Avery Dennison AP5.4 User manual

05/10 Version 5.05-00 USER MANUAL
AP5.4 – AP5.6
Commissioning and Operation
Installation ..................................................... 2
Unpacking and setting up the printer ........ 2
Checking the shipment ..............................3
Product description ....................................... 5
Operating controls on
AP5.4/5.6 “basic” and “peripheral” ............ 5
Operating controls on
AP5.4/5.6 dispenser ................................. 7
Functionality of AP5.4/5.6 dispenser ........ 9
Ports and connections ............................. 10
Warning signs on printer ......................... 12
Operation panel ....................................... 13
Operating modes ..................................... 14
Main operating steps ...................................16
Connecting the printer .............................16
Configuring the data interface ..................17
(De)activating the internal rewinder .........17
(De)activating the dispensing edge .........19
Setting the dispenser ...............................19
Operating in offline mode .........................20
Online operation ......................................21
Creating a print job ..................................22
Transferring a print job .............................23
Using SD cards ........................................25
Setting the real-time clock .......................26

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Installation
Unpacking and setting up the printer
[1] AP5.4 in the original packaging.
1. Remove all loose objects from the shipping box.
2. Carefully lift the printer out of the box together with the styrofoam packag-
ing.
¯Have a second person hold the box tightly.
3. Remove the styrofoam and plastic film from the printer.
¯Store the original packaging for possible shipping at a later date!
4. Place the printer on a flat surface.
¯To carry the printer, reach below the baseplate at the front and rear.
5. Open the front cover. Remove the styrofoam shipping lock from the print-
head.
6. Check that the shipment is complete, see Checking the shipment on
page 3.
WARNING!
Lethal hazard from mains power!
«Only use the device in enclosed rooms under normal ambient conditions
(office atmosphere)!
CAUTION!
To avoid damage to the printer, observe the following:
«Do not lift the printer using the plastic components on the front and rear.
«To lift the printer, do not reach below the front hood.

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Checking the shipment
AP5.4/5.6 “basic”
AP5.4/5.6 “peripheral” Delivery:
•Printer AP5.4/5.6 including 2 pairs of core adapters [2B] and one paper
core [2A] for rewinding thermotransfer ribbon.
•Mains power cable
•Documentation CD
Contains detailed operating manual for printer as well as Windows drivers
and Servicing manual.
•Short operating manual (multilingual)
•Torx screwdriver [2C] size 10 (fastened to baseplate using adhesive tape)
•Support hooks [2D] for optional cutter (fastened to baseplate using adhe-
sive tape)
[2] AP5.6 “peripheral” in delivered state.
B
A
C
D
E

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AP5.4/5.6 “peripheral”
with cutter If you have ordered a AP5.4/5.6 “peripheral” printer with an optional cutter [3],
the cutter will be provided in a special carrier at the top of the box.
[3] The cutter, if ordered, can be found in a special carrier at the top of the printer box.
For instructions on how to assemble the cutter, see Manual Cutter 2000 ,
“Fastening, Setting Up, Servicing”.
¯The support hook needed to assemble the cutter is taped to the printer
baseplate.
AP5.4/5.6
“basic” dispenser,
AP5.4/5.6
“peripheral” dispenser
If you have ordered a AP5.4/5.6 “basic” or “peripheral” dispenser, the follow-
ing parts are delivered separately:
•Housing front part, bottom side with screw [4A]
•Flange cover with screws [4B]
•Baffle plate [4C]
The baffle plate can be installed instead of the dispensing edge. With this
option, the printer is able to internally wind up the printed material.
¯We recommend installing all of the housing parts when the printer is to be
used in the standard way without dispensing or rewinding functionality.
[4] Components delivered separately with the AP5.4/5.6 dispenser.
AB
C

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Product description
Operating controls on AP5.4/5.6 “basic” and “peripheral”
[5] Outside view of AP5.4/5.6 “peripheral”.
AControl panel
LCD screen; 4 buttons; displays operating status of printer; allows param-
eter menu settings.
BConnection for additional devices:
(Only to AP5.4/5.6 “peripheral”). This is where the optional cutter or re-
winder (AP5.4 only) is connected.
CFront cover:
Open this to insert material and the ribbon.
A
B
C

