel Parts identification Printer Major Components Top View Printer Components Identification Print Head Assembly Upper and Lower Power Supply Components Identification CPU PC Board Component Identification Interface Board Ribbon Roll Shaft Detail Drive Assembly Detail Harness Description and Location Recommended Spare Parts List 203 DPI Printer Recommended Spare Parts List 305 DPI Printer...

Page 28: ...a host computer 3 ERROR Red LED lights when the operator presses the PAUSE key when a communication error occurs when the ribbon ends or the printer does not operate correctly 4 FEED Key feeds and tensions ribbon 5 RESET Key resets the printer when paused or when an error occurs 6 PAUSE Key Pauses printing Message displays Pause Message displays the number of labels yet to print Back View 1 TP T2M...

Page 29: ...0 Turn clockwise to increase tension on print alignment roller 7 TP T2MA0153 Print Head Knob manual knob to lower print head 8 TP T2033704 Print Head Edge type 4 wide 203 dpi or 5 wide 305 dpi head 9 TP T2MA10114 Mounting Brackets standard mounting brackets to T 1000 Bagger 10 TP T2MA0106 2 Alignment arm Pull upward or downward to position print location in machine direction 3 6 Printer Component ...

Page 30: ... Assembly 7 CN13 Connector to Stepper Motor 8 CN15 Connector to H3 Interface Board 9 CN17 Connector to print head power 10 CN18 Connector to Power Supply PC Board Dip Switch Settings Turn POWER OFF before changing switch settings DIP SWITCH 1 NO ON OFF FUNCTION 1 OFF Without Auto ribbon save ON With function 2 3 4 2 OFF OFF OFF English Language to display ON OFF OFF German LCD error message OFF ON...

Page 31: ...en DIP SW 5 ON 7 8 7 OFF OFF XON XOFF No XON is output at the power on time No XOFF is output at the power off time ON OFF READY BUSY DTR No XON is output at the power on time No XOFF is output at the power off time Data protocol 8 OFF ON XON XOFF READY BUSY XON is output at the power on time XOFF is output at the power off time ON ON XON XOFF No XON is output at the power on time No XOFF is outpu...

Page 32: ...gnal OFF when sending start pulse Connectors Connectors LED lights and other components are identified on the Interface boards illustrated in Fig 3 10 TYPE No DESCRIPTION HARNESS LOCATION H2 Head down sensor Bag out detector input connector Connects to the head down sensor and Bag out detector through the umbilical line to the head assembly INPUTS H3 Printer printing input signal connector Connect...

Page 33: ...ntroller Board2 Sensor interface harness TP T2MA0204 Connects CN11 on the main controller board2 to the ribbon drive assembly Ribbon drive harness TP T2MA0203 Connects CN13 on the main controller board2 to CN401 6 pin motor connector Stepper motor harness TP T2MA0202 Connects H3 on the interface board1 to CN15 on the main controller board2 Printer printing input signal harness TP T2MA0201 Connects...

Page 34: ...inter Quantity Part Number Description 3 TP 207024 3 0 Amp Fuses 1 TP T2032301 Ribbon Out Emmiter 1 TP T2032401 Ribbon Out Detector 1 TP 402255 4 Way Valve 1 TP 403144 Head Cylinder 1 TP T2MA0161 Head Down Sensor 1 TP T2033704 Print Head 305 dpi ...

Page 35: ...________________________ Sequence of Operation Test Printing Signalling Between Bagger Printer to Print In Line Display Operation Label Counters Clearing the Printer Memory Parameter Settings In Line Bar Code Verifier Setup Operation ...

Page 36: ...erform a test print air must be attached to the printer a label must be downloaded via a serial cable from a PC or printer controller PrintPad Without air the print head will not lower to the platen roller and the print head down sensor will cause no heat to transfer across the head The printer must then be signaled electronically to begin printing When test printing generate a label which is wide...

