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Diagraph PA/4000 Service Manual Download Page 110

PA/4000 User’s Manual

Section 10, Troubleshooting

Page 15

ACTION:

1. Make sure cables are connected as shown:

2.

 

If this doesn’t work, replace the Prodigy Plus

TM

 board.

Problem:            Performance Series Software appears to have a Lost Batch

Possible Cause:

A failed label is in the printer.

ACTION:

1. The batch is not lost, remove the failed label and the

PA/4000 will print and apply the entire batch.

Summary of Contents for PA/4000

Page 1: ...iagraph PA 4000 Label Printer Applicator 5802 929 Revision A 3401 Rider Trail South St Louis Earth City MO 1 800 521 3047 ServiceLine 1 800 526 2531 Diagraph Corporation 2000 B Y A L L E N B R A D L E...

Page 2: ...supply of this manual or the equipment to which it applies does not constitute or imply the transfer of any rights to any party The information contained in this manual is correct and accurate at the...

Page 3: ...Overview 4 1 4 2 Assembling the Stand 4 1 4 3 Mounting the Main Unit to the Stand 4 4 4 4 Mounting Attachments to the Main Unit 4 5 Mounting the Hand Held Terminal and Holster 4 6 Mounting the Air Fi...

Page 4: ...n 8 1 8 2 Media Supplies 8 3 Sample Label Printout 8 4 Start up and Shut down Procedures 8 1 8 5 Printing Labels with Performance Series 8 1 Section 9 0 Maintenance 9 1 Daily Maintenance 8 1 9 2 Weekl...

Page 5: ...ce converter The manufacturer of your computer will be able to recommend the proper protocol and interface converter between the system and the Prodigy Plus s asynchronous RS 232C interface An optiona...

Page 6: ...printer applicators with features that match various labeling application needs PA 4010 PA 4015 PA 4020 A description of the three PA 4000 systems and their features follows PA 4010 Printer Applicato...

Page 7: ...pplications where distance from the applicator to the pallet varies This pallet labeling system accommodates long distances between the applicator and the pallet with the extended length cylinder opti...

Page 8: ...up to 13 inches long to two adjacent sides of the carton for side front or side back labeling This unit is functional from either side of the conveyor The unique dual vacuum and slotted vacuum design...

Page 9: ...nit is a robust yoke mounted design of aluminum and steel It swivels to conform to common application orientations top down side panel and bottom up and then locks in place It accommodates different s...

Page 10: ...Hubs B The Label Supply Hub holds the roll of labels in place while the Label Rewind Hub collects the label backing material once the label is peeled off The Prodigy plusTM print engine C The Prodigy...

Page 11: ...Adjustment for Quality which provides exceptional quality while printing at high speeds This circuit monitors the printed data and automatically adjusts to provide maximum printhead performance Allows...

Page 12: ...licating ROM modules When using this feature the source module should be installed in the B slot and the blank module in the A slot A WRITE PROTECT switch on the Flash module can protect data stored o...

Page 13: ...1 x 25 25 4 mm x 6 mm Media Dimensions Max 4 x 13 101 6 mm x 330 mm Roll Capacity 13 330 mm outer diameter Fonts Nine internal fonts American and European uppercase and lowercase with descenders Six o...

Page 14: ...uch as Microsoft Word or Word Perfect These drivers provide compatibility for Windows based applications but do not take the place of a dedicated label creation and printing program Manuals Datamax Pr...

Page 15: ...label is on the tamp pad The printer will not print another label until the current label has been removed 2 The Auto Retract Sensor detects the product Once the product is detected the air cylinder w...

Page 16: ...d be checked An air dryer should be installed in the compressed air supply system if too much water condensation is present 2 5 Photosensor Assembly 5700 216 This assembly includes a diffuse type self...

Page 17: ...h a one line by sixteen character text display The four LEDs show power on and warn of error conditions The seven control keys are described in Section 5 2 The hand held terminal communicates with the...

Page 18: ...r pushes the unattached portion onto the second surface The PA 4000 supplies both electric 24 VDC and air 0 100 PSI power The assembly includes bracketry A a tee fitting B an interconnect cable C and...

Page 19: ...ons occur This assembly includes the tower the mounting hardware and a signal cable CONDITION GREEN YELLOW RED Label Low Solid Flashing OFF Ribbon Low Solid Flashing OFF Label Out OFF OFF Flashing Rib...

Page 20: ...odigy PlusTM Print Engine 1 PA 4000 User s Manual 1 Power Cord 1 Hand Held Terminal 1 Holster with mounting hardware 1 Cable 1 Label Inner Supply Disk 1 Label Outer Supply Disk 1 Photosensor with moun...

Page 21: ...2 screwdriver Small slotted tip screwdriver Medium slotted tip screwdriver Diagonal cutters 9 16 inch box wrench 15 16 inch open end wrench optional 4 2 Assembling the Stand Parts 1 Tee base 1 Uprigh...

Page 22: ...PA 4000 User s Manual Section 4 Installation Page 2...

Page 23: ...the base of the stand to roll under it so that the post can touch it 2 Roll the stand to the surface so that the base rolls under the surface and the post touches it 3 Lower the stand with the crank...

Page 24: ...m rear label supply disc A with the collar facing toward you onto the label supply hub The label sensor slot C on the disc allows the label low sensor B to sense when the label roll gets low After the...

