Diagraph LA/4700 User manual

4700-010
Revision B

Diagraph - an ITW Company LA/4700 User Manual - Revision B
Page 1
Diagraph, an ITW company, continually improves its
products, and reserves the right to change or discon-
tinue specifications and designs shown in this manual
without notice and without incurring obligation.
Diagraph has made every effort to verify the informa-
tion contained in this manual, but reserves the right to
correct any error at the time of the manual’s next
revision.
© 2009 Illinois Tool Works Inc. All rights reserved.
Printed in the United States of America

Diagraph - an ITW Company LA/4700 User Manual - Revision B
Introduction Page 2
Introduction
1.0 Introduction
1.1 The LA/4700 Label Applicators
The LA/4700 is a second generation, next label out, labeling system designed for modularity,
continuous labeling, self-diagnostics, and ease of use. Modularity of design provides the basis
for ease of installation, setup, and maintenance. The electronics system employs a hardware-
specific design, thus increasing reliability and throughput. The hardware was developed to
simplify construction, and increase longevity by using durable materials. This unit will perform
24/7 operation in harsh environments and operate trouble-free, given that the appropriate pre-
ventative maintenance is performed on regular service intervals.
1.2 Product Safety
Safety awareness is critical when working with equipment that contains moving parts and
extending pneumatic cylinders. Please read all warnings and cautions thoroughly before
operating this device.
This product meets the requirements of CAN/CSA-22.2 NO.60950-00 * UL 60950 using
Diagraph, an ITW Company, approved items. Units are only tested and qualified with Diagraph
an ITW Company approved parts and accessories. Use of other parts or accessories may
introduce potential risks that Diagraph, an ITW Company, can assume no liability for.
WARNINGS
• WARNING - Moving parts of this machine can present hazards. Components
that cannot be guarded because of loss of functionality are marked with a
warning symbol.
• Be aware of the tamp cylinder extension distance, and avoid accidental trig-
gering of the photosensor.
• When servicing the unit’s electronic assemblies, always remove the power
cord from the unit to prevent accidental shock.
• When running for extended periods of time, use caution when accessing the
drive module circuitry. The motor drive power transistors, motor case, and
motor heatsink can become hot under constant use.
• Always close the air inlet valve shutoff when removing or servicing pneu-
matic module or tamp cylinder.
• Wear personal protective equipment, as instructed by your supervisor, when
operating or working near this device.
COMPLIANCE
• CAUTION: Not for use in a computer room as defined in the Standard for
the Protection of Electronic Computer/ Data Processing Equipment, ANSI/
NFPA 75.

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Introduction Page 3
Introduction
• ATTENTION: Ne peut être utilissé dans une salle d’ordinateurs telle que
définie dans las norme. ANSI/NFPA 75 Standard for the Protection of Elec-
tronic Computer/ Data Processing Equipment
• This unit has been tested and found to comply with the limits for a Class A
device, pursuant to part 15 of the FCC Rules.
• This unit has been tested to comply with CE Standards.
• This unit is equipped with an Emergency Stop switch. Depressing this switch
will cause all machine operations to cease.
• This unit was tested and it was determined that a potential for tipping exists
in certain orientations. In compliance with UL safety standards, the stand
must be secured to the surface where it is located. Additionally, this type of
securing will result in greater product application accuracy.
1.3 Document Conventions
Formatting conventions are used throughout this manual as a method of providing consistency
for notes and warnings.
Goal: This indicates a particular objective for the section.
Note: This indicates that there is more information available for the in-depth reader.
.
1.4 Warranty Information
The LA/4700 systems, including all components unless otherwise specified, carry a limited
warranty.
For all warranty terms and conditions, contact Diagraph, an ITW Company, for a complete copy
of the Limited Warranty Statement.
WARNING This symbol indicates a danger of injury to the user. Hazards are
identified by the exclamation mark in a triangle and bold italics text.