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[6] Operating controls of AP5.4/5.6.
ARibbon unwinding mandrel:
Holds the new ribbon roll
BRibbon winding mandrel
Holds the cardboard core that rewinds the spent ribbon.
CConnection flange for additional devices
You can fasten either a cutter or rewinder (AP5.4 only) here. To do this,
you first have to remove the plastic cover.
DPressure lever
Opening the pressure lever lifts the printhead. You do this to insert materi-
al/ribbon or to clean the printhead/print roller.
EMaterial unwinder
This is where you install the roll with the label material.
FMaterial strain relief
Allows the label material to unroll evenly.
GGuiding disk
Prevents material roll from sliding out sideways.
HAdapter rings
For adapting unwinder to core diameter of material roll.
B
A
C
D
E
F
G
H

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Operating controls on AP5.4/5.6 dispenser
AP5.4/5.6 “basic” or
“peripheral” dispenser
[7] Additional operating controls on AP5.4/5.6 dispenser.
ADispensing edge:
This is where the labels are separated from the backing paper.
BPlugs:
Connector for dispensing edge sensor.
CDispensing roll:
This holds the material ribbon taut over the dispensing edge.
DButton for dispensing roll:
Press the red button to remove the dispensing roll.
EDeflecting shaft:
This deflects the backing paper.
FRewinder:
This rewinds the backing paper.
A
B
C
D
EF

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AP5.4/5.6 “basic” or
“peripheral”dispenser
in rewinder mode
[8] Additional operating controls of AP5.4/5.6 dispenser in rewinding mode.
ABaffle plate:
Deflects the printed labels without dispensing any of them.
BDeflecting shaft:
This deflects the labels.
CRewinder
Rewinds the label web.
A
B
C

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Functionality of AP5.4/5.6 dispenser
The AP5.4/5.6 dispenser allows freshly printed labels tobe dispensed (via the
dispensing edge) or rewound in the printer enclosure (via the defelector).
•When used as a dispenser, the label material is drawn around the dispens-
ing edge and only the backing paper is rewound.
•When used as a rewinder, the printed label is guided across a baffle plate
and rewound together with the backing paper.
The electronic components in the rewinder control the tensile force on the re-
lease paper so that the same force is applied for all winding diameters. This is
controlled independently of the material width and printing speed. The control-
ler can be set automatically or manually depending on the settings in the pa-
rameter menu.
¯The manual setting is only necessary in special cases and may only be per-
formed by qualified, authorised service personnel.
After switching on the printer, the rewinder is initialised and the backing paper
is tightened.
Onceaprintjob isreceived, theprintersearchesfor thefirst labelstartmarking
at reduced printing speed. To do this, the label material is moved by at least
the distance between the label sensor and the printhead (70mm). This dis-
tance is used by the rewinder controller to calculate the diameter of the previ-
ously wound backing paper. To allow the controller to calculate the diameter
even with endless material, in this case printing also does not start until the
material has moved 70mm. The print job is carried out at the speed that has
been set in the parameter menu or as specified by the print job.
If a fault occurs during operation, the rewinder shuts off automatically.
Once the maximum diameter of the backing paper has been reached, a mes-
sage appears on the display and the rewinder shuts off automatically.
Dispenser operating
modes The following operating modes are available for the dispenser:
•Dispenser mode with dispenser sensor:
The material feed ends at the dispensing edge, i.e., the label to be dis-
pensed remains hanging on the dispensing edge(set dispensing position).
The printer waits until the label is removed before moving the next empty
label beneath the printhead and then printing and dispensing it.
•Dispenser mode with foot switch:
Pressing the foot switch releases the label for printing and dispensing. Af-
terwards, the next empty label is positioned beneath the printhead.
See (De)activating the dispensing edge auf Seite 19.

