Advanced Poly-Packaging Ti-1000ZR Operation Manual
Oglas
Oglas
Ti-1000ZR
Operation Guide, Version 1A
Setup, Operation and Parts Manual
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Acknowledgments
Written By: Charles Tolbert, Updated by David Kolinski-Schultz
Reviewed By: Jeff Heath
Copyright
2019 (Version 1A), 2017 (Version 1) Advanced Poly-Packaging, Inc. (APPI). All rights reserved.
This manual and the program operating the equipment described in it are copyrighted. You may not copy this manual in whole or part without the consent of Advanced Poly-Packaging, Inc.
All information pertaining to the promotion, sale, distribution, operation, and maintenance of the Ti-1000Z including this manual, drawings, schematic, wiring diagrams, video, brochures, specification sheets, figures, charts, or any other information, due to its proprietary design and manufacture remain the property of Advanced Poly Packaging, Inc. Unauthorized duplication, distribution or disclosure to third parties without the expresses permission of Advanced Poly-Packaging, Inc. is strictly prohibited.
Trademarks
Roll-a-Print is a trademark of Advanced Poly-Packaging, Inc. Advanced Poly-Packaging, Inc. owns also the following trademarks: Advanced Poly-Bags, Advanced Poly-Bagger, Seal-a-Print, Inline Thermal Printer, Twin-Seal, Advanced Poly-Pack,
Advanced Poly-Bag, Advanced Bag.
Limited Warranty and Disclaimer
Warranty period is 12 months or 1,000,000 cycles whichever comes first. The warranty commences on the date of delivery of the equipment to the Purchaser. Print head warranty period is 90 days (wear item). APPI warrants to the Purchaser that the equipment is free from defects in workmanship or material under normal use and service. During the warranty period, APPI agrees to repair or replace, at its sole option, without charge to Purchaser, any defective component part of the equipment. To obtain service,
Purchaser must return the equipment or component to APPI or an authorized APPI distributor or service representative in an adequate container for shipping. Any shipping charges, insurance, or other fees must be paid by Purchaser and all risk for the equipment shall remain with Purchaser until such time as APPI takes receipt of the equipment. Upon receipt, APPI, the authorized distributor or service representative will promptly repair or replace the defective component and then return the equipment or component to Purchaser, shipping charges, insurance, and additional fees prepaid. APPI may 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 warranty is contingent upon proper use of the equipment by Purchaser and does not cover: expendable component part such as Print Heads, thermocouple wire, heater cartridge, rollers, bushings, and the like; or if damage is due to accident, unusual physical, electrical or electromechanical stress, neglect, misuse, failure of electric power, water damage (from airlines), improper environmental conditions, transportation, tampering with or altering of the equipment, packaging of corrosive or contaminating products or other products damaging to components, and equipment or components not owned or in the possession of original
Purchaser. APPI will not be liable for loss of production, profits, lost savings, special, incidental, consequential, indirect or other similar damages arising from breach of warranty, breach of contract, negligence, or their legal action even if APPI or its agent has been advised of the possibility of such damages or for any claim brought against the Purchaser by another party. This warranty allocates risks of equipment failure between Purchaser and APPI. APPI’s pricing reflects this allocation of risk and the limitations of liability contained in this warranty. The warranty set forth above is in lieu of all other express warranties, whether oral or written. The agents, employees, distributors, and dealers of APPI are not authorized to make modifications to this warranty, or additional warranties binding on APPI. Accordingly, additional statements such as dealer advertising or presentations, whether oral or written, do not constitute warranties by APPI and should not be relied upon.
Warranty on equipment is considered void when outstanding balances become delinquent (over 30 days late - 60 days after ship date). Equipment Integration to other Equipment: APPI assumes no responsibility for the integration of its products to other products or within a system unless APPI performs the integration, testing and provides the results of the tests to the purchaser in writing. Furthermore, APPI assumes no responsibility for bag sizing whether suggested or recommended.
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TABLE OF CONTENTS
Chapter 3: Touch Screen Operation 18
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Chapter 4: Settings, Adjustments, Maintenance and Troubleshooting 26
Chapter 5: Parts and Drawings 40
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Chapter 1: Introduction
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Welcome
Now that you have decided to update your Ti-1000Z Inline Thermal Printer, with Zebra Printer
Technology from Advanced Poly-Packaging, Inc., we thank you for selecting our equipment, materials, and service.
Overview
APPI printers are designed to lower your printing costs with high speeds, versatility, reliability, and simplicity.
High Speeds : Indexes, opens, seals, and tears off a bag at high speeds. Actual packaging speed depends on bag size, equipment options, product characteristics and loading method.
Versatility : Bags virtually any product including fasteners, hardware, injection molded parts, kits, crafts, foods, medical devices and more. Runs bags produced from LDPE, LLDPE, HDPE, Foil, Polypropylene,
Tyvek™ and various barrier films.
Reliability : Crafted from the highest quality components and materials to withstand the most rigorous manufacturing environment, sturdy mounts and rugged frame guarantee long life and usefulness with minimal maintenance.
Simplicity : A user-friendly, menu-driven touch screen program allows operators to set up the bag, options, and auxiliary equipment, save the settings in memory, and recall those settings for repeat runs.
Special Features
Ribbon 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 life of the touch screen.
Pass Code Protection : This feature protects setting screens from alteration by unauthorized individuals.
If enabled, a timer causes the pass code screen to be displayed from the Operation screen after a preset period of nonuse. Factory settings are protected by a Level 1 pass code. This pass code should only be provided to authorized maintenance personnel.