Diagraph - an ITW Company LA/4700 User Manual - Revision B
Introduction Page 4
Introduction
1.5 Specifications
General Specifications
Category Parameter
Dimensions
(with Yoke)
31 in. ( 79 cm ) L x 23 in. ( 58.5 cm ) H x
25 in. ( 63.5 cm ) D
Weight 85 lbs ( 38.5 kg ) (includes yoke, no stand)
Accuracy ±0.06 in. ( ±1.6 mm ) (Under consistent product presentation)
Certifications TUV, meets requirements of UL 60960, CAN/CSA
22.2 No. 60950, EN 60950
Supply Roll Capacity
LA/4700 14 in. (
355.6 mm )
Dispense Speed 15 to 300 Feet Per Minute ( 76 to 1500 cm/s )
Label Length 0.5 in. ( 12.7 mm ) Min. to 22.0 in. ( 558.8 mm ) Max.
Label Width
Narrow Web (5 in.)
Wide Web (9 in.)
0.5 in. ( 12.7 mm ) Min. to 4.0 in. ( 101.6 mm ) Max.
0.5 in. ( 12.7 mm ) Min. to 9.0 in. ( 228.6 mm ) Max.
Product Rate
LA/4700 800 PPM Max.
Temperature 41°F - 104°F ( 5°C - 40°C )
Humidity 10 to 85% RH, Non-Condensing
Electrical Specifications
Category Nominal Minimum Maximum
AC Voltage
Supply
100 - 240 VAC,
1.6A 50/60 Hz
90 VAC
47 Hz
264 VAC
63 Hz
Product Detector Low: 0 to 3 VDC
High: 3 to 5 VDC
Supplies 24VDC
0 VDC 24 VDC
Product Detector
Pulse Width
10 mS 1 mS Infinite
Auxiliary Output
Warning Tower
0 and 24 VDC
1 Amp sinking
0 VDC
0 mA
24 VDC
1.5 Amps sinking
Discrete Inputs
(Optional)
Low: 0 to 10 VDC
High: 10 to 24 VDC
0 VDC 26 VDC
Discrete Input
Pulse Width
Detection
10 mS 3 mS Infinite
Discrete Outputs
(Optional)
0 - 24 V AC/DC at
150 mA
0 V AC/DC,
13 ohms
30 V AC/DC at
170 mA

Mechanical Specifications - Pneumatic Systems
Category Nominal Minimum Maximum
Incoming Air Pressure 60 - 100 PSI 40 PSI 125 PSI
Tamp Cylinder Pressure 30 - 50 PSI 20 PSI 80 PSI
Vacuum/Blow Pressure 30 - 60 PSI 20 PSI 80 PSI
Tamp Stroke
(10 in. cylinder)
3 - 9 in.
76 -228 mm.
3 in.
76 mm.
9.5 in.
241.3 mm.
Tamp Stroke
(20 in. cylinder)
3 - 19 in.
76-482 mm.
3 in.
76 mm.
19.5 in.
495.3 mm.
Air Consumption while
running
2.5 CFM at
80 PSI
2.0 CFM at
80 PSI
5 CFM at
80 PSI
Tamp-Blow Distance
(Pad to product blow
distance)
0.5 in.
12.7 mm.
0 in.
0 mm.
1.0 in.
25.4 mm.
Diagraph - an ITW Company LA/4700 User Manual - Revision B
Introduction Page 5
Introduction
1.6 System Dimensions
WIPE TAMP
31 inches(787 mm)
31inches (787mm)
20inches(508mm)
20 inches (508 mm)
33 inches (838 mm)
24 inches (610 mm)

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System Modules Page 6
System Modules
2.0 System Modules
2.1 Drive Module
Drive Module P/N: 4700-800 (W/T)(5/9)(R/L)
Servo Assembly P/N: 4700-500 (W)
Thedrivemodulecontainsallofthenecessaryequipmenttoperformthefeedingandpeelingof
thelabel.Themoduleisavailableineight(8)differentconfigurationslistedbelow:
P/N: 4700-800W5L Narrow Web WIPE -Left Hand P/N: 4700-800W5R Narrow Web WIPE -Right Hand
P/N: 4700-800W9L Wide Web WIPE -Left Hand P/N: 4700-800W9R Wide Web WIPE -Right Hand
P/N: 4700-800T5L Narrow Web TAMP - Left Hand P/N: 4700-800T5R Narrow Web TAMP -Right Hand
P/N: 4700-800T9L Wide Web TAMP - Left Hand P/N: 4700-800T9R Wide Web TAMP - Right Hand
Tamp / FASA /
Drive Module
WASA
Wipe-On
Drive Module
Theservoassemblyiscomprisedofthese
components:
• BLDCMotor
• Pulleysandbelts
• ServoControllerBoard
• StatusLED
• NipSwitch
• DriveRoller
• PowerSupply
• Bracketry
ThisassemblyisatthecoreoftheDrive
Module,andiscommontoallmodesof
application(wipe,tamp,etc.)andsystem
configurations(rightorleft).
• 5inchshaftP/N:4700‐500
• 9inchshaftP/N:4700‐500W

