Diagraph PA/4000 User manual
Service/Technical
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 ©2000
BY ALLEN - BRADLEY TECHNOLOGY
TM
400.U0F46.D1
Diagraph PA/4000
OPERATIONS MANUAL
5802-928
Revision F
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.
The information contained in this manual is correct and accurate at the time of its publication.
Diagraph reserves the right to change or alter any information or technical specifications at
any time and without notice.
©2000 Diagraph, Inc. All rights reserved.
Printed in the United States of America
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
1.1 Specifications 1-1
1.2 Description of the Printer/Applicators in the Series 1-1
Section 2.0 Component Features and Specifications 2-1
2.1 Floor Stand Assembly 2-1
2.2 The Main Unit 2-5
2.3 Air Cylinder/Tamp Head Assembly 2-6
2.4 Air Filter 2-7
2.5 Photosensor Assembly
2.6 Hand-Held Terminal
2.7 Optional Components
2.8 Replaceable Components
Section 3.0 Packaging 3-1
3.1 Containers 3-1
Section 4.0 Installation 4-1
4.1 Overview 4-1
4.2 Assembling the Stand 4-1
4.3 Mounting the Main Unit to the Stand 4-4
4.4 Mounting Attachments to the Main Unit
4.5 Mounting the Hand-Held Terminal and Holster
4.6 Mounting the Air Filter Assembly to the Stand
4.8 Mounting the Optional Warning Tower to the Stand 4-6
4.9 Mounting the Photosensor 4-6
4.10 Mounting the Optional Secondary Wipe-Down 4-7
4.11 Electrical Connections 4.8
4.12 DIP Switch Settings
4.15 Loading the Label Roll 4-14
4.16 Loading the Ribbon Roll 4-15
4.17 Testing the PA/4000 4-14
4.18 Setting the Baud Rate and Word Length
4.19 Minimum and Maximum Distances for the PA/4000
4.20 Final Positioning 4-17
4.21 Secondary Wipe-Down Assembly 4-20
Section 5.0 Configuration
5.1 Hand-Held Terminal Configuration 5-1
5.2 PA/4000 Remote IO Configuration 5-2
PA/5000 Operations Manual
Table of Contents
Page 2
Section 6.0 Operations
6.1 Start of the Day 6-1
6.2 Adjustments during Operation 6-1
6.3 Stopping Label Application 6-1
6.4 End of Day 6-2
Section 7.0 Prodigy PlusTM Fonts and Bar Codes
7.1 Available Fonts and Bar Codes
7.2 Internal Font Examples
7.3 Bar Code Examples
Section 8.0 Printing Labels
8.1 Prodigy PlusTM Print Engine Description 8-1
8.2 Media Supplies
8.3 Sample Label Printout
8.4 Start-up and Shut down Procedures 8-1
8.5 Printing Labels with Performance Series 8-1
Section 9.0 Maintenance
9.1 Daily Maintenance 8-1
9.2 Weekly Maintenance 8-1
9.3 Monthly Maintenance 8-1
9.4 Six Month Maintenance 8-2
9.5 Intermittent Maintenance 8-2
9.6 Yearly Maintenance
Section 10.0 Troubleshooting
10.1 Diagnostics 9-1
10.2 Power Problems 9-2
10.3 Printing Problems 9-3
10.4 Tamping Problems 9-6
10.5 Error & Warning Messages 9-16
Section 11.0 Service Parts and Kits
Appendex A
Appendex BCable and Pin Connections
Glossary
Index
PA/4000 User’s Manual
Section 1, Product Features
Page 1
1.0 INTRODUCTION TO THE PA/4000 PRINTER/APPLICATOR SERIES
PA/4000 Series is comprised of three Printer/Applicators each designed with special
features for different uses. PA/4000 Series are print and apply systems designed for
high-speed, high-volume industrial applications. They are next-label-out systems that
provide true on-demand, variable data labeling. High quality print ensures excellent
legibility of critical information at every phase of the shipping process.