Page 25: ...Tighten the two 10 32 socket head screws B using a 3 32 inch Allen wrench 3 Fully retract the tamp pad The bottom of the tamp pad C should be 1 16 inch G lower than the peel blade E position To attai...

Page 26: ...AC C to the brass vacuum input located on the tamp pad Air Assist Tube Connection Connect the 1 8 inch clear air tube marked AIR ASSIST B to the input located on the blow tube of the print engine Air...

Page 27: ...nd Held Terminal with Holster Parts 1 Holster 1 Hand Held Terminal Assembly Mount the Holster to the Yoke The holster can be hung over the side of the yoke Place the Hand Held Terminal into the holste...

Page 28: ...he middle of the upright part of the stand assembly A Remove the E stop cover and use the opened box for a template for drilling the two holes needed to bolt it to the stand Secure it to the stand wit...

Page 29: ...ded Allen bolts A using a 3 16 inch Allen wrench Attach the ground cable from the main unit to the screw indicated at B This ground cable provides ground bonding between the stand upright and the PA 4...

Page 30: ...E with the 1 4 inch Allen bolts provided using a 3 16 inch Allen wrench 2 Loosen the cable grommet and the adjacent nut on the end of the warning tower Let the grommet and nut slide down the cable 3 H...

Page 31: ...to completion of the product delay on the first product Improper positioning will result in missed products Adjust the sensing distance of the photosensor with the potentiometer at the rear of the ph...

Page 32: ...Installation Page 12 4 11 Mounting the Optional Secondary Wipe Down Applicator If your system has a secondary wipe down applicator follow the installation and operation instructions in the Secondary W...

Page 33: ...otosensor trip Photosensor 2 Optional For the PA 4020 Dual Panel Applicator with the secondary wipe down applicator using a second photosensor Connect the photosensor cable to input J3 E Photosensor O...

Page 34: ...e left and through the label edge sensor K This sensor locates the leading edge of a label by measuring the level of opaqueness You can move it left and right to accommodate different activators label...

Page 35: ...ensor F and above the label edge sensor G 7 Pull the leader through past the ribbon shield H and over the top of the ribbon idler roller B 8 Pull the leader to the ribbon rewind roller C 9 Anchor the...

Page 36: ...nd Maximum Distances for the PA 4000 Top Down Application In this configuration the PA 4000 with a 6 inch tamp cylinder applies labels to the top panel of a carton The height of the conveyor plus the...

Page 37: ...Installation Page 17 Side Panel Application Nose Down In this configuration the PA 4000 applies labels to the side panel of a carton For this setup the height of the conveyor must be greater than 22...

Page 38: ...lation Page 18 Side Panel Application Nose Up In this configuration the PA 4000 applies labels to the side panel of a carton The distance from the back of the tamp plate to the floor must be greater t...

Page 39: ...or must be greater than 30 inches and less than 65 inches 4 16 Final Positioning 1 Disconnect power cords and the air line if they will hinder the movement of the PA 4000 2 Unlock casters 3 Carefully...

Page 40: ...ect voltage can damage the PA 4000 Disconnect the power cord before servicing the power module Pop the fuse assembly up and out of the power module with a flat head screwdriver Once out of the power m...

Page 41: ...e PA 4000 Disconnect the power cord before servicing the power module Pop the fuse assembly up and out of the power module with a flat head screwdriver Once out of the power module turn the fuse assem...

Page 42: ...tached to the yoke when not in use LCD Liquid Crystal Display Menu Window A The LCD menu window displays one line of text allowing up to sixteen characters It displays menu items see D or error condit...

Page 43: ...p or down arrow keys to control LCD Display contrast Up key to increase contrast down key to decrease contrast These keys are also used to scroll through menu items as discussed in D Menu Select or Di...

Page 44: ...r Product Delay Adjusts the input delay of photosensor 1 causing the tamp pad to delay before extending to apply a label Adjust from 0 999 Output Delay Adjusts the amount of time an external device li...

Page 45: ...pad while photosensor 2 triggers a secondary device The output pulse will be sent through photosensor 2 The drawing below shows the photosensor input signals of both photosensors 1 and 2 entering the...

Page 46: ...is not a label present on the tamp pad already the FEED key will advance the paper automatically to the first print position of the next label On a new size label two labels are usually fed before re...

Page 47: ...ng the STOP CLEAR key will NOT clear any PA 4000 Error conditions 2nd Key H The 2nd key works like the shift key on a PC keyboard Holding the 2nd key down while pressing another key accesses new funct...

Page 48: ...e RIBBON LED will flash and the ERROR LED will stay lit Replace the ribbon clear the error and resume printing Ribbon Low The ribbon in the printer is nearly depleted and should be changed soon The RI...

Page 49: ...formances Series for WindowsTM recommended by Diagraph you can set switches 4 through 8 through it 5 3 1 Setting the Baud Rate Switches 1 2 and 3 control the PA 4000 s baud rate Before you can send pr...

Page 50: ...d PRODIGY PRINTER When operating the PA 4000 this switch should be set to OFF SW1 5 Emulate Prodigy ON PA 4000 OFF SW1 6 Present Sensor Switch SW1 6 enables the label present sensor Setting this switc...