Predetermining Counter : Preset your printer to stop after a predetermined number of bags have been printed. Set the quantity of finished bags to complete a print job.
Totalizing Counter : Reset this counter at the beginning of each shift or day to record printing production over a period of time.
Next Bag Out Printing : The T-1000-S14 NBO features a patented method of printing the next bag out.
This feature prevents the mislabeling of pharmaceuticals, prescriptions, and other high cost items. The part number and other printing information can be changed for every bag without wasting materials.
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Dual Printing : Special programming allows the T-1000-S14 to operate with both the Next Bag Out printer and an offline printer in order to print on both sides of the bag. The offline printer is mounted upside down on the back of the bagger.
Using This Manual
This manual describes the features and operation of the Ti-1000Z Inline Thermal Printer. This manual functions as an operation and parts manual for the retro fit Ti-1000Z printer only. See T-1000 manual for information regarding the bagger.
NOTE: Only the Ti-1000Z and the Ti-1000Z RAP can operate as standalone machines.
The following manual conventions are frequently used to assist in understanding important information, to alert the operator of potentially dangerous or damaging practices and to describe the normal functions of the Ti-1000Z.
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Text: Normal text
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Italics: Used for emphasis
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Boldface:
CAUTION:
Used to identify heading names and touch screen buttons.
Warning messages. To avoid physical harm, damage to equipment or damage to the product, be sure to read these messages carefully.
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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 Friday 9:00 AM to 5:00 PM
EST. For technical assistance with current machinery, ask for Service . To order spare parts for your system, ask for Parts . To order auxiliary equipment for your current system, ask for Machine Sales . To place an order for bags, ask for Bag Sales .
You may also contact any of these departments by email:
Reach Service at [email protected]
Reach Parts at [email protected]
Reach Machine Sales at [email protected]
Reach Bag Sales at [email protected]
For general inquires: [email protected]
Or visit us online at www.advancedpoly.com
In order to provide the best service possible, please have model and serial number ready.
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Warranty Registration
This section must be completed and returned to Advanced Poly-Packaging, Inc. to register the printer for
Warranty Protection.
Serial Number:
(Serial Number located on the back panel)
Company Name and Address Contact Name(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 information above to: [email protected]
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Chapter 2: Getting Started
Cycle Operation of the Printer
Note on Adjustments to the Printer
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Chapter Summary
This chapter describes procedures to receive and set up the Ti-1000ZR, including safety precautions, uncrating and assembly instructions, environmental, air and power requirements, and height adjustments.
Additionally, this chapter describes how to turn on the printers and properly thread film and ribbon.
Safety, Risks
Many safety features have been included in the mechanical, electronic, and pneumatic systems of this machine. Despite these safety precautions, operators may receive lacerations, minor burns, or crushed or broken bone injuries if they come in contact with any moving components. Improper use, improper adjustments and neglect of preventative maintenance may result in serious personal injury. No special personal protective equipment is required to operate the equipment, but eye protection, gloves or other protection should be worn, depending on the characteristics of the product being packaged and the method of loading product.
Please carefully read the following precautions to operate the equipment properly and avoid injury:
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CAUTION: Initial setup of the machine must be performed by specialized personnel. Qualified service engineers should uncrate the equipment, assemble the equipment (if required), test and connect power sources, test the equipment for proper operation and otherwise set up the equipment for use.
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CAUTION: Do not attempt to adjust 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.
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CAUTION: Ensure that any height adjustments allow for sufficient movement of the operator.
Improper height adjustments could negatively affect operator movement, causing strain, added stress, discomfort and fatigue.
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CAUTION: To avoid injury, do not operate the equipment if funnels, guards, covers or other access panels have been removed. If any of these safety measures have been removed or modified or if any openings have been increased, the operator will have access to moving components and extreme temperatures that can cause crush, cut, or burn injuries to hands or fingers.
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CAUTION: To avoid injury, do not reach under the equipment, guards or elsewhere under the machine. Do not place hands or fingers in the seal area or near the seal bar, heater bar, load shelf or other moving components.
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CAUTION: Do not remove or loosen fasteners on the frame. If loosened, the equipment may drop suddenly, causing injury or damage to the machine.
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CAUTION: Be careful when opening the seal frame as it may drop suddenly, causing injury or damage to the equipment.
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CAUTION: To avoid injury, avoid coming in contact with pinch points including rollers, automatic funnel doors or other moving components.
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CAUTION: To avoid injury, avoid contact with roller “fingers” as they may be sharp.
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CAUTION: Exercise care when adjusting or relocating the touch screen. Movement of the touch screen could cause unexpected movement of the machine and injury to the operator.
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CAUTION: If control or air pressure settings are set too high, higher noise levels may result from increased part on part contact or part on machinery contact. Limit these settings and add guards or covers to reduce airborne noise.
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CAUTION: Exercise extreme care when clearing jams, replacing materials, changing controls or mechanical settings, and cleaning internal parts. Be sure to de-energize energy sources prior to removing guarding. Failure to do so may result in unexpected movement or flying objects, which could cause crush, cut, or eye injuries.
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CAUTION: Maintenance must be performed by specialized personnel. Qualified service engineers must remove guards or covers to gain access to electrical or mechanical areas.
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CAUTION: Maintenance must be performed regularly to ensure that the machine is operating properly and to protect against injury. Routine maintenance includes: periodic inspections, the replacement of worn or damaged components, the tightening of loose bolts or components, and regular cleaning and adjustments. Contact APPI and/or service centers for 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 skid, open the top and cut all four corners using a safety knife. Then, transport the machine to the operating location.
