Advanced Poly-Packaging Ti-1000ZR, Operation Manual

Page 1: ...0 Ti 1000ZR Operation Guide Version 1A Setup Operation and Parts Manual ...

Page 2: ...y use reconditioned or like new parts or units at its sole option when repairing any component or equipment Repaired products shall carry the same amount of outstanding warranty as from original purchase Any claim under the warranty must include a dated proof of delivery In any event APPI s liability for defective components or equipment is limited to repairing or replacing the components This war...

Page 3: ...res 12 Air and Power Requirements 12 Main Power 13 Rear Power Switch 13 Bag Threading 13 Ribbon Threading 13 Cycle Operation of the Printer 13 Adjusting Rear Tension 14 Note on Adjustments to the Printer 14 Chapter 3 Touch Screen Operation 18 Chapter Summary 19 Touch Screen Identification 19 Touch Screen Specifications Features 19 Touch Screen Program 19 Ti 1000ZR Operation 19 Start up 20 Operatio...

Page 4: ...Adjustments 27 Compression Nip Roller Adjustment 27 Idler Roller Guides 27 Machine Maintenance 28 Preventive Maintenance Checklist 28 Scheduled Maintenance Chart perform every 500 000 cycles 29 Troubleshooting Guide 30 Troubleshooting Checklist 30 PLC IO Listing 31 Electrical Drawings 31 4 14 1 TIZ E1_110VAC 32 4 14 1 TIZR E2_FPG IO 33 4 14 1 TIZ E3_AXH_rev1 34 4 14 1 TIZR E6_ZebraIF 35 4 14 1 TIZ...

Page 5: ...4 Mounting Assembly 44 Nip Roll Assembly 46 Printer Register 48 Zebra Printer Assembly 50 Zebra Printer Assembly Continued 52 ...

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Page 7: ...6 Chapter 1 Introduction Welcome Overview Special Features Using This Manual Contact Information Warranty Registration ...

Page 8: ... Saver Ribbon usage is based on the label download size in the software The print head lowers to print onto the film Energy Conservation and Component Saver To extend its life and conserve energy in your plant the Ti 1000Z the Ti 1000Z RAP and the T 1000 S14 NBO are programmed to sequentially shut down components when not in use for extended periods of time A screen saver is provided to extend the...

Page 9: ... heading names and touch screen buttons CAUTION Warning messages To avoid physical harm damage to equipment or damage to the product be sure to read these messages carefully NOTE Identifies important information Contact Information To better serve your bagging needs call 330 785 4000 or toll free 1 800 754 4403 for convenient service solutions Monday through Thursday 9 00 AM to 5 30 PM EST or Frid...

Page 10: ... s Title s Phone Number ________________________________ ________________________________ ________________________________ ________________________________________ ________________________________________ ________________________________________ Please email fax or mail this page to Service Manager Advanced Poly Packaging Inc 1331 Emmitt Road Akron OH 44306 USA Fax USA 330 785 4010 Email the infor...

Page 11: ... Chapter Summary Safety Risks Installation Procedures Air and Power Requirements Main Power Rear Power Switch Bag Threading Ribbon Threading Cycle Operation of the Printer Adjusting Rear Tension Note on Adjustments to the Printer ...

Page 12: ...djust the height without assistance and without supporting the weight of the machine Attempting to make a height adjustment without assistance could cause the machine to drop suddenly causing severe injury APPI offers several optional accessories that can reduce the risk of injury during height adjustments These accessories include carts motorized height adjustment components and stabilizing bars ...

Page 13: ...or service support if there is not sufficient maintenance staff at your facility to perform regular maintenance Installation Procedures The printer is transported completed assembled in a container designed to protect the machine during shipment If the printer is operating with the T 1000 S14 the printer will be bolted onto the bagger After removing the stretch wrapping remove the carton from the ...

Page 14: ...er s main power switch is located on the rear panel of the printer electronics box To turn the machine on press the red Printer Power switch When the machine s is turned on the green Power light on the touch screen will illuminate and the Introduction screen will be displayed The program version will also be identified The Introduction screen will only appear for a few seconds until automatically ...

