Godex AG3000, User Manual

Page 1: ...AG3000T USER MANUAL AG3000T AG3000T LS AG3000T print apply system with optional label unwinder User Manual AG3000T Version 1 0 Issue Date May 2016 ...

Page 2: ...9 4 1 Standard configuration with 170 mm effectivestroke 9 3 2 Checking the box contents AG 3000 110060 AG 3000 110100 9 3 2 1 Box 1 Printer Accessories 9 3 2 2 Box 2 Applicator components 11 5 Assembling the system 13 5 1 Required Tools 13 5 2 Assembling the stand 13 5 3 Installing the internal rewinder in the printer 17 5 4 Installing the applicator interface 19 5 5 Integrating the printer and a...

Page 3: ...adjustment 37 6 2 3 Horizontal adjustment without verticaladjustment 37 6 3 Air settings i blowing 38 6 4 Air settings ii vacuum 39 7 Connecting to auxiliary systems 40 7 1 Introduction 40 7 2 Triggering devices input signals 41 7 3 Outgoing signals 41 8 Options 42 9 Maintenance 42 10 Wire diagrams 43 10 1 Power and signals schematic 43 10 2 Control unit picture 43 10 3 Power circuits 44 10 4 Conn...

Page 4: ...AG3000T delivers an effective stroke of 170mm total stroke 300mm and the AG3000T LS of 370mm total stroke 500mm Various options are available to tune the AG3000T AG3000 LS to your particular needs 1 2 Applicator Specifications Summarized Type Item no AG3000 AG 3000 110060 AG 3000 110100 AG3000 LS AG 3000 22L060 AG 3000 22L100 Std head size 60mm x 60mm 100mm x100mm 60mm x 60mm 100mm x 100mm Opt hea...

Page 5: ...ice All relevant standards and regulations pertaining to the prevention of accidents and injuries relevant to the device installation site must also be adhered to Possible device handling risks The device was manufactured in accordance with relevant technical requirements and internationally recognized safety and technical standards However situations might still arise during the use of the device...

Page 6: ...ther legal safety regulations that may apply The device s keeper must ensure the performance of regular maintenance Routine maintenance must be carried out by properly trained and authorized personnel Failure to do so could result in device failure or injury and may breach health and safety laws The device may only be operated by properly trained and authorized personnel The device may only be use...

Page 7: ...to low voltage switch gear and EN ISO 12100 regarding the safety of machinery Connection to the power network supply must be made in compliance with the requirements specified in regulations and technical standards valid and applicable in the country of operation Any work on the device may only be performed by persons who are duly qualified according to the legislative code of the country where th...

Page 8: ...tric equipment covers or direct or indirect contact in the event of damage caused to insulating parts of a movable powercord Caused by damaged parts of electricalequipment Resulting from a failure to observe instructions regarding equipment connected to the power mains Configuring the pneumatic unit safety Excessive operating pressure maycause Injury by crushing Mechanical damage to parts of the l...

Page 9: ...u find an option list 3 2 Checking the box contents AG 3000 110060 AG 3000 110100 You have received two boxes Please check whether their content has arrived undamaged 3 2 1 and 3 2 2 will help you to check whether nothing is missing Please inform your supplier immediately if anything seems to be wrong 3 2 1 Box 1 Printer Accessories If you have received the printer parts for your AG3000 directly f...

Page 10: ...10 1x GoDEX ZX1 X 00i applicator interface item no GP 031 Z2i003 001 1x GoDEX ZX1 X00i peeler rewinder unit item no GP 031 Z21005 000 ...

Page 11: ...ts A Parts to build heavy duty floor stand item AG 2000 123322 B From left to right C Applicator machine clamp D Control Unit Positioner AG 2000 110110 AG 2000 110108 700mm tube AG 2000 110112 90 clamp for use with positioner AG 110106 ...

Page 12: ...12 E AG3000T applicator base plate piston mounting material applicator head Item AG 3000 110060 AG 3000 110100 AG 3000 22L060 or AG 3000 22L100 ...

Page 13: ...low here before you start assembling It will help you to anticipate on every step to come Picture 1 3 mount the four round feet to the corners of the 2 longer alloy profiles check also pic 4 5 Pic 1 Pic 2 Pic 3 Picture 4 mount the feet on the faces which do not have screw holes Picture 5 let the narrow ends of the screw holes face each other on the inside whilst mounting the feet Pic 4 Pic 5 ...

Page 14: ... the ends of the alloy profiles with the black plastic covers Pic 6 Pic 7 Picture 8 place the shorter alloy leg the one with holes on two faces between the longer legs Make sure the wider ends of the screw holes are on the same side as thefeet Picture 9 10 firmly connect the three legs Pic 8 Pic 9 Pic 10 ...

