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OPERATING INSTRUCTIONS Version 2 Keep for future use Thermal Transfer Printer topex 7000 topex GmbH • Daimlerstraße 2 • D-73268 Erkenbrechtsweiler • Germany • www.topex.de...
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No part of this documentation must be processed, reproduced, or distributed in any form, e.g., print, copy, microfilm, or any other procedures. Reprint, also in excerpts, is only permitted with the approval of topex GmbH. We reserve technical changes to the machine at any time in order to improve safety,...
Table of Contents Basic data ........................ 7 Manufacturer's address .................... 7 Service / spare parts ordering ................... 7 EC declaration of conformity or EC declaration of incorporation ....... 7 Document information ....................7 Operating instructions ....................7 Device models ......................8 Further applicable documents ...................
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6.3.9 topex standard handling (optional) ................37 6.3.10 Quick-change unit (optional) ................... 38 6.3.11 Control unit topex 7200 / 7250 ................39 6.3.12 Executions with different functional scope............... 39 Transport and setup ..................... 40 Safety provisions ....................40 Requirements to the executing staff ................ 40 Packing ........................
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Safety notes ......................42 Requirements to the executing staff ................ 43 Installation of the control unit .................. 43 Inserting / replacing the material rolls ..............45 8.4.1 Labelling of the rolls ....................45 8.4.2 Removing the label roll ................... 46 8.4.3 Inserting the label roll ....................
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11.3.1 Material groups ....................... 84 11.3.2 General ........................84 Index ........................85...
Basic data BASIC DATA MANUFACTURER'S ADDRESS topex GmbH Address Daimlerstraße 2 D – 73268 Erkenbrechtsweiler +49 (0)7026 / 9316 - 0 Email zentrale@topex.de Internet www.topex.de SERVICE / SPARE PARTS ORDERING Fill find your contact under the following link: https://www.topex.de/kontakt/ansprechpartner...
7054-12-300 7108-12-300 topex 7000 7162-12-300 R for right-hand and L for left-hand model Control unit topex 7200 / Version 5.xx 7250 FURTHER APPLICABLE DOCUMENTS All documents supplied also apply. They must be observed in addition to this manual for the safe use of the machine.
General GENERAL PURPOSE OF THE DOCUMENT The purpose of these operating instructions is providing you as the operator with data for the entire machine in a compressed form in one manual. You will receive information on • Working method, • Operation, •...
GmbH or its authorised partner to answer any questions. Please generally indicate the machine number or device type designation. It is recommended to use the support and services of topex GmbH or its authorised partners for special tasks. These are particularly •...
Note that the contents of the topex operating instructions and the production docu- mentation are not part of any former or existing agreement, promise or legal relation- ship or supposed to change these.
Basic safety provisions SYMBOL AND NOTE EXPLANATIONS • Observe these notes. • Do not expose yourself to these dangers. 3.2.1 Meaning of the signal words The following table shows the classification and meaning of the signal words in safety instructions and warnings. Signal word Severity Consequences of non-ob-...
Basic safety provisions 3.2.4 Symbols for warnings Symbol Explanation Symbol Explanation Warning: counter-rotating Warning of danger point rollers Warning of dangerous volt- 3.2.5 Symbols for protective equipment Symbol Explanation Symbol Explanation Wear a hairnet...
Basic safety provisions ORGANISATIONAL MEASURES • Keep the operating instructions at hand at the site of use of the machine at all times. • Observe the generally valid legal and other binding provisions on accident preven- tion and environmental protection in addition to the operating manual and instruct all persons charged with the work accordingly.
Basic safety provisions WARRANTY 3.4.1 General Our "general sales and delivery conditions" generally apply. These are available to the operator at the latest at conclusion of the contract. Warranty and liability claims in case of injury and property damage are excluded if due to one or several of the following causes: •...
If the operator's staff performs any repairs directly, observe the notes in these instruc- tions in all items. topex GmbH assumes no liability and warranty for any damage and operating faults as a consequence of non-observation of this manual or improper repairs by the operator's staff.
• Therefore, do not make any changes or supplements to any electrical/electronic components without the written consent of topex GmbH. 3.6.4 Safety devices • Before every start-up of the machine, all safety devices must be professionally in- stalled and functional.
Basic safety provisions PERSONNEL SELECTION AND QUALIFICATION – OVERVIEW • Work at the machine must only be performed by reliable staff. Observe the legally permitted minimum age. • Only use trained and instructed staff. • Clearly specify the responsibilities of the staff for operation, setup, maintenance, and servicing.