Page 51: ...the Air Cylinder Tamp pad The air flow controls B and C on the cylinder tamp pad control the air pressure needed to cause the tamp to extend and retract fully and with the appropriate force Record th...

Page 52: ...BETWEEN THE PA 4000 MAIN UNIT AND THE TAMP PAD 7 Press PAUSE RESUME on the Hand Held to resume the air cylinder tamp pad action This triggers the cylinder tamp pad to cycle Adjust the psi until the t...

Page 53: ...amp distance at 40 PSI completes its cycle in about 0 235 seconds Tamp cycle times are dependant on air flow control tamp air pressure psi and photosensor distance Note the air flow control instructio...

Page 54: ...Delay with the Hand Held Terminal The product input delay value controls the amount of time after the photosensor senses a product that the tamp pad delays before it extends to apply a label to that p...

Page 55: ...MILLISECONDS 0 72 2 5 90 4 10 111 5 25 170 9 50 277 9 75 376 9 100 479 2 150 681 7 200 884 4 250 1095 7 300 1300 350 1497 8 400 1708 7 450 1911 500 2116 3 550 2321 3 600 2523 8 650 2736 8 700 2939 3 7...

Page 56: ...is applied where you want it on the product 5 4 5 Setting the Position of the Label Present and Auto Retract Sensors The tamp pad assemblies for labels 4 inches long and greater will have more than o...

Page 57: ...4 Set the Tamp Dwell value From the Clear Count screen press the down arrow key once Press the MENU SELECT key once to enter edit flashing mode For example use the arrow keys to enter a Tamp Dwell va...

Page 58: ...want to place a label on the front edge of the box TO ACCEPT CHANGES Press the MENU SELECT key TO CANCEL Press and hold the 2nd key followed by the MENU SELECT key STEP 9 Set the Output Sensor From t...

Page 59: ...routed correctly See Section 4 13 2 Check that there is a ribbon roll loaded Make sure that it is intact and routed correctly through the print engine See Section 4 14 Step 4 Start Up 1 If there are n...

Page 60: ...SETTINGS TAMP CYLINDER FLOW CONTROLS See Section 5 4 1 for instructions on how to set air flow controls After air flow has been adjusted record here as a reference how many full turns clockwise was m...

Page 61: ...ar code verifier to adjust for optimum print quality 6 3 Stopping Label Application Stop the unit by pressing the STOP CLEAR key on the Hand Held Terminal 6 4 End of the Day Step 1 Stop Label Applicat...

Page 62: ...zero convention for distinguishing between the zero and the alphabetic O Character Fonts 0 1 and 2 include the upper and lowercase ASCII characters which include commonly used international character...

Page 63: ...1 ICODABAR 10 99 4 81 8 55 5 49 2 40 4 27 J I 2OF5W BARS 12 82 5 49 9 62 6 41 2 75 4 81 K PLESSEY 15 38 6 99 12 82 7 69 3 50 6 41 L UPC CASE 10 99 4 81 8 55 5 49 2 40 4 27 Pr odi gy Pl us act ualD PI...

Page 64: ...orizontal and vertical dot patterns Font 0 Identifies a 96 character alphanumeric font Uppercase and lowercase Characters are 7 dots high 5 dots wide and 1 dot spacing Prodigy Plus Prodigy Plus 152 Fo...

Page 65: ...racter alphanumeric upper and lowercase font Characters are 18 dots high 10 dots wide and 2 dots spacing Prodigy Plus Prodigy Plus 152 Font 3 Identifies a 62 character alphanumeric font uppercase Char...

Page 66: ...00 User s Manual Section 7 Fonts and Bar Codes Page 5 Font 4 Identifies a 62 character alphanumeric font uppercase Characters are 36 dots high 18 dots wide and 3 dots spacing Prodigy Plus Prodigy Plus...

Page 67: ...00 User s Manual Section 7 Fonts and Bar Codes Page 6 Font 5 Identifies a 62 character alphanumeric font uppercase Characters are 52 dots high 18 dots wide and 3 dots spacing Prodigy Plus Prodigy Plus...

Page 68: ...PA 4000 User s Manual Section 7 Fonts and Bar Codes Page 7 Font 6 Identifies a 62 character alphanumeric font uppercase Characters are 64 dots high 32 dots wide and 4 dots spacing Prodigy Plus...

Page 69: ...PA 4000 User s Manual Section 7 Fonts and Bar Codes Page 8 Prodigy Plus 152...

Page 70: ...tifies a font that prints OCR A size I Characters are 32 dots high 15 dots wide and 5 dots spacing Prodigy Plus Prodigy Plus 152 Font 8 Identifies a font that prints OCR B size III Characters are 28 d...

Page 71: ...anual Section 7 Fonts and Bar Codes Page 10 Font 9 Identifies the CG Triumvirate smooth font The characters are available in upper and lowercase Point sizes are selected by number in the bar code heig...

Page 72: ...PA 4000 User s Manual Section 7 Fonts and Bar Codes Page 11 Font 9 Continued Prodigy Plus 152...

Page 73: ...Numeric only bar code with a fixed length of 12 characters Eleven digits supplied by host or application software 12th digit checksum supplied by printer If the 12th digit is sent by the host the prin...

