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Carl Valentin APL 100 Operating Manual

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APL 100
Operating Manual

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  • Page 1 APL 100 Operating Manual...
  • Page 2 No part of this document may be reproduced in any form (print, photocopy or any other method) or edited, copied or distributed electronically without written permission from Carl Valentin GmbH. Due to the constant further development of our devices discrepancies between manual and device can occur.

  • Page 3: Table Of Contents

    Applicator APL 100 Table of contents Table of Contents   Table of Contents ................3     Introduction ................5 General Instructions ..............5     Intended Use ................5     Environmentally-Friendly Disposal .......... 6        ...
  • Page 4 Table of Contents Applicator APL 100     Error Messages ..............51 11.1 Error Messages of the Printer ..........51     11.2 Error Messages of the Applicator .......... 51         Declaration ................53 12.1 Extended Declaration ............53  ...

  • Page 5: Introduction

    Applicator APL 100 Introduction Introduction 1.1 General Instructions Important information and instructions in this document are designated as follows: DANGER identifies an extraordinarily great and immediate danger which could lead to serious injury or even death. WARNING identifies a possible danger would could lead to serious bodily injury or even death if sufficient precautions are not taken.

  • Page 6: Environmentally-Friendly Disposal

    Carl Valentin GmbH. Thereupon old equipment is professionally disposed. Thereby Carl Valentin GmbH observes all obligations in the context of old equipment disposal in time and makes therewith the smooth selling of products furthermore possible. Please understand that we can only take-back equipment that is send free of carriage charges.

  • Page 7: Safety Instructions

    Applicator APL 100 Safety Instructions Safety Instructions  Before mounting the delivered components disconnect the printer from the power supply and close the shutoff valve at the applicator.  Only connect the device to other devices which have a protective low voltage.

  • Page 8: Safety Marking

    Safety Instructions Applicator APL 100 2.1 Safety Marking 1 = Risk of crushing due to the movement of the pad Figure 1 CAUTION! There is a risk of injury due to the movement of the pad downwards and back up again.

  • Page 9: Operating Conditions

    Applicator APL 100 Safety Instructions 2.2 Operating Conditions Before initial operation and during operation these operating conditions have to be observed to guarantee save and interference- free service of our printers. Therefore please carefully read these operating conditions. Shipment and storage of our printers are only allowed in original packing.
  • Page 10 Safety Instructions Applicator APL 100 The installation of the power supply to connect our printers has to be Installation of effected according to the international rules and regulations, power supply especially the recommendations of one of the three following commissions: ...
  • Page 11 Applicator APL 100 Safety Instructions Immunity to interference according to EN 61000-6-2: 2005 Stray radiation and industrial sector immunity from disturbance  Stray radiation against discharge of static electricity according to EN 61000-4-2: 12-2001  Electromagnetic fields according to EN 61000-4-3: 11-2003, ENV 50204: 03-1995 ...
  • Page 12 Safety Instructions Applicator APL 100 To avoid inadmissible heating, free air convection has to be ensured. Air convection Protection according IP: 20 Limit values Ambient temperature °C (operation): Min. +5 Max. +35 Ambient temperature °C (storage): Min. −25 Max. +60 Relative air humidity % (operation): Max.

  • Page 13: Product Description

    Product Description Product Description The applicator APL 100 is an optional device to use with label printers of the Compa or Compa II series for automatically applying the printed label onto the product. The labels are transferred with a pad, which moves between the two positions, starting position and labelling position, by a compressed-air driven pneumatic cylinder.

  • Page 14: Important Characteristics

    Product Description Applicator APL 100 3.1 Important Characteristics  The supporting air and the vacuum as well as the speed of the cylinder are adjustable. That way the applicator can be adapted to different label materials and sizes.  The pressure for the cylinder movement is reduced in relation to the operating pressure of the entire labelling machine so that the danger of injury is reduced as much as possible.

  • Page 15: Device Overview

    Applicator APL 100 Product Description 3.3 Device Overview Front view Figure 2 11 = Upper cylinder throttle valve 02 = Stopper for the operation mode 'Blow on' 03 = Cylinder unit 04 = Pneumatic cylinder 05 = Lower cylinder throttle valve...
  • Page 16 Product Description Applicator APL 100 Rear view Figure 3 11 = Supporting air throttle valve 02 = Vacuum throttle valve 03 = Service unit 04 = Shutoff valve 05 = Compressed air connector 06 = Pins 07 = Interface to the printer...

  • Page 17: Pads

    Applicator APL 100 Product Description 3.4 Pads Universal tamp pad Universal tamp pad Tamp pads Standard sizes: Standard sizes: 70 x 60 mm and 90 x 90 mm 116 x 102 mm and 116 x 152 mm Figure 4 Figure 5 Universal tamp are available in different standard sizes.

