1. Manuals
  2. Brands
  3. Diagraph Manuals
  4. Label Maker
  5. PA/4000
  6. Service manual

Diagraph PA/4000 Service Manual

Label printer/applicator
Hide thumbs
Table of Contents

Advertisement

Quick Links

Service/Technical
Manual
Diagraph PA/4000
Label Printer/Applicator
5802-929
Revision A
T M
B Y A L L E N
-
B R A D L E Y
T E C H N O L O G Y
3401 Rider Trail South • St. Louis/Earth City, MO. • 1-800-521-3047, ServiceLine 1-800-526-2531
Diagraph Corporation ©2000

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PA/4000 and is the answer not in the manual?

Questions and answers

Related Manuals for Diagraph PA/4000

Summary of Contents for Diagraph PA/4000

  • Page 1 Service/Technical Manual Diagraph PA/4000 Label Printer/Applicator 5802-929 Revision A B Y A L L E N B R A D L E Y T E C H N O L O G Y 3401 Rider Trail South • St. Louis/Earth City, MO. • 1-800-521-3047, ServiceLine 1-800-526-2531...
  • Page 2 Information contained in this manual is commercially confidential and may not be reproduced or disclosed without the written permission of Diagraph, Inc. The supply of this manual or the equipment to which it applies does not constitute or imply the transfer of any rights to any party.

  • Page 3: Table Of Contents

    PA/4000 Operations Manual Table of Contents Page 1 PA/4000 OPERATIONS MANUAL TABLE OF CONTENTS Section 1.0 Introduction to the PA/4000 Printer/Applicator Series 1-1 Specifications Description of the Printer/Applicators in the Series Section 2.0 Component Features and Specifications Floor Stand Assembly...
  • Page 4 PA/5000 Operations Manual Table of Contents Page 2 Section 6.0 Operations Start of the Day Adjustments during Operation Stopping Label Application End of Day Section 7.0 Prodigy Plus Fonts and Bar Codes Available Fonts and Bar Codes Internal Font Examples Bar Code Examples Section 8.0 Printing Labels Prodigy Plus...

  • Page 5: Section 1.0 Introduction To The Pa/4000 Printer/Applicator Series

    Windows™, is available for creating, storing, and printing label formats from IBM ® or compatible - personal computers. The PA/4000 has a full-range of options available. It is flexible and can address a variety of design and custom application requirements: 1.

  • Page 6: Description Of The Printer/Applicators In The Series

    • PA/4010 • PA/4015 • PA/4020 A description of the three PA/4000 systems and their features follows. PA/4010 Printer/Applicator The PA/4010 Printer/Applicator is ideal for high-speed lines running many products per minute (actual number of products per...
  • Page 7 PA/4000 User’s Manual Section 1, Product Features Page 3 PA/4015 Pallet Printer/Applicator The PA/4015 Pallet Printer/Applicator is ideal for pallet applications where distance from the applicator to the pallet varies. This pallet labeling system accommodates long distances between the applicator and the pallet with the extended-length cylinder option.
  • Page 8 PA/4000 User’s Manual Section 1, Product Features Page 4 PA/4020 Dual-Panel Printer/Applicator The PA/4020 Dual-Panel Printer/Applicator combines a tamp applicator with a secondary wipe-down mechanism. This mechanism applies a wrap-around label up to 13 inches long to two adjacent sides of the carton for side/front or side/back labeling.

  • Page 9: Section 2.0 Component Features And Specifications

    The bolting holes are located on the t-base [E]. 2.2 The Main Unit The PA/4000 main unit is a robust, yoke- mounted design of aluminum and steel. It swivels to conform to common application orientations – top down, side panel and bottom up –...
  • Page 10 PA/4000 User’s Manual Section 2, Components Page 2 The Air Control Unit [A] The air control unit regulates the vacuum, air assist and tamp pressure. The vacuum holds the label against the tamp pad prior to application. The air assist guides the label (as it comes off the peel blade) on to the tamp pad.
  • Page 11 PA/4000 User’s Manual Section 2, Components Page 3 • All popular bar codes and nine different alphanumeric fonts resident in memory. • The 0.0049 inch print element prints high-density bar codes and easy-to-read characters at 203 dot-per-inch resolution. In addition, the pixel size can be multiplied by 2 in the horizontal, and 3 in the vertical direction producing even larger label formats.
  • Page 12 PA/4000 User’s Manual Section 2, Components Page 4 direct connect download of a label format (label formats can also be stored and recalled from RAM modules) or graphics (logos). Graphics can be loaded using programs with an image download function. The loading of images can also be done with minimal programming on most host computers.
  • Page 13 PA/4000 User’s Manual Section 2, Components Page 5 Module Slot locations The PA/4000 Printer/Applicator has two module slots in the rear of the print engine for use with optional memory modules and font modules. The upper slot is referenced, as “A” [A] and the lower slot is “B”...
  • Page 14 . Diagraph supports Performance Series (Premier, Express or Flash) as the software solution for label creation and printing on the PA/4000. Windows Drivers. Datamax provides print drivers through its web site for users who want to print labels from word processors such as Microsoft Word or Word Perfect.

  • Page 15: Air Cylinder/Tamp Head Assembly

    6, 12 and 18 inch. The Air Cylinder/Tamp pad Assembly attaches to the extended horizontal support bar on the PA/4000 main unit. It comes with a spare tamp pad kit. There are two sensors [A] located on the tamp pad: 1.

  • Page 16: Air Filter

    PA/4000 User’s Manual Section 2, Components Page 8 2.4 Air Filter 7505-103 The PA/4000 Air Filter takes the incoming factory air supply and filters out impurities and moisture to give a clean, air supply. The PA/4000 must be supplied with 95-120 psi of clean, dry, and unlubricated air.

  • Page 17: Hand-Held Terminal

    Section 5.2. The hand-held terminal communicates with the PA/4000 main unit through an RJ-11 cable that connects to J1 on the electrical panel on the back of the print engine (see Section 4.12). It sits in its holster attached to the yoke when not in use.

  • Page 18: Optional Components

    The PA/4000 supplies both electric (24 VDC) and air (0-100 PSI) power. The assembly includes bracketry [A]; a tee fitting [B]; an interconnect cable [C] and a photosensor [D] that acts as the signal source to initiate the cylinder stroke.
  • Page 19 PA/4000 User’s Manual Section 2, Components Page 11 2.7.2 Warning Tower 6150-320 The warning tower assembly provides visual feedback when error conditions occur. This assembly includes the tower, the mounting hardware and a signal cable. CONDITION GREEN YELLOW Label Low...

  • Page 20: Section 3.0 Packaging

    PA/4000 User’s Manual Section 3, Packaging Page 1 3.0 PACKAGING 3.1 Containers The basic PA/4000 without options ships in three containers. Unpacking requires two people. CONTAINER #1 1 Tee base 2 ¾ inch x 5 inch bolt with flat washer 1 Stand upright piece 1 ¾...

  • Page 21: Section 4.0 Installation

    4.0 INSTALLATION 4.1 Overview Instructions in this section show the PA/4000 in a top down configuration, that is with the print engine upright and labels applied on top of the product. The size of the PA/4000 necessitates two people for installation.
  • Page 22 PA/4000 User’s Manual Section 4, Installation Page 2...

