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Diagraph - an ITW Company PA/4600 & PA/6000 User Manual

Maintenance

Page 42

Maintenance

6.0 Maintenance

6.1 Maintenance Schedule

6.2 Updating the System Firmware

From time to time, improvements to system performance, corrections to errors, or additional
features and options may necessitate an upgrade to the system firmware. This is a simple
process of using a software application named MTool2. This can be located on the Diagraph web
site, under

. To perform a firmware upgrade, download the MTool2 and fill out the form

to request an access license. Once the MTool2 application is installed, change the system baud
rate to 115.2k, if the serial port is used. Start the MTool2 program and once the system’s param-
eters are read, select the tab to download new firmware. This takes approximately one minute,
and concludes by re-reading the parameters.

Maintenance Schedule Chart

Daily

Monthly

Every

Two

Years

Clean Printer Feed Rollers

√

Replace Printer Feed Rollers

√

Replace Printer Peel Blade

√

Clean Label Present and Auto-Retract Sensors (if present)

√

Clean Label Low Sensor (if present)

√

Clean Product Detector Sensor(s)

√

Inspect Rewind Belt

√

Replace Rewind Belt

√

Replace Unwind Dancer Spring

√

Clean Tamp Pad

√

Inspect Air Inlet Filter

√

Replace Air Inlet Filter

√

Replace Vacuum Generator Filter and Muffler

√

Replace Unwind Dancer Arm Spindle

√

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Summary of Contents for Diagraph PA/4600

Page 1: ...PA 4600 PA 4600 PRINTER APPLICATOR PRINTER APPLICATOR PA 6000 PA 6000 4600 010 Revision G ...

Page 2: ... tinue specifications and designs shown in this manual without notice and without incurring obligation Diagraph has made every effort to verify the informa tion contained in this manual but reserves the right to correct any error at the time of the manual s next revision 2008 Illinois Tool Works Inc All rights reserved Printed in the United States of America ...

Page 3: ...A 22 2 NO 60950 00 UL 60950 using Diagraph an ITW Company approved items Units are only tested and qualified with Diagraph an ITW Company approved parts and accessories Use of other parts or accessories may introduce potential risks that Diagraph an ITW Company can assume no liability for WARNINGS WARNING Moving parts of this machine can present hazards Components that cannot be guarded because of...

Page 4: ...compliance with UL safety standards the stand must be secured to the surface where it is located Additionally this type of securing will result in greater product application accuracy 1 3 Document Conventions Formatting conventions are used throughout this manual as a method of providing consistency for notes and warnings Goal This indicates a particular objective for the section Note This indicat...

Page 5: ...in 101 6 mm Max Product Rate PA 4600 PA 6000 50 PPM Max 110 PPM Max Temperature 41 F 104 F 5 C 40 C Humidity 10 to 85 RH Non Condensing Electrical Specifications Category Nominal Minimum Maximum AC Voltage Supply 100 240 VAC 1 6A 50 60 Hz 90 VAC 47 Hz 264 VAC 63 Hz Product Detector Low 0 to 3 VDC High 3 to 5 VDC Supplies 24VDC 0 VDC 24 VDC Product Detector Pulse Width 10 mS 1 mS Infinite Auxiliary...

Page 6: ...0 in cylinder 3 9 in 76 228 mm 3 in 76 mm 9 5 in 241 3 mm Tamp Stroke 20 in cylinder 3 19 in 76 482 mm 3 in 76 mm 19 5 in 495 3 mm Air Consumption while running 2 5 CFM at 80 PSI 2 0 CFM at 80 PSI 5 CFM at 80 PSI Tamp Blow Distance Pad to product blow distance 0 5 in 12 7 mm 0 in 0 mm 1 0 in 25 4 mm Diagraph an ITW Company PA 4600 PA 6000 User Manual Introduction Page 5 Introduction 1 6 System Dim...

Page 7: ...develop holding torque The rewind is belt driven using an automatic tensioner This belt should be inspected for wear at the recommended service intervals The tamp pad captures the label from the printer and holds it under vacuum until the time when the label is to be applied to the product There are several sizes of tamp pads to accommodate a wide variety of label dimensions Each pad can be ported...

