Avery Dennison AP5.4 Troubleshooting guide

09/10 Rev. 5.05-09 USER / SERVICE MANUAL
AP5.4 – AP5.6
Technical Data
Dimensions ................................................... 2
Measures .................................................. 2
Weight ....................................................... 2
Performance Data ......................................... 3
Print Technology ....................................... 3
Printhead Type .......................................... 3
Printhead characteristics ........................... 3
Label sensor .............................................. 3
Max. print length ........................................ 4
Zero line .................................................... 4
Fonts ......................................................... 4
Modifying Fonts ......................................... 4
Impression accuracy ................................. 4
Image formats ........................................... 5
Bar codes .................................................. 6
2-dimensional bar codes ........................... 6
GS1 Databar & CC bar codes ................... 6
Printer emulation ....................................... 6
Label Stock ................................................... 7
Material Types ........................................... 7
Material Thickness .................................... 7
Material Width ........................................... 7
Label Length ............................................. 7
Gap size .................................................... 7
Label Roll .................................................. 8
Thermotransfer Ribbon ................................. 9
Ribbon Roll ................................................ 9
Connections, device data ............................ 10
Protection class ....................................... 10
Mains Voltage ......................................... 10
Mains Frequency ..................................... 10
Power Consumption ................................ 10
Current Consumption .............................. 10
Interfaces .....................................................11
Electronic Configuration ..............................12
Specifications only for AP5.4/5.6 dispenser 13
Environmental Conditions ...........................14
Operating Temperature ...........................14
Storage Temp. .........................................14
Relative Humidity .....................................14
Protection category ..................................14
Noise ........................................................14
Test Marks, certificates ...............................15
CE ............................................................15
CTÜVUS-Mark ........................................15
TÜV-Mark ................................................15
CB ............................................................15
FCC .........................................................15
GOST R ...................................................15
Limitations ...................................................16
Print width limitations at AP5.6 ................16

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
2
Dimensions
Measures
[1] Dimensions of the AP5.6 and AP5.4 (H=Height, W=Width, D=Depth).
Weight
Printer Measures (H x W x D)
AP5.4 272 x 260 x 462mm
AP5.6 272 x 335,5 x 462mm
[Tab. 1] Measures
Printer Weight
AP5.4/5.6 14kg
AP5.4 basic / peripheral 14kg
AP5.4 dispenser / internal rewinder 16kg
[Tab. 2] Printer weight
H
B/W
T/D
dr

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
3
Performance Data
Print Technology
Thermodirect and thermotransfer printing
Printhead Type
•“Flat Head” type (ceramic thin film flat head)
•8.0dot/mm (203dpi)
•11.8dot/mm (300dpi)
Printhead characteristics
Label sensor
The dark/light change at the reflex sensor is taken as the label beginning
(= end of the reflex mark)
CAUTION!
The maximum achievable print width of the AP5.6 is limited by print speed
and print contrast.
Pay attention to the limitations, see Print width limitations at AP5.6 on
page 16.
Printer Resolution
(Dot/mm) Resolution (dpi)
Print-
speed
(mm/s)
Print-
speed
(Inch/s)
Max. printwidth
(mm)
AP5.4 8.0
11.8
203
300
50-200
50-150
2-8
2-6
104
105.7
AP5.6 8.0
11.8
203
300
50-200
50-150
2-8
2-6 168
[Tab. 3] Important printhead data.
Sensor type Settingrange
(Size c) Punch length (Size b) Punch width (Size a)
Transmission sensor
(Standard) 0–60mm 0.8–14mm min. 4mm
Reflex-sensor
(optional) 6–66mm 4mm (recommended) 12mm
(recommended)
[Tab. 4] Required punch measures.