Page 15: ... Pic 13 Picture 14 16 mount the adapter plate and clamp on the top of the vertical profile Pic 14 Pic 15 Pic 16 Picture 17 18 insert the 700mm tube into the floor stand Pic 17 Pic 18 i now first see the appendix AG3000 OPTIONS plier in case you also received the demonstration exhibition kit AG 3000 EXHKIT ...

Page 16: ...mount the positioner on the upper end of the 700mm tube POSITIONER AG 2000 110110 CLAMP AG 2000 110106 Pic 19 Pic 20 Picture 21 at a later stage the end of the horizontal positioner must be inserted in and firmly attached to clamp 110108 which is pre mounted on the applicatorunit Pic 21 ...

Page 17: ...inter cover Step 2 Remove the three screws holding the left side cover Step 3 Remove the lower front cover Step 4 Remove the plug from the center plate The rewinder bearings will be insertedhere Picture 2 Step 5 Remove the left cover Picture 3 Step 6 Insert the first bearing from the right side ...

Page 18: ...ep 13 Plug in the sensor connector Picture 6 Step 14 Remove the motor Step 15 Install the 22T cogwheel and its retainingring Step16 Install the motor and the rewinder drive belt Step 17 Install this gear set Step 18 Install this gear set Step 19 Install the clutch i The default torque setting of the clutch suits the AG3000 requirements Please check the printer service manual in case the torque nee...

Page 19: ...correct You may need to re configure the board to be compatible with the AG3000 The AG3000 requires the 24Volt configuration A wrong configuration may damage your equipment Picture 1 check whether the configuration of the applicator interface board is set correctly for use with the AG3000 applicator series Adjust it if necessary Picture 1 shows the correct configuration A The two pins on J4 must b...

Page 20: ...20 Picture 3 and 4 remove this cover on the back of theprinter Pic 3 Pic 4 Picture 5 and 6 connect the applicator interface to the socket on the mainboard Pic 5 Pic 6 ...

Page 21: ...21 Picture 7 8 place the external connector in the slot and tighten the screws from outside Pic 7 Pic 8 Picture 9 11 remount the left printercover ...

Page 22: ...applicator You do this by following the steps showed in the following pictures Picture 1 unscrew the screws indicated with 1 and remove the printer s back cover Picture 2 unscrew the screws indicated with 2 and remove the printer s front cover Pic 1 Pic 2 Picture 3 unscrew the screws indicated with 3 and remove the bottom plate from theprinter Pic 3 ...

Page 23: ...uding the slide and tubes and place the slide 5 against surface 6 Pic 4 Picture 5 mount the slider to the bracket with 4 bolts M5x16 and tighten properly step 7 mount the pneumatic cylinder bracket with 4 bolts M4x16 and tighten properly step 8 Picture 6 place adapter plate C onto the applicator main frame D step 9 Pic 5 Pic 6 ...

Page 24: ...23 Picture 7 place the prepared printer onto adapter plate C and main frame D Pic 7 Picture 8 mount the printer E on main frame D with 6x M4x16 and tighten properly step 10 Pic 8 ...

Page 25: ...r cable coming from the control box to the printer step 12 Picture 10 Remount the rear printer cover step 13 not applicable if you install the optional label unwind stand Picture 11 optional Mount the optional label unwind stand step13a Pic 9 Pic 10 Pic 11 Picture 12 your AG3000 system should look like this now and is ready Pic 12 ...

Page 26: ... place on the application head by a vacuum Subsequently the piston rod lowers the application plate onto the product to apply the label before the application plate is returned to its upper standby position thus completing the application cycle Data exchange may take place between the printer and auxiliary systems via one or more of the available interfaces on the printer USB LAN SERIAL USB Host a...

Page 27: ...ing the printer in applicator mode Set and lock the applicator mode in the printer menu to enable correct and reliable communication between the applicator control unit and the printer The procedure is as follows Pic 1 select main Pic 2 select devices Pic 3 select option setting Pic 4 select None will change to Applicator Pic 5 select option to lock the printer in applicator mode Pic 6 select chec...

Page 28: ...28 Pic 7 select the icon shown below to return to main menu Pic 8 Back on main menu ...

Page 29: ...ling the ZX printer please see the printer manual Putting the applicator into service 5 3 1 Air supply Connect the AG3000 to a pressed air supply The required pressure is at least 4 5bar The system s air intake valve protects the applicator against too high pressure You insert the end of an 8mm air hose into the quick coupler on the backside of the control box Picture 1 AG3000 air intake coupler 5...