Page 74: ...printer If the 7th digit is sent by the host the printer will check that character against the calculated checksum and will print the bar code as all zero if they do not match Addendum codes for this...

Page 75: ...ll of the standard upper case alphanumeric keyboard characters plus lower case alphabetic and special characters To select Code Subset B precede the data to be encoded with an ASCII B DEC 66 HEX 42 If...

Page 76: ...Example ATEST B123 Data Encoded TEST FNC2 123 Control Codes Control characters can be encoded into Code Subset A by sending the lowercase ASCII characters a z a SOH b STX c ETX and so on Font Sizing...

Page 77: ...ly specify size of elements since EAN type bar codes are element based and not ratio based Maximum 12 bar codes per label Prodigy Plus Prodigy Plus 152 Bar Code G Identifies the truncated EAN 8 bar co...

Page 78: ...lphanumeric bar code that is variable in length The valid ASCII characters for this font are 32 36 39 42 43 45 47 48 57 and 65 90 Code 3 of 9 s normal wide to narrow bar ratio is 3 1 Prodigy Plus Prod...

Page 79: ...hecksum calculation The ASCII range for the numeric codes is 48 57 Code I 2 of 5 s normal wide to narrow bar ratio is 5 2 Font D and L also print different forms of the I 2 of 5 bar code Maximum 8 bar...

Page 80: ...endum code for UPC fonts It is a numeric only bar code with a fixed length of 3 characters Two characters supplied by the host or application software the third digit checksum supplied by printer If t...

Page 81: ...t the printer can print are 1 1 2 2 3 3 4 4 6 6 and 8 8 These ratios actually specify size of elements since UPC type bar codes are element based and not ratio based It must be placed after the UPC EA...

Page 82: ...de followed with a checksum value Sometimes a two digit post office code will be attached to the zip code Bar Code Q UCC EAN 128 bar code This code must have 19 digits sent to the printer for the code...

Page 83: ...204000800015CM2160 CAM 112200000650065CM2160 CAM 191100502600020BMM CAMCORDER 191100502350020WITH REMOTE 191100302050020 Autofocus 191100301850020 High Fidelity Sound 191100301570020 8 1 Speed Zoom 19...

Page 84: ...0115L002028 1X1100001470235L002028 1X1100001770235L002026 1X1100001770185L002026 101100001500015NUMBER 101100001600015SERIAL 101100001500118PRODUCT 101100001500240BRAND 101100001800240LINE 10110000180...

Page 85: ...000100220Q30 421100000100135 Q 421100000100125QUANTITY 49110090085016830 1X1100000100113L002590 4a9305000100108P72715 FE3 0030 421100000100030 P 421100000100020PART NO 49110090085006272715 FE3 0030 49...

Page 86: ...S 4911005001002103300 12X12 CORDED TABLET WITH 491100500100230BUTTON INLINE CURSEOR PC 491100500100250100 110 1X1100000040180L004392 1X1100000040270L004392 491100400100295DIAGRAPH CORPORATION 4911004...

Page 87: ...ow Recorder Function you can record a sequence of keystrokes and mouse actions called a macro Using a macro can shorten any frequently used phrase or steps of any routine This software supports the fo...

Page 88: ...A configuration menu appears You must set three options under Printer Configuration to use Performance Series with the PA 4000 1 Click on Printer Model and set the to PA4000 2 Set the Offset Adjustmen...

Page 89: ...g label and format it To do this Click on the Open icon from the Menu bar and choose an existing label Click on View then on Change Format Specification You will see the Format screen Change the optio...

Page 90: ...ion to 1 4 For label offset of 95 must transmit 0198 5 For presentation position of 155 must transmit f283 Refer to Datamax Prodigy PlusTM Print Engine programming guide for more information The guide...

Page 91: ...LABEL OFFSET controls the offset value for a specific label in your database This is found under the View Change Format Specification menu when you have an existing label opened IMPORTANT The total o...

Page 92: ...3 Printing a Label Double click on the Performance Series icon The Performance Series Main Menu will appear Click on the Printer icon The Print Format screen will appear Click on a label to be printe...

Page 93: ...r s Manual Section 8 Printing Labels with Performance Series for Windows TM Page 7 Once you have sent a label to print the Print Request screen will appear Click OK to download the selected label to t...

Page 94: ...dry shop air to remove dust and adhesive Clean the Label Present Sensor on the Tamp Pad Blow off with dry shop air to remove dust and adhesive Clean the Auto Retract Sensor on the Tamp Pad Blow off w...

Page 95: ...t quality is noticed CAUTION Utilize the appropriate safety equipment as prescribed by your supervisor during the performance of routine periodic maintenance WARNING Loss of air pressure can cause the...

Page 96: ...t the tamp dwell setting is correct 10 1 POWER PROBLEMS Problem The power LED light is not lit Possible Cause Loss of power ACTION 1 Make sure that the power cord is undamaged and plugged into a 120V...

Page 97: ...Problem No power ACTION Power Problems see Section 10 2 Problem Won t print Possible Cause Printer could be in pause mode ACTION Press PAUSE RESUME key to resume printing Possible Cause Printer could...

Page 98: ...ossible Cause Wrong ribbon is loaded ACTION Different print engines have different ribbon requirements Make sure that the ribbon loaded in your print engine is compatible Check the print engine manual...