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
4
[2] Measures and setting range of the punch / reflex mark.
Max. print length
The maximum print length depends on the following:
•Printer type
•Printer resolution
•Firmware version
•Parameter settings regarding memory allocation (e.g. SYSTEM
PARAMETERS > Free store size)
Zero line
Offset of the material zero line to the print zero line: 1mm (what means that a
stripe of 1mm width at the inner label margin is unprintable)
Fonts
•17 Fixsize fonts , including OCR-A and OCR-B
•3 scalable fonts (Speedo fonts)
•Truetype fonts are supported
•Optionally can Truetype, Speedo and Fixsize fonts be stored on SD-card
Modifying Fonts
•Up to factor 8 scaling in x/y direction
•Rotation by 0, 90, 180 and 270 degrees
Impression accuracy
[3] The impression accuracy depends on the print position on the label: the longer the distance to the gap
is, the lower is the impression accuracy. The maximum impression accuracy is at the gap position with
+/- 1mm.
Reading examples:
A: Print positioin 1 is located 50mm behind the gap position. The maximum
possible deflection from the theoretical print position is +/- 1.5mm.
B: Print positioin 1 is located 250mm behind the gap position. The maximum
possible deflection from the theoretical print position is +/- 3.5mm.
Thosevaluesareempiricalfor typical applicationswith common labelstock
/ foil combinations. Since the deflection of the print position strongly depends
ontheappliedlabelstock/foilcombination,itcan turn outhigher ifunfavorable
combinations are used.
a
b
c
Z0211.cdr
A
A
B
B

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
5
Image formats
BMP, PCX, JPEG, TIFF, GIF, Easy Plug logos

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
6
Bar codes
All bar codes scalable in 30 different width and in the height.
2-dimensional bar codes
GS1 Databar & CC bar codes
Reduced Space Symbology (GS1 Databar) und Composite Component (CC)
bar codes:
Printer emulation
Easy-Plug
Codabar Code 128 A, B, C
Code 128 Code 128 UPS
Code 128 pharmacy ITF
Code 2/5 matrix MSI
Code 2/5 interleaved EAN 8
Code 2/5 5-line EAN 13 add-on 2
Code 2/5 interleaved ratio 1:3 EAN 13 add-on 5
Code 2/5 matrix ratio 1:2,5 EAN 128
Code 2/5 matrix ratio 1:3 Postcode (guide and identity code)
Code 39 UPC A
Code 39 extended UPC E
Code 39 ratio 2,5:1 Code 93
Code 39 ratio 3:1
Data Matrix Code (code according to ECC200)
Maxi Code
PDF 417
Codablock F
Code 49
QR matrix code
GS1 Databar-14 UPC-A + CC-A/CC-B
GS1 Databar-14 truncated UPC-E + CC-A/CC-B
GS1 Databar-14 stacked EAN 13 + CC-A/CC-B
GS1 Databar-14 stacked omnidirectional EAN 8 + CC-A/CC-B
GS1 Databar limited UCC/EAN 128 + CC-A/CC-B
GS1 Databar expanded UCC/EAN 128 + CC-C

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
7
Label Stock
Material Types
Thermodirect material, thermotransfer material, synthetic ribbons: PE, PP,
PVC, PA in rolls or fan-folded.
Material Thickness
•Self-adhesive labels: 60- 160g/m2
•Cardboard labels:
– AP5.4: max. 240g/m2
– AP5.6: max. 190g/m2
Material Width
Label Length
Gap size
Gap size between the labels on the backing material:
•min.: 1.0mm
•max.: Label length-15mm
Printer type Material width
AP5.4 15-120mm
AP5.4 dispenser 30-110mm a
a) The material passage width is limited by the dispensing sen-
sor, which is mounted at the side. If a dispensing edge wit-
hout a sensor is applied (foot switch operation), the passage
width is as large as at the standard printer.
AP5.6 50-185mm
AP5.6 dispenser 50-170mm a
[Tab. 5] Overview material width.
Printer Min. length Max. length
AP5.4 5mm max. print width a
a) See Max. print length on page 4.
AP5.4 dispenser 30mm 200mm
AP5.4 dispenser b
b) With optional label sensor for short labels.
5mm 200mm
AP5.6 5mm max. print width a
AP5.6 dispenser 30mm 200mm
[Tab. 6] Overview label length.

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
8
Label Roll
•Winding Direction: Labels facing inward or outward, internal rewinder: la-
bels facing outwards
•Roll diameter:
•Corediameter:38.1mm(1.5“), 76.2mm(3“)oder 101.6mm(4“); coreswith
76.2 (3“) or 101.6mm (4“) can be applied with the core adapter supplied
with the printer.
Roll / Conditions Roll Ø
Label roll for normal printing operation max. 210mm
Label roll for dispensing operation (with 100mm core-Ø) max. 190mm
Take-up roll for winding/dispenser operation max. 120mm
[Tab. 7] Diameter of material and winding roll

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
9
Thermotransfer Ribbon
Ribbon Roll
•Winding Direction: Colour-side rolled inwards or outwards
•Roll dimensions:
External Ø max. 80mm
Core Ø 25mm (1”)
Width a
a) Generally counts: The thermal transfer ribbon
must overlap the label 2mm on each side.
For labels width > max. print width count the foil
width: AP5.4: 110mm, AP5.6: 172mm.
AP5.4: 25-114mm
AP5.6: 54-172mm
Length max. 500m