  • Page 19: Installation

    Applicator APL 100 Installation Installation 4.1 Scope of Delivery NOTICE! Please keep the original packaging in case the applicator must be returned. Figure 8 1 = Applicator with cylinder 2 = Pad (according to command) 3 = Cylinder screw (part of the pad)

  • Page 20: Mounting The Applicator To The Printer

    Installation Applicator APL 100 4.2 Mounting the Applicator to the Printer CAUTION! Danger of injury by inadvertent move out of the cylinder.  Disconnect the printer from the power supply before mounting the applicator.  Connect the compressed air only after mounting the applicator to the printer.

  • Page 21: Piercing The Universal Tamp Pad

    Applicator APL 100 Installation 4.3 Piercing the Universal Tamp Pad On the bottom of the pads there are holes for sucking and holding the labels by vacuum. When an universal tamp pad is delivered these holes are covered by the sliding foil and must be opened according to the label size.

  • Page 22: Preparing For Using A Sprint-Mounted Tamp Pad

    Installation Applicator APL 100 4.4 Preparing for Using a Sprint-Mounted Tamp Pad NOTICE! For using a spring-mounted universal tamp pad (> 90 x 90 mm) the fitting of the cylinder unit must be changed. The cylinder unit (6) can be mounted on the bracket (1) in two different positions.

  • Page 23: Mounting The Pad

    Applicator APL 100 Installation 4.5 Mounting the Pad Figure 12 1. Pull the tube (6) out of the push-in-fitting. 2. Insert the pin (5) on the pad (8) into the hole on the bottom side of the pad holder (7).

  • Page 24: Mounting The Stopper

    Installation Applicator APL 100 4.6 Mounting the Stopper NOTICE! In the operating modes 'Stamp on' and 'Roll on' the stopper is not needed. Figure 13 When the applicator is delivered, the stopper (1) is mounted on the rods (4). With this stopper the labelling position for the operation mode 'Blow on' can be adjusted.

  • Page 25: Connections

    Applicator APL 100 Installation 4.7 Connections Figure 14 1. Prepare the printer connections to the power supply and to the computer (see operating manual of the label printer). 2. Close the shutoff valve (3 / lever at the valve is turned across the air flow direction).

  • Page 27: Configuration

    Applicator APL 100 Configuration Configuration The label applicator can be operated in different ways. While the original process stays the same, the operation mode can be chosen within the function menu of the connected label printer. The most important setting is the selection between the operating modes 'Stamp on', 'Blow on' and 'Roll on'.

  • Page 28: Settings In Printer Function Menu

    Configuration Applicator APL 100 5.2 Settings in printer function menu Switch on the label printer and the display shows the main menu. Press key to access the function menu. Press key as long as you arrive the Label applicator menu.
  • Page 29 Applicator APL 100 Configuration Press key to arrive the next parameter. The supporting air from the blow tube is not immediately switched on Support delay On at print start but only if the label has covered a distance. This delay helps to prevent a turning or swinging at the front of the label and consequently avoids faults when the label is being picked up from printer.
  • Page 30 Configuration Applicator APL 100 Press key to arrive the next parameter. This parameter is only active if the operating mode 'blow on' is Blow time selected. The time period can be adjusted, while the blowing air is switched on for transferring the label onto product.
  • Page 31 Applicator APL 100 Configuration Press key to arrive the next parameter. This menu serves for the applicator setup as well as for error tracing. Input/Output Input signals of the applicator can be monitored and output signals can be set or reset separately. With keys corresponding output for setting and/or resetting the output signals can be selected.

  • Page 32: Signal Diagrams

    Signal Diagrams Applicator APL 100 Signal Diagrams 6.1 Print - Apply Input: Print start Print process Delay On Delay Off Supporting air Vacuum Apply Blow on Cleaning time Output: Label print Figure 15 6.2 Apply - Print Figure 16 Operating Manual...

  • Page 33: Mechanical Adjustments

    Applicator APL 100 Mechanical Adjustments Mechanical Adjustments NOTICE! Perform the mechanical adjustments in two steps  Roughly align the pad in all directions to avoid collisions of the pad with other parts when switching on the compressed air.  Perform the fine adjustment with compressed air switched on to optimize the labelling process.

  • Page 34: Adjusting The Parallelism Between Pad And Dispense Edge

    Mechanical Adjustments Applicator APL 100 1. Loosen screw (2). Side adjustment 2. Shift the cylinder unit including the pad (4) inside the elongated hole in such a way, that the dispensed label is aligned centrally to the pad respectively to the open holes in an universal pad.

  • Page 35: Opening The Holes On The Blow Tube

    Applicator APL 100 Mechanical Adjustments 7.3 Opening the Holes on the Blow Tube 1 2 3 Figure 19 1. The blow tube (1) has holes for the supporting air in regular distances of 15 mm. 2. When the applicator is delivered only the two inner holes are open.

  • Page 36: Aligning The Blow Tube

    Mechanical Adjustments Applicator APL 100 7.4 Aligning the Blow Tube Figure 20 The blow tube (2) for the supporting air can be rotated around its axis. That way the direction of the supporting air can be optimized. 1. Loosen screw (1).