Page 99: ...l it correctly Clean the printhead with isopropyl alchohol Software Causes The message is blank has incorrect parameters such as Offset or is requesting something the printer does not understand such...

Page 100: ...that the transformer is bad Unplug all the prodigy cables except J5 J9 J6 and J7 from the rectifier block Replug one at a time while checking the 5 volt lead on J3 A bad cable will cause a voltage dr...

Page 101: ...psi Possible Cause Photosensor 1 problem ACTION 1 Check the cable connection between the photosensor and PA 4000 2 Clean the photosensor lens with a soft tipped swab and isopropyl alcohol 3 Adjust and...

Page 102: ...air pressure set too low ACTION Set the tamp air pressure regulator to 20 40 psi Possible Cause Cylinder airflow control is set incorrectly ACTION Review Section 5 4 1 Problem Label does not adhere pr...

Page 103: ...nce the tamp dwell delays retraction it also delays the auto retract sensor s product detection To compensate reduce the tamp dwell by no more than 10 ms at a time 2 Carefully re examine the above ope...

Page 104: ...cable ACTION Replace the sensor or sensor cable Problem Auto retract does not work Possible Cause Auto retract not ON on the hand held ACTION Turn auto retract ON Possible Cause Auto retract sensor is...

Page 105: ...Cause Incorrect setting for the photosensor edge ACTION 1 Determine which edge you want to use to sense the product leading or trailing 2 Verify Photosensor 1 edge setting 3 Carefully re examine the a...

Page 106: ...he above operation before running the conveyor Possible Cause Product delay distance set too long ACTION 1 Decrease the product delay time 2 Run sample labels to determine the change in label placemen...

Page 107: ...tance of the photosensor by turning its potentiometer clockwise Possible Cause Label is not adhering correctly ACTION 1 If the label placement is skewed adjust the yoke so that the tamp is parallel wi...

Page 108: ...re running the conveyor Possible Cause Intermittent product detection ACTION 1 Check the cable connection between the photosensor and connection J2 on the back of the print engine 2 Clean the photosen...

Page 109: ...em Label appear to be thrown off the tamp Possible Cause Cutter cable from applicator board to J11 on the circuit board is not connected in the correct orientation ACTION Make sure cables are connecte...

Page 110: ...cted as shown 2 If this doesn t work replace the Prodigy PlusTM board Problem Performance Series Software appears to have a Lost Batch Possible Cause A failed label is in the printer ACTION 1 The batc...

Page 111: ...Label Low Pause Flash On Off On Flash Off Flash Printer Paused Label low Cylinder Error Off Off Flash On Flash Off Flash Cylinder Error Label low Printer Error Off Off Flash On Flash Off Flash Printe...

Page 112: ...Ctrl K VT 11 0B 43 2B K 75 4B k 107 6B Ctrl L FF 12 0C 44 2C L 76 4C l 108 6C Ctrl M CR 13 0D 45 2D M 77 4D m 109 6D Ctrl N SO 14 0E 46 2E N 78 4E n 110 6E Ctrl O SI 15 0F 47 2F O 79 4F o 111 6F Ctrl...

Page 113: ...137 89 169 A9 201 C9 233 E9 138 8A 170 AA 202 CA 234 EA 139 8B 171 AB 203 CB 235 EB 140 8C 172 AC 204 CC 236 EC 141 8D 173 AD 205 CD 237 ED 142 8E 174 AE 206 CE 238 EE 143 8F 175 AF 207 CF 239 EF 144...

Page 114: ...2C The cable needed to connect the printer to the PC will be either a straight through or null modem cable CJ Pin Connections Pi n N um ber Connect i ons 1 Chas s i s 2 TXD RS 232 3 RXD RS 232 4 RTS 4...

Page 115: ...for typical connection to other DCE equipment with XON XOFF flow control Straight Cable MM PC DB25P To PA 4000 NOTE Cable used for connection to PC compatible with DB25P communication ports Flow cont...

Page 116: ...Page 3 PC DB9P to PA 4000 NOTE Cable used for connection to PC compatible with DB25P communication ports Flow control is either XON XOFF or CTS DTR RS 422 Connection PC PA 4000 SHIELD GROUND CTS NC T...

Page 117: ...useable with A B PLC model 5 11 or higher Controller PC with Allen Bradley 6200 Release 5 0 software or other software capable of programming PLCs Communication Specifications Cable Type Use Twinax ca...

Page 118: ...0B 5 40L 5 40E PLC 5 60B 5 60L PLC 5 80E Allen Bradley SLC Models Remote I O is supported on Models SLC5 02 or higher only In addition the SLC model that is used must have a Remote I O Scanner 1747 SN...

Page 119: ...PA 4000 User s Manual Appendix C PA 4000 Remote I O Page 3 Backplane Chassis Switches 1 2 3 4 5 6 7 8 OFF OFF OFF OFF ON ON OFF ON...

Page 120: ...the switches in S2 for RS 232C to run the sample program 1 2 3 4 5 6 7 ON ON ON ON ON ON OFF 1 2 3 4 5 6 7 8 9 10 RS 232C ON ON ON OFF OFF ON ON OFF ON OFF RS 422A OFF OFF ON OFF OFF OFF OFF OFF ON O...

