Advanced Poly-Packaging Ti-1000ZR User manual

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Ti-1000ZR
Operation Guide, Version 1A
Setup, Operation and Parts Manual

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Acknowledgments
Written By: Charles Tolbert, Updated by David Kolinski-Schultz
Reviewed By: Jeff Heath
Copyright
2019 (Version 1A), 2017 (Version 1) Advanced Poly-Packaging, Inc. (APPI). All rights reserved.
This manual and the program operating the equipment described in it are copyrighted. You may not copy this manual in whole or
part without the consent of Advanced Poly-Packaging, Inc.
All information pertaining to the promotion, sale, distribution, operation, and maintenance of the Ti-1000Z including this manual,
drawings, schematic, wiring diagrams, video, brochures, specification sheets, figures, charts, or any other information, due to its
proprietary design and manufacture remain the property of Advanced Poly Packaging, Inc. Unauthorized duplication, distribution
or disclosure to third parties without the expresses permission of Advanced Poly-Packaging, Inc. is strictly prohibited.
Trademarks
Roll-a-Print is a trademark of Advanced Poly-Packaging, Inc. Advanced Poly-Packaging, Inc. owns also the following
trademarks: Advanced Poly-Bags, Advanced Poly-Bagger, Seal-a-Print, Inline Thermal Printer, Twin-Seal, Advanced Poly-Pack,
Advanced Poly-Bag, Advanced Bag.
Limited Warranty and Disclaimer
Warranty period is 12 months or 1,000,000 cycles whichever comes first. The warranty commences on the date of delivery of the
equipment to the Purchaser. Print head warranty period is 90 days (wear item). APPI warrants to the Purchaser that the equipment
is free from defects in workmanship or material under normal use and service. During the warranty period, APPI agrees to repair
or replace, at its sole option, without charge to Purchaser, any defective component part of the equipment. To obtain service,
Purchaser must return the equipment or component to APPI or an authorized APPI distributor or service representative in an
adequate container for shipping. Any shipping charges, insurance, or other fees must be paid by Purchaser and all risk for the
equipment shall remain with Purchaser until such time as APPI takes receipt of the equipment. Upon receipt, APPI, the
authorized distributor or service representative will promptly repair or replace the defective component and then return the
equipment or component to Purchaser, shipping charges, insurance, and additional fees prepaid. APPI may use reconditioned or
like new parts or units, at its sole option, when repairing any component or equipment. Repaired products shall carry the same
amount of outstanding warranty as from original purchase. Any claim under the warranty must include a dated proof of delivery.
In any event, APPI’s liability for defective components or equipment is limited to repairing or replacing the components.
This warranty is contingent upon proper use of the equipment by Purchaser and does not cover: expendable component part such
as Print Heads, thermocouple wire, heater cartridge, rollers, bushings, and the like; or if damage is due to accident, unusual
physical, electrical or electromechanical stress, neglect, misuse, failure of electric power, water damage (from airlines), improper
environmental conditions, transportation, tampering with or altering of the equipment, packaging of corrosive or contaminating
products or other products damaging to components, and equipment or components not owned or in the possession of original
Purchaser. APPI will not be liable for loss of production, profits, lost savings, special, incidental, consequential, indirect or other
similar damages arising from breach of warranty, breach of contract, negligence, or their legal action even if APPI or its agent
has been advised of the possibility of such damages or for any claim brought against the Purchaser by another party. This
warranty allocates risks of equipment failure between Purchaser and APPI. APPI’s pricing reflects this allocation of risk and the
limitations of liability contained in this warranty. The warranty set forth above is in lieu of all other express warranties, whether
oral or written. The agents, employees, distributors, and dealers of APPI are not authorized to make modifications to this
warranty, or additional warranties binding on APPI. Accordingly, additional statements such as dealer advertising or
presentations, whether oral or written, do not constitute warranties by APPI and should not be relied upon.
Warranty on equipment is considered void when outstanding balances become delinquent (over 30 days late - 60 days after ship
date). Equipment Integration to other Equipment: APPI assumes no responsibility for the integration of its products to other
products or within a system unless APPI performs the integration, testing and provides the results of the tests to the purchaser in
writing. Furthermore, APPI assumes no responsibility for bag sizing whether suggested or recommended.