Page 30: ...pplicator head and peeler edge 1 must be 0 5mm to 1mm The applicator head and the peeler edge must be aligned perfectly parallel to each other The bottom of the applicator head should be the same height 2 as the upper end of the peeler edge If the height has been set correctly the label will slightly bend down to move forward under the head 3 Picture 1 Picture 2 ...

Page 31: ... the applicator head is not in its start position Observe the way the labels travel from the print head onto the applicator head and then towards the product If the label is transported correctly no mechanical adjustment is needed Also in the course of long term operation no adjustments are anticipated because the label position is determined by the alignment of printer and applicator which again ...

Page 32: ... or the sensor position is not correct The LED on the sensor must be on i as soon as RUN READY is displayed you can run a test cycle Image 3 the display will show ERROR In case an application cycle cannot be completed after a predetermined length of time time out function Image 4 the display will show ERRORPRINT In case the printer ran out ofmedia In case the printer ran out of inkribbon In case t...

Page 33: ...ication cycle and the cycle cannot be completed Possible examples are the applicator head being obstructed and lack of feedback from the printer Selecting and setting the parameters 1 The DOWN value will be blinking automatically Either change and confirm or only confirm the pre selected value with the enter key The cursor will jump to the TIME OUT value 2 Change and confirm or only confirm the pr...

Page 34: ...u the DOWN arrow further to the language settings or the START button back to theSTART menu 5 3 7 The LANGUAGE menu Image 1 in this menu you can select any language included in the AG3000 firmware 1 You access this menu from the MANUAL menu by selecting the DOWN arrow key 2 Use the arrow RIGHT key to select a language 3 Leave this menu by selecting the arrow LEFT key back to the MANUAL menu or the...

Page 35: ...ect the DOWN key again 6 2 Applicator head alignment It is required to align the applicator head in case In start position its bottom is higher than the upper end of the peeler edge In start position its bottom is lower than the upper end of the peeler edge The distance between the head and the peeler edge is less than 0 5mm The distance between the head and the peeler is more than 1 0mm The head ...

Page 36: ...36 Pictures 2 Picture 3 ...

Page 37: ... head towards the printer until it is 0 5mm 1 0mm from the peeler edge 2 Make sure the peeler edge and applicator head are placed perfectly parallel to each other 3 Select key 3 on the keypad to bring the applicator head in its lowest position 4 Tighten the screws A 5 Select key 3 again to bring the applicator head back in start position 6 Verify whether the horizontal position is correct If not r...

Page 38: ... pic 1 you loosen locker A shown on picture 2 turn the blow tube with in such way that the nozzles point in the right direction and fasten locker A again Picture 2 Changing the direction of the airflow Given the applicator head position and airflow direction are correct but labels still tend to drop before being attached to the applicator head the amount of air flowing through the nozzles is proba...

Page 39: ...d which keeps it there whilst travelling towards the product To properly distribute the sucking power the applicator head contains grooves over all of its surface The label width and the applicator head width must be equal The length of the applicator head should be equal to or bigger than the length of the label The vacuum cannot be regulated Picture 1 Groovedapplicator head Pic 1 ...

Page 40: ...ation can take place in various printer languages the commands being generated by drivers label software or the auxiliary system itself See the printer documentation for detailed information 2 The applicator control unit will receive start signals from the auxiliary system and can report certain status and error signals to thatsystem A schematic depiction of an AG3000 integrated in a higher contro...

Page 41: ...V leftmost connector BLUE to Ground second connector from the left BLACK to X1 1 7 3 Outgoing signals X1 6 X1 7 and X1 8 X1 9 form relay controlled switches In case of an application time out or printer error switch X1 6 X1 7 will be closed ON If the AG3000T is ready for the next print apply cycle switch X1 8 X1 9 will be closed ON See both picture 1 on this page and picture 1 on the previous page...

Page 42: ...0 HEAROL Applicator Head with Roll On Unit stock item high AG 3000 HEABLO Applicator Head with Blow On Unit Appr Sensor on request high AG 3000 AG3000 Label Unwinder O D max 280mm 40mm stock item n a AG 3000 AG3000 Label Unwinder Core Adapter 76mm stock item n a AG 3000 EXHKIT Set of product table switch cable tubes mounting materials stock item low Contact us or your GoDEX equipment supplier for ...

Page 43: ...43 10 Wire diagrams 10 1 Power and signals schematic 10 2 Control unit picture ...

Page 44: ...44 10 3 Power circuits 10 4 Connector rack detailed view ...

Page 45: ...41 10 5 Connector rack diagram ...

Page 46: ...42 10 6 Electro pneumatic diagram 10 6 PLC Printer applicator port diagram ...