Page 121: ...s in the illustration above Switch settings follow ROCK ER DOWN S3 BAUD RATE STOP BIT DATA BITS NOT USED 1 2 3 4 5 O F F 6 7 8 1 2 3 4 5 O F F 6 7 8 ROCK ER DOWN ROCK ER DOWN DATA RATE RACK SIZE LAST...

Page 122: ...ions Asterisks mark PA 4000 RIO factory default settings Bit 1 Bit 2 Quarter ON ON First Quarter OFF ON Second Quarter ON OFF Third Quarter OFF OFF Fourth Quarter Bit 3 ON OFF Rack Address 3 Bit 4 ON...

Page 123: ...irregularities Red LED Indicates a reset It flashes when a reset occurs and goes out when reset is complete Normal state is off Green LEDs 1 4 Signals a handshake If enabled they flash during a handsh...

Page 124: ...that prints messages with a PA 4000 It can serve as a first step in establishing successful communication between the PA 4000 and the PLC Equipment used to set up Sample Program The listing below deta...

Page 125: ...ew rate 8 0 per second H10 set head value to 10 z zero conversion to 0 to eliminate slash 1h420500040012712345678 rotation 1 0 degrees font h width multiplier 4 height multiplier 2 bar code height 050...

Page 126: ...Do not replace the cover of the PA 4000 until after a successful run of the Sample Program Diskette 5700 315 has a sample program that was developed with Allen Bradley 6200 software Copy the PA 4000 f...

Page 127: ...ix C PA 4000 Remote I O Page 11 Starting Allen Bradley 6200 Software 1 Set the current directory to IPDS 2 Type ABMENU and press Enter The MAIN MENU appears 3 Press F5 to choose PLC 5 The PLC 5 Progra...

Page 128: ...onfiguration 5 Use the function keys and change the configuration parameters to match those shown in the screen sample above 6 Save the configuration with F9 7 Press ESC to return to the PLC Programmi...

Page 129: ...PA 4000 User s Manual Appendix C PA 4000 Remote I O Page 13 2 Press F2 for Save Restore 3 Press F4 to start the Restore Program process 4 Select PA4000 with the arrow keys...

Page 130: ...PA 4000 User s Manual Appendix C PA 4000 Remote I O Page 14 5 Press F1 to begin the restore process 6 Press F7 for General Utility...

Page 131: ...O Page 15 7 Press F4 for Channel Overview 8 Use the arrow keys to pick Channel 1A 9 Press F5 for the Configuration Menu and set the variables as shown below Rack Address 3 Starting Group 0 Rack Size 1...

Page 132: ...PA 4000 User s Manual Appendix C PA 4000 Remote I O Page 16 10 Press ESC three times to return to the Program Directory for Processor 11 Press F8 for the Monitor File...

Page 133: ...board assy Prodigy Plus Mod 2804 320 Prodigy Plus CE front panel cable assy 2801 131 Prodigy Plus slip pulley 2801 130 Friction ribbon disk 2801 033 Label drive roller 2801 022 Prodigy Plus Printhead...

Page 134: ...0 2 mm long printable area 4 1 inches left justified LTS labels are made from a coated thermal transfer facestock which readily accepts ribbon transfer Labels are sold in full case quantities only ATS...

Page 135: ...h the stock The abrasive qualities of the stock are not as critical in thermal transfer applications because the thermal transfer ribbon is in direct contact with the printhead when the ribbon is inst...

Page 136: ...foot clear trailer for opaque ribbons opaque trailer for transparent ribbons Backcoating highly recommended One ribbon has the capacity to image two full 8 inch diameter rolls of labels wound on 3 in...

Page 137: ...end in a BAT or CMD extension If the files contain data they will probably end in TXT or DAT extensions aspect ratio The proportional measurement of image size in terms of horizontal length versus ver...

Page 138: ...m Entry at the end of a block of data corresponding to the binary sum of all information in the block Used in error checking procedures Code 2 of 5 Bar code used in the late sixties for warehouse stor...

Page 139: ...ce The font of this glossary is Times friction bearers Tire s on the edge of encoder cylinders full duplex Transmission of data in two directions simultaneously half duplex Transmission of data in onl...

Page 140: ...y 1 Optical property of a substrate material that quantifies transmission from the back side or the next sheet 2 Property of an ink that prevents the substrate from showing through operating system St...

Page 141: ...onds to a physical input serial data transmission Most common method of sending data from one data terminal to another To transmit data serially is to transmit it one bit at a time over a single chann...

Page 142: ...pping All numeric version of Code 128 used specifically for the UPC Serial Shipping Container Standard It generates a special MOD 10 check character that is a part of the specification UPC Version A S...

Page 143: ...rvice Technical Service Technical Manual Manual Manual Manual Diagraph PA 4000 Label Printer Applicator 5802 929 Revision A 3401 Rider Trail South St Louis Earth City MO 1 800 521 3047 ServiceLine 1 8...

Page 144: ...o change without notice This manual contains information protected by copyright with all rights reserved No part of this manual may be reproduced in any form without prior written consent from Diagrap...

Page 145: ...Set up the PA 4000 with the necessary air and power requirements Refer to Section 2 in the Users Manual Set the Menu Select Items using the Hand Held Terminal Refer to Section 4 of the User s Manual...

