Carl Valentin APL 100 User manual

APL 100
Operating Manual

Copyright by Carl Valentin GmbH / 7952505A11.13
Information on the scope of delivery, appearance, performance,
dimensions and weight reflect our knowledge at the time of printing.
We reserve the rights to make modifications.
All rights, including those regarding the translation, are reserved.
No part of this document may be reproduced in any form (print,
photocopy or any other method) or edited, copied or distributed
electronically without written permission from Carl Valentin GmbH.
Due to the constant further development of our devices discrepancies
between manual and device can occur.
Please check www.carl-valentin.de for the latest update.
Trademarks
Centronics®is a registered trademark of Data Computer Corporation.
Microsoft®is a registered trademark of Microsoft Corporation.
Windows 2000®, 2003®, XP®, Vista®, 7®, 8®, Windows ServerTM 2008,
Windows ServerTM 2008 R2, Windows ServerTM 2012 are registered
trademarks of Microsoft Corporation.
TrueTypeTM is a trademark of Apple Computer, Inc.
Zebra®and ZPL II®are registered trademarks of ZIH Corporation.
The pneumatic applicator complies with the following safety
guidelines:
CE EG Low-Voltage Directive (2006/95/EC)
EG Electromagnetic Compatibility Directive (2004/108/EG)
EG Machinery Directive (2006/42/EG)
Carl Valentin GmbH
Postfach 3744
78026 Villingen-Schwenningen
Neckarstraße 78 – 86 u. 94
78056 Villingen-Schwenningen
Phone
Fax
[phone]
+49 (0) )7720 9712-9901
E-Mail
Internet
[email protected]
www.carl-valentin.de

Applicator APL 100 Table of contents
11/13 Operating Manual 3
Table of Contents
Table of Contents............................................................................. 3
1Introduction............................................................................ 5
1.1General Instructions ................................................................ 5
1.2Intended Use ........................................................................... 5
1.3Environmentally-Friendly Disposal .......................................... 6
2Safety Instructions................................................................ 7
2.1Safety Marking......................................................................... 8
2.2Operating Conditions............................................................... 9
3Product Description............................................................ 13
3.1Important Characteristics ...................................................... 14
3.2Technical Data....................................................................... 14
3.3Device Overview.................................................................... 15
3.4Pads ...................................................................................... 17
4Installation............................................................................ 19
4.1Scope of Delivery .................................................................. 19
4.2Mounting the Applicator to the Printer ................................... 20
4.3Piercing the Universal Tamp Pad.......................................... 21
4.4Preparing for Using a Sprint-Mounted Tamp Pad ................. 22
4.5Mounting the Pad .................................................................. 23
4.6Mounting the Stopper ............................................................ 24
4.7Connections........................................................................... 25
5Configuration....................................................................... 27
5.1Configuration Parameter ....................................................... 27
5.2Settings in printer function menu...... Fehler! Textmarke nicht
definiert.
6Signal Diagrams .................................................................. 32
6.1Print - Apply ........................................................................... 32
6.2Apply - Print ........................................................................... 32
7Mechanical Adjustments .................................................... 33
7.1Aligning the pad..................................................................... 33
7.2Adjusting the Parallelism between Pad and Dispense Edge 34
7.3Opening the Holes on the Blow Tube.................................... 35
7.4Aligning the Blow Tube.......................................................... 36
7.5Adjusting the Stopper ............................................................ 37
8Pneumatic Adjustments ..................................................... 39
8.1Control Valves ....................................................................... 39
8.2Adjusting the Pad Movement Speed ..................................... 41
8.3Adjusting Vacuum and Supporting Air................................... 42
9Operation.............................................................................. 43
9.1Loading the Label Material .................................................... 43
9.2Setting the Dispenser Mode .................................................. 44
9.3Test Mode.............................................................................. 45
9.4Standard Operation ............................................................... 47
10Applicator Interface............................................................. 49
10.1Pin Assignment...................................................................... 49
10.2Internal Circuit of Outputs...................................................... 49
10.3Signal Assignment D-Sub 15 pin........................................... 50