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TABLE OF CONTENTS
Chapter 1: Introduction 6
Welcome................................................................................................................................ 7
Overview............................................................................................................................... 7
Special Features..................................................................................................................... 7
Using This Manual................................................................................................................ 8
Contact Information .............................................................................................................. 8
Warranty Registration........................................................................................................... 9
Chapter 2: Getting Started 10
Chapter Summary................................................................................................................ 11
Safety, Risks........................................................................................................................ 11
Installation Procedures........................................................................................................ 12
Air and Power Requirements .............................................................................................. 12
Main Power......................................................................................................................... 13
Rear Power Switch.............................................................................................................. 13
Bag Threading..................................................................................................................... 13
Ribbon Threading................................................................................................................ 13
Cycle Operation of the Printer ............................................................................................ 13
Adjusting Rear Tension..................................................................................................... 14
Note on Adjustments to the Printer................................................................................... 14
Chapter 3: Touch Screen Operation 18
Chapter Summary................................................................................................................ 19
Touch Screen Identification................................................................................................ 19
Touch Screen Specifications / Features .............................................................................. 19
Touch Screen Program........................................................................................................ 19
Ti-1000ZR Operation.......................................................................................................... 19
Start up ................................................................................................................................ 20
Operation............................................................................................................................. 20
Main Menu.......................................................................................................................... 20
Printer Settings.................................................................................................................... 20

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Stored Labels..................................................................................................................... 22
Counters ............................................................................................................................ 22
Tech Assist........................................................................................................................ 23
APPI Factory..................................................................................................................... 23
Printer Status..................................................................................................................... 23
PLC I/O Status .................................................................................................................. 24
Warning Messages ............................................................................................................ 24
Chapter 4: Settings, Adjustments, Maintenance and Troubleshooting 26
LabelView Setup Parameters Software Settings................................................................. 27
ZebraDesigner Driver Settings............................................................................................ 27
Adjustments, Maintenance and Troubleshooting................................................................ 27
Machine Adjustments.......................................................................................................... 27
Tracking and Alignment Adjustments ................................................................................ 27
Compression (Nip) Roller Adjustment ............................................................................... 27
Idler Roller Guides.............................................................................................................. 27
Machine Maintenance......................................................................................................... 28
Preventive Maintenance Checklist...................................................................................... 28
Scheduled Maintenance Chart (perform every 500,000 cycles) ....................................... 29
Troubleshooting Guide...................................................................................................... 30
Troubleshooting Checklist ................................................................................................ 30
PLC IO Listing.................................................................................................................. 31
Electrical Drawings........................................................................................................... 31
4.14.1 TIZ-E1_110VAC........................................................................................................ 32
4.14.1 TIZR-E2_FPG-IO....................................................................................................... 33
4.14.1 TIZ-E3_AXH_rev1 .................................................................................................... 34
4.14.1 TIZR-E6_ZebraIF....................................................................................................... 35
4.14.1 TIZR-E7_FP0R-GT02................................................................................................ 36
4.14.1 TIZR-E9_CB IF.......................................................................................................... 37
4.14.1 TIZ-E8_AuxIF_rev4................................................................................................... 38
Chapter 5: Parts and Drawings 40
Ti-1000Z Inline Thermal Printer......................................................................................... 41
Electronics Assembly.......................................................................................................... 42

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Mounting Assembly............................................................................................................ 44
Nip Roll Assembly.............................................................................................................. 46
Printer Register.................................................................................................................... 48
Zebra Printer Assembly....................................................................................................... 50
Zebra Printer Assembly, Continued.................................................................................... 52

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Chapter 1: Introduction
Welcome
Overview
Special Features
Using This Manual
Contact Information
Warranty Registration

