Carl Valentin Applicator APL 100 Operating instructions

Brand: Carl Valentin

Model: Applicator APL 100

Type: Operating instructions

APL 100

Operating Manual

Information on the scope of delivery, appearance, performance,

dimensions and weight reflect our knowledge at the time of printing.

We reserve the rights to make modifications.

All rights, including those regarding the translation, are reserved.

No part of this document may be reproduced in any form (print,

photocopy or any other method) or edited, copied or distributed

electronically without written permission from Carl Valentin GmbH.

Due to the constant further development of our devices discrepancies

between manual and device can occur.

Please check www.carl-valentin.de for the latest update.

Trademarks

All named brands or trademarks are registered brands or registered

trademarks of their respective owners and may not be separately

labelled. It must not be concluded from the missing labelling that it is

not a registered brand or a registered trademark.

The pneumatic applicator complies with the following safety

guidelines:

EG Low-Voltage Directive (2006/95/EC)

EG Electromagnetic Compatibility Directive (2004/108/EG)

EG Machinery Directive (2006/42/EG)

Carl Valentin GmbH

Postfach 3744

78026 Villingen-Schwenningen

Neckarstraße 78 – 86 u. 94

78056 Villingen-Schwenningen

Phone

Fax

+49 7720 9712-0

+49 7720 9712-9901

E-Mail

Internet

info@carl-valentin.de

www.carl-valentin.de

APL 100 
Table of Contents 
 
19 
Operating Manual 

 
Table of Contents 
Introduction ............................................................................ 5 
1  General Instructions ................................................................ 5 
2  Intended Use ........................................................................... 6 
3  Environmentally-Friendly Disposal .......................................... 6 
Safety Instructions ................................................................ 7 
1  Safety Marking ......................................................................... 8 
2  Operating Conditions ............................................................... 9 
Product Description ............................................................ 13 
1  Important Characteristics ...................................................... 14 
2  Technical Data ....................................................................... 14 
3  Device Overview .................................................................... 15 
4  Pads ...................................................................................... 17 
Installation ............................................................................ 19 
1  Scope of Delivery .................................................................. 19 
2  Mount the Applicator to the Printer ........................................ 20 
3  Pierce the Universal Tamp Pad ............................................. 21 
4  Prepare for Using a Sping-Mounted Tamp Pad .................... 22 
5  Mount the Pad ....................................................................... 23 
6  Mount the Stopper ................................................................. 24 
7  Connections ........................................................................... 25 
Configuration ....................................................................... 27 
1  Configuration Parameter ....................................................... 27 
2  Settings in printer function menu ........................................... 28 
Signal Diagrams .................................................................. 33 
1  Print - Apply ........................................................................... 33 
2  Apply - Print ........................................................................... 33 
Mechanical Adjustments .................................................... 35 
1  Align the Pad ......................................................................... 35 
2  Adjust the Parallelism between Pad and Dispensing Edge .. 36 
3  Open the Holes on the Blow Tube ........................................ 37 
4  Align the Blow Tube............................................................... 38 
5  Adjust the Stopper ................................................................. 39 
Pneumatic Adjustments ..................................................... 41 
1  Control Valves ....................................................................... 41 
2  Adjust the Pad Movement Speed .......................................... 43 
3  Adjust Vacuum and Supporting Air ....................................... 44 
Operation .............................................................................. 45 
1  Load the Label Material ......................................................... 45 
2  Set the Dispenser Mode ........................................................ 46 
3  Test Mode .............................................................................. 47 
4  Standard Operation ............................................................... 49 
Applicator Interface ............................................................. 51 
1  Pin Assignment ...................................................................... 51 
2  Internal Circuit of Outputs ...................................................... 51 
3  Signal Assignment D-Sub 15 pin ........................................... 52 
Error Messages .................................................................... 53 
1  Error Messages of the Printer ............................................... 53 
2  Error Messages of the Applicator .......................................... 53 

Table of Contents

APL 100

Operating Manual

12.19

12 Declaration ........................................................................... 55

12.1 Extended Declaration ............................................................ 55

12.2 EC-Declaration of Conformity ................................................ 56

13 Index ..................................................................................... 57

APL 100

Introduction

12.19

Operating Manual

1 Introduction

1.1 General Instructions

Important information and instructions in this document are

designated as follows:

DANGER identifies an extraordinarily great and immediate

danger which could lead to serious injury or even death.

WARNING identifies a possible danger would could lead

to serious bodily injury or even death if sufficient

precautions are not taken.

WARNING of cutting injuries.

Pay attention that cutting injuries caused by blades, cutting

devices or sharp-edged parts are avoided.