CAUTION: Do not attempt to lift the machine from the carton without first cutting all sides open. To prevent injury, do not attempt to lift the machine without assistance.
Operating Environment / Location : The printer should be placed in an area free of excessive heat, moisture, dirt, and dust. Operating room temperature should range from 50-100° Fahrenheit. (10-
37.7°Celcius)
Air and Power Requirements
Ti-1000Z : Provision must be made for 110 VAC, 60 Hz line current with ground. Optional 220 VAC /
50 Hz voltage may have been supplied based on your local electrical requirements. The full load current for the Ti-1000Z is 5 Amps.
NOTE: APPI recommends a dedicated 15 Amp circuit for the Ti-1000Z
CAUTION: A qualified electrician should ensure that the machine’s power outlet is properly
grounded, voltages are as required and amperage capacity is sufficient.
Ti-1000Z : At least 0.5 CFM free air is required, regulated from 25 to 60 PSI (1.72 to 4.13 Bar), to obtain the best print quality and drive roller compression.
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An air regulator is provided to adjust the pressure to the print head assembly. This regulator should be set from 35 to 50 PSI (2.41 to 3.45 Bar) to obtain the best print quality. A separate air regulator is provided to adjust the pressure to the compression rollers. The pressure should be sufficient to drive the film, but not high enough to cause the film to wrinkle. This regulator should be set from 20 to 30 PSI. (1.38 to 2.07
Bar)
An air-line supply should be fed to the Ti-1000Z with 3/8" (0.95 cm) ID flexible tubing. This tubing affixes to the coupler adapter (quick disconnect not provided). Connect the air to the regulator by holding the regulator firmly in one hand and pushing the air line connector on the male regulator connector. Insert the Ti-1000Z power cord into an 110VAC, 60Hz, grounded power outlet.
Main Power
If your printer is operating with the T-1000-S14, the main power switch that turns on both machines is located on the bagger’s side cover. To turn the machines on, turn the switch from its vertical OFF position to its horizontal ON position. If you wish to turn on the printer only or if your printer is operating as a standalone machine or with a bagger other than the T-1000-S14, the printer’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 changing to the Operation screen or Main
Menu.
Rear Power Switch
The Rear Power Switch is located in the back of the machine and is used to turn on the power to the printer only, without affecting the PLC function. The power is separated to allow the printer to be reset, which will also clear the memory of the printer, or errors.
Bag Threading
Refer to Figures 2-1 and 2-2 for proper bag / film threading of the Ti-1000Z and Ti-1000Z RAP, respectively. Alternate threading may be required based on your bagger. Refer to your bagger’s operation guide for additional information.
Ribbon Threading
Refer to Figure 2-6 for proper ribbon threading of the Ti-1000Z. The print head assembly can be rotated up and back for easy ribbon changes. Release the locking mechanism and raise the print head assembly.
CAUTION: To avoid injury or damage to the print head, do not release the print head assembly. Lower the assembly carefully into position and lock the mechanism before operating the printer.
Cycle Operation of the Printer
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If all prior installation procedures were performed properly, the printer should be in its operating location with air and power connected. All covers should be in position and securely fastened.
NOTE: The web of bags may track right or left for a few feet until “settled” on the web path. The roll of bags or the roller guide may require readjustments or realignment after the first few feet of bags are indexed.
To test cycle the printer with a test label that has been downloaded from APPI, load Label 001 from the
Stored Labels screen (if the printer is operating as a standalone machine) or from the printer’s Setup screen (if the printer is operating with the T-1000-S14). To load this label, press the Label # button, enter
“001” and press the
ENT button. Then, while 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 unwind. Heavy rolls may require a driven unwind stand and dancer system. If the film cannot properly feed through the nip rollers, first try to increase, or decrease the nip pressure by adjusting the air pressure. If the film does not feed properly through the nip rollers, increase, or decrease film tension (rear tension).
Note on Adjustments to the Printer
Upon receipt, it is not unusual for the print head to be out of alignment due to shipping and excessive handling. Unless physically damaged, the printer will function properly after minor adjustments are made.
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Ti-1000Z THREADING DIAGRAM
Figure 2-1
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Ti-1000Z WITH T-1000-S14 THREADING DIAGRAM
SINGLE DANCER
Figure 2-2
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Ti-1000Z RIBBON THREADING DIAGRAM
Figure 2-3
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Chapter 3: Touch Screen Operation
Touch Screen Specifications / Features
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Chapter Summary
This chapter describes the identification, operation, and settings of the touch screen program for the Retro
Fit Ti-1000Z printers. This section is focused on the setup and operation of the printer through a small 3” color touch screen.
Touch Screen Identification
BACK PANEL:
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RS-232 Communication port to PLC
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Programming (For APPI use only)
Power Supply: Power terminal for touch screen operation.
CAUTION: Do not attempt to reprogram the PLC or touch screen. Doing so may cause an unsafe operating condition and void the warranty. Additionally, do not change the DIP switch settings.
Touch Screen Specifications / Features
Specifications
Screen Resolution
LCD
Memory
Communication
Touch Key Res.
Languages
Dimension
Back Light
Power Supply
3” 128 x 64 pixels
Green, Red, Orange
384 Kb
RS232C
Free, Analog
English, Spanish, French, German, Italian,
Japanese, Chinese, Korean
110 x 72 x 28 mm (W x H x D)
No Backlight
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 used for operation consistency and to identify functions:
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Black: Text information, borders.