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Welcome
Now that you have decided to update your Ti-1000Z Inline Thermal Printer, with Zebra Printer
Technology from Advanced Poly-Packaging, Inc., we thank you for selecting our equipment, materials,
and service.
Overview
APPI printers are designed to lower your printing costs with high speeds, versatility, reliability, and
simplicity.
High Speeds: Indexes, opens, seals, and tears off a bag at high speeds. Actual packaging speed depends
on bag size, equipment options, product characteristics and loading method.
Versatility: Bags virtually any product including fasteners, hardware, injection molded parts, kits, crafts,
foods, medical devices and more. Runs bags produced from LDPE, LLDPE, HDPE, Foil, Polypropylene,
Tyvek™ and various barrier films.
Reliability: Crafted from the highest quality components and materials to withstand the most rigorous
manufacturing environment, sturdy mounts and rugged frame guarantee long life and usefulness with
minimal maintenance.
Simplicity: A user-friendly, menu-driven touch screen program allows operators to set up the bag,
options, and auxiliary equipment, save the settings in memory, and recall those settings for repeat runs.
Special Features
Ribbon Saver: Ribbon usage is based on the label download size in the software. The print head lowers
to print onto the film.
Energy Conservation and Component Saver: To extend its life and conserve energy in your plant, the
Ti-1000Z, the Ti-1000Z RAP and the T-1000-S14 NBO are programmed to sequentially shut down
components when not in use for extended periods of time. A screen saver is provided to extend the life of
the touch screen.
Pass Code Protection: This feature protects setting screens from alteration by unauthorized individuals.
If enabled, a timer causes the pass code screen to be displayed from the Operation screen after a preset
period of nonuse. Factory settings are protected by a Level 1 pass code. This pass code should only be
provided to authorized maintenance personnel.
Predetermining Counter: Preset your printer to stop after a predetermined number of bags have been
printed. Set the quantity of finished bags to complete a print job.
Totalizing Counter: Reset this counter at the beginning of each shift or day to record printing production
over a period of time.
Next Bag Out Printing: The T-1000-S14 NBO features a patented method of printing the next bag out.
This feature prevents the mislabeling of pharmaceuticals, prescriptions, and other high cost items. The
part number and other printing information can be changed for every bag without wasting materials.

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Dual Printing: Special programming allows the T-1000-S14 to operate with both the Next Bag Out
printer and an offline printer in order to print on both sides of the bag. The offline printer is mounted
upside down on the back of the bagger.
Using This Manual
This manual describes the features and operation of the Ti-1000Z Inline Thermal Printer. This manual
functions as an operation and parts manual for the retro fit Ti-1000Z printer only. See T-1000 manual for
information regarding the bagger.
NOTE: Only the Ti-1000Z and the Ti-1000Z RAP can operate as standalone machines.
The following manual conventions are frequently used to assist in understanding important information,
to alert the operator of potentially dangerous or damaging practices and to describe the normal functions
of the Ti-1000Z.
•Text: Normal text
•Italics: Used for emphasis
•Boldface: Used to identify heading names and touch screen buttons.
•CAUTION:Warning messages. To avoid physical harm, damage to equipment or damage to the
product, be sure to read these messages carefully.
•NOTE: Identifies important information.
Contact Information
To better serve your bagging needs, call [phone] or toll free 1-[phone] for convenient
service solutions, Monday through Thursday, 9:00 AM to 5:30 PM EST, or Friday 9:00 AM to 5:00 PM
EST. For technical assistance with current machinery, ask for Service. To order spare parts for your
system, ask for Parts. To order auxiliary equipment for your current system, ask for Machine Sales. To
place an order for bags, ask for Bag Sales.
You may also contact any of these departments by email:
Reach Service at [e-mail]
Reach Parts at [e-mail]
Reach Machine Sales at [e-mail]
Reach Bag Sales at [e-mail]
For general inquires: [e-mail]
Or visit us online at www.advancedpoly.com
In order to provide the best service possible, please have model and serial number ready.