  • Page 23: Mounting The Main Unit To The Stand

    4. Raise the main unit up and off the surface with the crank handle on the top of the stand and roll the unit away from the surface for further assembly. Parts: 1 PA/4000 main unit [B] Assembly: Attach the main unit to the yoke with bolts provided [A].

  • Page 24: Mounting Attachments To The Main Unit

    PA/4000 User’s Manual Section 4, Installation Page 4 4.4 Mounting Attachments to the Main Unit 4.4.1 Attaching the Label Supply Disc Parts: 1 Aluminum Rear Label Supply Disc [A] 1 Smokey Plexiglass front Label Supply Disc [F] Assembly: 1. With an Allen wrench, loosen the set screw [D] on the plastic collar that is attached to the aluminum rear label supply disc.
  • Page 25 Assembly: 1. Slide the air cylinder/tamp pad assembly onto the extended horizontal support bar [A] on the PA/4000 main unit. 2. Position the assembly so the tamp pad [C] rests 3/16 inch [D] from the peel blade [E] on the print engine. Before...
  • Page 26 PA/4000 User’s Manual Section 4, Installation Page 6 4.5 Air Tube Connections Parts: 1 1/4 inch clear air tube marked “VAC” 1 1/8 inch clear air tube marked “AIR ASSIST” 1 1/4 inch clear air tube marked “TOP” 1 1/4 inch clear air tube marked “BOTTOM”...

  • Page 27: The Main Unit

    PA/4000 User’s Manual Section 4, Installation Page 7 4.6 Mounting the Hand-Held Terminal with Holster Parts: 1 Holster 1 Hand-Held Terminal Assembly: Mount the Holster to the Yoke The holster can be hung over the side of the yoke. Place the Hand-Held Terminal into the holster and plug...
  • Page 28 PA/4000 User’s Manual Section 4, Installation Page 8 4.7 Mounting the E-stop to the Stand The E-stop attaches to the middle of the upright part of the stand assembly [A]. Remove the E-stop cover and use the opened box for a template for drilling the two holes needed to bolt it to the stand.

  • Page 29: Mounting The Air Filter Assembly To The Stand

    [B]. This ground cable provides ground bonding between the stand upright and the PA/4000 Main Unit. Attach the air output hose from the main unit to [C]. Attach the factory input air hose to [G]. Use clean unlubricated air supply (95-120 psi –...

  • Page 30: Mounting The Optional Warning Tower To The Stand

    PA/4000 User’s Manual Section 4, Installation Page 10 4.9 Mounting the Optional Warning Tower to the Stand If your system does not have a warning tower, move to the next section. Parts: 1 Warning Tower [A] with cable [D], mounting plate and...

  • Page 31: Mounting The Photosensor

    Section 4, Installation Page 11 4.10 Mounting the Photosensor The distance between the photosensor and the PA/4000 is not crucial. A good guideline is to place the photosensor as close as possible to the applicator. Parts: 1 Diagraph photosensor kit P/N 5700-216 Assembly: 1.

  • Page 32: Mounting The Optional Secondary Wipe-Down

    PA/4000 User’s Manual Section 4, Installation Page 12 4.11 Mounting the Optional Secondary Wipe-Down Applicator If your system has a secondary wipe-down applicator, follow the installation and operation instructions in the Secondary Wipe-down User’s Manual (5802-930).

  • Page 33: Electrical Connections

    PA/4000 User’s Manual Section 4, Installation Page 13 4.12 Electrical Connections The following installation notes cover ALL cable connections. Skip any directions for connecting devices that are not included in your system. Rear Panel Inputs Hand-Held Terminal Connect the RJ-11 cord to input J1 [C]. Place the terminal in its holster when not in use.

  • Page 34: Loading The Label Roll

    PA/4000 User’s Manual Section 4, Installation Page 14 4.13 Loading the Label Roll Follow the label web path shown on the label inside the print engine. Remove the outer supply disk from the label supply hub [F] and set aside.

  • Page 35: Loading The Ribbon Roll

    PA/4000 User’s Manual Section 4, Installation Page 15 4.14 Loading the Ribbon Roll Follow the diagram of the ribbon path inside the print engine cover. 1. Raise the printhead lift lever [A]. 2. Remove remaining ribbon from the ribbon rewind roller [C].

  • Page 36: Minimum And Maximum Distances For The Pa/4000

    4.15 Minimum and Maximum Distances for the PA/4000 Top Down Application In this configuration, the PA/4000, with a 6 inch tamp cylinder, applies labels to the top panel of a carton. The height of the conveyor plus the tallest box must be greater than 10 inches and...
  • Page 37 Page 17 Side Panel Application, Nose Down In this configuration, the PA/4000 applies labels to the side panel of a carton. For this setup, the height of the conveyor must be greater than 22 inches and less than 58 inches.
  • Page 38 Page 18 Side Panel Application, Nose Up In this configuration, the PA/4000 applies labels to the side panel of a carton. The distance from the back of the tamp plate to the floor must be greater than 30 ½ inches and less than 62 inches.

  • Page 39: Final Positioning

    2. Unlock casters. 3. Carefully push the PA/4000 into its position next to the conveyor. 4. Bolt the PA/4000 to the floor through the holes in the t-base. 5. Make necessary connections such as power cords, airline and photosensor cable.

  • Page 40: Section 5.0 Configuration

    5.1.1 Configuring the Power Module for the 110/120VAC Application Failure to use proper fuses and/or install the fuse assembly for correct voltage can damage the PA/4000. Disconnect the power cord before servicing the power module. Pop the fuse assembly up and out of the power module with a flat head screwdriver.
  • Page 41 PA/4000 User’s Manual Section 5, Configuration Page 2 5.1.2 Configuring the Power Module for the 220/240VAC Application Failure to use proper fuses and/or install the fuse assembly for correct voltage can damage the PA/4000. Disconnect the power cord before servicing the power module.