Page 15: ...le in Setup mode press the Manual Cycle MC button This procedure will cause the compression nip roller to clamp onto the film Then the print head will lower and the nip rollers will pull the film through the print head while printing Label 001 has graphics small print and a line that provides a good test for print quality Adjusting Rear Tension The printer is not designed to cause heavy rolls to u...

Page 16: ...15 Ti 1000Z THREADING DIAGRAM Figure 2 1 ...

Page 17: ...16 Ti 1000Z WITH T 1000 S14 THREADING DIAGRAM SINGLE DANCER Figure 2 2 ...

Page 18: ...17 Ti 1000Z RIBBON THREADING DIAGRAM Figure 2 3 ...

Page 19: ...ary Touch Screen Identification Touch Screen Specifications Features Touch Screen Program Ti 1000ZR Operation Start up Operation Main Menu Printer Settings Stored Labels Counters Tech Assist APPI Factory Printer Status PLC I O Status Warning Messages ...

Page 20: ...k Light No Backlight Power Supply 5Vdc 0 20A Touch Screen Program The touch screen program is a user friendly menu driven setup and operation program Popup windows are incorporated for quick and easy setting adjustments Each time a setting is changed the settings are saved so that if power is lost the job will be recalled automatically without the need for reprogramming A general color scheme is u...

Page 21: ...Takes you to the operation screen Settings Make changes to the printer s functionality Labels To load labels into the printer Either from stored or labels created on an approved software Counters View total cycles the printer has ran cycles during a production shift and hours the printer has been on Tech Assist Troubleshoot issues with the printer View I O Printer Settings The Printer Settings scr...

Page 22: ...verridden This screen also displays the downloaded label parameters including the Darkness setting the Speed setting the Quantity setting and the Length setting The Darkness Print Speed Quantity and Length parameters are set up in the label software They are displayed on the OFL Printer Setup screen for informational purposes However the Darkness and Length settings can be changed on this screen P...

Page 23: ... numeric keypad and press the ENT button The Clear Labels button can clear the downloaded label format or the label format that is recalled from stored memory However if data records are downloaded from a database this button will not erase stored labels unless there are less than 90 records remaining Press the Clear Error button to clear an error with the printer and continue operation NOTE APPI ...

Page 24: ...age when turned on and after each print If an error occurs the actual error message will be displayed on the Printer Status Screen To reset the status press the Clear Status button To recall the status press the Read Status button Print Config Press this button to print the parameters for the printer onto the bag i e Darkness Speed Print Network Press this button to print the network configuration...

Page 25: ...ess info to view the descriptions for I O port Warning Messages Various warnings and errors will pop up to get the operators attention that something needs to be corrected to continue operation Descriptions of the action to take will be displayed with the pop up Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 ...

Page 26: ...25 Figure 3 15 Figure 3 16 Figure 3 17 Figure 3 18 ...

Page 27: ...djustments Maintenance and Troubleshooting Machine Adjustments Tracking and Alignment Adjustments Compression Nip Roller Adjustment Idler Roller Guides Machine Maintenance Preventive Maintenance Checklist Scheduled Maintenance Chart perform every 500 000 cycles Troubleshooting Guide Troubleshooting Checklist PLC IO Listing Electrical Drawings ...

Page 28: ...lified maintenance technicians familiar with safety practices including but not limited to equipment lock out tag out voltages and pneumatics If you are not familiar with the equipment or have not received training on the Ti 1000Z Ti 1000Z RAP you should consult with APPI technical support before attempting adjustments or repairs Tracking and Alignment Adjustments Tracking problems can cause the t...

Page 29: ...tem Description Period Filter Air regulator Drain water from filter D Air regulator Adjust pressure to required tested settings varies D Drive rollers Clean with alcohol D Perforation sensor Clean sensor assembly with alcohol D Platen print roller Inspect for nicks or cuts clean with alcohol D Print head Clean with alcohol also after each ribbon change D Micron filter Venturi Inspect for contamina...

Page 30: ...venness O O O O O O O O O O Steel upper roll Clean w alcohol inspect for burs O O O O O O O O O O Printed circuit boards wiring Blow off with clean dry air inspect for loose wires connectors O O O O O O O O O O Cylinders Listen for air leakage replace or repair as required O O O O O O O O O O Air blower filter Inspect for contamination replace as necessary O O O O O O O O O O Air lines and connect...