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Warranty Registration
This section must be completed and returned to Advanced Poly-Packaging, Inc. to register the printer for
Warranty Protection.
Serial Number:
(Serial Number located on the back panel)
Company Name and Address Contact Name(s) / Title(s) / Phone Number
________________________________
________________________________
________________________________
________________________________________
________________________________________
________________________________________
Please email, fax, or mail this page to:
Service Manager
Advanced Poly-Packaging, Inc.
1331 Emmitt Road
Akron, OH 44306
USA
Fax # (USA) 330-785-4010
Email the information above to: [email protected]

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Chapter 2: Getting Started
Chapter Summary
Safety, Risks
Installation Procedures
Air and Power Requirements
Main Power
Rear Power Switch
Bag Threading
Ribbon Threading
Cycle Operation of the Printer
Adjusting Rear Tension
Note on Adjustments to the Printer

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Chapter Summary
This chapter describes procedures to receive and set up the Ti-1000ZR, including safety precautions,
uncrating and assembly instructions, environmental, air and power requirements, and height adjustments.
Additionally, this chapter describes how to turn on the printers and properly thread film and ribbon.
Safety, Risks
Many safety features have been included in the mechanical, electronic, and pneumatic systems of this
machine. Despite these safety precautions, operators may receive lacerations, minor burns, or crushed or
broken bone injuries if they come in contact with any moving components. Improper use, improper
adjustments and neglect of preventative maintenance may result in serious personal injury. No special
personal protective equipment is required to operate the equipment, but eye protection, gloves or other
protection should be worn, depending on the characteristics of the product being packaged and the
method of loading product.
Please carefully read the following precautions to operate the equipment properly and avoid injury:
•CAUTION: Initial setup of the machine must be performed by specialized personnel. Qualified
service engineers should uncrate the equipment, assemble the equipment (if required), test and
connect power sources, test the equipment for proper operation and otherwise set up the
equipment for use.
•CAUTION: Do not attempt to adjust the height without assistance and without supporting the
weight of the machine. Attempting to make a height adjustment without assistance could cause
the machine to drop suddenly, causing severe injury. APPI offers several optional accessories
that can reduce the risk of injury during height adjustments. These accessories include carts,
motorized height adjustment components and stabilizing bars.
•CAUTION: Ensure that any height adjustments allow for sufficient movement of the operator.
Improper height adjustments could negatively affect operator movement, causing strain, added
stress, discomfort and fatigue.
•CAUTION: To avoid injury, do not operate the equipment if funnels, guards, covers or other
access panels have been removed. If any of these safety measures have been removed or
modified or if any openings have been increased, the operator will have access to moving
components and extreme temperatures that can cause crush, cut, or burn injuries to hands or
fingers.
•CAUTION: To avoid injury, do not reach under the equipment, guards or elsewhere under the
machine. Do not place hands or fingers in the seal area or near the seal bar, heater bar, load
shelf or other moving components.
•CAUTION: Do not remove or loosen fasteners on the frame. If loosened, the equipment may
drop suddenly, causing injury or damage to the machine.
•CAUTION: Be careful when opening the seal frame as it may drop suddenly, causing injury or
damage to the equipment.
•CAUTION: To avoid injury, avoid coming in contact with pinch points including rollers,
automatic funnel doors or other moving components.