Page 37: ...hermal and Hot Stamp printers use ribbon to transfer ink to the surface of the bag To turn ON the signal to a printer press ENTER at the highlighted PRINTER menu option Fig 3 16 Press F3 to enable operation of the Thermal Transfer TT printer Press F4 to enable operation of the Hot Stamp HS printer and press F2 to disable the operation of the printer Fig 3 21 4 4 Display Operation The operator pane...

Page 38: ...memory so that another label may be downloaded simply turn the power to the print OFF wait 5 seconds and turn the power to the ON position Note When the power is turned OFF all downloaded label formats will be erased from memory 4 7 Parameter Settings In order to activate the parameters menu press and hold the FEED and PAUSE buttons while turning the power ON Hold the buttons until the following m...

Page 39: ... PC 8 PC 850 Selects character code PC 850 ZERO FONT O Ø Sets slash no slash in zero O CODE AUTO I ESC LF NULL Selects Automatic or manual control code AUTO RIBBON TRANS NON TRANS Ribbon type transmissive or non transmissive TRANS TEST PRINT WARNING THIS FUNCTION IS FOR FACTORY TESTING ONLY DO NOT USE SENSOR ADJUST WARNING THIS FUNCTION IS FOR FACTORY CALIBRATION ONLY REFER TO MANUFACTURER FOR PRO...

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Page 41: ...______ Threading Adjustment Bag Web Guides Constant Film Bag Tension Bagger Film Tracking Alignment Print Head Replacement Note on Print Quality Print Head Course Alignment Print Head Fine Adjustment Lever Arm Adjustment Head Down Sensor Inserting the Optional Flash Memory Card ...

Page 42: ...ation per cycle On the T 1000 Advanced Poly Bagger TM the amount of web tension is controlled by the brake tension strap and dancer assembly Thinner bags require less tension than thick bags The brake tension is adjusted by relocating the brake strap spring to an alternate mounting hole on the dancer rail consult T 1000 manual To increase tension locate the spring to a hole farther away from the m...

Page 43: ...int following the steps in section 5 5 5 5 Note on Print Quality Print quality is achieved through proper pressure head temperature and print speed Barring any equipment excess wear or failure of components insufficient pressure or poor alignment too much or too little temperature or too fast print speed may cause poor print quality skipping smearing 5 6 Print Head Course Alignment With the air di...

Page 44: ...cover of the upper print head assembly Fig 5 6 Item 1 Loosen head down lever collar set screw Fig 5 5 Item 1 so that arm moves freely on the shaft Note Two persons may be required to perform the following steps Push the CONNECTING LINK forward Fig 5 5 Item 6 to the maximum forward position and hold with some force exerted in the forward direction shown While holding connecting link forward turn KN...

Page 45: ...e may occur While observing the HEAD DOWN LED on the Interface PC Board Fig 5 8 Item 1 perform the following steps Turn KNOB Fig 5 6 Item 2 clockwise until PRINT HEAD Fig 5 6 Item 4 contacts print head If the head down LED turns ON at the instant that the print head touches the platen roller the HEAD DOWN SENSOR FLAG collar Fig 5 5 Item 4 is set properly Test again and ensure that the LED turns on...

Page 46: ...ING Turn the power OFF prior to inserting or removing the flash memory card to avoid damaging the printer or card Note Protect the flash memory card when it is not in use in the printer by putting it into a protective cover Doe not subject the card to any shocks or excessive forces Do not expose the card to excessive heat or place it in direct sunlight Do not wipe card with wet cloth or store it i...

Page 47: ...___________ Key Maintenance Data Recommended Tools Accessories Equipment Cleaning Cleanliness of Materials Print Head Cleaning Roller Cleaning Preventative Maintenance Checklist Scheduled Maintenance Chart Preventative Maintenance PM Performed Additional Maintenance Record Other Maintenance Performed ...