Page 146: ...ro Auto Retract sensor is only active when Auto Retract is turned ON using the Hand Held Terminal The PA 4000 applies the printed label to the box PRINTING STAGE During this stage of the Print and App...

Page 147: ...assist air pressure and tamp cylinder air pressure is at the Air Control Unit The Print Engine prints the labels and moves them to the tamp pad Label Supply Hub is where the label roll is placed After...

Page 148: ...and it s interface assemblies The Applicator section consists of the Applicator Board the Connector Board the Regulator Assembly and the Hand Held Terminal The following sections explain the function...

Page 149: ...tor which should read 4 3 Vdc 0 5 volts The return signal from the sensor is brought onto the Applicator Board on Pin 2 When the ribbon is not low the voltage on this pin will be less than 0 5 Vdc Whe...

Page 150: ...connections for the external hardware There is also a 20 Pin connector P1 on the back of the board which provides the interconnect path to the Applicator Board 6105 119 The Connector Board interfaces...

Page 151: ...his pin will be greater than 4 0 Vdc When the cylinder is extended the voltage at this pin will be less than 0 5 Vdc Pin 4 is the return signal from the Present sensor on the tamp pad When a label is...

Page 152: ...es to the Hand Held Terminal via an RS232 type protocol scheme The Hand Held Terminal cable connects to the Hand Held Terminal at the J3 connector The J3 connector on the Hand Held Terminal provides t...

Page 153: ...sically flipped the switches replace this chip first Replace the switch bank later if necessary U3 is the microprocessor If the board has voltage and nothing seems to run you may try replacing U3 U4 t...

Page 154: ...signal to be on in 24 sec microsecond increments The system default is 3125 for a 75 msec millisecond The cutter signal is a low going pulse on J4 pin 2 PIN CONNECTIONS FOR J4 1 LOGIC GROUND 2 CUTTER...

Page 155: ...nsor it can no longer be sensed When the Label Low condition occurs the Label Low sensor sends a signal to the applicator logic board The applicator board will light the yellow Warning Tower light lig...

Page 156: ...lso has a write protect switch to prevent users from over writing important data The module can be programmed when the write protection is off this means the switch on the module should be moved towar...

Page 157: ...0 0V 4 0V Stepper Motor Voltage TP5 5 1V 0 5V Motor driver power voltage Right Side Voltage should drop slowly on power down TP6 10mv less than Battery Current With Power OFF After the time and date h...

Page 158: ...the checks are looking for current the voltage drops across the resistors has already been determined Wiring Diagrams I O Cable Configuration Part Number Description 2800 875 Prodigy Plus to PC 9 Pin...

Page 159: ...OTE Cable is used for typical connection to other DCE equipment with XON XOFF flow control STRAIGHT CABLE MM NOTE Cable is used for typical connection to other DCE equipment with XON XOFF flow control...

Page 160: ...nnection to PC compatible with DB25P communication Ports Flow control is either XON XOFF or CTS DTR PC DB9P TO PRODIGY PLUS NOTE Cable is used for connection to PC compatible with DB25P communication...

Page 161: ...t off valve is in the ON position Check air line for blockage and make sure the line is not obstructed Tamp vacuum and air assist controls may not be set Set the tamp regulator to 20 40 psi and the ai...

Page 162: ...HOME position Push the cylinder all the way up with your hand until the red LED lights Make sure the photocell cable is connected to the PA 4000 see Section 2 for more information Cylinder HOME switc...

Page 163: ...end a batch of labels Check RS 232 cable connection Make sure the lock printhead lift lever is down Remove ribbon or labels and re web Clear any labels or leader from the front of the present sensor C...

Page 164: ...tion Re web ribbon or labels NOTE If the ribbon is placed in the PA 4000 backwards you must clean the printhead before re webbing the ribbon Replace printhead Remove any stray label stock Be sure you...

Page 165: ...embly 2 Disconnect all air and electrical connections 3 Rotate the PA 4000 to a comfortable working position 4 Open the electrical box assembly by loosening then removing the two support screws 5091 3...

Page 166: ...t the Stepper Motor cable to J5 G on Figure 2 4 Connect the Cutter cable to J11 H on Figure 2 4 REPLACING THE APPLICATOR LOGIC BOARD 6105 119 See Engineering Drawing 6105 150 to further illustrate thi...

Page 167: ...ing Drawing 6105 107 to further illustrate this procedure 1 Remove the Air Supply Cover 6105 256 2 Turn the black plastic mounting nut 1901 219 to the left to loosen 3 Remove all air tubing from the A...

Page 168: ...Technician s Guide 2 34 3 Remove the filter inside the housing 4 Reverse the previous steps to replace the Vacuum Filter Assembly...

Page 169: ...le working position 4 Remove the four buttonhead screws 38 on ENG DWG 6105 100 using a 5 16 inch Allen wrench 5 Remove the rear panel 6105 284 of the Main Power Box REPLACING THE TRANSFORMER See Engin...

Page 170: ...he spade lug with a pair of pliers 17 Connect the black white and the brown white wires to the cable extension with the larger spade lug part 6105 399 D on Figure 2 5 18 Connect the cable extension as...

Page 171: ...and air connections 3 Open the Main Power Box Assembly 4 Disconnect all wires from the bridge rectifier 5 Loosen the screw holding the bridge rectifier to the PA 4000 using a 9 64 inch allen wrench 6...