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System Modules
Drive Roller P/N: 4700-630 (W)
Nip Assembly Kit P/N: 4700-952 (W)
Snorkel Assembly Kit P/N: 4700-950 (W)(RH/LH)
Thedriverollerisasubcomponentofthe
ServoAssembly.Thisrollerismadeof
polyurethaneandisresponsiblefor
advancingthelabellinerthroughthe
applicator.Thisisawearitemthatcanbe
obtainedindividually.Therearetwo
versionsofthiscomponent:
• 5inchshaftP/N:4700‐630
• 9inchshaftP/N:4700‐630W
Thenipassemblyholdsthelabellinerin
constantcontactwiththedriveroller.Ituses
anon‐stickcoatingtoavoidlabelbuild‐up.
Thisassemblyincludesthenipleverarm,
knob,pivotblock,andniproller.
• 5inchshaftP/N:4700‐952
• 9inchshaftP/N:4700‐952W
Thesnorkelassemblyisusedforwipe‐on
applications.Itcontainsthelabelgapsensor,
supportarmsandbrackets,peelblade
support,andpeelblade.Therearefour
versionsofthisassembly:
• 5inchwide,right‐handP/N:4700‐950‐RH
• 5inchwide,left‐handP/N:4700‐950‐LH
• 9inchwide,right‐handP/N:4700‐950W‐RH
• 9inchwide,left‐handP/N:4700‐950W‐LH

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System Modules Page 8
System Modules
Tamp Peel Blade Assembly P/N: 4700-951 (W)
Optional Photo Speed Encoder P/N: 4700-907 [kit]
Optional Clear Label Sensor P/N: 4700-908 [kit]
Thetamppeelbladeassemblyisusedfor
tamp‐on,blow‐on,WASA,andFASA
applications.Itcontainsthelabelgapsensor,
peelbladesupport,andpeelblade.Thereare
twoversionsofthisassembly:
• 5inchwide,P/N:4700‐951
• 9inchwide,P/N:4700‐951W
ThePhotoSpeedEncoderor“Photocoder”is
anoptionaldevicethatallowsthefeedspeed
andlabelplacementtobesynchronizedwith
changinglinespeeds.ThePhotocoderuses
twophotosensorsthatarespacedafixed
distanceapart.Bymeasuringthetime
betweeneachphotosensortrigger,thesystem
canaccuratelydeterminethelinespeed.This
isacosteffectivealternativetoarotary
encoder,withasimplifiedmountingscheme.
TheClearLabelSensorisusedwhenthe
standardlabelgapsensorisunabletodetect
thelabelgaps.Thissensoruseschangesto
capacitivefieldtosensethelabelgapand
avoiddetectionproblemsduetocolor,
reflectivity,andlinerthickness.Thisoption
canbeinstalledinthefieldasconditions
determinetheneed.