Table of Contents Applicator APL 100
4 Operating Manual 11/13
11Error Messages.................................................................... 51
11.1Error Messages of the Printer ............................................... 51
11.2Error Messages of the Applicator .......................................... 51
12Declaration........................................................................... 53
12.1Extended Declaration ............................................................ 53
12.2EC-Declaration of Conformity................................................ 54
13Index ..................................................................................... 55

Applicator APL 100 Introduction
11/13 Operating Manual 5
1 Introduction
1.1 General Instructions
Important information and instructions in this document are
designated as follows:
DANGER identifies an extraordinarily great and immediate
danger which could lead to serious injury or even death.
WARNING identifies a possible danger would could lead
to serious bodily injury or even death if sufficient
precautions are not taken.
CAUTION indicates a potentially dangerous situation
which could lead to moderate or light bodily injury or
damage to property.
NOTICE gives you tips. They make a working sequence
easier or draw attention to important working processes.
Gives you tips on protecting the environment.
Handling instruction
Optional accessories, special fittings
Time Information in the display
1.2 Intended Use
The device is a state-of-the-art device which complies with the
recognized safety-related rules and regulations. Despite this, a
danger to life and limb of the user or third parties could arise and
the device or other property could be damaged while operating
the device.
The device may only be used while in proper working order and
for the intended purpose. Users must be safe, aware of potential
dangers and must comply with the operating instructions. Faults,
in particular those which affect safety, must be remedied
immediately.
The applicator mounted on a label printer of the Compa II series is
intended to print suitable media which have been approved by the
manufacturer. Any other or additional use is not intended. The
manufacturer/supplier is not liable for damage resulting from
misuse. Any misuse is at your own risk.
Intended used includes heeding the operating manual, including
the maintenance recommendations/regulations specified by the
manufacturer.
NOTICE!
The complete documentation is included in the scope of
delivery on CD ROM and can also currently be found in the
internet.

Introduction Applicator APL 100
6 Operating Manual 11/13
1.3 Environmentally-Friendly Disposal
Manufacturers of B2B equipments are obliged to take-back and
dispose old equipment which was manufactured after 13 August 2005.
In principle, these old equipments may not be delivered to communal
collecting points. They may only be organised used and disposed by
the manufacturer. Valentin products accordingly labelled can therefore
in future be returned to Carl Valentin GmbH.
Thereupon old equipment is professionally disposed.
Thereby Carl Valentin GmbH observes all obligations in the context of
old equipment disposal in time and makes therewith the smooth
selling of products furthermore possible. Please understand that we
can only take-back equipment that is send free of carriage charges.
Further information on the WEEE directive is available on our website
www.carl-valentin.de.

Applicator APL 100 Safety Instructions
11/13 Operating Manual 7
2 Safety Instructions
Before mounting the delivered components disconnect the printer
from the power supply and close the shutoff valve at the
applicator.
Only connect the device to other devices which have a protective
low voltage.
Switch off all affected devices (computer, printer, accessories)
before connecting or disconnecting.
In operation, moving parts are easily accessible. This applies
especially for the zone, where the pad is moved between the
starting and the labelling position. During operation do not reach
into that zone and keep long hair, loose clothes, and jewellery
distant.
Before any manipulations in those areas, close the shutoff valve.
The device may only be used in a dry environment, do not expose
it to moisture (sprays of water, mists, etc.).
Do not use the device in an explosive atmosphere.
Do not use the device close to high-voltage power lines.
Operate the direct print module only in an environment protected
against abrasive dust, swarf and other similar impurity.
NOTICE!
With the open printing unit (due to construction) the requirements
of EN60950-1 regarding fire protection casing are not fulfilled.
These must be ensured by the installation into the end device.
Carry out only the actions described in these operating
instructions. Any work beyond this may only be performed by the
manufacturer or upon agreement with the manufacturer.
Unauthorized interference with electronic modules or their
software can cause malfunctions.
Other unauthorized work on or modifications to the device can
also endanger operational safety.
Always have service work done in a qualified workshop, where the
personnel have the technical knowledge and tools required to do
the necessary work.
There are warning stickers on the direct print modules that draw
your attention to dangers. Therefore the warning stickers are not
to be removed as then you and others cannot be aware of
dangers and may be injured.
When incorporating the unit into the overall system, make sure
that safety precautions are taken so that no-one is able to reach
into the working area.
The direct print module must be integrated with the Emergency
Stop circuit when it is incorporated into the overall machine.
Before starting the machine, all protective guards must be fitted.

