Avery Dennison AP4.4 Troubleshooting guide

09/09 Rev. 5.03-01 USER / SERVICE MANUAL
AP4.4 – AP5.4
Specifications
Device Types, Application .............................2
AP4.4 ........................................................ 2
AP5.4 ........................................................ 2
Options ...................................................... 3
Technical Specifications ............................... 4
Dimensions ............................................... 4
Performance Data ..................................... 4
Label Stock ............................................... 8
Thermotransfer Ribbon ............................. 9
Connections, Interfaces ............................ 9
Electronic Configuration .......................... 10
Specifications only for AP5.4 dispenser /
AP5.4 Internal rewinder .......................... 10
Environmental Conditions ....................... 10
Test Marks .............................................. 10

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
AP4.4 – AP5.4
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Device Types, Application
AP4.4
•Monotone printing of label stock for thermal and thermotransfer processes
•Printing on different materials, e.g. cardboard or self-adhesive labels
•Processing roll and fan-folded material
•Resolution: optionally 203 or 300dpi
•Print speed up to 200mm/sec (8”/s)
•Print width up to 105mm
•Interfaces: RS-232, USBCentronics, and connection for foot switch
AP5.4
The AP5.4 is available in 3 versions, which additionally offers the following
equipment features:
•Basic
Like the AP4.4, but additionally equipped with the following: Keyboard
connection, slot for CF card, Ethernet port
The following options can be integrated:
– Reflex sensor
– I/O board
•Peripheral
Like the AP5.4 basic, but with capability to add the following extra option:
– External cutter
– External rewinder
– Internal rewinder
•Peripheral with internal winder
Like the AP5.4 peripheral with additional built-in internal rewinder. In con-
nection with an optional dispensing edge, this printer can also be used as
a dispenser.

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
AP4.4 – AP5.4
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Options
The optional features – with the exception of the foot switch – can only be in-
tegrated into the AP5.4.
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
•Contact brush for narrow label web (< 30mm); recommended for AP5.4
with „Rewinder 2000“.
External Options …do not require any special alterations to the printer, however, the printer
must be prepared for the use of peripheral devices:
•Cutter
•Rewinder for material rolls with 38mm (1.5”), 75mm (3”) or 100mm (4”)
cores („Rewinder 2000“)
•Keyboard for offline operation
•Foot switch for foot-operated label dispensing (printer must additionallybe
equipped with an I/O board)
•Dispensing edge (only for dispensing versions)

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
AP4.4 – AP5.4
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Technical Specifications
Dimensions
[1] Dimensions of the AP4.4 and AP5.4.
H x W x D: 272 x 260 x 462mm
Weight
Performance Data
Print Technology Thermodirect and thermotransfer printing
Printer Head Type •“Flat Head” type (ceramic thin film flat head)
•8.0dot/mm (203dpi): Kyocera KPA 104
•11.8dot/mm (300dpi): Kyocera KPA 106
Printhead
Characteristics
H
B/W
T/D
d
r
Printer Weight
AP4.4 14kg
AP5.4 basic / peripheral 14kg
AP5.4 dispenser / internal rewinder 16kg
[Tab. 1] Printer weight
Printer Resolution
dot/mm
Resolution
dpi
Printspeed
mm/s
Printspeed
inch/s
Max. print-
width / mm
AP4.4 8.0
11.8
203
300
50-200
50-150
2-8
2-6
104
105
AP5.4 8.0
11.8
203
300
50-200
50-150
2-8
2-6
104
105
[Tab. 2] Important printhead data.

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
AP4.4 – AP5.4
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Punch sensor Transmission sensor, adjustable from the left side about half of the material
width (0-60mm) [2].
Reflex sensor •The reflex sensor for AP5.4 is optionally available (for reflex marks on the
material underside)
•Adjustable from the left side about half of the material width (6-66mm)
•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.
Max. print length The maximum print length depends on the following:
•Printer type
•Printer resolution
•Firmware version
•Parameter settings (e.g. SYSTEM PARAMETERS > Free store size)
Zero line Offset of the material zero line to the print zero line: 1mm
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 a CF-card
Modifying Fonts •Up to factor 8 scaling in x/y direction
•Rotation by 0, 90, 180 and 270 degrees
Sensor type Setting range
(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. 3] Required punch measures.
a
b
c
Z0211.cdr
Punch / Reflex markPunch sensor Label web