Page 8: ...ols the operation of the tamp cylinder and the delivery of the label from the printer to the product The manifold has two pressure regulators one for tamp pressure and the other controls both vacuum and blow Two flow controls limit the volume of air going to the air assist and blow valves There are two pressure gauges that monitor the pressure set by the regulators A pressure sensor monitors the i...

Page 9: ...f the cylinder air assist or vacuum to change The Main Controller Assembly III is a third generation of Diagraph designed micro controller coupled with an interface board The Microcontroller Unit MCU is designed to execute real time applicator functions with accuracy down to a fraction of a millisecond This board is easily removed for replacement or testing The Interface Board acts as an interconn...

Page 10: ... up to 6 inches per second and has an option for a real time clock calendar The rewind is designed around a brushless DC motor which uses three coils activated in sequence according to three Hall effect sensors This is an inherently closed loop motor control since the motor s magnetic field is controlled by reading the rotor position via the Hall effect sensors Using this type of motor versus less...

Page 11: ...d ensure it is a 24 VDC NPN type The tamp pad sensors auto retract and label present and the label low sensor are diffuse light sensors All three sensors are identical with a quick disconnect M8 threaded coupling When the sensor is used for label present it is capable of detecting a wide range of materials colors including clear and textures When used for auto retract the sensor can detect object ...

Page 12: ...implicity in design The sensor should not require adjustments since the threshold levels are set at the factory The sensor constantly monitors pressure and triggers an error on the system if the air pressure drops below the predetermined level Digitally the pressure is updated three 3 times a second In conjunction to the digital readout the bargraph displays the pressure and fluctuations ...

Page 13: ...capable of rotating and pitching about various axes to accommodate a wide range of label placement opportunities Select the best orientation from the given measurements and desired label locations Keep in mind that if barcodes are to be printed some feel that rotated barcodes print the best Top Down Side Apply Nose Down Nose Up Min 13 in Max 50 in Max 45 in Min 10 5 in Min 24 in Max 63 in Max 69 i...

Page 14: ...ed AC line drop is preferred This eliminates problems caused by other AC loads on the same line such as motors which create back EMF Disturbances such as these can cause erratic behavior system resets and other anomalies Connect the dry compressed air line supplying 60 psi or greater at 2 5 CFM or better to the inlet air filter regulator of the system with the OSHA valve closed Next connect the AC...

Page 15: ... supplied mounting bracket Sub Step b Adjust the sensor s sensitivity to detect just the product and ignore the background This can be done by placing the actual product in the path of the sensor s view Adjust the sensitivity setscrew A until the yellow light B illuminates and the green light C is steady and bright The yellow light shows that the output is active The green light shows the relative...

Page 16: ... in the One Time Setting OTS Screens on page 26 Power On Step 5 Enter Values for the System Settings Goal Enter System information pertaining to Application Mode Serial Baud Rate and Passcode Map Beginning in the Offline mode press the Settings button From the Settings Menu which can be passcode protected default passcode from the factory is 9999 select the System button choice This enters the Sys...

Page 17: ...ay 50 mS Print Activation Tamp Return Auto Retract 25 mS Step 7 Adjust the Inlet Filter Regulator Goal Apply air to the system adjust the incoming regulator and verify air quality Be certain that nothing is going to interfere with the cylinder extending or retracting and apply air line pressure to the system by switching on the OSHA approved shutoff switch on the inlet filter regulator Adjust the ...

Page 18: ...lade feed liner through the nip roller arm and close printhead latch and nip roller arm Take the liner to the rewind H and use the clasp to retain it With the printer offline press the feed button to register the first label before the printer is returned online and the system begins running The label change out can be accomplished in less than a minute by an experienced user Sub Step d RIBBON MAT...