Safety Instructions Applicator APL 100
8 Operating Manual 11/13
2.1 Safety Marking
1
Figure 1
CAUTION!
There is a risk of injury due to the movement of the pad
downwards and back up again.
Do not reach into the working area of the pad.
Keep hair, loose clothing and items of jewellery out of
this area.
When incorporating the unit into the overall system,
safety precautions must be taken so that no-one is
able to reach into the working area.
1 = Risk of crushing due to
1 = the movement of the pad

Applicator APL 100 Safety Instructions
11/13 Operating Manual 9
2.2 Operating Conditions
Before initial operation and during operation these operating
conditions have to be observed to guarantee save and interference-
free service of our printers.
Therefore please carefully read these operating conditions.
Shipment and storage of our printers are only allowed in original
packing.
Installation and initial operation of printer is only allowed if operating
conditions were fulfilled.
Commissioning is prohibited until it can be established that, where
relevant, the machine into which the partly completed machinery is to
be incorporated complies with the provisions of Machinery Directive
2006/42/EC.
Initial operation, programming, operation, cleaning and service of our
printers are only recommended after careful study of our manuals.
Operation of printer is only allowed by especially trained persons.
NOTICE!
Perform trainings regularly.
These indications are also valid for someone else's equipment
supplied by us.
Only use original spare and exchange parts.
CPU of printer is equipped with a lithium battery (type CR 2032) for
which the battery regulation is to apply. This regulation plans that
unloaded batteries have to be given to used battery collecting
containers of trade and public carries. In case that batteries were not
completely discharged you have to make arrangements for short-
circuits. At a shutdown of printer the battery has to be disposed in
either case separately from printer.
DANGER!
Danger of life by explosion!
Use non-conducting tools.
The installation place of printer should be even, free of vibration and
currents of air are to be avoided.
The printers have to be installed to ensure optimal operation and
servicing.
Instructions for
lithium battery
Conditions for
installation place

Safety Instructions Applicator APL 100
10 Operating Manual 11/13
The installation of the power supply to connect our printers has to be
effected according to the international rules and regulations,
especially the recommendations of one of the three following
commissions:
International Electronic Commission (IEC)
European Committee for Electro technical Standardisation
(CENELEC)
Verband Deutscher Elektrotechniker (VDE)
Our printers are constructed according to VDE and have to be
connected to a grounded conductor. The power supply has to be
equipped with a grounded conductor to eliminate internal interfering
voltage.
Power line voltage and power line frequency: See type plate
Allowable tolerance of power line voltage:
+6% to −10% of nominal value
Allowable tolerance of power line frequency:
+2% to −2% of nominal value
Allowable distortion factor of power line voltage: <=5%
In case your net is infected (e.g. by using thyristor controlled
machines) anti-interference measures have to be taken. You can use
one of the following possibilities:
Provide separate power supply to our printers.
In case of problems please connect capacity-decoupled isolation
transformer or similar interference suppressor in front of our
printers.
Emitted interference according to EN 61000-6-3: 2007
industrial sector
Interference voltage to wires according to EN 55022: 09-2003
Interference field power according to EN 55022: 09-2003
System perturbation according to EN 61000-3-2: 09-2006
Flicker according to EN 61000-3-3: 1955 + A1:2001 + A2:2005
Installation of
power supply
Technical data of
power supply
Anti-interference
measures
Stray radiation and
immunity from
disturbance