Page 48: ... are not considered periodic tasks 6 1 Key Maintenance Data MTBF mean time between failure 10 000 hours MTBSC mean time between service calls 18 Months MTTI main time to install 45 minutes PM preventative maintenance cleaning and lubrication PL product life 50 Million Print Inches HL head life 2 Million Print Inches Note based upon average environmental and operational conditions 6 2 Recommended T...

Page 49: ...t head the print head will not last as long without the properly cleaning of components and storage of materials Caution Turn the power OFF and disconnect air prior to cleaning components of the printer Then remove the lexan cover 6 4 Print Head Cleaning With the print head raised Fig 6 1 Item 1 using a clean cotton swab soaked with alcohol or a print head cleaner wipe gently across the heat eleme...

Page 50: ...ectors tighten as needed M Air lines Valves Cylinders Inspect for loose air lines listen for leaks tighten or replace poly tubing as needed M Compartments Covers Remove all covers clean and blow out compartments with compressed air to remove dust and dirt M Side plates Clean and wipe down with lightweight oil based upon environmental humidity conditions M Drive belts Inspect for wear fraying repla...

Page 51: ...cy dependent on environment and product O O O O O Alum rollers Inspect for free movement O O O O O O O O O O Roller bearings Inspect for free movement O O O O O O O O O O Rubber rollers Inspect for cuts unevenness O O O O O O O O O Printed circuit boards Blow off with clean dry air inspect for loose wires connectors O O O O O O O O O O Head down cylinder Listen for air leakage replace or repair as...

Page 52: ...6 8 Preventative Maintenance PM Performed additional Options Auxiliary Equipment ITEM DESCRIPTION 1 2 3 4 5 6 7 8 9 10 Inspected by Initials Note Each chart change represents 1MM cycles or linear inches ...

Page 53: ...Chapter 7 Trouble Shooting _______________________________________ Trouble Shooting Checklist Trouble Shooting Error Messages ...

Page 54: ...es and effect the correction Make only one adjustment at a time checking the results of each adjustment If an adjustment does not help or escalates the problems return the settings back to the former position CAUTION These tests and repairs should be performed only by qualified mechanics or electricians and at their own risk NOTE When trouble shooting the Ti 1000 functioning on a bagger first ensu...

Page 55: ...ve Valve Air line increase pressure Turn printer on in T 1000 Options Menu Check LED s on Solenoid Should go out to lower print head 6 No main power light 1 Blown fuse 2 Defective switch 3 Input voltage is not within the rated voltage 4 CPU PC board not receiving voltage from power supply 5 Defective CPU board Replace fuse Replace power switch Check voltages replace power cable Check for 5V on uni...

Page 56: ...own then release to come back up With the air off on the bagger the Ti 1000 air is now off Turn the print head knob clockwise if it doesn t move the cam pushing down on the spring plate moved to far forward Turn the knob counter clockwise to allow the cam to reset on the spring then reinstall the air Ribbon could be sticking to bag refer to Problem Ribbon sticking to bags when printing 12 Print he...

Page 57: ...rint quality Refer to instructions on How to align print head Page 57 59 of the Ti 1000 manual 17 Printer does not cycle with bagger when printer option is on and labels are loaded H4 plug on IF board not plugged in all the way or bad connection on plug 18 Print head goes down but ribbon rollers don t advance ribbon Head down sensor adjusted incorrectly Remove air remove large cover turn print hea...

Page 58: ...Defective print head 3 Print head alignment problem Clean print head and roller Defective print head replaced See pg 55 59 Refer to pages 57 59 25 Bag is not printed between two printed bags 1 Bagger cycled two bags in one sequence bag may have been spliced Perf not detected lower inner frame and straighten perf sensor Clean replace perf sensor Contact APPI for High Voltage Board Adj 26 Poor regis...