  • Page 42: Hand-Held Terminal Configuration

    Page 3 5.2 Hand-Held Terminal Configuration The Hand-Held Terminal for the PA/4000 is designed for industrial environments. It controls applicator functions that print and apply labels. It features a one-line sixteen character text LCD display, four LED lights that show power on and warn of error conditions and seven control keys that are described below.
  • Page 43 PA/4000 User’s Manual Section 5, Configuration Page 4 LCD Contrast or Scroll Keys [C] Hold the 2 key down while pressing the up or CONTRAST down arrow keys to control LCD Display contrast. Up key to increase contrast, down key to decrease contrast.
  • Page 44 Product Delay – Adjusts the input delay of photosensor 1 causing the tamp pad to delay before extending to apply a label. Adjust from 0-999. Output Delay – Adjusts the amount of time an external device like the PA/4000 secondary wipe-down unit delays before it triggers. Adjust from 0-999.
  • Page 45 With the output sensor set to 1 the output pulse will be sent through photosenser 1. The drawing below shows the input signal from Photosensor 1 coming into the PA/4000 triggering the tamp pad, and with the same signal triggering a secondary device (both using the same edge of the product, leading or trailing).
  • Page 46 Page 7 Auto-Retract - Enables or Disables the Auto-Retract feature of the PA/4000. The Auto-Retract sensor is located on the tamp pad. It senses the product when the tamp pad extends to apply a label, then commands the tamp pad to retract to the home position. If the sensor does not detect...
  • Page 47 PA/4000's memory. If you press the STOP/CLEAR key USE/ STOP/ CLEAR twice, you will clear two print jobs from the PA/4000's memory. Once you press this key, you must press the PAUSE/RESUME key to resume printing. NOTE: Pressing the STOP/CLEAR key will NOT clear any PA/4000 Error conditions.
  • Page 48 PA/4000 User’s Manual Section 5, Configuration Page 9 5.2.1 Error or Indications Menu The Error Menu indicates problems the system is currently experiencing. An error messages will appear on the Hand-Held Terminal display screen. When the red Error LED lights on the hand-held terminal, you will need to check the Error Menu by holding down the 2nd key and pressing the MENU/SELECT key twice.
  • Page 49 The eight position DIP Switch block labeled SWS1 [A] is located on top of the PA/4000 main unit next to the RS-232 connector. Switches 1, 2 and 3 control the baud rate while switches 4-8 control printer features such as word length, compatibility, present sensor, ribbon sensor and cutter enable.
  • Page 50 Page 11 5.3.2 Setting Other Printer Features The PA/4000 can accept 7 or 8 bit data, while ignoring parity. It also requires at least 1 stop bit. This configuration assures the greatest compatibility with most serial devices, even if the data format arrangement of the host cannot be modified.
  • Page 51 5.4 Configuring the Air Cylinder/Tamp Pad This section assumes that you have already made all electrical and air pressure connections and that a label has been sent to the PA/4000 from an outside source; ie: a PC with Performance Series for Windows Labeling Software.
  • Page 52 Record the turns on the PA/4000 Configuration Sheet (see Section 6). You may have to readjust the tamp air pressure [F] to get the correct amount of air pressure.
  • Page 53 Note the air flow control instructions in Section 5.4.1. Tamp Dwell settings and cycle time times for the PA/4000 are in the following chart: 6. Press the MENU/SELECT key to save Tamp Complete the new value.
  • Page 54 (with no missed products). NOTE: Following this procedure will minimize the possibility of damage to the PA/4000 or the product if the auto-retract does not detect the product. 5.4.4 Setting the Product Delay with the Hand-Held Terminal...
  • Page 55 PA/4000 User’s Manual Section 5, Configuration Page 16 DELAY TIME (MILLISECONDS) 72.2 90.4 111.5 170.9 277.9 376.9 479.2 681.7 884.4 1095.7 1300 1497.8 1708.7 1911 2116.3 2321.3 2523.8 2736.8 2939.3 3140.1 3344.9 3548.0 3758.4 3962.5 4160.4...
  • Page 56 Page 17 To set the Product Delay value: 1. Start the conveyor. 2. Take the PA/4000 out of pause mode by pressing the PAUSE/RESUME key on the Hand-Held terminal. 3. From the Menu screen, press the down arrow key three times.
  • Page 57 5.5 Example Job Setup The following section shows an example job setup based on PA/4010. NOTE: Move the PA/4000 away from the line until your Hand-Held Terminal settings are correct. STEP 1: After system installation and configuration, check for any errors. If the system is operating normally, the screen will display ALL OK.
  • Page 58 PA/4000 User’s Manual Section 5, Configuration Page 19 STEP 7: Set the Transfer. • From the Output Delay screen, press the down arrow key twice. • Press the MENU/SELECT key once to enter edit (flashing) mode. • Use the arrow keys to enter a Transfer value of OFF.

  • Page 59: Section 6.0 Operations

    6.1 Start of the Day Step 1 – Check Configuration. Look at the configuration sheet attached to the PA/4000 (see page 3 of this section). Check all system settings against those recorded on the sheet. Step 2 – Check Power.
  • Page 60 PA/4000 User’s Manual Section 6, Operations Page 3 PA/4000 CONFIGURATION SHEET Serial No.__________________________________________________________________ Production Line_____________________________________________________________ THESE VALUES SHOULD ONLY BE CHANGED BY MAINTENANCE OR OTHER TRAINED PERSONNEL HAND HELD MENU SETTINGS The values recorded on this sheet will be different from one production line to the next. Factors such as line speed, distance from the PA4000 tamp pad to the product, and the location of the product sensor will determine the actual values.

  • Page 61: Adjustments During Operation

    Section 6, Operations Page 5 6.2 Adjustments during Operation Print Quality PA/4000 Print engine has adjustments for controlling the quality of print on the labels. Two of most important adjustments are print darkness (printhead temperature) and print speed. If you are using Performance Series for Windows software, review chapter 5 on Printing Formats in the Performance Series User’s...

  • Page 62: Section 7.0 Prodigy Plus

    PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 1 7.0 Prodigy Plus Internal Fonts and Bar Code Examples This section describes all character fonts and bar codes internally available in the Prodigy Plus print engine. 7.1 Explanation of Fonts and Bar Codes...

  • Page 63: Bar Codes

    PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 2 7.1.2 Bar Codes Ratio Based Bar Codes with Human Readable fonts (UPPERCASE) Pr odi gy Pl us ( act ual D P I - 203) Rat i o 2: 1...

  • Page 64: Internal Font Examples

    PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 3 7.2 Internal Font Examples These font examples are of all nine Prodigy Plus standard internal fonts. They are numerically named. All examples are printed with a 10 x 10 mil pixel size, and a 1x magnification on the horizontal and vertical dot patterns.
  • Page 65 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 4 Font 2 Identifies a 138-character alphanumeric upper and lowercase font. Characters are 18 dots high, 10 dots wide, and 2 dots spacing. Prodigy Plus Prodigy Plus 152 Font 3 Identifies a 62-character alphanumeric font, uppercase.
  • Page 66 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 5 Font 4 Identifies a 62-character alphanumeric font, uppercase. Characters are 36 dots high, 18 dots wide, and 3 dots spacing. Prodigy Plus Prodigy Plus 152...
  • Page 67 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 6 Font 5 Identifies a 62-character alphanumeric font, uppercase. Characters are 52 dots high, 18 dots wide, and 3 dots spacing. Prodigy Plus Prodigy Plus 152...
  • Page 68 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 7 Font 6 Identifies a 62-character alphanumeric font, uppercase. Characters are 64 dots high, 32 dots wide, and 4 dots spacing. Prodigy Plus...
  • Page 69 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 8 Prodigy Plus 152...
  • Page 70 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 9 Font 7 Identifies a font that prints OCR-A, size I. Characters are 32 dots high, 15 dots wide, and 5 dots spacing. Prodigy Plus Prodigy Plus 152 Font 8 Identifies a font that prints OCR-B, size III.
  • Page 71 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 10 Font 9 Identifies the CG Triumvirate smooth font. The characters are available in upper and lowercase. Point sizes are selected by number in the bar code height. Prodigy Plus...
  • Page 72 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 11 (Font 9 Continued) Prodigy Plus 152...