Applicator APL 100 Safety Instructions
11/13 Operating Manual 11
Immunity to interference according to EN 61000-6-2: 2005
industrial sector
Stray radiation against discharge of static electricity according to
EN 61000-4-2: 12-2001
Electromagnetic fields according to EN 61000-4-3: 11-2003,
ENV 50204: 03-1995
Fast transient burst according to EN 61000-4-4: 07-2005
High-frequency tension according to EN 61000-4-6: 12-2001
NOTICE!
This is a machine of type A. This machine can cause
interferences in residential areas; in this case it can be required
from operator to accomplish appropriate measures and be
responsible for it.
EN 415-2 - Safety of packaging machines
EN 60204-1:2006 - Safety of machinery – Electrical equipment of
machines – Part 1
All connecting lines have to be guided in shielded lines. Shielding has
to be connected on both sides to the corner shell.
It is not allowed to guide lines parallel to power lines. If a parallel
guiding cannot be avoided a distance of at least 0.5 m has to be
observed.
Temperature of lines between: −15 to +80 °C.
It is only allowed to connect devices which fulfil the request 'Safety
Extra Low Voltage' (SELV). These are generally devices which are
checked corresponding to EN 60950.
The data cables must be completely protected and provide with metal
or metallised connector housings. Shielded cables and connectors are
necessary, in order to avoid radiant emittance and receipt of electrical
disturbances.
Allowable lines
Shielded line:
4 x 2 x 0,14 mm² ( 4 x 2 x AWG 26)
6 x 2 x 0,14 mm² ( 6 x 2 x AWG 26)
12 x 2 x 0,14 mm² (12 x 2 x AWG 26)
Sending and receiving lines have to be twisted in pairs.
Maximum line length:
with interface V 24 (RS-232C) - 3 m (with shielding)
with Centronics - 3 m (with shielding)
USB - 5 m
Ethernet - 100 m
Stray radiation and
immunity from
disturbance
Machine safety
Connecting lines to
external machines
Installation of
data lines

Safety Instructions Applicator APL 100
12 Operating Manual 11/13
To avoid inadmissible heating, free air convection has to be ensured.
Protection according IP: 20
Ambient temperature °C (operation): Min. +5 Max. +35
Ambient temperature °C (storage): Min. −25 Max. +60
Relative air humidity % (operation): Max. 80
Relative air humidity % (storage): Max. 80
(bedewing of printers not allowed)
We do not take any responsibility for damage caused by:
Ignoring our operating conditions and operating manual.
Incorrect electric installation of environment.
Building alterations of our printers.
Incorrect programming and operation.
Not performed data protection.
Using of not original spare parts and accessories.
Natural wear and tear.
When (re)installing or programming our printers please control the
new settings by test running and test printing. Herewith you avoid
faulty results, reports and evaluation.
Only specially trained staff is allowed to operate the printers.
Control the correct handling of our products and repeat training.
We do not guarantee that all features described in this manual exist in
all models. Caused by our efforts to continue further development and
improvement, technical data might change without notice.
By further developments or regulations of the country illustrations and
examples shown in the manual can be different from the delivered
model.
Please pay attention to the information about admissible print media
and the notes to the printer maintenance, in order to avoid damages
or premature wear.
We endeavoured to write this manual in an understandable form to
give and you as much as possible information. If you have any queries
or if you discover errors, please inform us to give us the possibility to
correct and improve our manual.
Air convection
Limit values
Guarantee

APL 100 Series Product Description
11/13 Operating Manual 13
3 Product Description
The applicator APL 100 is an optional device to use with label printers
of the Compa or Compa II series for automatically applying the printed
label onto the product. The labels are transferred with a pad, which
moves between the two positions, starting position and labelling
position, by a compressed-air driven pneumatic cylinder.
In the starting position, the label is picked up from the printer.
A sensor at the cylinder signals when the pad is in the starting
position.
The label is removed from the carrier ribbon directly at the
dispense edge of the printer. It is sucked on the pad by a vacuum
via drillings at the bottom of the pad.
For support, the label is also blown against the pad (supporting
air) with an air current coming from a blow tube.
The correct transfer of the label is controlled by a vacuum sensor.
Next, the pad is moved down into the labelling position. Reaching
the labelling position is confirmed by another sensor (labelling
position sensor).
In the labelling position the label is transferred onto the product.
While the pad is moving back into the starting position, the
vacuum sensor checks whether the label has been removed from
the pad.
The label can be applied with three different methods:
Stamp on
The label is pressed directly onto the product.
Blow on
The pad moves to a pre-adjusted position approximately 10 mm away
from the product. The label is blown onto the product by an air stream.
Roll on
In the starting position the label is forwarded until touching the roller of
the roll on pad. At the labelling position the roller is pressed onto the
product. Then the label is applied and rolled on by the movement of
the product.
Application
of the label