Each system in the series comes equipped with:
•An air cylinder tamp head assembly with auto-retract that apply labels with
great accuracy at high conveyor speeds
•A Prodigy PlusTM print engine manufactured by DataMax
•A hand-held terminal device that allows for control of applicator functions
•An air filter assembly
The PA/4000 connects to almost any computer through either the RS-232C or the RS-
422 serial interface. If your PC uses an interface other than ASCII character based RS-
232 or RS-422 you will need an interface converter. The manufacturer of your
computer will be able to recommend the proper protocol and interface converter
between the system and the Prodigy Plus’s asynchronous RS-232C interface.
An optional software package recommended by Diagraph, called Performance Series for
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. Product labeling using labels as large as 4.5 inches x 13 inches
2. Colored ribbons are available
3. Pharmaceutical and electronics packaging
4. Popular UPC bar codes
5. High-quality fonts and graphics
1.1 Specifications
Input Devices Hand-Held Terminal and PC
Communications Serial, RS-232 or RS-422 (300 to 19,200 Baud)
Software
(recommended) Diagraph’s Performance Series for WindowsTM
Applicator Tamp with auto-retract available in 6” 12” and 18” cylinder lengths
Air 20-60 PSI minimum, 3 cfm
Electrical 100-140 VAC, 60 Hz, 5 A;
200-240 VAC, 50 Hz, 5 A.
Dimensions 38” W X 25” H x 25” D without stand
Weight 150 lbs. (includes print engine) without applicator assembly or stand
Environmental
Requirements 41º F-100ºF; 20-85% RH non-condensing
PA/4000 User’s Manual
Section 1, Product Features
Page 2
1.2 Description of the Printer/Applicators in the Series
The Diagraph PA/4000 Printer/Applicator Series is comprised of three printer
applicators with features that match various labeling application needs:
• 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
minute depends on several factors including label size).
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. The applicator can be configured in either
horizontal or vertical orientations.
This unit handles label sizes from 4 x 4 inches to 4.5 x 12 inches.
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. This unit is functional from either side of the conveyor.
The unique dual-vacuum and slotted-vacuum design delivers a
high degree of label control.
The reliable twin-rod air cylinder [A] tamps the first half of the
label onto the carton as the secondary wipe-down roller [B] wraps
the label around the corner and onto the adjacent side of the
carton.
[A]
[B]
PA/4000 User’s Manual
Section 2, Components
Page 1
2.0 COMPONENT FEATURES AND SPECIFICATIONS
2.1 Floor Stand Assembly
This assembly includes a tee base with
casters [D]; an upright post with a height-
adjustable mounting plate [B]; a yoke [C];
and a crank handle for adjusting the
height [A]. The stand can be bolted to the
floor for stability. The bolting holes are
located on the t-base [E].
2.2
2.22.2
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 – and then locks in
place. It accommodates different sizes of
tamp cylinders for variable distance and
variable label size applications. It
provides easy access to configuration
controls – switches, air control, print
engine and sensor adjustments. This unit
connects to almost any computer through
either the RS-232C or the RS-422 serial
interface. It has three main components:
•The air control unit [A]
•label supply and rewind hubs [B]
•Prodigy PlusTM print engine [C].
[A]
[C]
[B]
[B]
[A]
[B]
[D]
[C]
[E]
[E]
[E]
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. The tamp pressure controls
how much air goes into the cylinder
(between 20-40 psi is the usual range).
Label Supply and Rewind Hubs [B]
The Label Supply Hub holds the roll of
labels in place while the Label Rewind
Hub collects the label backing material
once the label is peeled off.
The Prodigy plusTM print engine [C]
The Prodigy PlusTM print engine is a high-
performance direct thermal and thermal
transfer label printer.
Some Prodigy PlusTM print engine features:
•Clear side door that allows for
viewing of the label and ribbon
functions.
•Internal time and date clock
•Label feed counter
•Choice of English or metric label data
input.
•Equipped with die cut, or blackstripe sensing media.
•Easy-to-load mechanism for label stock and transfer ribbon
[A]
[B]
[B]
[C]
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