Page 59: ...pressure is supplied to the print head while printing Set Regulator to 50 PSI Platen roller beneath print head has an accumulation of debris causing premature wear to the print head during the printing cycle Cleaning the head platen roller with anything other than Isopropyl alcohol will cause damage to the roller head Cleaning the print head roller infrequently will cause premature wear on both th...

Page 60: ...en printing 1 Check software 2 Check pressure on EQPT 3 Dirty print head or platen roller 4 Incorrect ribbon 5 Print head out of alignment Go to label view edit label setup and adjust heat setting decrease Adjust regulator to 50 PSI Clean print head and black platen roller with Isopropyl alcohol only Change ribbon Refer to PG 57 58 59 for corrective action 35 Ribbon advances after down load 1 Loos...

Page 61: ...ing a label with a graphic graphic gets eliminated after printing format on poly bag Software setting incorrect Go to configuration and make sure that graphic overwrite has a check mark in the box 39 Ti 1000 when down loading a label with a picture or PCX file etc Label downloads but omits the picture and comes up with error when printing Incorrect Software Settings Go to configuration and make su...

Page 62: ...ard causing labels to be erased Reset connection and redownload labels 43 A required DLL File WS23Z Dll was not found Can t use V6 05 LBV Pro with Windows 95 Use with Windows 98 or higher 44 5 User network software on 3rd PC stuck in demo mode Main Server has Key and all other computers looking at that server for the Key Uninstall Labelview and delete any other labelview software that did not unin...

Page 63: ...int head cylinder Valve Turn ON printer from option screen Check air regulator air pressure 50 PSI minimum Check print head connectors Check LED s D3 D4 if OFF Check connection between H3 on the I F Board CN15 on the CPUBoard Check cylinder 8 by activating valve 10 manually Check valve 10 24V DC 51 Print head lowers when bagger cycles but does not print no error message is displayed 1 No labels ar...

Page 64: ...7 3 Trouble Shooting Checklist Error Messages Error Message Possible Cause Action ...

Page 65: ...r has occurred while formatting a flash memory card 1 Turn the power off remove and reinsert the flash memory card 2 Use another card 9 FLASH CARD FULL No more data can be saved in the flash memory card 1 Replace the card with a new one 2 Resend from the beginning of the unfinished data Note Max capacity of the card is 1MB 10 COMMS ERROR A communication error has occurred with the host 1 Turn the ...

Page 66: ...Changing Parameters ...

Page 67: ...m Pause 4 Hit Pause until you Tone ADJ T 0 BACK ADJ 0 0mm Pause 5 Hit Feed Button until 0 is 0 X ADJ 0 0mm 6 Hit Pause you ll see tone ADJ D 0 Tone ADJ T 0 Pause 7 Hit Reset until it reads 0 Tone ADJ D 0 Pause 8 Hit Pause till you get back to 2 parameter set Font Code PC 850 Pause 9 Turn off power to Ti 1000 Zero Font 0 not Ø Pause 10 Turn on power Code Auto Pause Ribbon Trans Pause Ribbon ADJ For...

Page 68: ... turn off or D15 does not illuminate then replace the interface board STEP 6 The head should now lower and activate D1 head down sensor If the head does not lower then check the following Do you have air going to the valve Can the valve be activated manually Is the LED on the valve illuminating If the valve can be activated manually check the harness between H9 in the interface board and the head ...

Page 69: ...ned to Advance Poly Packaging Inc to register the RAP 1400 for Warranty Protection See warranty contained in this manual for specific warranty information Company Name Address Contact Name s Title s Phone Number ________________________________ ________________________________ ________________________________ _______________________________________________ _________________________________________...

Page 70: ...Cylinders no leaking air Mech Assembly Tracking compression alignment adj Mech Assembly Belts tension adj Mech Assembly Screws fasteners secured no loose mech components Mech Assembly Roller Spin Freely Mech Assembly All fasteners secured tightly Mech Assembly Print head rear nip rollers adjusted Total hours run tested _________________________ Total cycles printed ___________________________ Note...

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