  • Page 73: Bar Code Examples

    PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 12 7.3 Bar Code Examples Bar Code A Identifies the Code 3 of 9 bar code with a human readable font. Code 39 is an uppercase, alphanumeric bar code that is variable in length. The valid ASCII characters for this font are: 32, 36-37, 42-43, 45-47, 48-57, 65-90.
  • Page 74 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 13 Option V- Identifies Random Weight UPC bar code. The seventh digit supplied by the host or application software must be an uppercase V followed by 4 digit weight information. Eleven digit checksum is supplied by the printer.
  • Page 75 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 14 Bar Code E Identifies the Code 128 variable length bar code with modulo 103 checksum calculation. Code 128 can encode the entire 128 ASCII character set, including both uppercase and lowercase alpha characters.
  • Page 76 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 15 As an example, to get FNC2 to be encoded into a Code Subset A bar code, send the ASCII & (ASCII 38, HEX 26) followed by an ASCII B (DEC 66, HEX 41), code FNC2 will be encoded.
  • Page 77 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 16 Bar Code F Identifies the standard EAN-13 bar code, Numeric-only bar code; fixed in length. Twelve digits are supplied by host or application software, 13th digit checksum supplied by printer. If the 13th digit is sent by the host, the printer will check that character against the calculated checksum and will print the bar code as all zeros if they do not match.
  • Page 78 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 17 Bar Code H Identifies the HIBC (modulo 43 checksum) version of the code 3 of 9 bar code. The checksum will be placed at the end of the data string that is received from the host. The host device must supply a leading + to identify the data format type.
  • Page 79 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 18 Bar Code J Identifies an I 2 of 5 bar code with modulo 10 checksum calculation. The ASCII range for the numeric codes is 48-57. Code I 2 of 5’s normal wide to narrow bar ratio is 5:2.
  • Page 80 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 19 Bar Code L Identifies an I 2 of 5 bar code with modulo 10 checksum (UPC shipping container symbology) that does the special human readable formatting for and adds bearer bars to the top and bottom of bars when encoding 13 digits.
  • Page 81 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 20 Bar Code N Identifies the 5 digit addendum code for UPC fonts. It is a numeric-only bar code with a fixed length of 6 characters. Two characters supplied by the host or application software, the sixth digit checksum supplied by printer.
  • Page 82 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 21 Bar Code P Postnet bar code. This is the small bar code on letters encodes Zip codes. It usually contains a 9 digit code followed with a checksum value. Sometimes a two digit post office code will be attached to the zip code.
  • Page 83 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 22 7.4 Sample Label Parameters and Fonts The sample label parameters and fonts illustrated apply to the standard Prodigy Plus 203 dpi. 191100900000055CM2160-CAM 1a6204000800015CM2160-CAM 112200000650065CM2160-CAM 191100502600020BMM CAMCORDER 191100502350020WITH REMOTE 191100302050020* Autofocus...
  • Page 84 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 23 1911002014500552345 1E2212500000005C005940928123401&E^ 1X1100001450010B300060002002 1X1100001750012L296002 1X1100001470115L002028 1X1100001470235L002028 1X1100001770235L002026 1X1100001770185L002026 101100001500015NUMBER 101100001600015SERIAL 101100001500118PRODUCT 101100001500240BRAND 101100001800240LINE 101100001800015PLANT 191100301740070P-12621 191100301740190KK 19110030174027501 191100201450159005940 191100201450268928 4a3104000000380ABCDE12345 121100103000000PRODIGY PLUS WITH RIBBON SAVER...
  • Page 85 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 24 491100600850333000001 4a9305000100380S000001 421100000100328 (S) 4211000001003128SERIAL 1X1100004130305L002090 1X1100005030305L002090 4a9305000100300V032380 421100000100248 (V) 421100000100238SUPPLIER 491100600850252032380 1X1100000100225L002590 4a9305000100220Q30 421100000100135 (Q) 421100000100125QUANTITY 49110090085016830 1X1100000100113L002590 4a9305000100108P72715-FE3-0030 421100000100030 (P) 421100000100020PART NO. 49110090085006272715-FE3-0030 491100200100393 1X1100002900115L110003 1X1100004100227L175003 1X1100005100227L175003...
  • Page 86 PA/4000 User’s Manual Section 7, Fonts and Bar Codes Page 25 4a620500020008533121111111 49110060020003533121111111 431100002300025(1P) 4a6205000200174AA10000 491100600200123AA10000 431100001700115(S) 4911005001002103300 12X12 CORDED TABLET WITH 491100500100230BUTTON INLINE CURSEOR - PC 491100500100250100/110 1X1100000040180L004392 1X1100000040270L004392 491100400100295DIAGRAPH CORPORATION 4911004001003123401 RIDER TRAIL SOUTH 491100400100347 USA 491100400100363 (800) 521-3047...

  • Page 87: Section 8.0 Printing Labels

    .BMP, .PCC and .PCX. This section describes printer configuration and label formatting specifically for the PA/4000. This section does not contain information about creating, editing or deleting labels from your database. For information on these topics, consult your Diagraph Performance Series for Windows Software Manual.
  • Page 88 PA/4000 User’s Manual Section 8, Printing Labels with Performance Series for Windows Page 2 Click on the Settings from the Menu bar. Click on Printer Configuration. You will see the Printer Configuration menu. Click on the printer you will use.
  • Page 89 PA/4000 User’s Manual Section 8, Printing Labels with Performance Series for Windows Page 3 8.2 Label Format Setup After the Printer Configuration options have been set, you are ready to open an existing label and format it. To do this: Click on the Open icon from the Menu bar and choose an existing label.
  • Page 90 PA/4000 User’s Manual Section 8, Printing Labels with Performance Series for Windows Page 4 2. Set the Presentation Position to 0. (May need to be adjusted. If you are driving the PA4000 directly with custom software, set the DIP switch positions DSW1 as shown below).
  • Page 91 PA/4000 User’s Manual Section 8, Printing Labels with Performance Series for Windows Page 5 2. SPECIFIC LABEL OFFSET - controls the offset value for a specific label in your database. This is found under the View – Change Format Specification menu when you have an existing label opened.

  • Page 92: Printing A Label

    PA/4000 User’s Manual Section 8, Printing Labels with Performance Series for Windows Page 6 8.3 Printing a Label Double-click on the Performance Series icon. The Performance Series Main Menu will appear. Click on the Printer icon. The Print Format screen will appear. Click on a label to be printed and click Open.
  • Page 93 PA/4000 User’s Manual Section 8, Printing Labels with Performance Series for Windows Page 7 Once you have sent a label to print, the Print Request screen will appear. Click OK to download the selected label to the PA/4000.

  • Page 94: Section 9.0 Maintenance

    PA/4000 User’s Manual Section 9, Maintenance Page 1 9.0 MAINTENANCE 9.1 Daily Maintenance Clean the Printhead. ! Turn OFF the printer and unplug the unit from the outlet before cleaning the printhead. Clean the printhead after each ribbon/label change. Clean with alcohol and swabs.