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System Modules
2.2 Mechanical SubSystem
Unwind P/N: 4600-605
Rewind P/N: 4600-606
Tamp Pad P/N: 4600-610-W.WWxLL.LL [W and L in inches]
Theunwindisdesignedtocapturesupply
rollsupto12inchesindiameter,with3inch
cores.Thissubsystemusesahub‐basedfin
designtocapturethesupplyrollwithout
needforanouterdisk.Thisreduces
downtimeinperformingsupplyroll
changeouts,andallowssmallvariationsin
corediameters.
TherewindisdrivenbyabrushlessDC
motor,whichgreatlyincreasesthelifeofthe
rewindsystem.Thissubsystemrequiresno
adjustments.Thereisnoclutchonthe
rewind,itusesthemotor’smagneticfieldto
developholdingtorque.Therewindisbelt
driven,usinganautomatictensioner.This
beltshouldbeinspectedforwearatthe
recommendedserviceintervals.
Thetamppadcapturesthelabelfromthe
drivemodule,andholdsitundervacuum
untilthetimewhenthelabelistobeapplied
totheproduct.Thereareseveralsizesof
tamppads,toaccommodateawidevarietyof
labeldimensions.Eachpadcanbeported,
typicallyonce,foraparticularlabelsize.The
padvacuumholesarearrangedintocolumns,
whicharenotpunchedthrough.Whenapad
isported,thepropercolumnsarepunched
outsothatvacuumcandrawthelabelonto
thepad.Formostapplications,thecolumn
closesttothepeelbladeandthecolumnon
thefurthestendofthelabel(fromthepeel
blade)areported.
Thetamppadhasprovisionsformounting
thelabelpresentandautoretractsensors.
Thesesensorsmustbemountedflushtothe
bottomofthepad,foroptimumsensing.

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System Modules Page 10
System Modules
Stand P/N: 6160-329
2.3 Pneumatics SubSystem
PAM (Pneumatic Air Manifold) P/N: 4600-701
Tamp Cylinder P/N: 4600-743 (10 inch), 4600-745 (20 inch)
Thestandholdstheyokeassemblyofthe
LA/4700andallowsthesystemtobe
orientatedinavarietyofpositionstosuit
applicationrequirements.Thestandemploys
ahandcranktosetverticalposition,anda
seriesofmountingpointsforitemssuchas:
warningtower,remoteuserinterface,and
inletfilter/regulator.Thestandcontainsthree
lockablecastersthatpreventrolling
movement,aswellasrotationalmovement.
Thecolumnofthestandisdesignedtobe
rotated,whichcanhelpinstallationswhere
thefrontlegofthet‐baseinterfereswith
existingequipment.
Theairmanifoldcontrolstheoperationof
thetampcylinderandthedeliveryofthe
labelfromthedrivemoduletotheproduct.
Themanifoldhastwopressureregulators,
onefortamppressureandtheothercontrols
bothvacuumandblow.Twoflowcontrols
limitthevolumeofairgoingtotheairassist
andblowvalves.Therearetwopressure
gaugesthatmonitorthepressuresetbythe
regulators.Apressuresensormonitorsthe
incomingairlevelanddisplaysitonadigital
readoutandbargraph.Anerroristriggeredif
theincomingpressuredropsbelowtheset
pointvalue.
Thetampcylinderemploysadual‐rod
designtoachieveveryhighspeedextension
andretraction,withoutrotation.Thetamp
cylinderextensionandretractionspeedis
controlledbymeansofthetamppressure
settingontheairmanifoldandtheflow
controlsonthecylinderbody.Anadjustable
aircushiononthetopofthecylinder
dampensthereturnenergy.Amagneticreed
switch,attachedtothetopofthecylinder,
detectstheimmediatereturnofthecylinder
toitshomeposition.

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System Modules Page 11
System Modules
Inlet Filter/Regulator/Shutoff P/N: 4600-705
2.4 Electrical SubSystem
MCA III P/N: 4600-500
TheinletairfiltrationprovidesanOSHA‐
approvedshutoff,withlock‐out,anda
pressureregulator.Itusesa5micronfilter
elementandautomaticallypurges
condensationtrappedinthefilterbowl.The
regulatorensuresthatfluctuationsinthe
supplyairwillnotcausetheoperationofthe
cylinder,airassist,orvacuumtochange.
TheMainControllerAssemblyIIIisathird
generationofDiagraph‐designedmicro‐
controllercoupledwithaninterfaceboard.
TheMicrocontrollerUnit(MCU)isdesigned
toexecutereal‐timeapplicatorfunctions,
withaccuracydowntoafractionofa
millisecond.Thisboardiseasilyremovedfor
replacementortesting.TheInterfaceBoard
actsasaninterconnectionpointforthe
cabling.ThisboardenablestheMCUtobe
verymodular,thusenablingasingle,simple
connection.TheMCAIII,asasystem,isfully
protectedagainstshort‐circuits,ESD,and
over‐voltages.Thisdesigngivessuperiority
overgeneric,polled‐inputPLC’s.