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
10
Connections, device data
Protection class
„I“
Mains Voltage
100-240V (AC)
Mains Frequency
50-60Hz
Power Consumption
•Max. 320W
•In standby mode depending on the equipment 30-40W
Current Consumption
3.0-1.5A

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
11
Interfaces
Detailed information on the interfaces can be found in the Service Manual, top-
ic section Service Electronics , chapter “CPU boards”, “Interfaces”.
Interface Details
RS-232 Baud: 1200-115200, 8- bit; suitable connection cord: 1:1
D-Sub 9 extension lead (connector-jack)
RS-422/485 On optional I/O board, D-Sub 15, Baud: 1200-115200,
8-bit
Ethernet 10/100 Base T with TCP/IP, LPD, RawIP printing, DHCP,
HTTPD, FTPD, SNMP
USB (V1.1) USB-A host port, USB-B device port, Transmission rate
12Mbps
Signal interface On optional I/O board, D-Sub 15
[Tab. 8] Data interfaces at AP5.4/5.6

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
12
Electronic Configuration
Feature Details
CPU 32bit (NetLogic)
RAM 64MB SDRAM
ROM 4MB Flash
Memory card SD
Realtime-clock Present
Control Panel 4 buttons; LCD graphics display with 128x32 pixels; ty- pically used to display two text lines with 16 characters
each
[Tab. 9] Electronic configuration of the AP5.4/5.6.

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
13
Specifications only for AP5.4/5.6 dispenser
•Speed, while the rewinding-Ø is calculated: 75mm/s (3“/s)
•Speed, while the material is fed back: 75mm/s (3“/s)
•Distance dispensing edge - print zero line: 25mm
•Distance punch sensor - print zero line: 71mm
•Max. admissible outer diameter of the rewoundbacking paper roll: 120mm

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
14
Environmental Conditions
Operating Temperature
5 to 35°C
Storage Temp.
-4 to 60°C
Relative Humidity
35-75% (non-condensing)
Protection category
IP 21
Noise
< 70dB(A)

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
15
Test Marks, certificates
CE
EU conformity: The devices fulfil the requirements of the following EU direc-
tives:
•Machinery Directive
•EMC Directive
For details refer to EC Declaration of conformity 
CTÜVUS-Mark
TÜV test mark for USA and Canada:
•USA: tested according to UL60950-1
•Canada: tested according to CAN/CSA-C22.2 No 60950-1
TÜV-Mark
TÜV test mark for EU: tested according to EN60950-1
CB
CB test certificate: tested according to IEC60950-1
FCC
Declaration of conformity: FCC rules, part 15 class B devices
GOST R
Meets the requirements of the following GOST R standards:
•MEK 60950-1-2005
•51318.22-2006
•51318.24-99
•51317.3.2-2006
•51317.3.3-2008

01/11 Rev. 5.05-09 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
16
Limitations
Print width limitations at AP5.6
If the max. values given in the following tables are exceeded, malfunction of
the power supply will be most probably the consequence, followed by a restart
of the printer.
203dpi printhead
300dpi printhead
Print speed Limitations
mm/s Inch/s
51 2 Max. admissible print contrast: 120%
76/102 3/4
Max. admissible print contrast at
print width > 100mm: 110%
Max. admissible print width at
print contrast > 110%: 100mm
127/152 5/6
Max. admissible print contrast at
print width > 75mm: 85%
Max. admissible print width at
print contrast > 85%: 75mm
178/203 7/8
Max. admissible print contrast at
print width > 55mm: 67%
Max. admissible print width at
print contrast > 67%: 55mm
[Tab. 10] Print width limitations for AP5.6 with 203dpi printheads.
Print speed Limitations
mm/s Inch/s
51/76 2/3 Max. admissible print contrast: 120%
102 4
Max. admissible print contrast at
print width > 100mm: 105%
Max. admissible print width at
print contrast > 105%: 100mm
127 5
Max. admissible print contrast at
print width > 75mm: 88%
Max. admissible print width at
print contrast > 88%: 75mm
152 6
Max. admissible print contrast at
print width > 65mm: 74%
Max. admissible print width at
print contrast > 74%: 65mm
[Tab. 11] Print width limitations for AP5.6 with 300dpi printheads.