  • Page 95: Six Month Maintenance

    This can damage the PA/4000. To prevent this, be sure there are no products on the line or pull the PA/4000 away from the line before sliding the air valve to OFF.

  • Page 96: Section 10.0 Troubleshooting

    PA/4000 User’s Manual Section 10, Troubleshooting Page 1 10.0 TROUBLESHOOTING Attention to detail and common sense will greatly reduce the risk of accidents. For safety, always stop the conveyor first. Whenever troubleshooting, always start by checking for error messages on the Hand-Held Terminal.

  • Page 97: Printing Problems

    Press PAUSE/RESUME key to resume printing. Possible Cause: Printer could be stopped. ACTION: Press PAUSE/RESUME key to resume printing. Possible Cause: PC has not sent a batch of labels to the PA/4000. ACTION: Send the labels. Possible Cause: Label present sensor saturated. ACTION: Shade the PA/4000 from all ambient light.
  • Page 98 ACTION: Different print engines have different ribbon requirements. Make sure that the ribbon loaded in your print engine is compatible. Check the print engine manual or call Diagraph at 1-800-526-2531. Possible Cause: Failed true type font and/or graphic download. ACTION: Check both the manual for your label-formatting software and the print engine manual.
  • Page 99 Accumulated material on the label drive roller located behind the peel blade. ACTION: Pause the PA/4000. Release the printhead lift lever. Remove label stock from printer. Clean debris from the label drive roller. Roller can be turned by hand. Reload label stock and lower printhead lift lever to lock the printhead in place.
  • Page 100 PA/4000 User’s Manual Section 10, Troubleshooting Page 5 Problem: No cutter signal. ACTION: Check cutter cable connections and conditions. May need to replace Prodigy Plus Board. Problem: No solenoid reset (clicking) on turning switch ON. Probable Cause: Transformer is bad or there is a bad cable.

  • Page 101: Tamping Problems

    20-40 psi. Possible Cause: Photosensor 1 problem. ACTION: 1. Check the cable connection between the photosensor and PA/4000. 2. Clean the photosensor lens with a soft-tipped swab and isopropyl alcohol. 3. Adjust and direct Photosensor 1 at the product.
  • Page 102 PA/4000 User’s Manual Section 10, Troubleshooting Page 7 Problem: Cylinder extends but retracts before reaching products. Possible Cause: Tamp dwell time set too small 1. The dwell time must be greater than 30 ms to extend the ACTION: cylinder. If it is less than 30 ms, increase the value no more than 10 ms at a time.
  • Page 103 Possible Cause: Cylinder rods are bent ACTION: Determine what caused the cylinder to bend and call Diagraph Service for replacement cylinder kit (6150-830 for a 6-inch cylinder assembly, 6150-831 for 12-inch cylinder assembly and 6150-832 for an 18-inch cylinder assembly).
  • Page 104 ACTION: Turn auto-retract ON. Possible Cause: Auto-retract sensor is saturated. ACTION: Shade the PA/4000 from all ambient light Possible Cause: Auto-retract sensor is out of its focal range. ACTION: Align the tamp cylinder with the product by extending the tamp cylinder until the tamp pad makes contact with the product, or rotate the yoke until the pad lays flat against the product.
  • Page 105 PA/4000 User’s Manual Section 10, Troubleshooting Page 10 read 5VDC. With paper under the retract sensor it should read under 1/2 V. Possible Cause: Applicator board is bad. ACTION: If there is still no voltage, replace the applicator board. Problem: Label applied too early.
  • Page 106 PA/4000 User’s Manual Section 10, Troubleshooting Page 11 5. Carefully re-examine the above operation before running the conveyor. Problem: Label applied too late. Possible Cause: Photosensor distance set too long. ACTION: 1. Carefully measure the distance from the peel blade to Photosensor 1.
  • Page 107 2. If the labels are not adhering firmly to the product due to inadequate tamp pressure, increase the tamp pressure. 3. If the label stock is incorrect, call Diagraph to order correct label stock. Possible Cause:...
  • Page 108 Print speed set too slow. ACTION: Increase the print speed of your print engine. Problem: PA/4000 feeds label correctly, but will not tamp. Possible Cause: Cutter cable from applicator board to J11 on the circuit board is not connected in the correct orientation. ACTION:...
  • Page 109 Section 10, Troubleshooting Page 14 Problem: PA/4000 feeds too many labels at a time and air assist will not shut off. Possible Cause: Cutter cable from applicator board to J11 on the circuit board is not connected in the correct orientation.
  • Page 110 Problem: Performance Series Software appears to have a Lost Batch Possible Cause: A failed label is in the printer. ACTION: 1. The batch is not lost, remove the failed label and the PA/4000 will print and apply the entire batch.

  • Page 111: Error & Warning Messages

    PA/4000 User’s Manual Section 10, Troubleshooting Page 16 10.5 Error and Warning Messages The LCDs on the Hand-Held Terminal reports both error and warning messages. An error message appears when: ! The system can not print or apply ! The safety of the system is in jeopardy...
  • Page 112 PA/4000 User’s Manual Appendix A, ASCII Control Code Chart Page 1 APPENDIX A ASCII Control Code Chart Code page 850. 1–127 available characters printed. C har Dec Hex C har Dec Hex C har Dec Hex C har Dec Hex...
  • Page 113 PA/4000 User’s Manual Appendix A, ASCII Control Code Chart Page 2 ASCII Control Code Chart Code page 850. 128–255 available characters printed. C har Dec Hex C har Dec Hex C har Dec Hex C har Dec Hex Ç á...
  • Page 114 PA/4000 User’s Manual Appendix B, Cable and Pin Connections Page 1 APPENDIX B Cable and Pin connections For most applications, the interface between the Prodigy Plus and the PC will be RS- 232C. The cable needed to connect the printer to the PC will be either a straight through or null modem cable.
  • Page 115 Appendix B, Cable and Pin Connections Page 2 Cable Connections Straight Null Modem Cable (MXM) NOTE: Cable used for typical connection to other DCE equipment with XON/XOFF flow control. Straight Cable (MM) PC (DB25P) To PA/4000 PA/4000 SHIELD 3RXD TXD2 2TXD RXD3...
  • Page 116 PA/4000 User’s Manual Appendix B, Cable and Pin Connections Page 3 PC (DB9P) to PA/4000 PA/4000 SHIELD 3RXD TXD3 2TXD RXD2 20BUSY GROUND 4RTS 5CTS DB9S DB25P NOTE: Cable used for connection to PC compatible with DB25P communication ports. Flow control is either XON/XOFF or CTS/DTR.