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•CAUTION: To avoid injury, avoid contact with roller “fingers” as they may be sharp.
•CAUTION: Exercise care when adjusting or relocating the touch screen. Movement of the
touch screen could cause unexpected movement of the machine and injury to the operator.
•CAUTION: If control or air pressure settings are set too high, higher noise levels may result
from increased part on part contact or part on machinery contact. Limit these settings and add
guards or covers to reduce airborne noise.
•CAUTION: Exercise extreme care when clearing jams, replacing materials, changing controls
or mechanical settings, and cleaning internal parts. Be sure to de-energize energy sources
prior to removing guarding. Failure to do so may result in unexpected movement or flying
objects, which could cause crush, cut, or eye injuries.
•CAUTION: Maintenance must be performed by specialized personnel. Qualified service
engineers must remove guards or covers to gain access to electrical or mechanical areas.
•CAUTION: Maintenance must be performed regularly to ensure that the machine is operating
properly and to protect against injury. Routine maintenance includes: periodic inspections, the
replacement of worn or damaged components, the tightening of loose bolts or components, and
regular cleaning and adjustments. Contact APPI and/or service centers for service support if
there is not sufficient maintenance staff at your facility to perform regular maintenance.
Installation Procedures
The printer is transported completed assembled in a container designed to protect the machine during
shipment. If the printer is operating with the T-1000-S14, the printer will be bolted onto the bagger.
After removing the stretch wrapping, remove the carton from the skid, open the top and cut all four
corners using a safety knife. Then, transport the machine to the operating location.
CAUTION: Do not attempt to lift the machine from the carton without first cutting all sides open. To
prevent injury, do not attempt to lift the machine without assistance.
Operating Environment / Location: The printer should be placed in an area free of excessive heat,
moisture, dirt, and dust. Operating room temperature should range from 50-100° Fahrenheit. (10-
37.7°Celcius)
Air and Power Requirements
Ti-1000Z: Provision must be made for 110 VAC, 60 Hz line current with ground. Optional 220 VAC /
50 Hz voltage may have been supplied based on your local electrical requirements. The full load current
for the Ti-1000Z is 5 Amps.
NOTE: APPI recommends a dedicated 15 Amp circuit for the Ti-1000Z
CAUTION: A qualified electrician should ensure that the machine’s power outlet is properly
grounded, voltages are as required and amperage capacity is sufficient.
Ti-1000Z: At least 0.5 CFM free air is required, regulated from 25 to 60 PSI (1.72 to 4.13 Bar), to obtain
the best print quality and drive roller compression.

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An air regulator is provided to adjust the pressure to the print head assembly. This regulator should be set
from 35 to 50 PSI (2.41 to 3.45 Bar) to obtain the best print quality. A separate air regulator is provided to
adjust the pressure to the compression rollers. The pressure should be sufficient to drive the film, but not
high enough to cause the film to wrinkle. This regulator should be set from 20 to 30 PSI. (1.38 to 2.07
Bar)
An air-line supply should be fed to the Ti-1000Z with 3/8" (0.95 cm) ID flexible tubing. This tubing
affixes to the coupler adapter (quick disconnect not provided). Connect the air to the regulator by holding
the regulator firmly in one hand and pushing the air line connector on the male regulator connector. Insert
the Ti-1000Z power cord into an 110VAC, 60Hz, grounded power outlet.
Main Power
If your printer is operating with the T-1000-S14, the main power switch that turns on both machines is
located on the bagger’s side cover. To turn the machines on, turn the switch from its vertical OFF position
to its horizontal ON position. If you wish to turn on the printer only or if your printer is operating as a
standalone machine or with a bagger other than the T-1000-S14, the printer’s main power switch is
located on the rear panel of the printer electronics box. To turn the machine on, press the red Printer
Power switch.
When the machine(s) is turned on, the green Power light on the touch screen will illuminate and the
Introduction screen will be displayed. The program version will also be identified. The Introduction
screen will only appear for a few seconds until automatically changing to the Operation screen or Main
Menu.
Rear Power Switch
The Rear Power Switch is located in the back of the machine and is used to turn on the power to the
printer only, without affecting the PLC function. The power is separated to allow the printer to be reset,
which will also clear the memory of the printer, or errors.
Bag Threading
Refer to Figures 2-1 and 2-2 for proper bag / film threading of the Ti-1000Z and Ti-1000Z RAP,
respectively. Alternate threading may be required based on your bagger. Refer to your bagger’s operation
guide for additional information.
Ribbon Threading
Refer to Figure 2-6 for proper ribbon threading of the Ti-1000Z. The print head assembly can be rotated
up and back for easy ribbon changes. Release the locking mechanism and raise the print head assembly.
CAUTION: To avoid injury or damage to the print head, do not release the print head assembly. Lower
the assembly carefully into position and lock the mechanism before operating the printer.
Cycle Operation of the Printer