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Basic safety provisions Work Transport Setup Make supply connections Commissioning Setup, setting Operation Operational maintenance Troubleshooting Fault removal mechanical Fault removal electrical Servicing Decommissioning Storage Disposal Key: X ... permitted -- ... not permitted...
Special safety notes SPECIAL SAFETY NOTES OPERATING PHASES 4.1.1 Normal operation Operate the workstation only: • if all required safety devices and protective covers are available • under constant supervision, or ensure the matching monitor function 4.1.2 Maintenance / servicing, fault - prerequisites •...
Special safety notes SYMBOLS AT THE MACHINE Observe all safety notes directly attached to the machine. Keep them completely legible. Figure 2 Positions of the symbols on the machine Pos. Symbol Explanation Warning: counter-rotating rollers Warning of dangerous voltage SAFETY DEVICES Figure 3 Safety devices Pos.
Special safety notes 4.3.1 Separating guard .. DANGER Missing safety devices or safety devices without function pose a risk of serious injury or death. ► Operate the machine only with properly working safety devices! ► Shut down the machine at once if you find any defective or ineffective safety device.
Special safety notes 4.4.1 Danger areas Danger areas are: • friction • the electrical parts at the machine, • movement areas of the linear axis (if available) • movement areas of the pneumatic elements In these areas, permanently present dangers or unexpectedly appearing dangers oc- cur.
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Special safety notes .. DANGER Touching live components and the electrical control cabinet poses a risk of se- rious injury or death due to electric shock. ► Never open the electrical control cabinet. ► Never work on any live parts. ►...
Any other or additional use is deemed non-intended and is abuse of the machine. topex GmbH shall not be liable for any damage that results from any other or additional use. The risk shall be assumed by the user alone.
Product description TECHNICAL DATA General data • Adjustable label tape guide • Spring-loaded pendulum arm with brake Execution • Stepper motor • Left- or right-hand model Installation option Position independent • Optical via fork light barrier IGS63B/6.3 Label synchronization, auto- •...
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Product description Labels • Adhesive labels according to the order specific data Materials • Special materials only after approval by topex • min. 10 x 4 mm Label formats • topex approval required Label spacing Min. 6 mm for full-surface prints •...
Optional PC programs Top term: Terminal program supporting the data transfer between PC and control unit. See oper- ating instructions for more details: Control topex 7200 /7250. TopTerm RemoteControl: Graphical user interface for creating handling PLC programs. Requires an optional I/O card for the PLC on the control unit.
Product description LUBRICANTS AND CLEANING AGENTS ATTENTION There is a risk of damage to the product and components due to the use of lub- ricants. ► The components of the machine require no lubricants. • Only clean the machine with common household cleaners, but not with any acid, lye, or solvent-containing agents.
Setup and function SETUP AND FUNCTION MECHANICAL SETUP Figure 5 Overview printer (left-hand model) Pos. Designation Pos. Designation Label roll unwinder Dispensing edge Base plate Printhead with thermocouple Transfer film take-up Label synchronisation sensor Sensor transfer film end Drive unit Transfer film unwinder Liner take-up Auxiliary air...
Setup and function FUNCTION DESCRIPTION The thermal transfer printer unrolls prefabricated labels, prints the desired label layout on them, and transfers them synchronously to a handling system at the dispensing edge. The empty label liner and the used transfer film are rolled up. The course for the label tape is indicated by numbers on the rolls (see Figure 14).
Setup and function Adjustable friction clutches are located on the axes of the liner take-up and the transfer film take-up and unwinder. 6.3.3 Label rolls The label rolls can be wound with the labels facing in or out. The roll core of the thermal transfer printer is interchangeable and depends on the rolls used.
Setup and function 6.3.6 Label printing A transfer film is specifically heated by a thermal strip in the printhead and pressed against the label surface by a counter pressure roller in the thermal transfer process. The transfer film releases ink onto the label surface. Figure 7 Principle of thermal transfer printing Pos.
6.3.7 Interfaces on the thermal transfer printer For operation, the labelling machine is connected to the topex 7200 /7250 control unit via a connection cable. The control unit also supplies the electrical energy for the step- per motor and the printhead.
Setup and function LEDs that indicate the status of interface signals. Designation Assignment LED LABEL, green from light barrier for label synchronisation from the light barrier for the thermal transfer film (on the LED FOIL, green printer) LED PRINT, green from I/O interface pin 6 LED DELETE, green from I/O interface pin 7 LED ERROR, yellow...