  • Page 117: Communication Specifications

    PA/4000 with an Allen-Bradley PLC. For successful implementation, you should be able to program and operate an Allen-Bradley PLC and be able to program block transfer instructions. You will also need access to the PA/4000 host commands and their parameters.
  • Page 118 The instructions in this section cover setting the backplane switches in an Allen- Bradley 1771 I/O chassis and the DIP switches in a PLC. Specifically, they cover the configuration of an Allen-Bradley PLC to run the Diagraph sample program through RIO on the PA/4000.
  • Page 119 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 3 Backplane Chassis Switches...
  • Page 120 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 4 PLC Switches DIP Switch Bank S1 Switch 7 is not used. DIP Switch Bank S2 RS-232C ON ON ON OFF OFF ON ON OFF ON OFF RS-422A OFF OFF ON OFF OFF OFF OFF OFF ON OFF...
  • Page 121 RATE BITS USED LAST STOP RACK Disconnect the power from the PA/4000 and remove the four screws that secure the top (the plate with the LED status markings). Note the DIP switch positions in the illustration above. Switch settings follow.
  • Page 122 DIP switch bank S1 sets both the rack quarter and the rack address. Use the tables below to set the switches to match your PLC configuration. A valid rack address depends on the type of PLC in use. The tables below show available variations. Asterisks mark PA/4000 RIO factory-default settings. Bit 1 Bit 2...
  • Page 123 Normal state is off. Green LEDs 2 & 5 Signals communication to the PLC from the PA/4000. It flashes during send or receive. LED 5 blinks when communication occurs between the RIO board and the controller.
  • Page 124 Sample Program for RIO The diskette included with this system has a sample ladder logic program that prints messages with a PA/4000. It can serve as a first step in establishing successful communication between the PA/4000 and the PLC. Equipment used to set up Sample Program The listing below details a configuration verified by Diagraph that successfully ran the Sample Program.
  • Page 125 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 9 Sample Program 1 Rung-by-Rung Rung 1 - Message Creation and Print/Apply When B3/1 bit is latched the PLC transmits data to create and print/apply labels: \02(STX)RN disable ribbon saver \02(STX)f283...
  • Page 126 Rung 2 - When the transfers in rung 2 are complete, the B3/2 bit is automatically unlatched (set back to 0). Rung 3 - When the Remote I/O Module receives data from the PA/4000 that needs to be transmitted back to the PLC, it sets a discrete bit. When the module resides on Rack Address 3 Group 0, that bit is I:030/10.
  • Page 127 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 11 Starting Allen-Bradley 6200 Software 1. Set the current directory to \IPDS. 2. Type ABMENU and press Enter. The MAIN MENU appears. 3. Press F5 to choose PLC-5. The PLC-5 Programming Software menu appears.
  • Page 128 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 12 4. Press F2 for Online Configuration 5. Use the function keys and change the configuration parameters to match those shown in the screen sample above. 6. Save the configuration with F9.
  • Page 129 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 13 2. Press F2 for Save/Restore. 3. Press F4 to start the Restore Program process. 4. Select "PA4000" with the arrow keys.
  • Page 130 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 14 Press F1 to begin the restore process. 6. Press F7 for General Utility.
  • Page 131 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 15 7. Press F4 for Channel Overview. 8. Use the arrow keys to pick Channel 1A. 9. Press F5 for the Configuration Menu and set the variables as shown below: Rack Address...
  • Page 132 PA/4000 User’s Manual Appendix C, PA/4000 Remote I/O Page 16 Press ESC three times to return to the Program Directory for Processor. 11. Press F8 for the Monitor File.

  • Page 133: Media Supplies

    PA/4000 User’s Manual Appendix D, Replaceable Components and Supplies Page 1 APPENDIX D REPLACEABLE COMPONENTS AND MEDIA SUPPLIES Replaceable components and media supplies can be ordered from Diagraph. To order call 1-800-521-3047. Replaceable Components Component Description Part Number 1770-078 Regulator...
  • Page 134 Media Supplies Labels Diagraph recommends its LTS line of labels for thermal transfer printing, and its ATS line for direct-thermal printing. Stock sizes can range from 2 inches (50.8 mm) wide by 1 inch (25.4 mm) long to 4.5 inches (114.3 mm) wide to 13.00 inches (330.2 mm) long, printable area 4.1 inches left justified.
  • Page 135 Prodigy Plus print engine. Use of ribbons other than those supplied by Diagraph Value Added Resellers (VARs) or by Diagraph may result in a poor quality printing of bar codes and their ability to be scanned. This may invalidate the printhead warranty.
  • Page 136 Additional sizes other than those listed above are available on a custom order basis. Lists of Approved Media For a current list of Diagraph approved standard media for use in Diagraph thermal and thermal transfer printers, please contact your Diagraph Sales Representative at 1-800-521-3047.
  • Page 137 This type of file is used in building a turnkey application that requires very little input from a user before starting. Auto-Retract—Feature of the PA/4000 that causes the tamp cylinder to return to the home position when it encounters resistance. background—In bar codes, the lighter portion of the printed code which includes the quiet zones.
  • Page 138 (elite) prints twelve characters per inch; ten pitch (pica) prints ten characters per inch. character string—A group of characters, such as “JOHN SMITH” or “DIAGRAPH.” check digit—Character used in a bar code to provide additional data security and checks errors; derived with an algorithm employing the other digits in the code.
  • Page 139 download -Transmission of data from a central computer to a smaller computer or a computer at a remote site. To upload is the exact opposite. downtime—Periods of time when a computer or manufacturing system is not available to perform work. dpi—dots per inch.
  • Page 140 PCX—File extension for bit-mapped graphics file for PC-Paintbrush and other applications that support the PCX format (300 dpi). Peel Blade—A metal plate inside the PA/4000’s print engine that separates the label stock from its non-adhesive leader. Photocell—A light-sensing device that detects a product on a conveyor line and triggers the PA/4000 to print and apply a label.
  • Page 141 RJ-11—A telephone-type connector used to connect the Hand-Held Terminal to the PA/4000 RJS—Manufacturer of bar code verifiers. ROM—Acronym for Read Only Memory, semiconductor memory containing fixed data that cannot be changed once programmed in manufacture.
  • Page 142 thermal transfer printing—An imprinting method that uses heat and pressure to melt a wax-based ink onto a label. transducer—Device that converts signal from one physical form to another. UCS—Uniform Container Symbols UPC E/UPC Version E0/—The zero suppression version of UPC A. Specified for use in the Retail environment.
  • Page 143 Service/Technical Service/Technical Service/Technical Service/Technical Manual Manual Manual Manual Diagraph PA/4000 Label Printer/Applicator 5802-929 Revision A 3401 Rider Trail South • St. Louis/Earth City, MO. • 1-800-521-3047, ServiceLine 1-800-526-2531 Diagraph Corporation ©1995...
  • Page 144 Information in this manual is subject to change without notice. This manual contains information protected by copyright, with all rights reserved. No part of this manual may be reproduced in any form without prior written consent from Diagraph Corporation. Printed in the U.S.A.