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Green : General background of the touch screen environment.
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Red : Indicates a error, warning
Ti-1000ZR Operation
If you purchased the Ti-1000Z with the T-1000-S14 Advanced Poly-Bagger, please refer to the following sections for information about the printer’s operation.
The T-1000-S14 touch screen program controls the operation of the Ti-1000Z, an offline printer mounted behind the bagger. To access operation, settings, and status screens specific to Ti-1000Z, press the
TI1000Z button on the Bagger Options Menu. Refer to the T-1000-S14 Operation Guide for information about the bagger’s program.
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Start up
When the printer is first turned on, a screen will pop up for only a few seconds before changing to the operation screen.
This screen displays your equipment type,
HMI program and PLC program. It’s important to note this information if you ever lose your program due to a loss of power to the
PLC.
Operation
After the startup screen disappears, the operation screen will show. This screen will just display a quick status of the printer.
Figure 3-1
Main Menu
This screen is used for navigating the program. Many settings and options can be accessed through this interface.
Operation : Takes you to the operation screen.
Figure 3-2
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.
Figure 3-3
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 screen displays the printer’s status and label parameters. It also allows for adjustment of the stored label settings. Refer to Figure 3-3 (above). This screen is accessed by pressing the <settings> button on the Main Menu.
Press the ON / OFF toggle button to turn the printer on and off. To manually cycle one bag through the printer, press the Test button.
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Settings can only be adjusted while the printer is in Setup mode. An error will be displayed on the baggers touch screen. After adjustments and test are complete, return the printer to run mode by pressing <setup>. Do the same to take the printer out of run mode.
The Printer Settings screen features rectangular indicators that display the printer’s status:
Figure 3-4
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Power OFF indicates that the printer is off. This box will also display “Self-Test” when the printer is first turned on and “Ready” during startup if an error does not exist.
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No Label / Label indicates whether or not a label has been downloaded.
This box will also display “Error,” “Printing” and “No Ribbon” during various stages of operation.
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ReprintBuffer : If “ReprintBuffer” is displayed, the printer is continuously printing a preset amount of the same label. If “ReprintBuffer” is displayed in grey, the reprint function is not activated. If “New Label” is displayed, a new label has been downloaded. If “StoredLabel” is displayed, a label has been recalled from stored memory.
The second column on the Printer Setup screen serves as a further indicator of the printer’s status. This box will display Reprint OFF , if the reprint function has been turned off, Reprint ON if the reprint function has been turned on and OverWrite if previous label settings are overridden.
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.
Print Delay : This setting causes the nip rollers to compress first, thus delaying the print head from lowering. This will ensure that the film is captured and ready to start feeding before the print head lowers.
Increasing this delay time will cause loss of production. To change this setting, press the Print Delay button, enter a value on the numeric keypad and press the ENT button.
PrHead Del : This setting is the amount of time, in seconds, before the machine cycles again after completing the previous cycle. To change this setting, press the PrHead Del button, enter a value into the numeric keypad and press the ENT button.
Darkness : Darkness can be set between 1 and 30. Darkness settings can be set in your label software, but can also be overridden by adjusting the Darkness setting on the OFL Printer Setup screen. Increase the
Darkness setting to improve print quality. A typical setting is 20. To change this setting, press the
Darkness button, enter a value into the numeric keypad and press the ENT button.
The Stored Label button will expand the options to include Label # and Length .
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Stored Labels
Label # : This button allows the operator to recall a label. To recall a label, press the Label# button and type in a number from 001 to 999, depending on the label you would like to recall. Enter the desired label number into the numeric keypad and press the ENT button. From the factory, APPI has included at least one sample label format (001) for testing.
Length : This setting allows the operator to adjust the label length.
Because the length of the label is not saved when downloading labels in memory, APPI recommends that stored labels are the same length.
Otherwise, you must use a chart that describes the label format length for each stored label. To change this setting, press the
Length button, enter a value into the numeric keypad and press the
ENT button.
Figure 3-5
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 resells several software packages including: Labelview, Zebra Design Pro and Bartender.
If you are using other software, APPI may not be familiar with the specific settings available in your software. Refer to your software manual for print speed and darkness settings.
Counters
Total: displays how many cycles between resets. Only total can be reset.
Maintenance: Displays the amount of cycles the printer has ran. This cannot be reset.
Hours: Displays the amount of time the machine has been turned on and operating.
Figure 3-6
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Tech Assist
Several screens are available to view under tech assist to help the operator trouble shoot a machine and change critical printer settings. This screen should only be accessed by experienced personnel and APPI service.
Figure 3-7
APPI: Press to change between Xi3/Xi4, 200/300dpi and APPI?
Factory: View the printer’s status, networks, and configurations. PLC Info: View PLC I/O, status of I/O and descriptions of each I/O.
APPI Factory
Pressing Xi4/Xi3 will toggle the button to change between the two. These settings should match the hardware your machine has on it.
Printer Status
The printer sends a status message 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).
Figure 3-8
Figure 3-9
Print Network : Press this button to print the network configuration, including the current IP address onto a bag.
Printer Reset button : Press this button to clear labels and start a self-test. This is similar to restarting a computer.
The Head Cold ON / OFF toggle button allows the operator to turn the Head Cold Warning feature on and off. If the Head Cold Warning feature is on, the machine will automatically stop if the print head gets too cold.