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System Modules
Rewind Motor P/N: 4600-503
Power Supply P/N: 4600-522
Label Gap Sensor P/N: 6146-615(R/L) or 6146-527
Therewindisdesignedaroundabrushless
DCmotorwhichusesthreecoilsactivatedin
sequence,accordingtothreeHall‐effect
sensors.Thisisaninherentlyclosed‐loop
motorcontrolsincethemotor’smagnetic
fieldiscontrolledbyreadingtherotor
positionviatheHall‐effectsensors.Using
thistypeofmotor,versuslessexpensive
motorssuchasstepperorAC,hasthedistinct
advantagesofincreaseddurability,
eliminationofanyclutchordancerarm,and
limitswitch.Thecontrolcurrentsetbythe
system,inaccordancetothestateof
operation,directlycontrolstherewind’s
tension.Thesystemeliminatesupto50%of
thecomponentsusedcomparedtoother
conventionalrewinddesigns.
Thepowersupplyisauto‐ranging,sothatan
ACvoltageinputbetween100Vand240V
willprovideasteady24voltDCoutput.The
supplyhasagreenLEDtoindicateactive
operation.
Thelabelgapsensorisusedtodetectthe
transitionfromonelabeltothenextand
allowstheaccuratepositioningofthelabel
ontotheproduct.Thesensorismountedinto
ahousingtoprotectandshieldit.Thereare
threeversions:
• Snorkel,right‐handP/N:6146‐615R
• Snorkel,left‐handP/N:6146‐615L
• TampPeelBladeP/N:6146‐527

Diagraph - an ITW Company LA/4700 User Manual - Revision B
System Modules Page 13
System Modules
Product Sensor P/N: 4600-900
Tamp Pad and Label Low Sensors P/N: 6000-903 [kit]
Warning Tower P/N: 6150-828
Theproductsensorisaninfrared,diffused
lightmodel,capableofsensingobjectsat
distancesupto3ft.(900mm).Thesensorhas
twoLED’s,oneisayellowdetection
indicatorandtheotherservestwopurposes.
Ifnoobjectiscurrentlydetected,thegreen
LEDactsasapoweronindicator.Ifthe
sensorisdetectinganobject,thegreenLED
turnsintoasignalstrengthindicator.The
greenLEDwillbecomebrighterwitha
strongreturnsignalanddimmerwithaweak
detection.Thesensorcanbemountedonthe
baseplate,snorkel(wipesystem),orremotely
onamountingbracket.Ifadifferentsensor
isrequired,ensureitisa24VDC,NPNtype.
6000-903 as shown
4600-903 is the older
style with a flat lens
Thetamppadsensors,auto‐retractandlabel
present,andthelabellowsensorarediffuse
lightsensors.Allthreesensorsareidentical
withaquickdisconnectM8threaded
coupling.Whenthesensorisusedforlabel
present,itiscapableofdetectingawide
rangeofmaterials,colors(includingclear),
andtextures.Whenusedforauto‐retract,the
sensorcandetectobjectpresenceupto3
inches(forwhiteopaque,2inchforbrown
corrugate)awayfromthetamppad.Asa
labellowsensor,thepresenceofmaterial
remainingontherollatafixeddiametercan
bedetermined.
Thewarningtowerincorporatesthree
incandescentbulbs,withthreecolored
lenses.Thesebulbsare24volt,5watt,and
canbechangedtoLEDbulbs(6145‐503)for
longerlife.Thegreensegmentindicatesa
warninganderror‐free,onlinecondition.
Theyellowsegmentindicatesawarningor
offlinecondition.Theredsegmentindicates
anerrorconditionwheretheunitisplaced
offline.