Page 31: ...sensor dirty damaged 3 Perf sensitivity out of adjustment 4 Ungrounded perf sensor circuit 5 Seal point value too high 6 Feed distance too high 7 Zero perf function incorrectly set 1 Straighten bag thread bags again 2 Clean replace perf sensor 3 Adjust pot on High Voltage PCB 4 Attach grounding rod to roller 5 Change seal point setting 6 Set value to zero 7 Reset Zero Perf Bag does not completely ...

Page 32: ...inter Busy X4 INL Print Request Y4 Auxiliary Printer Fault X5 Spare Y5 Auxiliary Printer Ready X6 Spare Y6 Nip Roll Solenoid X7 Spare Y7 Spare X8 RAP Accum Empty Bagger Stop Top Y8 Reprint Zebra X9 RAP Accum Full Print Suspend Bottom Y9 Start Print Zebra XA Spare YA Pause Toggle Zebra XB Label Ready Zebra YB AB180 Cycle XC Printer Error Zebra YC Spare XD End Print Printing Zebra YD Not Used XE Rib...

Page 33: ...32 4 14 1 TIZ E1_110VAC Electrical Drawing Figure 4 1 ...

Page 34: ...33 4 14 1 TIZR E2_FPG IO Electrical Drawing Figure 4 2 ...

Page 35: ...34 4 14 1 TIZ E3_AXH_rev1 Electrical Drawing Figure 4 3 ...

Page 36: ...35 4 14 1 TIZR E6_ZebraIF Electrical Drawing Figure 4 4 ...

Page 37: ...36 Figure 4 5 4 14 1 TIZR E7_FP0R GT02 Electrical Drawing ...

Page 38: ...37 4 14 1 TIZR E9_CB IF Electrical Drawing Figure 4 6 ...

Page 39: ...38 4 14 1 TIZ E8_AuxIF_rev4 Electrical Drawing Figure 4 7 Figur ...

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Page 41: ...40 Chapter 5 Parts and Drawings Ti 1000Z Inline Thermal Printer Electronics Assembly Mounting Assembly Nip Roll Assembly Printer Register Zebra Printer Assembly Zebra Printer Assembly Continued ...

Page 42: ...rinter T Ti1000Z ITEM NO QTY PART NO DESCRIPTION 1 1 TA T2Z 2000 MOUNTING ASSEMBLY 2 1 TA T2Z 8010 ZEBRA PRINTER ASSEMBLY 3 1 TA T2Z 2000 1 PRINTER NIP ASSEMBLY 4 1 TA T2Z 1000 PRINTER ELECTRONICS 5 1 TA T2Z 4000 PRINTER REGISTER ...

Page 43: ... TP 218020 DIN RAIL 11 1 TP 212160 5 POSI MINI DIM 12 1 TP 112240 POWER CORD STRAIN RELIEF 13 1 VP Z P1053360 016 017 LOGIC BOARD XI4 8MB 64MB 14 1 TP 213361 24VDC 65W POWER SUPPLY 15 1 TP 205108 FILTER RFI 10A 16 1 TP 501156 DC MOTOR DRIVE DRIVEN PRINT ROLL 17 1 TP T2Z1007 OVERLAY 18 1 TP T2Z1004 APPLICATOR BOARD MOUNT 19 1 VP Z P1011156 XI4 24 28V APPLICATOR INTERFACE OPTION MAINTENANCE KIT 20 1...

Page 44: ...43 Electronics Assembly TA T2Z 1000 ...

Page 45: ... 2 TP 504097 BEARING 9 1 TP T2Z2006 PRINT HEAD ROLLER 10 1 TP T1MC00052 STANDARD ROLLER 11 1 TP T2Z2022 TUBING COVER 12 1 TP T2Z2013 BELT COVER 13 1 TP T2Z2012 COVER PANEL STAND OFF 14 1 TP T15M8007 BELT TENSIONER 15 1 VP Z G46199M 300 DPI ZEBRA MOTOR 16 2 TP 106106 SLOTTED SPRING PIN 17 2 TP 108099 COMPRESSION SPRING 18 2 TP 111010 SPRING CLOSURE COLLAR 19 1 TP 111108 SHAFT COLLAR 20 1 TP 104186 ...