WARNING of hand injuries.

Pay attention that hand injuries caused by closing

mechanical parts of a machine/equipment are avoided.

WARNING of hot surfaces.

Pay attention so as not to come into contact with hot

surfaces.

CAUTION indicates a potentially dangerous situation

which could lead to moderate or light bodily injury or

damage to property.

NOTICE gives you tips. They make a working sequence

easier or draw attention to important working processes.

Gives you tips on protecting the environment.



Handling instruction



Optional accessories, special fittings

Datum

Information in the display

Introduction

APL 100

Operating Manual

12.19

1.2 Intended Use

• The device is a state-of-the-art device which complies with the

recognized safety-related rules and regulations. Despite this, a

danger to life and limb of the user or third parties could arise and

the device or other property could be damaged while operating

the device.

• The device may only be used while in proper working order and

for the intended purpose. Users must be safe, aware of potential

dangers and must comply with the operating instructions. Faults,

in particular those which affect safety, must be remedied

immediately.

• The applicator mounted on a label printer of the Compa II series is

intended to print suitable media which have been approved by the

manufacturer. Any other or additional use is not intended. The

manufacturer/supplier is not liable for damage resulting from

misuse. Any misuse is at your own risk.

• Intended used includes heeding the operating manual, including

the maintenance recommendations/regulations specified by the

manufacturer.

NOTICE!

The complete documentation is included in the scope of

delivery on CD ROM and can also currently be found in the

internet.

1.3 Environmentally-Friendly Disposal

Manufacturers of B2B equipments are obliged to take-back and

dispose old equipment which was manufactured after 13 August 2005.

In principle, these old equipments may not be delivered to communal

collecting points. They may only be organised used and disposed by

the manufacturer. Valentin products accordingly labelled can therefore

in future be returned to Carl Valentin GmbH.

This way, you can be sure your old equipment will be disposed of

correctly.

Carl Valentin GmbH thereby fulfils all obligations regarding timely

disposal of old equipment and facilitates the smooth reselling of these

products. Please understand that we can only take back equipment

that is sent free of carriage charges.

The electronics board of the printing system is equipped with a

battery. This must only be discarded in battery collection containers or

by public waste management authorities.

Further information on the WEEE directive is available on our website

www.carl-valentin.de.

APL 100

Safety Instructions

12.19

Operating Manual

2 Safety Instructions

• Before mounting the delivered components disconnect the printer

from the power supply and close the shutoff valve at the

applicator.

• Only connect the device to other devices which have a protective

low voltage.

• Switch off all affected devices (computer, printer, accessories)

before connecting or disconnecting.

• In operation, moving parts are easily accessible. This applies

especially for the zone, where the pad is moved between the

starting and the labelling position. During operation do not reach

into that zone and keep long hair, loose clothes, and jewellery

distant.

Before any manipulations in those areas, close the shutoff valve.

• The device may only be used in a dry environment, do not expose

it to moisture (sprays of water, mists, etc.).

• Do not use the device in an explosive atmosphere.

• Do not use the device close to high-voltage power lines.

• Operate the direct print module only in an environment protected

against abrasive dust, swarf and other similar impurity.

NOTICE!

With the open printing unit (due to construction) the requirements

of EN 60950-1/EN 62368-1 regarding fire protection casing are

not fulfilled. These must be ensured by the installation into the end

device.

• Maintenance and servicing work can only be carried out by trained

personnel.

• Operating personnel must be trained by the operator on the basis

of the operating manual.

• Carry out only the actions described in these operating

instructions. Any work beyond this may only be performed by the

manufacturer or upon agreement with the manufacturer.

• Unauthorized interference with electronic modules or their

software can cause malfunctions.

• Other unauthorized work on or modifications to the device can

also endanger operational safety.

• Always have service work done in a qualified workshop, where the

personnel have the technical knowledge and tools required to do

the necessary work.

• There are warning stickers on the direct print modules that draw

your attention to dangers. Therefore the warning stickers are not

to be removed as then you and others cannot be aware of

dangers and may be injured.

• When incorporating the unit into the overall system, make sure

that safety precautions are taken so that no-one is able to reach

into the working area.

• Before starting the machine, all protective guards must be fitted.

Safety Instructions

APL 100

Operating Manual

12.19

2.1 Safety Marking

Figure 1

CAUTION!

There is a risk of injury due to the movement of the pad

downwards and back up again.

 Do not reach into the working area of the pad.

 Keep hair, loose clothing and items of jewellery out of

this area.