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PLC I/O Status
This screen allows the operator or service personnel to view the currently active inputs or outputs.
Press <info> to view the descriptions for
I/O port.
Figure 3-10
Figure 3-11 Figure 3-12
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 3-13
Figure 3-14
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Figure 3-15
Figure 3-16
Figure 3-17 Figure 3-18
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Chapter 4: Settings, Adjustments, Maintenance and Troubleshooting
LabelView Setup Parameters Software Settings
Adjustments, Maintenance and Troubleshooting
Tracking and Alignment Adjustments
Compression (Nip) Roller Adjustment
Preventive Maintenance Checklist
Scheduled Maintenance Chart (perform every 500,000 cycles)
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LabelView Setup Parameters Software Settings
APPI machines that are equipped with the Xi4 driver, including the Ti-1000Z, Ti-1000Z RAP, and T-
1000-S14 NBO, have LabelView software available to setup parameters for labels. The screens may change, or information in the parameter settings may change, based on the software version. Please refer to the LabelView Pro addendum for further instruction.
ZebraDesigner Driver Settings
The ZebraDesigner is a label design software which can be included with the Designer Pro Version of the
Zebra software. This setup applies to APPI machines equipped with the Xi4 driver, including the Ti-
1000Z, Ti-1000Z RAP and the T-1000-S14 NBO. Please refer to the addendum for further instruction.
Adjustments, Maintenance and Troubleshooting
If you purchased the Ti-1000Z or the Ti-1000Z RAP, please refer to the following sections for adjustments, maintenance and troubleshooting information. If you purchased the T-1000-S14 NBO, please refer to the T-1000-S14 Operation Guide for specific instructions.
Machine Adjustments
Periodically, the Ti-1000Z / Ti-1000Z RAP will require readjustment or realignment of components to ensure proper operation. Adjustments may be required after transportation, excessive handling or due to normal wear and tear.
CAUTION: Machine adjustments, electrical troubleshooting and component replacement should be performed by qualified 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 thermally printed information to be out of the proper location.
To avoid printing problems, machine adjustments to correct the tracking and alignment of the web of bags may be required.
However, before considering adjustment, ensure there is sufficient tension on the film / bag web. When feeding or stopping, the bag roll should not spin freely or feed excess film.
Compression (Nip) Roller Adjustment
The drive roll compression is the force that exists between the two feed rolls (rubber covered grooved roll and grooved steel roll). Too much drive roll compression will cause extra wear on the drive roll and the motor. Adjust the regulator pressure to adjust the nip roller tension. Pressure should be set as low as possible to cause the film to pull the film through the print head evenly without wrinkling.
Idler Roller Guides
Two plastic web guides are located on the rear idler roller. These guides are used for fine adjustment of tracking. Once the web is tracking within +/- 1/8" (3.175 cm) left to right, the plastic web guides can be used to further assist tracking. Hold the upper roller in place while turning and sliding the plastic guides close to the bags without touching the bags.
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NOTE: If the bags are not tracking properly, the plastic guides could cause the bag web to turn or fold over. If this occurs, slide the guides further away from the web and make adjustments to correct tracking issues
Machine Maintenance
To extend the life of the Ti-1000Z / Ti-1000Z RAP, qualified maintenance personnel must perform all required maintenance tasks. Failure to perform scheduled and preventive maintenance may cause excessive wear to components and will void the warranty. This section covers two types of machine maintenance: preventative and scheduled.
For the purpose of this manual, preventive maintenance (PM) tasks are considered periodic tasks that should be performed on a daily, weekly, or monthly basis. Scheduled maintenance tasks are performed when the Ti-1000Z / Ti-1000Z RAP Maintenance Chart Number changes to a higher number. Scheduled maintenance tasks (CHART items) are performed depending on the number of machine cycles and therefore are not considered “periodic” tasks.
CAUTION: Unplug the power cord and disconnect the air-line prior to removing guards, funnels, or covers. Preventive maintenance must be performed by qualified maintenance personnel.
Preventive Maintenance Checklist
Item
Filter / Air regulator
Air regulator
Drive rollers
Perforation sensor
Platen print roller
Print head
Micron filter / Venturi
Wiring / Connectors
Air lines / Valves / Cylinders
Description
Drain water from filter
Adjust pressure to required/tested settings (varies)
Clean with alcohol
Clean sensor assembly with alcohol
Inspect for nicks or cuts, clean with alcohol
Clean with alcohol (also after each ribbon change)
Inspect for contamination of filter, replace as needed
Inspect for blockage / air restriction
Inspect for loose wiring / connectors, tighten as needed
Inspect for loose air lines, listen for leaks, tighten, or replace poly tubing as needed
Compartments / Covers
Compression (drive rollers)
Drive belt
Remove all covers, clean, and blow out compartments with compressed air to remove dust and dirt
Inspect to ensure parallel w/ each other (bag tracking)
Inspect for wear / fraying, replace if needed
Drive Belt (print head assembly) Inspect for wear, looseness, tighten as required
Head Down Cam
Apply a small amount of grease on both sides of the
Head Down Cam and on both sides of the Clevis to prevent them from binding. Apply a small amount of grease between the Head Down Shaft and the Head
Down Cam to keep the Cam from binding. Apply a small amount of grease to the front of the Head Down
Cam to prevent wear on the back of the print head plate.
LEGEND: D = Daily W = Weekly M = Monthly
Period
D
D
D
D
D
D
W
M
M
M
M
M
M
M
28
CAUTION: Unplug the power cord and disconnect the air-line prior to removing guards, funnels, or covers. Preventative maintenance must be performed by qualified maintenance personnel.