Product Description Applicator APL 100
14 Operating Manual 11/13
3.1 Important Characteristics
The supporting air and the vacuum as well as the speed of the
cylinder are adjustable. That way the applicator can be adapted to
different label materials and sizes.
The pressure for the cylinder movement is reduced in relation to
the operating pressure of the entire labelling machine so that the
danger of injury is reduced as much as possible.
To avoid contamination within the vacuum channels they are
cleaned by air pressure impulse at the end of each application.
For integration into a superordinated process the printers are
equipped with 'Dispenser I/O'.
3.2 Technical Data
Label transfer method Stamp on Blow on Roll on
Labe width (mm) 25 - 176 25 - 176 25 - 176
Label height (mm) 25 - 200 25 - 100 80 - 200
Cylinder stroke (mm) 300 300 300
Pad stroke below printer (mm) 180 180 180
Compressed air pressure 5 bar 5 bar 5 bar
Product surface flat flat flat
Product height variable 
Product height fixed 
Product fixed 
Product linear movement 

Applicator APL 100 Product Description
11/13 Operating Manual 15
3.3 Device Overview
1
2
3
4
5
6
7
8
10
9
Figure 2
11 = Upper cylinder throttle valve
02 = Stopper for the operation mode 'Blow on'
03 = Cylinder unit
04 = Pneumatic cylinder
05 = Lower cylinder throttle valve
06 = Pad holder
07 = Pad (application specific)
08 = Blow tube for supporting air
09 = Knurled screw for attaching the applicator to the printer
10 = Main pressure manometer
Front view

Product Description Applicator APL 100
16 Operating Manual 11/13
1
2
34
5678910
Figure 3
11 = Supporting air throttle valve
02 = Vacuum throttle valve
03 = Service unit
04 = Shutoff valve
05 = Compressed air connector
06 = Pins
07 = Interface to the printer
08 = Knurled screw for attaching the applicator to the printer
09 = Pre-dispense key
10 = Blow tube for supporting air
Rear view

Applicator APL 100 Product Description
11/13 Operating Manual 17
3.4 Pads
Universal tamp pad Universal tamp pad
Standard sizes:
70 x 60 mm and 90 x 90 mm
Standard sizes:
116 x 102 mm and 116 x 152 mm
Figure 4 Figure 5
Universal tamp are available in different standard sizes. According to
the size of the label the holes may be pierced by the customer. For
that purpose a piercing pin is included in the delivery contents.
On request, tamp pads customized to the label sized are delivered.
Figure 6
Roll-on pads are only produced on request customized to the label
size.
Figure 7
Blow pads are only produced on request customized to the label size.
Tamp pads
Roll-on pads
Blow pads

Applicator APL 100 Installation
11/13 Operating Manual 19
4 Installation
4.1 Scope of Delivery
NOTICE!
Please keep the original packaging in case the applicator must
be returned.
1234
Figure 8
1 = Applicator with cylinder
2 = Pad (according to command)
3 = Cylinder screw (part of the pad)
4 = Piercing pin (at universal tamp pads only)
CAUTION!
The label printer and the applicator can be damaged by
moisture and water.
Set up the label printer with applicator only in dry locations
protected from splash water.

Installation Applicator APL 100
20 Operating Manual 11/13
4.2 Mounting the Applicator to the Printer
CAUTION!
Danger of injury by inadvertent move out of the cylinder.
Disconnect the printer from the power supply before
mounting the applicator.
Connect the compressed air only after mounting the
applicator to the printer.
12 34
Figure 9
1. Insert the pins (6, Figure 3) on the back of the applicator (2) into
the holes (3) of the printer.
2. Press the applicator against the printer. That way the plug of the
applicator will be connected to the peripheral port (4) of the
printer.
3. Fix the applicator (2) with the screw (1).
CAUTION!
Malfunctions by inadequate operational surface space.
Ensure a stable standing of the printer.