Page 19: ...ough the nip roller arm and close printhead latch and nip roller arm Take the liner to the rewind H and use the clasp to retain it With the printer offline press the feed button to register the first label before the printer is returned online and the system begins running The label change out can be accomplished in less than a minute by an experienced user Sub Step f RIBBON MATERIAL CHANGEOUT Rem...

Page 20: ...spensed covers the ported vacuum holes and covers the label present sensor if equipped These screws adjust the tamp pad height in relation to the peel blade edge Before locking the screws in place from adjusting the in and out position set the height The labels are optimally transferred to the tamp pad when the pad is 1 8th inch below the peel blade edge This keeps any label curl at the end of the...

Page 21: ...ses speed Conversely turning the setscrew counter clockwise increases the speed Sub Step c The air cushion absorbs the shock of the tamp returning to the fully retracted or home position To increase the amount of cushion turn setscrew B clockwise to decrease it turn it counter clockwise Too much air cushion can delay the tamp return to home thus reducing throughput and possibly causing a label to ...

Page 22: ...pressure and counter clockwise to increase it Since the blow valve has an additional trim of a dedicated flow control set the pressure as high as necessary for vacuum Typically a pressure range between 30 and 60 psi will be acceptable with the possibility of making this higher if this is a blow or tamp blow application Too much pressure will make the label buckle as it is fed to the pad too little...

Page 23: ...ntains some sample text barcode incrementing 8 digit counter a time and date stamp and a box border If the printer is not equipped with a time date clock option the information in these fields will be some default text Sub Step c After selecting the correct format size and printer option press the Send Format button If the printer does not show a batch quantity on its display or if there is a Fram...

Page 24: ... Diagraph offers Sub Step a Select the baud rate and other communication specific parameters This is typically found under the Windows Printers select specific printer Properties Ports select port number Configure Port Sub Step b In the program s printer setup screens check to make sure Cutter is not selected Continuous Print is not selected Speed is set to a rate optimal for both print quality an...

Page 25: ...returning home but can impact the final return time of the tamp pad to the home position Increase the air cushion adjustment so that no metallic clank is heard when the cylinder retracts but not so much that the final half inch of return is belabored This adjustment is impacted by changes to the tamp pressure setting so re adjustments may be required Use the Pneumatics menu in Diagnostics to test ...

Page 26: ...ks well for the beginning 80 of the roll but equally as well for the remaining 20 If the vacuum is too high it will be most notable when the transfer to the product suffers It will also be noticeable over time in the frequency of filter cleaning required Sub Step d Auto Retract if equipped The auto retract delay time can be adjusted to suit the needs of the particular application By setting the co...

Page 27: ...ined by facing in the direction of the feed of the labels If the printer is right of the baseplate then the configuration is Right Handed If the printer is left of the baseplate then select Left Handed Select the choice that matches the installed printer in the unit For the PA 4600 the correct choice is SATO Lt for the PA 6000 any choice other than SATO Lt is acceptable The selections are leading ...

Page 28: ...on 2 Tamps 1 product trigger to 2 cycles of tamp each controlled by a separate product delay distance 2 Tamp Blows 1 product trigger to 2 cycles of tamp blow each controlled by a separate product delay distance 1 Blow 1 product trigger to 1 blow on a blow box application 2 Blows 1 product trigger to 2 blows on a blow box application Select the baud rate that matches the printer s setting which sho...

Page 29: ...uct at the desired location Only displayed if the system Apply Mode page 27 is set to 2 Tamps 2 Tamp Blows or 2 Blows Calculated the same as above but with extra time to allow the second label to print and be ready for the second application If the second label is not ready in time a Timing Violation warning will be given This setting controls the extension stroke time If the auto retract sensor i...

Page 30: ...ttempts of the same label The repeat print function can set a limit to the number of labels fed to the tamp pad for a single application cycle Likewise the repeat tamp function can prevent applying the wrong label to the next product In applications where each label contains unique information for the product this setting can stop the system from continuing if the label returns with the tamp pad a...

Page 31: ...essing the TEST button This will activate the motor briefly to verify operation and correct direction The motor s RPM will be displayed to verify that the motor s feedback sensors are working as well The Printer Diagnostic screen tests the function of print without the system s influence of settings and modes By pressing the Print button the unit will print one label provided there is a batch in t...