Scheduled Maintenance Chart (perform every 500,000 cycles)
CHART
Item
Drive belt
(left panel)
Guide rollers
Description
Adjust/Inspect for wear, replace when necessary.
Inspect for free movement
Roller bearings
Perf sensor and spring
Inspect for free movement
Inspect for wear, replace if required.
Rubber drive roll Inspect for cuts, unevenness
Steel upper roll Clean w/ alcohol, inspect for burs
Printed circuit boards / wiring
Blow off with clean, dry air, inspect for loose wires, connectors
Cylinders
Air blower filter
Air lines and connectors
Listen for air leakage, replace or repair as required
Inspect for contamination, replace as necessary
Print platen roller Inspect for free movement, inspect for wear, replace roller or bearings as required.
Print head belt
Inspect for wear, cuts, leaking, replace as required
Inspect for tightness and wear, tighten, or replace as required.
Print head Clean, inspect for wear, inspect print quality (missing pixels), replace as required.
INITIALS
1 2 3 4 5 6 7 8 9 10
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O
29
Troubleshooting Guide
The items included in this section cover the common causes of trouble that an operator might encounter during the operation of the Ti-1000Z / Ti-1000Z RAP. When operating difficulties occur, the best procedure is to observe what is happening and attempt to isolate the problem. Make only one adjustment at a time, checking the results of each adjustment. If an adjustment does not help or escalates the problems, return the settings back to the former position.
CAUTION: These tests and repairs should be performed by qualified mechanics or electricians.
Troubleshooting Checklist
Problem
Touch screen does not display
Cause
1. Screen saver is active
2. Power off
3. Loose connection
4. Fuse blown
5. Cable shorted / failed
No main power light 1. Blown fuse
2. Bulb out
Two bags index from rollers
1. Bag is folded over
2. Perf 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
Bag does not completely index
First bag after threading indexing multiple bags
Bags web breaking prematurely in machine
1. Perf is sensing hole in bag (vent)
2. Seal position setting too low
3. Zero perf function incorrectly set
1. Thread bags not at proper seal position
2. Perf Sensor not sensing bag
3. Dirty / damaged sensor
4. Pot on High Voltage PCB out of adjustment
1. Improper web tension
2. Index speed too high
3. Improper threading / web contact
4. Bag roll side-plates bent inward
Action
1. Touch the screen
2. Plug in power cord / turn on
3. Tighten connections
4. Replace fuse(s)
5. Replace cable
1. Replace fuse
2. Replace bulb
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.
1. Reposition bag left or right
2. Increase seal position setting
3. Reset Zero Perf.
1. Pull bags through pinch rollers to proper seal point, then cycle machine again.
2. Clean / replace sensor
3. Clean / replace sensor
4. Adjust Pot
1. Adjust tension
2. Reduce speed setting
3. Rethread / remove obstructions
4. Repair / remove side-plates
30
PLC IO Listing
The Main PLC and Expansion PLC IO Listings are provided to assist in troubleshooting the Ti-1000Z and Ti-1000Z RAP. Refer to the T-1000-S14 Operation Guide for the PLC IO Listing for printers operating with the T-1000-S14.
Main PLC
Input Description
X0 NOT USED
Output
Y0
Description
Not Used
X1 Out of Bags Sensor
X2 NOT USED
Y1 Not Used
Y2 Ribbon Drive Enable
X3 Perf Sensor
X4 INL Print Request
X5 Spare
X6 Spare
X7 Spare
Y3 Auxiliary Printer Busy
Y4 Auxiliary Printer Fault
Y5 Auxiliary Printer Ready
Y6 Nip Roll Solenoid
Y7 Spare
X8
RAP: Accum. Empty - Bagger Stop
(Top)
X9
RAP: Accum. Full - Print Suspend
(Bottom)
XA Spare
XB Label Ready - Zebra
XC Printer Error - Zebra
XD End Print (Printing) - Zebra
XE Ribbon Out - Zebra
XF Foot Switch
Y8 Reprint - Zebra
Y9 Start Print - Zebra
YA Pause Toggle - Zebra
YB AB180 Cycle
YC Spare
YD Not Used
YE Spare
YF Print Head Down Solenoid
Electrical Drawings
Electrical drawings are provided at the end of this chapter to assist in troubleshooting the Ti-1000Z Inline
Thermal Printer.
31
4.14.1
TIZ-E1_110VAC
Electrical Drawing
Figure 4-1
32
4.14.1
TIZR-E2_FPG-IO
Electrical Drawing
Figure 4-2
33
4.14.1
TIZ-E3_AXH_rev1
Electrical Drawing
Figure 4-3
34
4.14.1
TIZR-E6_ZebraIF
Electrical Drawing
Figure 4-4
35
4.14.1
TIZR-E7_FP0R-GT02
Electrical Drawing
Figure 4-5
36
4.14.1
TIZR-E9_CB IF
Electrical Drawing
Figure 4-6
37
4.14.1
TIZ-E8_AuxIF_rev4
Electrical Drawing
Figure 4-7
38
Figure 4-8
This page intentionally left blank.
39
Chapter 5: Parts and Drawings
Ti-1000Z Inline Thermal Printer
Zebra Printer Assembly, Continued
40
Ti-1000Z Inline Thermal Printer
T-Ti1000Z
ITEM
NO.