Setup and function 6.3.9 topex standard handling (optional) Left-hand model = L Right-hand model = R Figure 10 Handling (optional) The handling takes up and positions the push-on unit. It is equipped with a pneumatic mini slide. This will take over the travelling movement from the dispensing edge. The label is pressed onto the product by a pneumatic linear drive.
Setup and function 6.3.10 Quick-change unit (optional) Figure 11 Quick-change unit (optional) The unwinding label roll can be completely removed from the axle after opening the quick-release fastener (1) in the special version with quick-change units (optional). The deflecting roller (2) is equipped with a quick-change unit at the same time.
6.3.11 Control unit topex 7200 / 7250 All versions of the topex 7000 thermal transfer printer use the topex 7200 control. The control consists of the control unit and the associated firmware. It is used to position the stepper motor and to control the printhead. The control unit is operated via a touch panel.
Transport and setup TRANSPORT AND SETUP Objective: Explaining the prerequisites for safe transport, setup and/or installation in an existing machine. SAFETY PROVISIONS .. WARNING The machine or machine parts falling down pose a risk of serious injury. ► Never stay below a suspended or lifted load. ►...
The machine is covered in foil and enclosed in a wooden crate to protect it from the weather. • If required, individual machines can be mounted on a transport frame by topex. • The machine will be fixed to the pallet base.
Commissioning and operation COMMISSIONING AND OPERATION • The machine may only be used for its intended use. • Before activating the machine, read about the correct behaviour in case of faults. • Carry out functional checks before activating the machine: - on all protection devices, - on the emergency stop switches of the superordinate system.
7200 /7250 control. More detailed information on the control commands and printer functions can be found in the programming manual for the topex 7200 control unit. • Ensure that the maximum permissible mains voltage is not exceeded.
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Service PC 230 V sensors Camera IP = 192.168.1.230 Handling Data host Data host customer valve clus- PLC or PC PLC or PC Figure 13 Block diagram of the topex 7200 /7250 control Information Optional devices are indicated by dashed lines.
Commissioning and operation INSERTING / REPLACING THE MATERIAL ROLLS Objective: • Removing and inserting the label roll • Removing and inserting the transfer film roll 8.4.1 Labelling of the rolls The rolls in contact with the label material are numbered from 1 to 9. The rolls in con- tact with the transfer film are labelled with letters from A to D.
Commissioning and operation Unwinding (Figure 14, pos. 1) of the label roll is provided with a core support. This is labelled with the corresponding running direction and version. (wound inwards - Figure 16, pos. 1 or externally wound - Figure 16, pos. 2) Figure 16 Core support for the label roll (right / left) 8.4.2 Removing the label roll...
Commissioning and operation Remove the label roll from the roll core. Remove the liner from the liner take-up. Information Check the deflecting rollers for contamination and wear, see chapter 10.4. 8.4.3 Inserting the label roll Information Refer to the threading sketch enclosed with this documentation. Place the label roll on the roll core.
Commissioning and operation 8.4.4 Changing the transfer film roll Information Refer to the threading sketch enclosed with this documentation. Open the printhead on the clamping device (Figure 17, pos. 4). Remove the remaining transfer film from the thermal transfer printer (if available). Remove the wound transfer film from the take-up (if available).
Commissioning and operation CHANGING THE ROLL CORE (ONLY WITH QUICK-CHANGE UNIT OPTION) If a different label size is used, the roll cores must be changed and the tape realigned if necessary. Figure 19 Replacing the roll core Pos. Designation Pos. Designation Clamping ring with flanged wheel Core support...
Commissioning and operation SETTING THE SENSOR If the format/material is changed or a sensor is replaced, its position and sensitivity must be reset. Information Please refer to the sensor data sheets in the sub-suppliers documentation folder. 8.6.1 Optical fork light barrier for label synchronisation IGS63B Figure 20 Optical fork light barrier IGS63B Pos.
LED WARN – red is off when teaching is completed without errors. • Then, a calibration run is necessary (see operating instructions for topex 7200 / 7250 control, "Calibr" button). • Compare the values of the calibration run displayed in the control unit with the ac- tual values.
Commissioning and operation ACTIVATION 8.7.1 Inspecting before activation • Make sure that all protective covers are properly attached. .. DANGER Missing safety devices or safety devices without function pose a risk of serious injury or death. ► Operate the machine only with properly working safety devices! ►...
Commissioning and operation SWITCHING OFF There are various methods for switching off the thermal transfer printer, that also de- pend on the switch-off time. 8.8.1 Switching off for a longer interruption of operation • Switch off the control unit of the thermal transfer printer. •...