 When incorporating the unit into the overall system,

safety precautions must be taken so that no-one is able

to reach into the working area.

1 = Risk of crushing due to

1 = the movement of the pad

APL 100

Safety Instructions

12.19

Betriebsanleitung

2.2 Operating Conditions

Before initial operation and during operation these operating

conditions have to be observed to guarantee save and interference-

free service of our printers.

Therefore please carefully read these operating conditions.

Shipment and storage of our printers are only allowed in original

packing.

Installation and initial operation of printer is only allowed if operating

conditions were fulfilled.

Commissioning is prohibited until it can be established that, where

relevant, the machine into which the partly completed machinery is to

be incorporated complies with the provisions of Machinery Directive

2006/42/EC.

Initial operation, programming, operation, cleaning and service of our

printers are only recommended after careful study of our manuals.

Operation of printer is only allowed by especially trained persons.

NOTICE!

Perform trainings regularly.

These indications are also valid for someone else's equipment

supplied by us.

Only use original spare and exchange parts.

Emitted interference according to EN 61000-6-3: 2007

industrial sector

• Interference voltage to wires according to EN 55022: 09-2003

• Interference field power according to EN 55022: 09-2003

• System perturbation according to EN 61000-3-2: 09-2006

• Flicker according to EN 61000-3-3: 1955 + A1:2001 + A2:2005

Stray radiation and

immunity from

disturbance

Safety Instructions

APL 100

Operating Manual

12.19

Immunity to interference according to EN 61000-6-2: 2005

industrial sector

• Stray radiation against discharge of static electricity according to

EN 61000-4-2: 12-2001

• Electromagnetic fields according to EN 61000-4-3: 11-2003,

ENV 50204: 03-1995

• Fast transient burst according to EN 61000-4-4: 07-2005

• High-frequency voltage according to EN 61000-4-6: 12-2001

NOTICE!

This is a machine of type A. This machine can cause

interferences in residential areas; in this case it can be required

from operator to accomplish appropriate measures and be

responsible for it.

• EN 415-2 - Safety of packaging machines

• EN 60204-1:2006 - Safety of machinery – Electrical equipment of

machines – Part 1

To avoid inadmissible heating, free air convection has to be ensured.

Ambient temperature °C (operation): Min. +5 Max. +35

Ambient temperature °C (storage): Min. −25 Max. +60

Relative air humidity % (operation): Max. 80

Relative air humidity % (storage): Max. 80

(bedewing of printers not allowed)

Stray radiation and

immunity from

disturbance

Machine safety

Air convection

Limit values

APL 100

Safety Instructions

12.19

Betriebsanleitung

We do not take any responsibility for damage caused by:

• Ignoring our operating conditions and operating manual.

• Incorrect electric installation of environment.

• Building alterations of our printers.

• Incorrect programming and operation.

• Not performed data protection.

• Using of not original spare parts and accessories.

• Natural wear and tear.

When (re)installing or programming our printers please control the

new settings by test running and test printing. Herewith you avoid

faulty results, reports and evaluation.

Only specially trained staff is allowed to operate the printers.

Control the correct handling of our products and repeat training.

We do not guarantee that all features described in this manual exist in

all models. Caused by our efforts to continue further development and

improvement, technical data might change without notice.

By further developments or regulations of the country illustrations and

examples shown in the manual can be different from the delivered

model.

Please pay attention to the information about admissible print media

and the notes to the printer maintenance, in order to avoid damages

or premature wear.

We endeavoured to write this manual in an understandable form to

give and you as much as possible information. If you have any queries

or if you discover errors, please inform us to give us the possibility to

correct and improve our manual.

Guarantee

Safety Instructions

APL 100

Operating Manual

12.19

APL 100

Product Description

12.19

Operating Manual

3 Product Description

The applicator APL 100 is an optional device to use with label printers

of the Compa or Compa II series for automatically applying the printed

label onto the product. The labels are transferred with a pad, which

moves between the two positions, starting position and labelling

position, by a compressed-air driven pneumatic cylinder.

• In the starting position, the label is picked up from the printer.

• A sensor at the cylinder signals when the pad is in the starting

position.

• The label is removed from the carrier ribbon directly at the

dispensing edge of the printer. It is sucked on the pad by a

vacuum via drillings at the bottom of the pad.

• For support, the label is also blown against the pad (supporting

air) with an air current coming from a blow tube.

• The correct transfer of the label is controlled by a vacuum sensor.

• Next, the pad is moved down into the labelling position. Reaching

the labelling position is confirmed by another sensor (labelling

position sensor).

• In the labelling position the label is transferred onto the product.