1
2
3
4
5
QTY. PART NO.
1 TA-T2Z-2000
1 TA-T2Z-8010
1 TA-T2Z-2000-1
1 TA-T2Z-1000
1 TA-T2Z-4000
DESCRIPTION
MOUNTING ASSEMBLY
ZEBRA PRINTER ASSEMBLY
PRINTER NIP ASSEMBLY
PRINTER ELECTRONICS
PRINTER REGISTER
41
Electronics Assembly
TA-T2Z-1000
ITEM
NO.
1
2
3
4
5
13
14
15
16
17
18
9
10
11
12
6
7
8
19
20
21
22
23
QTY. PART NO. DESCRIPTION
1
4
1
1
1
1
1
1
1
1
1
2
1
1
TP-T2Z1005
1
1
1
1
TP-212247
TP-215384
TP-218020
TP-2205
21
,
214111, 220516
TP-212246
TP-207216, TP-207224
TP-212410
14 TP-208142
1 TP-218020
1
1
TP-212160
TP-112240
1
VP-Z-P1053360-016 (017)
TP-213361
TP-205108
TP-501156
TP-T2Z1007
TP-T2Z1004
VP-Z-P1011156
VP-Z-P1006134
TP-214273
TP-T2Z1018
ELECTRONICS BASE
PIN D-SUB FEMALE
POWER SWITCH
DIN RAIL
PLC, BATTERY & COMM 2 CAS
9-PIN D-SUB MALE CUP
FUSE HOLDER & 5A FUSE
AC OUTLET
TERMINAL BLOCK
DIN RAIL
5-POSI MINI DIM
POWER CORD STRAIN RELIEF
LOGIC BOARD, XI4, 8MB (64MB)
24VDC, 65W POWER SUPPLY
FILTER, RFI, 10A
DC MOTOR DRIVE, DRIVEN PRINT ROLL
OVERLAY
APPLICATOR BOARD MOUNT
XI4 24-28V APPLICATOR INTERFACE
OPTION. MAINTENANCE KIT
RIBBON OUT SENSOR MAINTENANCE KIT
STAND-OFF, NYLON, 1/2", #4-40
POWER SUPPLY MOUNT
VP-Z-1058301 XI4 ZEBRA POWER SUPPLY (REV A)
42
Electronics Assembly
TA-T2Z-1000
43
Mounting Assembly
TA-T2Z-2000
12
13
14
15
8
9
10
11
ITEM
NO.
1
2
3
4
5
6
7
16
17
18
19
20
21
22
23
QTY.
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
PART NO.
TP-T2Z2002-1
TP-T2Z2002-2
TP-T2Z2007
TP-T14M1035
TP-T2Z2004
TP-T2Z2005
TP-T2Z2011
TP-504097
TP-T2Z2006
TP-T1MC00052
TP-T2Z2022
TP-T2Z2013
TP-T2Z2012
TP-T15M8007
VP-Z-G46199M
TP-106106
TP-108099
TP-111010
TP-111108
TP-104186
TP-504138
TP-306010
TA-T2Z-2000-1
DESCRIPTION
MOUNTING SIDE PLATE - RIGHT SIDE
MOUNTING SIDE PLATE - LEFT SIDE
SUPPORT BRACE
GUIDE ROD HOLDER
PIVOT SHAFT
LATCH BAR
BEARING PLATE
BEARING
PRINT HEAD ROLLER
STANDARD ROLLER
TUBING COVER
BELT COVER
COVER PANEL STAND-OFF
BELT TENSIONER
300 DPI ZEBRA MOTOR
SLOTTED SPRING PIN
COMPRESSION SPRING
SPRING CLOSURE COLLAR
SHAFT COLLAR
SPACER
CAM FOLLOWER
RUBBER EDGE TRIM
PRINTER NIP ASSEMBLY
44
Mounting Assembly
TA-T2Z-2000
45
Nip Roll Assembly
TA-T2Z-2000-1
7
8
9
10
11
12
13
ITEM
NO.
1
2
3
4
5
6
14
15
16
17
18
19
20
QTY. PART NO.
1 TP-T2Z2016
2 TP-403236
2 TP-103533
2 TP-T2Z2029
2 TP-T2Z2028
1 TP-T2Z2027
2 TP-504129
1 TP-T2Z2019
2 TP-401277
2 TP-402186
2 TP-401254
1 TP-402175
1 TP-402255
2 TP-504106
1 TP-T2Z2025
1 TP-T2Z2026
2 TP-404263
1 TP-401265
1 TP-T2Z2032
1 TP-216112
DESCRIPTION
NIP ROLL SUPPORT BRACE
AIR CYLINDER
SCREW, 1/4-28 x 1 SET
MODIFIED CLEVIS
BEARING HOUSING
DRIVEN NIP ROLL
RADIAL BEARING
DRIVEN NIP ROLL
ELBOW, 1/4 TUBE
FLOW CONTROL VALVE, #10-32
UNION TEE, 1/4"
AIR VALVE BRACKET, SX3000-16-1A
AIR VALVE WITH CONNECTOR
BEARING, NICE
NIP ROLL DEAD SHAFT
ROLLER TUBE
MUFFLER
STRAIGHT CONNECTOR
SENSOR BRACKET
PHOTOELECTRIC SENSOR
46
Nip Roll Assembly
TA-T2Z-2000-1
47
Printer Register
TA-T2Z-4000
13
14
15
16
9
10
11
12
ITEM
NO.
1
2
3
4
5
6
7
8
17
18
19
QTY.