  • Page 145: Theory Of Operation

    NORMAL OPERATION To begin normal printing and applying: • Set up the PA/4000 with the necessary air and power requirements (Refer to Section 2 in the Users Manual) • Set the Menu Select Items using the Hand-Held Terminal (Refer to Section 4 of the User’s Manual) •...
  • Page 146 Plus generates a cutter signal, marking the end of the print cycle. • The applicator board turns the Air Assist OFF when it receives the cutter signal. • The PA/4000 is now ready to apply the next label and the cycle continues. Technician’s Guide...
  • Page 147 By adding the Secondary Wipe Down Assembly to the system, labels can be applied to both the side/front or side back of a box. The PA/4000 vertical positioning is flexible as well and can be adjusted with the crank handle on top of the stand.
  • Page 148 The Applicator Logic Board is a microprocessor based board that controls the Applicator function of the PA/4000. It monitors the tamp pad sensors as well as controlling the valves that actuate the cylinder that applies the label to the product. The Applicator Board also communicates to the Hand-Held Terminal and interfaces with the Prodigy Plus Board.
  • Page 149 Prodigy Plus Board. Pin 2 voltage is greater than 4.5 Vdc, when there is no cutter signal, and it changes to less than 0.5 Vdc when the cutter signal occurs. Remember that the PA/4000 must have the Cutter Cable (6105-273) attached to the J7 connector and it must have the Cutter option enabled in the Performance Series software for the unit to operate correctly.
  • Page 150 Photo Cell 1 and Photo Cell 2 also come onto the Applicator Board through the P1 connector. CONNECTOR BOARD (6105-138) The Connector Board provides the cable connections for the PA/4000’s external hardware. The external hardware consists of the following items:...
  • Page 151 (6105-263) must be connected to the P1 connector for the PA/4000 to operate correctly. REGULATOR ASSEMBLY (6105-384) To broaden the range of sensors that can be used, future revisions of the PA/4000 will have a Regulator board that takes the 33 Vdc +/- 3 volts from the Prodigy Plus board and regulates it to 24 Vdc +/- 0.5 volts.
  • Page 152 4.0 of the User’s Manual contained in Section 1 of this manual. PRODIGY PLUS BOARD (2801-027) The PA/4000's control board contains the power supplies, CPU, memory, serial I/O, motor I/O logic, and logic for supplying data to the printhead. The board is intensively controlled by software and, except for correcting the obvious, it is most likely more economical to replace than to repair the PA/4000's control board.
  • Page 153 U2, the 74HC245 in the upper left hand corner, buffers the settings of SW1 on the back of the PA/4000 from the control board data buss. If the self test patterns (see the Prodigy Plus Operator's Manual) indicate that the switches do not change when you have physically flipped the switches, replace this chip first.
  • Page 154 To enable the cutter signal, SW1-8 on the back of the PA/4000 must be in the ON position. A serial command may be sent to the PA/4000 to set the length of time the signal is active during each print cycle. The cutter signal instruction as listed in the Prodigy Plus Operator's Manual, is the "Hnnnn"...
  • Page 155 The stepper motor is a 6V DC stepper motor designed to pull media through the PA/4000. If problems occur that you feel are related to the stepper motor, first check for a jam in the PA/4000 on both the media side and the mechanical drive side of the PA/4000 center plate.
  • Page 156 The 512K ram module contains ram memory which may be written to in either bank A or B. The 512K ram is used in the upper bank (A). 256K will be used for the PA/4000's dot memory buffer and 256K will be used for graphic images, font data, and label formats. When the 512K ram module is used in lower bank B all 512K will be used for graphic images, font data, and label formats.
  • Page 157 Battery Current * With Power OFF * After the time and date has been set 20.0V +/- 1.0V Regulated Print Head Voltage PA/4000 must be printing to check Figure 2-3 Other Voltage Checks U1 PIN 8 4.6V +/- 0.3V...
  • Page 158 less than 10mV Anti noise current Right Side After a label feed 50mV to 90mV Idle current Left Side After a label feed WARNING: Be very careful to avoid shorting the test probes when checking the following voltage. Red Wire 33.0V +/- 3.0V Unregulated Head Voltage NOTE:...
  • Page 159 NOTE: Cable is used for typical connection to other DCE equipment with XON/XOFF flow control. STRAIGHT CABLE (MM) NOTE: Cable is used for typical connection to other DCE equipment with XON/XOFF flow control. PC (DB25P) TO PRODIGY PLUS Technician’s Guide 2-15...
  • Page 160 NOTE: Cable is used for connection to ìPCî compatible with DB25P communication Ports. Flow control is either XON/XOFF or CTS/DTR. PC (DB9P) TO PRODIGY PLUS NOTE: Cable is used for connection to ìPCî compatible with DB25P communication Ports. Flow control is either XON/XOFF or CTS/DTR. Technician’s Guide 2-16...
  • Page 161 Tamp not operating. No air • Factory air supply may not be connected to the PA/4000. Connect incoming air supply to the air filter (see Section 2 for more information). Tamp cylinder extends into • Make sure the OSHA air shut-off valve the box path.
  • Page 162 Too much ambient light in the room. Tamp head is hitting the Auto-Retract is not • Check to be sure the PA/4000 is level, box too hard or too soft. working properly/DWELL secure and parallel to the product. value is set too high •...
  • Page 163 Printer stopped. Press the PAUSE/RESUME key on the hand- held terminal. • PC has not sent a batch of labels to the PA/4000. Send a batch of labels. Loose Connection (s) • Check RS-232 cable connection. • Make sure the lock printhead lift lever is down.
  • Page 164 Tighten ribbon (see Section 2 for more information). Ribbon or labels not webbed correctly • Re-web ribbon or labels. NOTE: If the ribbon is placed in the PA/4000 backwards, you must clean the printhead before re-webbing the ribbon. Dirty or bad printhead •...
  • Page 165 2.3.1 ELECTRICAL BOX ASSEMBLY OPENING THE ELECTRICAL BOX ASSEMBLY See Engineering Drawing #6105-150 to further illustrate this procedure. Turn PA/4000’s power switch to the OFF position. Shut off the air valve on the filter assembly. Disconnect all air and electrical connections.
  • Page 166 CABLE CONNECTIONS FOR THE PRODIGY PLUS BOARD (2801-027) Figure 2-4 • Connect the Memory Module ribbon cable to J1 (A on Figure 2-4) • Connect the Control Panel ribbon cable to J3 (B on Figure 2-4) • Connect the Printhead ribbon cable to J8 (C on Figure 2-4) •...
  • Page 167 2.3.2 AIR SUPPLY ASSEMBLY OPENING THE AIR SUPPLY BOX See Engineering Drawing #6105-107 to further illustrate this procedure. Turn PA/4000’s power switch to the OFF position. Shut off the air valve on the filter assembly. Disconnect all air and electrical connections.
  • Page 168 Remove the filter inside the housing. Reverse the previous steps to replace the Vacuum Filter Assembly. Technician’s Guide 2-34...
  • Page 169 PROCEDURE FOR OPENING THE MAIN POWER BOX ASSEMBLY See Engineering Drawing 6105-100 to further illustrate this procedure. Turn PA/4000’s power switch to the OFF position. Shut off the air valve on the filter assembly. Disconnect all air and electrical connections.
  • Page 170 Tighten in place. 23. Place the retrofit label on the cover of the transformer case. 24. Reconnect the PA/4000’s power cable. 25. Turn the POWER switch to the ON position. 26. Make sure the hand-held display reads ALL OK.
  • Page 171 REPLACING THE 2.0 AMP FUSE (6105-383) See Engineering Drawing #6105-100 to further illustrate this procedure. 1. Turn the PA/4000’s power switch to the OFF position and unplug AC power cord. 2. Using the flat blade screwdriver, push down on the fuse assembly and turn counter- clockwise.
  • Page 172 PA/4000. You may need to adjust the angle supporting the hinged plastic cover to accomplish this. Align the plastic tie wrap mount with the hole in the PA/4000 as shown in Figure 2-6. 10. Secure the plastic tie wrap mount to the PA/4000 using the #6-32 flat head screw.
  • Page 173 Cut the tie wrap holding the sensor cable to the top of the air cylinder. Remove the cable from J5 on the rear panel of the PA/4000. Set aside. Find the sensor marked “P” (Present) and place it over the correct hole, facing the print engine.
  • Page 174 Be sure that the Adjustment Screw Bracket is positioned as far back as possible before re-tightening the screw. 10. Close the Electrical Box. 11. Return the system to normal operating mode. Technician’s Guide 2-40...
  • Page 175 REPLACING THE PRINTHEAD (2801-022) See Engineering Drawing #6105-101 to further illustrate this procedure. Turn the PA/4000’s power switch to the OFF position. Shut air OFF. Move the unit away from the production line and remove the power cord. Remove existing label stock and ribbon completely from the PA4000.
  • Page 176 Hand-Held Terminal to compensate for any differences between printheads. Technician’s Guide 2-42...
  • Page 177 PROCEDURE FOR REPLACING THE STEPPER MOTOR (6105-050) See Engineering Drawing #6105-101 to further illustrate this procedure. Turn PA/4000’s power switch to the OFF position. Shut off the air valve on the filter assembly. Open the plastic Print Engine Cover (6105-040).
  • Page 178 Turn the PA/4000’s power switch to the OFF position. Remove the two support screws using a 5/32 Allen wrench. Slide the Tamp Cylinder Assembly away from the PA/4000 until it detaches from the mounting bar. Slide the replacement Tamp Cylinder Assembly onto the mounting bar and towards the PA/4000 as far as it will go.
  • Page 179 Technician’s Guide 2-45...
  • Page 180 Turn the PA/4000’s power switch to the OFF position. Open the Print Engine Cover. Hold the Collar on the Electronics side of the PA/4000 and rotate the outer part of the Ribbon Take-up Hub until the set screw is accessible through the notch in the hub.
  • Page 181 Regular cleaning will keep all items free from residue. Clean the exterior of the PA/4000 using a soft damp (not wet) cloth. A mild detergent may be used to remove heavier stains. Do not use abrasive cleaners.
  • Page 182 Printhead Pressure and Support Adjustment The PA/4000’s printhead pressure comes from two springs in the head mount assembly which apply a fixed 9.5 pounds of force upon the printhead. If greater or lesser head pressure is desired, contact Diagraph Corporation at 1-800-521-3047.
  • Page 183 Phillips screws holding the label guide standoff. Loosen, but do not remove the screw. On the label side of the PA/4000 adjust the hex set screw that comes in contact with the center plate. This will raise or lower the extrusion and adjust the flow of the labels which will adjust the tracking of the labels.
  • Page 184 Feed three or four labels and observe the ribbon as it comes from the supply hub. Again, there should be no wrinkles evident. Next, feed the ribbon and paper out the front of the PA/4000 together and check the ribbon for drifting to one side away from the paper stock. If the ribbon overlaps one edge of the paper stock, the ribbon and paper are not following the same path.