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Ports and connections
For instructions on how to use the network connections, see topic section “Ad-
vanced Applications”, chapter Data Transmission with Ethernet on page 18.
[9] The rear side of the AP5.4/5.6 with I/O board (option) installed.
AStart/stop signal input
Connections for a foot switch (signal starts printer) or stacker (signal stops
printer)
BSignal port (option)
4 inputs / 3 outputs on optionally available I/O board
CAUTION!
Using poor quality auxiliary equipment can damage the printer.
«Only connect the printer to devices that fulfil the SELV (safety extra-low
voltage) circuit requirements in accordance with EN60950.
«Only connect original accessories.
A
D
B
C
E
F
G
H
I
J

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CMemory card slot
For SD cards where you can store fonts, logos, graphics, etc.
DSerial port (option):
RS232 or RS422/485 on optionally available I/O board
EUSB port (host)
For USB sticks, keyboards, etc.
FUSB port (device)
For serial transfer of printer data.
GRS232 port
For serial transfer of printer data.
HEthernet port
Interface for “Ethernet 10/100 Base T” network
IMains power switch
On/Off switch for printer
JMains socket
Mains socket for connection to mains using supplied cable.

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Warning signs on printer
[10] Warning signs on AP5.4/5.6.
The warning sign [10A] warns users about the pinching hazard on moving
parts of the printer (part no. A5346).
The warning sign [10B] warns users about the hazard of getting hands or
fingers burned at hot surfaces close to the printhead (part no. A5640).
WARNING!
If warning signs are missing on the printer, possible hazards may not be no-
ticed in time.
«Do not remove warning stickers.
«Replace any warning stickers if they become lost or illegible.
WARNING
!
Pinch point.
Keep hands clear
of rollers.
A5346
A
B

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Operation panel
[11] Operation panel of AP5.4/5.6.
ADisplay
The display contains two rows of 32 digits for displaying operating modes,
parameters, values, statuses and messages. Users can adjust the display
language so that the text appears in their native language. The backlight-
ing ensures that the screen is easily legible.
BCut button
–Offline: Starts a cut (prerequisite: cutter is installed and activated)
–Parameters menu: navigates to deeper menu levels or selects menu
options.
–Parameters menu: Decreases values
COnline button
– Switches between online and offline mode.
– Confirms entries, menu options or status messages.
– Selects print job and enters field data for printer in standalone mode.
DFeed button
–Offline: Starts material feed
–Online: Starts printing process after it has been paused
–Parameters menu: Navigates to higher menu levels or selects menu
options.
–Parameters menu: Increases values.
A
CB
D
E

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EProg button
–Offline: Opens Parameters menu
–Parameter menu: Moves back one step in Parameters menu or quits
the menu.
For more functions and more details, see
•section Offline mode auf Seite 14 and section Online mode auf
Seite 14
•topic section InfoPrintouts and Parameters 
Operating modes
Offline mode
No print jobs are queued.
In Offline mode, you can change the printer settings. This operating mode is
normally active when the printer is first turned on. Printjobs are received at the
selected port but not processed.
¯To set the printer so that it immediately switches to online mode after being
turned on, set SYSTEM PARAMETER > Turn-on mode to “Online”.
Online mode In Online mode, printjobs are received and immediately processed.
•No print jobs are queued.
•If data is currently being transferred to the printer, this is indicated by a sin-
gle dot to the lower right of the displayed number of current jobs.
An additional dot at mid-line height indicates when the interpreter is active.
–No dot: no data to interpret.
–Dot: The interpreter is currently running (there is still data in the spool-
er)
–Flashing dot: The interpreter is waiting for more data in order to com-
plete a command (no data in spooler).
•During printing, the number of jobs in process (13) are displayed as well as
the remaining quantity (25) of labels to be printed in the current job.
•If a print job has been specified as continuous, the remaining quantity for
this job will be endless.
¯To stop the printing process, press the Online button.
OFFLINE 0 JOBS
ONLINE 0 JOBS
ONLINE 0: JOBS
ONLINE 13 JOBS
Restcount: 25
ONLINE 13 JOBS
Restcount: endless