Diagraph - an ITW Company LA/4700 User Manual - Revision B
System Modules Page 14
System Modules
Pressure Sensor P/N: 4600-905
Thepressuresensorhasseveralgreat
features,andstillmaintainsasimplicityin
design.Thesensorshouldnotrequire
adjustmentssincethethresholdlevelsareset
atthefactory.Thesensorconstantlymonitors
pressureandtriggersanerroronthesystem
iftheairpressuredropsbelowthe
predeterminedlevel.Digitally,thepressure
isupdatedthree(3)timesasecond.In
conjunctiontothedigitalreadout,the
bargraphdisplaysthepressureand
fluctuations.

Diagraph - an ITW Company LA/4700 User Manual - Revision B
Configuration Identity Page 15
System Modules
3.0 Configuration Identity
The LA/4700 shares the same platform as the other Platinum Series units. This allows systems
in the Platinum Series to share optional modules, applicator modules, and features which adds a
great deal of diversity to the product line. In this simplification, the same MCU firmware and GUI
memory run both the Printer-Applicators (PA/4600, PA/6000) and the Label-Applicator (LA/
4700). For the system to distinguish between these two different modes, a jumper must be in
position to have the system run in Label-Applicator mode.
To have the system run as a Label-Applicator, with the correct screens, a jumper block
must be in place across J1 pin 1 and pin 2.

Diagraph - an ITW Company LA/4700 User Manual - Revision B
Setup Page 16
Setup
4.0 Setup
Step 1 - Determine the System Orientation
Goal: Determine the best machine orientation for application. The LA/4700 are capable of rotating
and pitching about various axes to accommodate a wide range of label placement
opportunities. Select the best orientation from the given measurements and desired label
locations.
Top-Down Side-Apply
Top-Down
WIPE
WASA
41 inches
2.13 inches
(5.4 cm)
(104 cm) 24.25 inches
(61.6 cm)
63 inches
(160 cm)

Step 1 - Determine the System Orientation
Goal: Determine the best machine orientation for application. The LA/4700 are capable of rotating
and pitching about various axes to accommodate a wide range of label placement
opportunities. Select the best orientation from the given measurements and desired label
locations.
Top-Down
Side-Apply
Nose-Down
Nose-Up
Top-Down
TAMP
FASA
50 in.
127 cm
13 in.
33 cm
45 in.
114.3 cm
10.5 in.
26.7 cm
63 in.
160 cm
24 in.
61 cm
69 in.
175.3 cm
30 in.
76.2 cm
Diagraph - an ITW Company LA/4700 User Manual - Revision B
Setup Page 17
Setup

Step 2 - Connect AC Power
Goal: Connect the power supply to a noise-free AC power line.
Note: When connecting the AC power outlet, do not use extension cords to power the unit.
Extension cords can reduce the amount of current supplied to the unit and introduce
electrical noise. A dedicated AC line drop is preferred. This eliminates problems caused by
other AC loads on the same line, such as motors, which create back EMF. Disturbances such
as these can cause erratic behavior, system resets, and other anomalies.
Connect the AC line to a dedicated line drop supplying noise-free power. The unit will turn on
automatically.
Electrical
Do Not Use Extension Cords
Do Not Share Circuit Line
Diagraph - an ITW Company LA/4700 User Manual - Revision B
Setup Page 18
Setup

** Step 3 - Connect Compressed Air
Goal: Provide the unit with clean, dry compressed air (Tamp and FASA applicator modules only)
and connect the power supply to a noise-free AC power line.
Note: The system employs an automatic drain air filter, which will remove most of the condensation
in the incoming pneumatic line. Since the purged water will exit from the bottom of the filter
bowl, it may be desirable to add a short hose to the drain valve to route the water to a
nearby floor drain.
Connect the clean, dry compressed air line supplying 60 psi or greater at 2.5 CFM or better to the
inlet air filter/regulator of the system with the OSHA valve closed. The air should be free of oil,
lubricants and water, since the pneumatics are lubricated with internal grease, and contaminants will
greatly decrease the life of the unit and void the warranty. Turn on the air valve to the system by
pressing down and turning the valve clockwise, be aware that the cylinder will move to the home
position once air is supplied.
Compressed Air
OSHA Valve Closed
OSHA Valve Open
Do Not Use Inline Oilers
TAMP
FASA
Diagraph - an ITW Company LA/4700 User Manual - Revision B
Setup Page 19
Setup