4
1
1
2
2
4
2
4
1
1
1
1
1
2
1
2
2
2
2
PART NO.
TP-T2Z4001
TP-T2Z4002
TP-406259
TP-T2Z4003
TP-T2Z4005
TP-T2Z4004
TP-107108
TP-T2Z4007
TP-T1MC00052
TP-106106
TP-T2Z4010
TP-108099
TP-111010
TP-106109
TP-T2Z4006
TP-109149
TP-102126
TP-101123
TP-102144
DESCRIPTION
PRINTER MOUNTING BRACKET
RACK MOUNT
MINI-REG ASSEMBLY
SHORT GEAR RACK
GEAR
GEAR
FLANGED BUSHING
ROLLER TUBE
GUIDE ROLLER (PRINT REG)
SPRING PIN
BUSHING CAGE
COMPRESSION SPRING
SPRING CLOSURE COLLAR
1/8” X 3/4” SLOTTED SPRING PIN
ROLLER SHAFT
HANDLE, KNURLED STEEL
WASHER, 3/8” EXTERNAL TOOTH LW
NUT, 3/8-16 HEX JAM NUT
WASHER, 3/8” FLAT
48
Printer Register
TA-T2Z-4000
49
Zebra Printer Assembly
TA-T2Z-8010
13
14
15
16
17
18
9
10
11
12
5
6
7
8
ITEM
NO.
1
2
3
4
QTY.
2
1
1
2
2
2
3
2
2
2
1
1
3
3
1
1
1
1
PART NO.
TA-T15-8000-Z
TP-T2Z8101
TP-T2Z8102
TP-T2Z2010
TP-T2Z2014
TP-T15M8105
TP-103212
TP-102103
TP-101103
TP-102132
TP-102152
TP-103207
TP-102154
TP-103216
TP-103123
TP-103395
TP-102101
TP-103214
DESCRIPTION
ZEBRA PRINTER ASSEMBLY
HINGE ASSEMBLY
LEXAN PRINTER GUARD
STOP BAR
PIVOT BLOCK BRACKET
BLADE DRAW LATCH
SCREW, BHCS 8-32 X 1/2 S.S.
WASHER, #8 INT. TOOTH LW
NUT, #8-32 HEX
WASHER, #6 FLAT
WASHER, #6 LOCK
SCREW, BHCS 6-32 X 3/8
WASHER, #10 LOCK
SCREW, BHCS 10-24 X 1/2" S.S.
SCREW, SHCS 10-24 X 1/2" S.S.
SCREW, FHCS #8-32 X 5/8
WASHER, #4 INT. TOOTH LW
SCREW, BHCS 8-32 X 1”
50
Zebra Printer Assembly
TA-T2Z-8010
51
QTY.
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
1
2
5
1
1
1
2
1
1
2
2
2
2
1
2
1
1
1
2
Zebra Printer Assembly, Continued
TA-T15-8000
18
19
20
21
22
13
14
15
16
17
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
23
24
25
26
27
28
29
30
31
32
33
34
35
PART NO.
TP-T15M8001
TP-T15M8002
TP-T15M8003
TP-T15M8004
TP-T15M8005
TP-T15M8006
TP-T15M8007
TP-T15M8008
TP-T15M8010
TP-T15M8011
TP-T15M8012
TP-T15M8013
TP-T15M8014
TP-T15M8030
TP-T15M8031
TP-T15M8032
TP-T15M0036
TP-T15M8038
TP-T15M8042
TP-T15M8043
TP-T15M8044
TA-Z-41150M
TP-108133
TP-108099
TP-106304
TP-111107
TP-402260
TP-401265
TP-401294
TP-403140
TP-404263
VP-Z-P1006058
VP-Z-P1004230
VP-Z-46198M
TP-401294-1
DESCRIPTION
PRINTER SIDE PLATE
MOUNTING PLATE PRINT HEAD
ADJUSTMENT BLOCK
SUPPORT ROD
CAM-PRINT HEAD
CYLINDER MOUNT
BELT TENSIONER
BELT GUARD
LOCATING SPACER
SENSOR BRACKET
SPRING MOUNT
ADJUSTMENT ROD
ADJUSTMENT ROD BLOCK
END PLATE
ROLLER SHAFT
SHAFT MOUNT
PIVOT BLOCK
WEAR SURFACE
RIBBON TAKE-UP PULLEY
LOCATING SPACER
SUPPLY SPOOL SPACER
RIBBON TAKE-UP SPINDLE
SPRING
COMPRESSION SPRING,.040 GAUGE
10MM DOWEL PIN
COLLAR CLAMP
PNEUMATIC VALVE
AIR FITTING
1/8-INCH FITTING
AIR CYLINDER
MUFFLER xi4 RIBBON SUPPLY SPINDLE KIT
PRINT HEAD
203 DPI Zebra Motor
MALE CONNECTOR, 1/8" TUBE
52
53
41
42
43
44
45
36
37
38
39
40
1
1
2
1
1
1
1
1
1
1
TP-404148
TP-402175
TP-109225
TP-504138
TP-503113
TP-504175
TP-107116
TP-102119
TP-104112
VP-Z-P1006134
CLEVIS
BRACKET
FINGER KNOB
CAM FOLLOWER
BELT
CLUTCH BEARING
SLEEVE BUSHING
NYLON WASHER
NYLON SPACER
ZEBRA RIBBON OUT SENSOR
Zebra Printer Assembly
TA-T15-8000
54
Prenesi
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