  • Page 185: Darkness Adjustment

    It is connected to the front panel board by a cable and is on a shaft that goes through the center plate of the PA/4000 just below the printhead. With label stock loaded in the PA/4000, remove some labels from the backing and position the backing material in between the "fingers"...
  • Page 186 Move the Auto-Retract sensor up to see the product later - retract later - Too soft. The auto-retract sensor must be positioned slightly above the level of the pad contact surface. If the sensor is positioned even with or below the pad contact surface, the auto- retract will not function correctly.
  • Page 187 3. Release all three keys simultaneously. 4. Press the PAUSE/RESUME key. (The ERROR LED will blink). 5. The PA/4000 will now print multiple copies of the label shown in Figure 2-8. 6. Pull the labels away from the present sensor as they print.
  • Page 188 These lines list the results and values of all RAM and ROM Checksums. SERIAL PORT BAUD RATE IS 9600 This line contains the PA/4000’s Serial Port baud rate setting. TRANSFER SWITCH IS ON This line states whether the Transfer setting is ON or OFF.
  • Page 189 SETUP SWITCH OFF OFF OFF OFF OFF OFF OFF OFF This line contains the positions of the PA/4000’s DIP switches. ANALOG INPUT VALUES: PAPER: 236 EDGE: 184 TEMP: 064 POT ADJ: 139 BAT VOL: 204 These lines list the values of the sensors and adjustment potentiometers within the Printer.
  • Page 190 SECTION 3: TECHNICAL DOCUMENTATION This section contains all the technical documents you will need to service the PA/4000. To use this section, first locate the appropriate assembly using the Family Tree in Section 3.1. Next, use Table 3-1 to locate the correct Engineering Drawing in Section 3.2.
  • Page 191 3.1 FAMILY TREE...
  • Page 192 The following drawings are for reference only. Not all of the parts listed in Sections 3.2 and 3.3 are available for sale as individual items. Diagraph reserves the right to supply only the main assemblies and spare parts kits. Refer to Section 3.3 for more...
  • Page 193 3.3 SPARE PARTS KITS 6105-185 PA/4000 Level 1 Kit (Mech) Applies to all Rev. Levels Kit #6105-185 Description Quantity includes: 6105-383 Fuse, 2.0 Amp 1770-036 Gauge 1770-078 Regulator 2801-022 Printhead, Prodigy Plus 2801-033 Roller, Label Driver 2801-130 Disk, Friction Ribbon...
  • Page 194 6105-186 PA/4000 Level II Kit (Elect) Applies to Rev. Levels A-J Kit #6105-186 Description Quantity includes: 2801-027AS Prodigy Plus Board Assembly, MOD 2801-811 Rectifier Bridge 5700-216 Photocell Assembly 6105-045 Cable Assembly, Ribbon Sensor 6105-046 Cable Ass’y, Paper Edge Sensor 6105-047...
  • Page 195 6105-187 Secondary Wipe-Down Level I Kit (Mech.) Kit #6105-187 Description Quantity includes: 1741-002 Spring, Torsion – Right 1741-003 Spring, Torsion, Left 1770-036 Gauge 1770-078 Regulator 6105-092 Tamp Cylinder, 12” Twin Rod 6105-141 Roller, Latex (White) 2.0 X 4.5 6105-188 Secondary Wipe-Down, Level II Kit (Elec.) This applies to Rev A &...
  • Page 196 3.4 SPECIFICATIONS PA/4010 Tamp PA/4015 Pallet PA/4020 Dual Panel Print Method Direct Thermal/Thermal Transfer Print Speed Software selectable up to 8 inches (203mm) per second Print Resolution 203 dpi (8 dots per mm) Application Methods Tamp Tamp with auto-retract Tamp with secondary wipe- down mechanism Media Minimum 2 in.

Table of Contents