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If all prior installation procedures were performed properly, the printer should be in its operating location
with air and power connected. All covers should be in position and securely fastened.
NOTE: The web of bags may track right or left for a few feet until “settled” on the web path. The roll of
bags or the roller guide may require readjustments or realignment after the first few feet of bags are
indexed.
To test cycle the printer with a test label that has been downloaded from APPI, load Label 001 from the
Stored Labels screen (if the printer is operating as a standalone machine) or from the printer’s Setup
screen (if the printer is operating with the T-1000-S14). To load this label, press the Label # button, enter
“001”and press the ENT button. Then, while in Setup mode, press the Manual Cycle (MC) button. This
procedure will cause the compression (nip) roller to clamp onto the film. Then, the print head will lower
and the nip rollers will pull the film through the print head while printing. Label 001 has graphics, small
print and a line that provides a good test for print quality.
Adjusting Rear Tension
The printer is not designed to cause heavy rolls to unwind. Heavy rolls may require a driven unwind stand
and dancer system. If the film cannot properly feed through the nip rollers, first try to increase, or
decrease the nip pressure by adjusting the air pressure. If the film does not feed properly through the nip
rollers, increase, or decrease film tension (rear tension).
Note on Adjustments to the Printer
Upon receipt, it is not unusual for the print head to be out of alignment due to shipping and excessive
handling. Unless physically damaged, the printer will function properly after minor adjustments are made.

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Ti-1000Z THREADING DIAGRAM
Figure 2-1

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Ti-1000Z WITH T-1000-S14 THREADING DIAGRAM
SINGLE DANCER
Figure 2-2

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Ti-1000Z RIBBON THREADING DIAGRAM
Figure 2-3

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Chapter 3: Touch Screen Operation
Chapter Summary
Touch Screen Identification
Touch Screen Specifications / Features
Touch Screen Program
Ti-1000ZR Operation
Start up
Operation
Main Menu
Printer Settings
Stored Labels
Counters
Tech Assist
APPI Factory
Printer Status
PLC I/O Status
Warning Messages

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Chapter Summary
This chapter describes the identification, operation, and settings of the touch screen program for the Retro
Fit Ti-1000Z printers. This section is focused on the setup and operation of the printer through a small 3”
color touch screen.
Touch Screen Identification
BACK PANEL:
•RS-232 Communication port to PLC
•Programming (For APPI use only)
•Power Supply: Power terminal for touch screen operation.
CAUTION: Do not attempt to reprogram the PLC or touch screen. Doing so may cause an unsafe
operating condition and void the warranty. Additionally, do not change the DIP switch settings.
Touch Screen Specifications / Features
Specifications
Screen Resolution
3” 128 x 64 pixels
LCD
Green, Red, Orange
Memory
384 Kb
Communication
RS232C
Touch Key Res.
Free, Analog
Languages
English, Spanish, French, German, Italian,
Japanese, Chinese, Korean
Dimension
110 x 72 x 28 mm (W x H x D)
Back Light
No Backlight
Power Supply
5Vdc, 0.20A
Touch Screen Program
The touch screen program is a “user-friendly”, menu-driven setup and operation program. Popup
windows are incorporated for quick and easy setting adjustments. Each time a setting is changed, the
settings are saved so that if power is lost, the “job” will be recalled automatically without the need for
reprogramming. A general color scheme is used for operation consistency and to identify functions:
•Black: Text information, borders.
•Green:General background of the touch screen environment.
•Red: Indicates a error, warning
Ti-1000ZR Operation
If you purchased the Ti-1000Z with the T-1000-S14 Advanced Poly-Bagger, please refer to the following
sections for information about the printer’s operation.
The T-1000-S14 touch screen program controls the operation of the Ti-1000Z, an offline printer mounted
behind the bagger. To access operation, settings, and status screens specific to Ti-1000Z, press the
TI1000Z button on the Bagger Options Menu. Refer to the T-1000-S14 Operation Guide for information
about the bagger’s program.