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Message mode Status messages are used to indicate errors or certain operating statuses.
Whenstatusmessages appear,thebackgroundcolourofthedisplay becomes
red. When a status message is present, the printer waits until the error has
been eliminated and/or acknowledged. When the error is acknowledged, the
printer switches from message mode to offline mode (depending on the error
and state of previous process).
Status messages consist of the status number together with a brief descrip-
tion:
For instance, status message 5001 (see above) appears when the printer is
configured for punched label material but continuous material (unpunched) is
inserted. In this case, the printer continues to transport the material for a few
more seconds until the error message appears.
For more on the status messages as well as a detailed list of all status mes-
sages, see Status Reports .
Standalone mode In standalone mode (operation without data connection to computer), print
jobs are not transferred via data cable but are instead stored on a SD card.
From there, you can access them from the control panel or using a connected
keyboard.
For more information on standalone mode, see topic section “Advanced Appli-
cations”, chapter Standalone Operation on page 9.
Status 5001
No punch detected

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Main operating steps
Connecting the printer
[12] Rear side of AP5.6.
1. Make sure that the printer is switched off (mains switch [12C] at “0” posi-
tion).
2. Connect the mains cable [12A] to the mains connector at the printer.
3. Connect the mains cable into a mains socket.
4. Connect the printer and computer or printer and network using suitable
data cable (example: USB cable to USB (device) port [12B] of printer and
to USB port of host computers).
5. Turn on the unit using the mains power switch (position “1”).
As soon as the printer is ready, the following appears:
¯If SYSTEM PARAMETERS > Turn-on mode is set to “Online”, the printer
switches directly into online mode after turning on the printer!
WARNING!
This unit operates at mains voltage! Contacting electrically live components
can cause potentially lethal electrical shocks and burns.
«Make sure that the machine has been switched off before connecting the
mains cable.
«Only operate the printer at the mains voltage given on the type plate.
«Only connect the printer to a properly installed mains socket with protec-
tive earth.
«When installing the mains cable, ensure the following:
a) Nobody can stumble over the cable
b) Mains plug can be pulled in case of emergency
OFFLINE 0 JOBS
B
A
C

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Configuring the data interface
The AP5.4/5.6 has been pre-configured at our factory for data transmission
through the USB port. Alternatively, printer data can also be transmitted via
RS232, RS422/485 (only with optional I/O board), USB or Ethernet port.
«Choosing the port: INTERFACE PARA > EASYPLUGINTERPR > Interface
«Configuring the port:
•RS232 (COM1): INTERFACE PARA > COM1 PORT > …
•RS232/422/485 (COM3): INTERFACE PARA > COM3 PORT > …
•Ethernet: INTERFACE PARA > NETWORK PARAM. > …
¯We recommend that your network administrator configures the network
settings.
•USB: no configuration required
For more information on how to set the parameters, see topic section “Info
Printouts and Parameters”, Operating the Parameter Menu .
The order numbers for network and data cables are given in topic section
Accessories .
For more information on how to use the Ethernet port, see topic section
“Advanced Applications”, chapter Data Transmission with Ethernet on
page 18.
(De)activating the internal rewinder
¯Only applies to AP5.4/5.6 dispensers with baffle plate installed.
Activate ¯Ensure that material has been inserted before you activate the rewinding
function, otherwise a fault message will appear!
For information on inserting material, see topic section “Setup”, chapter
Inserting Label Material on page 6.
Set
1. SYSTEM PARAMETER > Periph. device to “Intern Rewinder”.
¯Do not confuse this with “Rewinder” because this setting activates the
external rewinder (additional device)!
After being activated, the system checks the direction of rotation of the re-
winder.
“Facing outside” is set by default.
2. If required, press the cut/feed button to change the direction of rotation.
3. Press the ENTER button to confirm your selection.
The printer restarts. Afterwards, an additional menu REWINDER PARA can
be opened from the main menu, and this contains the Rewind direction para-
meter. Using this parameter, you can change the direction of rotation.
Rewinder direct.
Facing outside