  • Page 37: Adjusting The Stopper

    Applicator APL 100 Mechanical Adjustments 7.5 Adjusting the Stopper NOTICE! For operating mode 'Blow on' only. Figure 22 CAUTION! Danger of injury by inadvertent move out of the cylinder.  Switch off the printer and close the shutoff valve for the compressed air at the service unit.

  • Page 39: Pneumatic Adjustments

    Applicator APL 100 Pneumatic Adjustments Pneumatic Adjustments 8.1 Control Valves 1 2 1 6 7 8 9 10 11 Figure 23 For adjustments of certain applicator functions it is possible to release the control valves in the pneumatic system. ...
  • Page 40 Pneumatic Adjustments Applicator APL 100 1 2 1 6 7 8 9 10 11 Figure 24 Double 2-way valve (4) for blow air In the operation mode 'Blow on' the label will blow up to the product. In the operating modes 'Stamp on' and 'Roll on' the blow air is switched on for a short time after each application to avoid contaminations within the vacuum channels.

  • Page 41: Adjusting The Pad Movement Speed

    Applicator APL 100 Pneumatic Adjustments 8.2 Adjusting the Pad Movement Speed Figure 25 The adjustment of pad movement speed can be regulated with two throttle valves (1, 3).  Adjust the pad movement speed as necessary.  To increase the downward speed turn the screw (4) at the lower valve (3) anticlockwise.

  • Page 42: Adjusting Vacuum And Supporting Air

    Pneumatic Adjustments Applicator APL 100 8.3 Adjusting Vacuum and Supporting Air Figure 26 Adjusting the supporting air With the valve (1) the supporting air for blowing the label to the pad can be varied.  Adjust the supporting air in such way that the label is blown on the pad without swirling.

  • Page 43: Operation

    Applicator APL 100 Operation Operation 9.1 Loading the Label Material NOTICE! In dispensing mode the labels are removed after printing, and only the liner is wound up internally. Figure 27 NOTICE! For detailed information about inserting the material please read the operating manual of the label printer.

  • Page 44: Setting The Dispenser Mode

    Operation Applicator APL 100 9.2 Setting the Dispenser Mode NOTICE! To operate the label printer in dispenser mode a print order must be started and the printer is to be in 'waiting' mode. Switch on the label printer and the display shows the main menu.

  • Page 45: Test Mode

    Applicator APL 100 Operation 9.3 Test Mode Test Mode Using the Pre-dispense Key without Print Job Figure 28 The whole labelling process can be simulated without the need of a print job or a connection to a computer by pressing the key the pre-dispense key (1).
  • Page 46 Operation Applicator APL 100 Test Mode Using the Pre-dispense Key without Print Job This method allows to check the labelling process with real print data using the pre-dispense key (1, Figure 28).  Send a print job. The test mode is executed in two half-cycles.

  • Page 47: Standard Operation

    Applicator APL 100 Operation 9.4 Standard Operation 1. Check all external connections (see chapter 4.7, page 25). 2. Load the transfer ribbon and the label material (see chapter 9.1, page 43). NOTICE! Ensure that the locking system (4, Figure 27) is closed.

  • Page 49: Applicator Interface

    Applicator APL 100 Applicator Interface 10 Applicator Interface 10.1 Pin Assignment Figure 29 10.2 Internal Circuit of Outputs Figure 30 The outputs are realized by optocouplers. With an active signal the collector emitter line of the optopoupler is conductive. 11/13...

  • Page 50: Signal Assignment D-Sub 15 Pin

    Applicator Interface Applicator APL 100 10.3 Signal Assignment D-Sub 15 pin D-Sub 15 pin female connector APL 100 Signal Description Active state Collector signal Upper final Tamp pad is in the final Collector position position in which the emitter line...

  • Page 51: Error Messages

    Applicator APL 100 Error Messages 11 Error Messages 11.1 Error Messages of the Printer In case an error occurred the printer stops and the print order is interrupted. Information to causes and remedies of printer errors e.g. no label found are to be taken from the printer manual.

  • Page 53: Declaration

    Applicator APL 100 Declaration 12 Declaration 12.1 Extended Declaration 11/13 Operating Manual...

  • Page 54: Ec-Declaration Of Conformity

    Declaration Applicator APL 100 12.2 EC-Declaration of Conformity Operating Manual 11/13...

  • Page 55: Index

    Applicator APL 100 Index 13 Index B  Blow tube, adjusting ................36 C  Circuit output, internal ................ 49 Configuration Operating mode ................27 Parameter ..................27 Connections ..................25 Control valves ................39, 40 D  Declaration ................... 53, 54 Device overview Front view ..................
  • Page 56 Index Applicator APL 100 L  Label application ................13 Label material, loading ............... 43 M  Mounting to printer ................20 O  Operating conditions ............9, 10, 11, 12 Output circuit, internal ................ 49 P  Adjusting ..................34 Mounting ..................23 Movement speed ................
  • Page 58 Carl Valentin GmbH Neckarstraße 78 – 86 u. 94 . 78056 Villingen-Schwenningen Phone +49 (0)7720 9712-0 . Fax +49 (0)7720 9712-9901 info@carl-valentin.de . www.carl-valentin.de...

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