Page 46: ...45 Mounting Assembly TA T2Z 2000 ...

Page 47: ... 7 2 TP 504129 RADIAL BEARING 8 1 TP T2Z2019 DRIVEN NIP ROLL 9 2 TP 401277 ELBOW 1 4 TUBE 10 2 TP 402186 FLOW CONTROL VALVE 10 32 11 2 TP 401254 UNION TEE 1 4 12 1 TP 402175 AIR VALVE BRACKET SX3000 16 1A 13 1 TP 402255 AIR VALVE WITH CONNECTOR 14 2 TP 504106 BEARING NICE 15 1 TP T2Z2025 NIP ROLL DEAD SHAFT 16 1 TP T2Z2026 ROLLER TUBE 17 2 TP 404263 MUFFLER 18 1 TP 401265 STRAIGHT CONNECTOR 19 1 T...

Page 48: ...47 Nip Roll Assembly TA T2Z 2000 1 ...

Page 49: ...P 107108 FLANGED BUSHING 8 1 TP T2Z4007 ROLLER TUBE 9 2 TP T1MC00052 GUIDE ROLLER PRINT REG 10 4 TP 106106 SPRING PIN 11 2 TP T2Z4010 BUSHING CAGE 12 4 TP 108099 COMPRESSION SPRING 13 4 TP 111010 SPRING CLOSURE COLLAR 14 1 TP 106109 1 8 X 3 4 SLOTTED SPRING PIN 15 1 TP T2Z4006 ROLLER SHAFT 16 2 TP 109149 HANDLE KNURLED STEEL 17 1 TP 102126 WASHER 3 8 EXTERNAL TOOTH LW 18 1 TP 101123 NUT 3 8 16 HEX...

Page 50: ...49 Printer Register TA T2Z 4000 ...

Page 51: ...15M8105 BLADE DRAW LATCH 7 3 TP 103212 SCREW BHCS 8 32 X 1 2 S S 8 3 TP 102103 WASHER 8 INT TOOTH LW 9 3 TP 101103 NUT 8 32 HEX 10 2 TP 102132 WASHER 6 FLAT 11 2 TP 102152 WASHER 6 LOCK 12 2 TP 103207 SCREW BHCS 6 32 X 3 8 13 2 TP 102154 WASHER 10 LOCK 14 1 TP 103216 SCREW BHCS 10 24 X 1 2 S S 15 1 TP 103123 SCREW SHCS 10 24 X 1 2 S S 16 2 TP 103395 SCREW FHCS 8 32 X 5 8 17 2 TP 102101 WASHER 4 IN...

Page 52: ...51 Zebra Printer Assembly TA T2Z 8010 ...

Page 53: ...P T15M8030 END PLATE 15 1 TP T15M8031 ROLLER SHAFT 16 1 TP T15M8032 SHAFT MOUNT 17 1 TP T15M0036 PIVOT BLOCK 18 1 TP T15M8038 WEAR SURFACE 19 1 TP T15M8042 RIBBON TAKE UP PULLEY 20 1 TP T15M8043 LOCATING SPACER 21 1 TP T15M8044 SUPPLY SPOOL SPACER 22 1 TA Z 41150M RIBBON TAKE UP SPINDLE 23 2 TP 108133 SPRING 24 2 TP 108099 COMPRESSION SPRING 040 GAUGE 25 2 TP 106304 10MM DOWEL PIN 26 2 TP 111107 C...

Page 54: ...BRACKET 38 1 TP 109225 FINGER KNOB 39 1 TP 504138 CAM FOLLOWER 40 1 TP 503113 BELT 41 1 TP 504175 CLUTCH BEARING 42 1 TP 107116 SLEEVE BUSHING 43 2 TP 102119 NYLON WASHER 44 1 TP 104112 NYLON SPACER 45 1 VP Z P1006134 ZEBRA RIBBON OUT SENSOR ...

Page 55: ...54 Zebra Printer Assembly TA T15 8000 ...