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During the initialisation, the printer attempts to tighten the label strip.
Deactivate Set
«SYSTEM PARAMETER > Perip. device to “None”.
Possible fault The following error message may appear briefly after activating the internal re-
winder:
Possible causes include:
•No material has been inserted or end of material has not been fastened to
rewinder. Fasten end of material to rewinder and press Online button.
•The material strip is sagging in front of the rewinder. Press the Online
button.
Modifying main
initialisation After this, the printer is ready for the first job. As soon as a job is received, the
rewinder controller calculates the main initialisation values for the rewinding
process on the basis of the given material width and printing speed. These val-
ues are suitable for a wide range of applications.
However, these settings may cause too much printer offset in certain special
applications. In these cases, the main initialisation values will have to be modi-
fied. Such applications include printing on:
•Very narrow labels
•Very coarse backing paper
•Very thick backing paper compared to the label
•Labels stuck on the backing paper
•Backing paper perforated along label contour
¯Only qualified service technicians are permitted to edit the main initialisa-
tion values!
Status 5004
Rewinder mat. tear

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(De)activating the dispensing edge
¯Only applies to AP5.4/5.6 dispensers with dispensing edge installed!
Activating Set
«SYSTEM PARAMETER > Periph. device to “Dispenser”.
The printer restarts. Afterwards, an additional menu DISPENSER PARA can be
accessed that contains all of the parameters required for dispensing mode:
For more on the listed parameters, see Info Printouts and Parameters .
Deactivating Set
«SYSTEM PARAMETER > Periph. device to “None”.
Setting the dispenser
Application A The label should be dispensed to that a narrow strip still sticks to the backing
paper above the dispensing edge. After manually removing the dispensed la-
bel, the next label is printed and dispensed.
Set
«DISPENSERPARA >Dispenseposition to -6.0mm (for strong adhesives, this may
have to be reduced to -8.0mm).
Set
«DISPENSER PARA > Start source to “Light barrier”.
Application B The label should be printed and dispensed after receiving a signal from the
connected foot switch.
Set
«SYSTEM PARAMETER > External signal to “Singlestart”.
Set
«DISPENSERPARA >Dispenseposition to -6.0mm (for strong adhesives, this may
have to be reduced to -8.0mm).
Set
«DISPENSER PARA > Start source to “Foot switch”.
Parameters Possible settings
Dispenser mode True 1:1 mode (default), Batch mode, Normal 1:1 mode
Dispensing position Configurable in millimetres (default: 0.0mm)
Display mode Remaining qty. in job (default), dispenser counter
Dispense counter Quantity presetting (default = 0)
Application mode Safe mode (default), immediate mode
Start source Foot switch, light sensor (default)
[Tab. 1] Parameters in DISPENSER PARA menu.

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Label length
< 40mm ¯If very short labels are to be printed (PRINT PARAMETERS > Material length is
set to < 40mm), the printer is automatically initialised for the material before
printing.
For more information, see the parameter description DISPENSER PARA >
Calibration mode under Info Printouts and Parameters .
Operating in offline mode
•Changing from offline to online mode:
•Switching into online mode when print job is stopped
•Slow material and ribbon feed:
•Material is reversing below the printhead:
•Reset
•Opening the parameter menu
•Feeding material to next punch or while button is pressed:
•Setting the label length automatically:
For more information, see topic section “Setup”, chapter Setting the label
length automatically .
OFFLINE x JOBS ONLINE x JOBS
OFFLINE x JOBS
Stopped xx ONLINE x JOBS Stopped xx
OFFLINE x JOBS OFFLINE x JOBS
feeding...
OFFLINE x JOBS OFFLINE x JOBS
feeding...
OFFLINE x JOBS OFFLINE x JOBS
OFFLINE x JOBS PRINT INFO
OFFLINE x JOBS OFFLINE x JOBS
feeding...
OFFLINE x JOBS OFFLINE x JOBS
Man Calibrate
Online
Online
Feed
Online
Cut Online
C
ut
O
nline Feed
Prog
Feed
Feed Prog