• While the pad is moving back into the starting position, the

vacuum sensor checks whether the label has been removed from

the pad.

The label can be applied with three different methods:

Stamp on

The label is pressed directly onto the product.

Blow on

The pad moves to a pre-adjusted position approximately 10 mm away

from the product. The label is blown onto the product by an air stream.

Roll on

In the starting position the label is forwarded until touching the roller of

the roll on pad. At the labelling position the roller is pressed onto the

product. Then the label is applied and rolled on by the movement of

the product.

Application

of the label

Product Description

APL 100

Operating Manual

12.19

3.1 Important Characteristics

• The supporting air and the vacuum as well as the speed of the

cylinder are adjustable. That way the applicator can be adapted to

different label materials and sizes.

• The pressure for the cylinder movement is reduced in relation to

the operating pressure of the entire labelling machine so that the

danger of injury is reduced as much as possible.

• To avoid contamination within the vacuum channels they are

cleaned by air pressure impulse at the end of each application.

• For integration into a superordinated process the printers are

equipped with 'Dispenser I/O'.

3.2 Technical Data

Stamp on

Blow on

Roll on

Labe width (mm)

25 … 176

Label height (mm)

25 … 200

25 … 100

80 … 200

Cylinder stroke (mm)

Pad stroke below printer

(mm)

300

180

300

180

300

180

Cylinder stroke (mm)

Pad stroke below printer

(mm)

400

280

400

280

400

280

Compressed air pressure

5 bar

Product surface

flat

Product height variable



Product height fixed



Product fixed



Product linear movement



APL 100

Product Description

12.19

Betriebsanleitung

3.3 Device Overview

Figure 2

1 =

Upper cylinder throttle valve

2 =

Stopper for the operation mode 'Blow on'

3 =

Cylinder unit

4 =

Pneumatic cylinder

5 =

Lower cylinder throttle valve

6 =

Pad holder

7 =

Pad (application specific)

8 =

Blow tube for supporting air

9 =

Knurled screw for attaching the applicator to the printer

10 =

Main pressure manometer

Front view

Product Description

APL 100

Operating Manual

12.19

5678910

Figure 3

1 =

Supporting air throttle valve

2 =

Vacuum throttle valve

3 =

Service unit

4 =

Shutoff valve

5 =

Compressed air connector

6 =

Pins

7 =

Interface to the printer

8 =

Knurled screw for attaching the applicator to the printer

9 =

Pre-dispense key

10 =

Blow tube for supporting air

Rear view

APL 100

Product Description

12.19

Betriebsanleitung

3.4 Pads

Universal tamp pad

Standard sizes:

70 x 60 mm and 90 x 90 mm

Standard sizes:

116 x 102 mm and 116 x 152 mm

Figure 4

Figure 5

Universal tamp are available in different standard sizes. According to

the size of the label the holes may be pierced by the customer. For

that purpose a piercing pin is included in the delivery contents.

On request, tamp pads customized to the label sized are delivered.

Figure 6

Roll-on pads are only produced on request customized to the label

size.

Figure 7

Blow pads are only produced on request customized to the label size.

Tamp pad

Roll-on pads

Blow pads

Product Description

APL 100

Operating Manual

12.19

APL 100

Installation

12.19

Operating Manual

4 Installation

4.1 Scope of Delivery

NOTICE!

Please keep the original packaging in case the applicator must

be returned.

1 2 3 4

Figure 8

1 =

Applicator with cylinder

2 =

Pad (according to command)

3 =

Cylinder screw (part of the pad)

4 =

Piercing pin (at universal tamp pads only)

CAUTION!

The label printer and the applicator can be damaged by

moisture and water.

 Set up the label printer with applicator only in dry locations

protected from splash water.

Installation

APL 100

Operating Manual

12.19

4.2 Mount the Applicator to the Printer

CAUTION!

Danger of injury by inadvertent move out of the cylinder.

 Disconnect the printer from the power supply before

mounting the applicator.

 Connect the compressed air only after mounting the

applicator to the printer.

1 2 3 4

Figure 9

1. Insert the pins (6, Figure 3) on the back of the applicator (2) into

the holes (3) of the printer.

2. Press the applicator against the printer. That way the plug of the

applicator will be connected to the peripheral port (4) of the

printer.

3. Fix the applicator (2) with the screw (1).

CAUTION!

Malfunctions by inadequate operational surface space.

 Ensure a stable standing of the printer.

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Carl Valentin Applicator APL 100 Operating instructions

Carl Valentin Applicator APL 100 Operating instructions

Carl Valentin Applicator APL 100 Operating instructions

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