Faults FAULTS Contents • Error messages at system level, with plain text on the touch panel • Error messages on the PLC programme if a PLC programme is activated in the control unit. SAFETY NOTES • Prevent unauthorised persons from accessing the vicinity of the machine's working area.
Faults Is the handling option part of the machine: WARNING There is a risk of serious injury to hands, arms, and head due to moved parts. ► Do not support yourself in the work space. ► Avoid dangerous places. ► Set up devices and aids in the work space of the machine so that they can be reached well from the operator's side.
(TCP/IP) Interface parameters on the control unit are not correct If necessary, adjust interface parameters, see operating in- structions for the topex 7200 / The control unit 7250 control unit does not respond RS232: Check data line to external data...
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Check the label parameters of the control Correct temperature setting, see Temperature too high operating instructions for topex 7200 / 7250 control unit Transfer film con- Friction coupling of the transfer stantly burns film take-up set too weak through...
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- on: clean, replace if necessary see operating in- • Vacuum dust filter contami- structions of nated: clean, replace if neces- topex 7200 / sary • Auxiliary air set incorrectly: re- 7250 control adjust Clean, reset or replace vacuum Vacuum control not switched control.
With plain text display on the touch panel. Information For more details, see operating instructions of topex 7200 / 7250 control. More detailed information on the control commands and printer functions can be found in the programming manual for the topex 7200 control unit.
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Faults Fault Cause Remedy Runtimeerror / ER- Cause see Compileerror For remedy, see Compileerror. ROR 092 The I/O card used to imple- Check the I/O card for correct ment the printer functions is loCard Error seating in the PCIex slot, re- defective.
Only if a PLC program is activated in the control unit. Information For more details, see operating instructions of topex 7200 / 7250 control. More detailed information on the control commands and printer functions can be found in the programming manual for the topex 7200 control unit.
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Faults Fault Cause Remedy The special input can be pro- grammed with a timeout, i.e., Special input if the object in the step chain Check the condition that is mon- timeout is active, this input must carry itored with the special input the "High"...
Servicing / Maintenance SERVICING / MAINTENANCE Objective • Restoration of the target condition. • Operational maintenance is an aid in order to contribute to smooth and efficient pro- cesses in production. Information Please refer to the maintenance plan, which is part of this technical documentation. 10.1 SAFETY NOTES ..
Servicing / Maintenance ATTENTION There is a risk of damage to the machine if the wrong cleaning agents are used. ► Do not use dilutions, acids or basic solutions as cleaning agent, not even in low concentrations. ► Do not use compressed air or high-pressure cleaners for cleaning. ►...
Position of the components to be cleaned Figure 23 Cleaning Position Cleaning agents Designation Deflecting rollers / Friction roller / Label remover topex KWN0052 Punch (optional) blue marking Thermal strip Cleaning pen topex KMS00033 red marking Drive roll (1) Counter pressure roller...
Servicing / Maintenance 10.5 MAINTENANCE WORK Designation Position Work to be carried out Replace label roll Label roll See chapter 8.4 Change the transfer film roll Transfer film roll See chapter 8.4.4 Clean with cleaning agent Thermal strip See chapter 10.4.1 •...
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Servicing / Maintenance Designation Position Work to be carried out • Check for contamination and make sure it can be easily all deflecting roll- moved ers / pendulum arm • Clean if necessary, See chapter 10.4 • Check the braking function of the pendulum arm, readjust if Brake / label un- necessary, see chapter 10.5.3...
Servicing / Maintenance 10.5.1 Opening access to the drive side Figure 24 Housing of the thermal transfer printer You must remove the rear panel of the housing to access the drive side, e.g., to change the timing belts. Proceed as follows: Loosen the 4 screws (1).
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Servicing / Maintenance Figure 25 Rear without protective cover Pos. Designation Pos. Designation Axis transfer film take-up Timing belt for transport roller Connection sensor film end trans- Drive motor axis fer film Interface circuit board Printhead connections Axis liner take-up Motor connection Round belts for transfer film take- Round belts for liner take-up...
Servicing / Maintenance 10.5.2 Replacing the brake belt Figure 26 Brake belt Pos. Designation Pos. Designation Oblong holes Round holes Inside, brake side Outside The brake belt has a fin structured (yellow) side (Figure 26, pos. 2). It must be placed insides towards the axis (brake side).