Page 172: ...ghten 12 Secure ribbon low sensor cable to the tie wrap mount using tie wraps 13 Route loose end of the ribbon low sensor cable through the electrical box assembly and connect it to J6 on the applicat...

Page 173: ...r marked A Ambient Light and place it over the correct hold located on the other side of the Tamp Pad 13 Bundle all three wires together and fold the bottom part of the coil cable onto the adhesive ba...

Page 174: ...ician s Guide 2 40 9 Be sure that the Adjustment Screw Bracket is positioned as far back as possible before re tightening the screw 10 Close the Electrical Box 11 Return the system to normal operating...

Page 175: ...rtion of printhead cable 6 Carefully push the jig towards the label rewind to unplug the connector 7 Loosen the screw that holds the printhead onto the printhead mount This is a captive screw so it wi...

Page 176: ...Technician s Guide 2 42 Hand Held Terminal to compensate for any differences between printheads...

Page 177: ...FIRMWARE ON THE APPLICATOR BOARD 1 Turn the PA 4000 s power switch to the OFF position Remove the power cord Disconnect all air hose and electrical connections 2 Rotate PA 4000 to a comfortable workin...

Page 178: ...of an inch away from the PA 4000 6 Manually extend the replacement Tamp Cylinder to check for obstructions If any component restricts the movement of the Tamp Cylinder slide the Tamp Cylinder assembly...

Page 179: ...Technician s Guide 2 45...

Page 180: ...t Engine Cover 3 Hold the Collar on the Electronics side of the PA 4000 and rotate the outer part of the Ribbon Take up Hub until the set screw is accessible through the notch in the hub 4 Loosen the...

Page 181: ...sopropyl Alcohol can be used to clean these areas Regular cleaning will keep all items free from residue Clean the exterior of the PA 4000 using a soft damp not wet cloth A mild detergent may be used...

Page 182: ...ate underneath Tighten the two mount screws to secure the support plate and test to make sure the print is not dark on the outside edge NOTE The mount screws which secure the head support plate also s...

Page 183: ...idth media and ribbon for this adjustment procedure 2 Install thermal transfer ribbon and media into PA 4000 but do not secure the ribbon to the ribbon rewind hub 3 Press the FEED button several times...

Page 184: ...tock If the ribbon overlaps one edge of the paper stock the ribbon and paper are not following the same path In this case the paper tracking may need to be re adjusted If there is no ribbon overlap go...

Page 185: ...PA 4000 should advance one label at a time The voltage at TP1 should go above 2 volts DC 2 4 4 DARKNESS ADJUSTMENT You can adjust the Darkness value using the Hand Held Terminal Pressing the arrow up...

Page 186: ...he auto retract sensor must be positioned slightly above the level of the pad contact surface If the sensor is positioned even with or below the pad contact surface the auto retract will not function...

Page 187: ...print multiple copies of the label shown in Figure 2 8 6 Pull the labels away from the present sensor as they print Figure 2 8 2 5 2 PRODIGY BOARD SELF TEST 1 Turn the PA 4000 s power switch to the O...

Page 188: ...on of the Configuration Test Label The following is an explanation of the Configuration Label in Figure 2 9 THU NOVEMBER 17 1994 12 25 321 This line contains the date and time You can set the date usi...

Page 189: ...inters internal counter information It includes the counter set date and the total amount in inches 10 inch increments of labels printed 2 5 3 APPLICATOR RESET 1 Turn the PA 4000 s power switch to the...

Page 190: ...embly using the Family Tree in Section 3 1 Next use Table 3 1 to locate the correct Engineering Drawing in Section 3 2 If you need to replace the assembly see Section 3 3 for the part number of the co...

Page 191: ...3 1 FAMILY TREE...

Page 192: ...y 6105 180 181 182 PA 4000 Tension Assembly 6105 290 PA 4000 Rewind Assembly 6105 292 PA 4010 PA 4015 Systems 6105 406 412 418 PA 4020 System 6105 506 PA 4000 Tamp Pad Assemblies 6105 OWWWLLL Table 3...

Page 193: ...1 641 Pulley Slip Clutch 1 2801 758 Hub Flat Spring 1 Core 1 2801 759 Spring 1 Rewind Retrofit 1 2801 817 Roller Label Assist 1 2801 822 Pulley 48 GR Timing 1 2801 827 Pulley Dampener 1 2801 828 Sprin...

Page 194: ...296 Sensor Low Label PA 4000 1 6105 383 Fuse 2 0 AMP 2 6105 401 PA 4000 Transformer Retro Fit Kit 1 6105 193 PA 4000 Level II Kit Elect Applies to Rev K and Greater Kit 6105 193 includes Description...

Page 195: ...n Level II Kit Elec This applies to Rev A B Secondary Wipe Down Units Kit 6105 187 includes Description Quantity 5700 216 Photocell Assembly 1 6101 000 Banner On Off Delay 1 6101 001 Banner One Shot L...

Page 196: ...ilt in smooth font CG Triumvirate All fonts expandable 10x Bar Codes Code 39 Interleaved 2 of 5 UPC A UPC E UPC 2 and 5 digit addenda UPC random weight EAN 8 EAN 13 EAN 2 and 5 digit addenda Code 128...

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