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
AP4.4 – AP5.4
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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.
¯Those values are empirical for typical applications with common label
stock / foil combinations. Since the deflection of the print position strongly
depends on the applied label stock / foil combination, it can turn out higher if
unfavorable combinations are used.
Image formats BMP, PCX, JPEG, TIFF, GIF, Easy Plug logos
A
A
B
B

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
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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:
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 13 add-on 2
Code 2/5 5-line EAN 13 add-on 5
Code 2/5 interleaved ratio 1:3 EAN 128
Code 2/5 matrix ratio 1:2,5 Postcode (guide and identity code)
Code 2/5 matrix ratio 1:3 UPC A
Code 39 UPC E
Code 39 extended Code 93
Code 39 ratio 2,5:1
Code 39 ratio 3:1
Data Matrix Code (code according to ECC200)
Maxi Code
PDF 417
Codablock F
Code 49
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

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
AP4.4 – AP5.4
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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: max. 240g/m2
Material Width
Label Length •Normal printing: 5mm up to max. print length
•Dispensing: 30-200mm
•Dispensing with optional punch sensor for short labels: 5-200mm
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“) oder 101.6mm(4“); coreswith
76.2 (3“) or 101.6mm (4“) can be applied with the core adapter supplied
with the printer.
•Material width: 12 to 120mm, for dispenser version: 15 to 110mm
Printer type / Application Material width
AP4.4, AP5.4 basic, AP5.4 peripheral 15-120mm
AP5.4 with internal rewinder 15-120mm
AP5.4 dispenser 30-110mm
AP5.4 dispenser,if afootswitchis used insteadof thelabel
sensor to trigger the printer 15-110mm
[Tab. 4] Admissible material width of the different printer types.
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. 125mm
[Tab. 5]Diameter of material and winding roll

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
AP4.4 – AP5.4
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Thermotransfer Ribbon
Ribbon Roll •WindingDirection:Colour-sidepreferablyrolledinwards(coloursidefacing
outwards can be used)
•Roll measurements:
Connections, device data
Protection class I
Mains Voltage 100-240V (AC)
Mains Frequency 50-60Hz
Power Consumption •Max. 250W
•In standby mode depending on the equipment 30-40W
Current Consumption max. 3.2A
Interfaces
External Ø max. 80mm
Core Ø 25mm (1”)
Width 25-114mm
Length max. 500m
Interface AP4.4 AP5.4 Details
Centronics X X Bi-directional; conforms with IEEE 1284; nibble mode;
connector at the printer: type C
RS-232 X X
Baud: 1200-115200, 8- bit;
suitable connection cord: 1:1
D-Sub 9 extension lead (connec-
tor-jack)
RS-422/485 O Baud: 1200-115200, 8- bit
Ethernet X 10/100BaseTwithTCP/IP,LPD, RawIP printing, DHCP, HTTPD,
FTPD, SNMP
USB slave V1.1 X X
Transmissionrate12Mbps.Ifthe
printer is connected to a host run-
ning under Windows, the hosts
OS will search for a matching
printer driver.
Keyboard Connector X PS/2
Connector for Additio-
nal Devices X
[Tab. 6] X=present; O=optionally available

09/09 Rev. 5.03-01 USER / SERVICE MANUAL Specifications
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You can find detailed information on the interfaces in the Service Handbook,
under the “Service Electronics” headingin the section on “CPU Boards”, “Plug
Connectors”.
Electronic Configuration
Specifications only for AP5.4 dispenser /
AP5.4 Internal rewinder
•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 4 to 38°C
Storage Temp. -4 to 60°C
Relative Humidity 30-85% (non-condensing)
Protection category IP 21
Noise 70dB(A)
Characteristic AP5.4 AP4.4 AP4.4 RoHS a)
a) RoHS conform printer - is built approx. from 08/2006 on.
Processor 32-bit IDT with 32-bit data bus
SDRAM 16MB 8MB 16MB
ROM 4MB Flash 2MB Flash 4MB Flash
Plug-in Cards A slot for Compact Flash cards of type T1
with up to 64MB -- --
Real-time Clock Present;printout ofdate
and time possible -- --
Control Panel 4 buttons; LCD graphics display with 122x32 pixels; typi-
cally used to display two text lines with 16 characters each.
[Tab. 7] Electronic Configuration