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Servicing / Maintenance Figure 27 Label unwinding Proceed as follows: Remove the flanged wheel (Figure 27, pos. 1) of the label unwinding by pressing and holding the clamping ring (Figure 27, pos. 2). Measure the distance between the base plate (Figure 27, pos. 3) and the stop disc (Figure 27, pos.
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Servicing / Maintenance Figure 28 Brake belt - installation Pos. Designation Pos. Designation Belt block Belt end Clamping plate, oblong holes Screws Screws Clamping plate, round holes Remove the clamping screws (Figure 28, pos. 3 + 5) on the belt block (Figure 28, pos.
Servicing / Maintenance 10.5.3 Readjusting the brake tension on the pendulum arm Figure 29 Overview pendulum arm suspension (example) Pos. Designation Pos. Designation Spring-loaded pendulum arm 2 clamping screws Horizontal bores on aluminium Eccentric rounding on pendulum Spring suspension, screw Lever Flat head screw, rotation axis of Spring on pendulum arm...
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Servicing / Maintenance Figure 30 Label unwinding Remove the flanged wheel (Figure 30, pos. 1) of the label unwinding by pressing and holding the clamping ring (Figure 30, pos. 2). Measure the distance between the base plate (Figure 27, pos. 3) and the stop disc (Figure 30, pos.
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Servicing / Maintenance 10.5.3.2 Adjusting the spring suspension on the pendulum arm The spring (Figure 29, pos. 4) on the pendulum arm has adjustable suspensions at both ends. The spring suspension (Figure 29, pos. 5) is vertically adjustable via several tapped bores in the sheet metal of the pendulum arm mounting (Figure 29, pos.
"Setup" – "Quality". Information For more details, see operating instructions of topex 7200 / 7250 control. More detailed information on the control commands and printer functions can be found in the programming manual for the topex 7200 control unit.
Servicing / Maintenance 10.5.5 Printhead settings 10.5.5.1 Opening the printhead Figure 31 Opening the printhead Open the locking lever (2) on the clamping lock (1) and fold down the lower part of the printhead. 10.5.5.2 Adjustment of the dot strip to the counter pressure roller Figure 32 Printhead with thermal strip pulled out –...
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Servicing / Maintenance You can move and turn the thermohead by turning the two outer Allen screws (Fig- ure 33, pos. 1). Information Use a 2.5 mm Allen key to adjust the screws evenly. Clockwise rotation moves the printhead towards the dispensing edge, anti-clockwise rotation moves the printhead away from the dispensing edge.
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Servicing / Maintenance 10.5.5.4 Disassembly and assembly of the thermal strip Figure 34 Mounting the thermal strip with printhead Figure 35 Thermal strip, dot strip facing upwards Disassembly Switching off the control unit. Open the printhead. Pull the thermal strip forwards out of the holder (Figure 32, pos. 5). You must over- come the resistance of the two plug connectors (Figure 35, pos.
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Servicing / Maintenance 10.5.5.5 Aligning the guide strip for the transfer film Figure 36 Aligning the guide rail The transfer film is deflected at the guide bar for rewinding (Figure 36, pos. 2) after the printing process. It must be aligned so that the transfer film is guided to the take-up cleanly and without creases.
Decommissioning / disposal DECOMMISSIONING / DISPOSAL Objective • Professional preparation for storage. • Maintenance of the target condition of the machine during storage. Information Decommissioning and storage are among the work to be performed very rarely. .. DANGER Missing safety devices or safety devices without function pose a risk of serious injury or death.
Decommissioning / disposal .. WARNING There is a risk of serious injury to hands, arms, and head due to pneumatic / electric movements. ► Do not support yourself in the work space. ► Avoid dangerous places. ► Only reach into the work space for equipment, removal and cleaning. ►...
Decommissioning / disposal 11.3 FINAL DECOMMISSIONING / DISPOSAL • If necessary, wait until the machine is in home position. • First, secure all operating media, e.g., compressed air, against accidental recom- missioning. • Switch the thermal transfer printer to no voltage. •...
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Clean..............66 Mechanical setup ..........31 Commissioning ........... 42 Contact pressure setting ........79 Control unit topex 7200 / 7250 ......39 Opening the drive side ........69 Conversions and spare parts ......16 Operation ............42 Counter pressure roller ........78 Optical fork light barrier for label synchronisation ...............
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Index Sensor settings ........... 50 Symbol and note explanations ......13 Service ..............7 Symbols ............14, 22 Servicing ............. 63 Setting the sensor ..........50 Technical data ............ 27 Setup..............40 Threading diagram ..........48 Spare parts ordering ..........7 Timing belt ............
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