Page 32: ...bon Low Gap Sensor LOW Label Low PD2 Product Detector 2 AUX Auxiliary Input CYL Cylinder Home PD1 Product Detector 1 The Pneumatics Diagnostic screen permits testing of the various valves on the module and displays useful information captured during tests The Tamp button will extend the tamp cylinder for a fixed time of 1 second The Vac button will turn on the vacuum valve for 1 second same as the...

Page 33: ...or Unit is offline due to error This includes Media Out Air Pressure Out Printer Errors Repeat Print or Tamp Threshold Exceeded etc Steady Warning Unit has experienced a condition that requires attention but it is still able to run online Steady or intermittent depending on event Cycle Complete The apply cycle is finished Momentary 20 mS Cycle Start The apply cycle is beginning Dependent on extens...

Page 34: ...ch input event Screen Functionality Input Event Description None No input event assigned Online Enter online mode Level activated Cannot enter online mode if there is an error Deactivate signal for offline mode Product Detector 1 Trigger product detector 1 signal This can start the print cycle if print activation is set for Prod Sens 1 and start the apply cycle Pulse activated Product Detector 2 T...

Page 35: ...mation Screens Map Note Information screens can be entered while running online or offline The below columns indicate the menu structure for the given information area Web Path System Parts HELP RFID The Part Screens continue beyond these listed here Please see unit screen for all of the listed parts ...

Page 36: ...tched 24 VDC supply are turned off Once off the screen will transition to the next following screen for turning it back on If this screen is entered but no selection is made within 10 seconds the screen will transition back to the offline home screen In this screen the unit can be turned on by pressing the Power On button This resets the unit and returns it to the offline state Screen Functionalit...

Page 37: ...encoded tag information once applied to product Serial Cmd Error W06 System received data that did not match any known commands Timing Violation W07 System received a product detection trigger but could not start timing sequence since the apply cycle was not complete On a FASA system this could mean that the second apply cycle has a product delay that is too short Print on Detector 1 System is wai...

Page 38: ...Note Any of the following errors will place the unit in offline thus stopping operation Screen Screen Screen E01 Printer E02 Repeat Print Cycle E03 Repeat Tamp Cycle E04 Cylinder Not Home E05 Ribbon Supply Out E06 Air Pressure Out E07 Rewind Tension E08 Label Supply Out E09 Second Apply Error E10 External Input ...

Page 39: ...sent see page 26 Label Format is not set for applicator mode Check format to ensure that the format is set up for an applicator system and not a tabletop printer A printed label is fed followed by one or more blank label s Rewind tension is too high liner is not permitted to backfeed Check the motor connections MCU board and verify that the Printer Model selected is SATO Lt see page 26 Printer gap...

Page 40: ...r is operational by placing an object in front of the sensor Verify that the yellow light is illuminated on the sensor Try adjusting the sensor away from the tamp pad surface and re check label presence Check that the sensor s signal is detected at the MCA by entering Diagnostics and view the Sensor screen Cover and uncover the sensor and verify the Diagnostics screen shows the same see page 31 Ta...

Page 41: ...home sensor position too low Move the cylinder home sensor to a position where the cylinder is detected home later Air cushion set too slow The air cushion slows cylinder travel at the return position Too much cushion cause reduce speed at the home position Set cushion at optimal position between slow return and end of travel contact see page 20 Air Pressure Out Error Air pressure below minimum al...

Page 42: ...damentally simple as a roll of labels would appear there are a few key areas that can cause problems and these problems are sometimes falsely associated with the equipment and not the label The typical symptoms may include labels not peeling labels falling off of the tamp pad and labels jamming inside the printer The respective possible causes are the diecut is too deep the label adhesive is too a...

Page 43: ...e MTool2 application is installed change the system baud rate to 115 2k if the serial port is used Start the MTool2 program and once the system s param eters are read select the tab to download new firmware This takes approximately one minute and concludes by re reading the parameters Maintenance Schedule Chart Daily Monthly Every Two Years Clean Printer Feed Rollers Replace Printer Feed Rollers R...

