Avery Dennison AP5.4 Troubleshooting guide

04/10 Rev. 5.05-00 USER / SERVICE MANUAL
AP5.4 – AP5.6
Technical Data
Application, Device Types .............................2
Application ................................................. 2
Device types .............................................. 2
Options ...................................................... 3
Technical Specifications ............................... 4
Dimensions ............................................... 4
Performance Data ..................................... 5
Label Stock ............................................... 9
Thermotransfer Ribbon ........................... 10
Connections, device data ........................10
Interfaces .................................................10
Electronic Configuration ...........................11
Specifications only for
AP5.4/5.6 dispenser ................................11
Environmental Conditions ........................11
Test Marks, certificates ............................12

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
2
Application, Device Types
Application
•Monotone printing of label stock for thermal and thermotransfer processes
•Printing on different materials, e.g. cardboard or self-adhesive labels,
which are suitable for thermal- or thermotransfer printing
•Processing roll and fan-folded material
•Resolution: 8.0 or 11.8Dot/mm (203 or 300dpi)
•Print speed up to 200mm/sec (8”/s)
•Print width:
– AP5.6: up to 168mm
– AP5.4: up to 105mm
•Interfaces: RS-232, USB,, Ethernet, and connection for foot switch
Device types
AP5.4 and AP5.6 are available in 4 versions:
Basic AP5.4/5.6 equipped with serial, USB and Ethernet interface and SD-card slot.
Possible upgrade to „peripheral“ version.
The following options can be integrated:
•Reflex sensor (top and/or bottom)
•I/O board (signal interface and additional serial interface)
Peripheral Like the AP5.4/5.6 basic, but with capability to add the following options:
•External rewinder (for AP5.4 only)
•Cutter
„Basic dispenser“ or
„peripheral dispenser“ AP5.4/5.6 with additional built-in internal rewinder. In connection with an op-
tional dispensing edge, this printer can also be used as a dispenser. If the dis-
pensing edge is replaced by a deflection plate, the printed labels are not
dispensed, but rewound together with the backing paper.

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
3
Options
Internal Options …should be factory-fitted or installed by a service engineer:
•Reflex Sensor Kit: Light barrier fitting that apart from the transmission sen-
sor, also contains a reflex sensor.
•Label sensor for short labels. Recommended for label length < 30mm.
•Internal rewinder kit: To retrofit the internal rewinder; contains the rewinder
as well as the driver board and material guide
•I/O board: RS-422/485 interface, signal interface
External Options …do not require any special alterations to the printer:
•Cutter (required printer: AP5.4/5.6 peripheral)
•AP5.4 only: (External) rewinder for material rolls with 38mm (1.5”), 75mm
(3”) or 100mm (4”) cores (required printer: AP5.4 peripheral)
•Keyboard for standalone operation
•Foot switch for foot-operated label dispensing
•Dispensing edge (required printer: AP5.4/5.6 „basic“ or „peripheral“ with
internal rewinder)

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
4
Technical Specifications
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 337 x 462mm
[Tab. 1] Measures
H
B/W
T/D
d
r
Printer Weight
AP5.4/5.6 14kg
AP5.4 basic / peripheral 14kg
AP5.4 dispenser / internal rewinder 16kg
[Tab. 2] Printer weight

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
5
Performance Data
Print Technology Thermodirect and thermotransfer printing
Printer Head 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)
[2] Measures and setting range of the punch / reflex mark.
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.
a
b
c
Z0211.cdr
Punch / Reflex markPunch sensor Label web

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AP5.4 – AP5.6
6
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

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
7
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.
¯Thosevaluesare empiricalfortypicalapplicationswithcommon label stock
/ foil combinations. Since the deflection of the print position strongly depends
ontheappliedlabelstock /foilcombination,itcanturnouthigherifunfavorable
combinations are used.
Image formats BMP, PCX, JPEG, TIFF, GIF, Easy Plug logos
A
A
B
B

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
8
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

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
9
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
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“)oder101.6mm(4“);coreswith
76.2 (3“) or 101.6mm (4“) can be applied with the core adapter supplied
with the printer.
Printer type Min. width Max. width Passage width
AP5.4 15mm 115mm 120mm
AP5.4 dispenser 30mm 105mm 110mm a)
a) The material passage width is limited by the dispensing sensor, which is mounted at the side. If a dis-
pensing edge without a sensor is applied (foot switch operation), the passage width is as large as at
the standard printer.
AP5.6 50mm 180mm 185mm
AP5.6 dispenser 50mm 170mm 175mm 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 6.
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.
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

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
10
Thermotransfer Ribbon
Ribbon Roll •Winding Direction: Colour-side rolled inwards or outwards
•Roll measurements:
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 max. 3.2A
Interfaces
Detailed information on the interfaces can be found in the Service Manual, top-
ic section Service Electronics , chapter “CPU boards”, “Interfaces”.
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 wider than 168mm counts: Foil
width = 172mm (max. ribbon width).
AP5.4: 25-114mm
AP5.6: 50-172mm
Length max. 500m
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

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
11
Electronic Configuration
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
Environmental Conditions
OperatingTemperature 5 to 40°C
Storage Temp. -4 to 60°C
Relative Humidity 30-85% (non-condensing)
Protection category IP 21
Noise 70dB(A)
Feature Details
CPU 32bit RMI
RAM 32MB SDRAM
ROM 4MB Flash
Memory card SD
Realtime-clock Present
Control Panel 4 buttons; LCD graphics display with 128x32 pixels; typi-
cally used to display two text lines with 16 characters each
[Tab. 9] Electronic configuration of the AP5.4/5.6.

04/10 Rev. 5.05-00 USER / SERVICE MANUAL Technical Data
AP5.4 – AP5.6
12
Test Marks, certificates
CE EU conformity: The devices fulfil the requirements of the following EU direc-
tives:
•EMC Directive
•Low Voltage 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