Page 44: ...4600 817 SATO Lt 408 Power Supply 4600 818 SATO Lt 408 LCD PCB 4600 819 SATO Lt 408 Timing Belt 218mm Ribbon Drive 4600 820 SATO Lt 408 Timing Belt 260mm Stepper Main 4600 821 SATO Lt 408 Timing Belt 186mm Platen Drive 4600 822 SATO Lt 408 Ribbon Sensor 4600 823 SATO Lt 408 Torque Limiter ribbon take up 4600 824 SATO Lt 408 Torque Limiter ribbon supply 4600 825 SATO Lt 408 Roller bearing all rolle...

Page 45: ... Belts 3 Spindles 2 ea Springs 3 Unwind Fins 3 Web guides 4600 720 MAINTENANCE KIT Replacement Filter Set Includes Vacuum Inlet Filter Regulator Mufflers 4600 701 Pneumatic Air Manifold 4600 743 Tamp Cylinder 10 inch stroke w Home Sensor 4600 745 Tamp Cylinder 20 inch stroke w Home Sensor 4600 765 Pneumatic hose kit 4600 900 Product Detector OPTIONS 6150 828 Warning Tower Assembly 6145 501 Warning...

Page 46: ...Diagraph an ITW Company PA 4600 PA 6000 User Manual Maintenance Page 45 Maintenance 6 4 Assembly Views and Part Numbers ...

Page 47: ...Diagraph an ITW Company PA 4600 PA 6000 User Manual Maintenance Page 46 Maintenance ...

Page 48: ...Diagraph an ITW Company PA 4600 PA 6000 User Manual Maintenance Page 47 Maintenance ...

Page 49: ...Diagraph an ITW Company PA 4600 PA 6000 User Manual Maintenance Page 48 Maintenance ...

Page 50: ...mation 7 1 Product Detector J2 J3 DB9 Female PIN Pin Description Pins 1 2 N C Pin 3 Ground Pins 4 5 N C Pin 6 24 VDC Supply Pin 7 N C Pin 8 Product Detector Input Pin 9 N C 7 2 Auxiliary Port Pin Out J4 DB9 Male PIN Pin Description Pin 1 2 N C Pin 3 Ground Pin 4 Aux Input Pin 5 N C Pin 6 24 VDC Pin 7 N C Pin 8 Aux Output Active Low Pin 9 N C ...

Page 51: ...1 2 3 N C Pin 4 Red Ground Switched Pin 5 Yellow Ground Switched Pin 6 24 VDC Supply Pin 7 Green Ground Switched Pin 8 9 N C 7 4 Serial Communication Pin Out J1 DB25 Female PIN Pin Description Pin 1 Shield Ground Pin 2 Receive Pin 3 Transmit Pin 4 RTS Pin 5 CTS Pin 6 DSR Pin 7 Signal Ground Pin 8 DCD Pins 9 17 N C Pin 18 Switched 24 VDC Supply Pin 19 N C Pin 20 DTR Pin 21 25 N C ...

Page 52: ...ures Detected In troubleshooting an application it may be desirable to determine if the supplied compressed air has caused an intermittent error condition Once the system detects that the pressure is too low to reliably run it will trigger an error and go offline If the pressure is restored it may appear that the unit falsely triggered an error The sensor maintains a record of the minimum and maxi...

Page 53: ... Standards Conducted Emissions EN55 011 Harmonics EN 61000 3 2 Flicker EN 61000 3 3 Radiated Emissions EN55 011 Electrostatic Discharge ESD EN 61000 4 2 Radiated Immunity EN 61000 4 3 Fast Transient Burst EN 61000 4 4 Surges EN 61000 4 5 Conducted Immunity EN 61000 4 6 Power Frequency Magnetic Field EN 61000 4 8 Voltage Dips and Interrupts EN 61000 4 11 Information Technology EN60950 2000 Equipmen...

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