Godex AG4000T User manual

Godex AG4000T User Manual Page 1of 42
AG4000T
USER MANUAL
AG-4000-400001, AG-4000-600001
AG4000T (print & apply system)
User Manual: AG4000T Version: 1.1 draft (needs revision)
Issue Date: April 2021

Godex AG4000T User Manual Page 2of 42
1 Contents
1 Contents ....................................................................................................................................... 2
2 Introduction.................................................................................................................................. 4
2.1 Overview................................................................................................................................ 4
2.2 Applicator Specifications Summarized............................................................................... 4
2.3 Dimensions AG4000T –400 mm............................................................................................ 5
2.4 Dimensions AG4000T –600 mm............................................................................................ 6
3 Basic Safety Precautions ............................................................................................................. 7
3.1 Coverage .............................................................................................................................. 7
3.2 Following the instructions in this operating manual ............................................................. 7
3.3 Possible device handlingrisks ............................................................................................... 7
3.4 Environmental conditions of the device operation ............................................................ 7
3.5 Occupational health and safety rules ................................................................................. 8
3.6 Safety instructions.................................................................................................................. 8
3.7 Never:..................................................................................................................................... 9
3.8 Applied harmonized standards and the safe use of electrical appliances..................... 9
3.9 The possible risks of electric shocks if working with the applicator.................................. 10
3.10 Configuring the pneumatic unit,safety ...................................................................... 10
4 Contents of delivery - what’s in thebox? ................................................................................. 11
4.1 Standard configuration with 250 mm effective stroke ..................................................... 11
4.2 Checking the box contents (AG-4000-400001) ................................................................ 11
4.2.1 Box 1: Printer + Accessories .......................................................................................... 11
4.2.2 Box 2: Applicator unit components............................................................................. 12
4.2.3 Box 3: Stand components ............................................................................................ 13
5 Assembling the system.............................................................................................................. 14
5.1 Required Tools ..................................................................................................................... 14
5.2 Assembling the stand .......................................................................................................... 14
5.3 Installing the internal rewinder and GPIO card in the printer .......................................... 17
5.4 Installing the label dispensing edge ................................................................................. 20
5.5 Assembling the applicator unit .......................................................................................... 22
6 Applicator unit adjustments. Fine tuning. ................................................................................ 24
6.1 Adjusting the applicator head distance from the dispensing edge .............................. 24
6.2 Adjusting the applicator head vertical resting position................................................... 25
6.3 Adjusting the support air angle and pressure................................................................... 26
7 Operating your AG4000T........................................................................................................... 27
7.1 Print & apply cycle: the basics ........................................................................................... 27
7.2 Printer configuration for applicatoruse ............................................................................. 27
7.2.1 Power on the system..................................................................................................... 27

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7.2.2 Setting the printer to the right GPIO Mode and Applicator setting lock ................. 28
7.2.3 Creating label format and loading media................................................................. 29
8 Connecting to auxiliarysystems............................................................................................... 30
8.1 Introduction ......................................................................................................................... 30
8.2 Operation modes................................................................................................................ 31
8.3 Inputs and Outputs ............................................................................................................. 32
8.3.1 Outputs .......................................................................................................................... 33
8.3.2 Inputs ............................................................................................................................. 34
9 Maintenance.............................................................................................................................. 35
10 Annex 1 ZX1000i printer GPIO (General Purpose Input Output) module functions........ 36

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2 Introduction
2.1 Overview
Godex AG4000T print & apply systems employ ZX1000(X)i printers, either with 203, 300 or 600dpi
print resolution, with high end, air-driven tamp applicators with the purpose of print and apply
labels on demand.
AG4000T print & apply systems are available as easy to install, ready-to-use solutions, but you
can also configure your own customized systems by combining the components in a different
way. The AG4000T applies the last printed label to the product, what enables you to attach
unique information to each single product coming down the production - or packaging line.
With the very same standard applicator head you can apply labels from 20x10 mm up to
100x100 mm. With custom heads AG4000T can handle any label size from 20x10 mm up to
100x200 mm. Suspended heads are available for use to label skew products that are not
perfectly parallel to the applicator head. Tamp applicators are typically used to label non-
moving items on intermittent conveyor systems, in robotized processes, and in manual
workflows. With roll-on and blow-on heads, available on request, they will also label moving
products accurately. AG-4000-400001 delivers an effective stroke of 250mm (total stroke
400mm) and the long stroke version AG-4000-600001 delivers 450mm (total stroke 600mm).
Various customization options are available on request to tune the AG4000T to your particular
needs.
2.2 Applicator Specifications Summarized
(The effective stroke equals the maximum allowed height difference between the
products in one production batch)
Label sizes min 20mm x 10mm, max 100 x 200mm
Label roll diameter 200mm standard inside the printer
280mm optional with external holder
Performance* up to 30 labels/min of 100mm x 100mm
at an effective stroke of 170mm
up to 60 labels/min of 20mm x 20mm
at an effective stroke of 10mm
Compatible printers ZX1200i (203dpi) / ZX1300i (300dpi) / ZX1600i (600dpi)
ZX1200Xi (203dpi) / ZX1300Xi (300dpi)
*: the process speed depends on variables such as label size, the type and source of the data processed,
stroke length (product height), required product contact time and conveyor speed.
Type:
AG4000T –400 mm
AG4000T –600 mm
Item no:
AG-4000-400001
AG-4000-600001
Std. head size:
100mm x 100mm
100mm x 100mm
Opt. head sizes:
20mm x 20mm up to 100mm x 200mm
20mm x 20mm up to 100mm x 200mm
Stroke
400mm
600mm
Effective Stroke
250mm
450mm
Effective stroke
Full stroke
Pic. 1

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2.3 Dimensions AG4000T –400 mm
Pic. 2
Pic. 3
Pic. 4
Pic. 5

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2.4 Dimensions AG4000T –600 mm
Pic. 6
Pic. 7
Pic. 8
Pic. 9

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3 Basic Safety Precautions
3.1 Coverage
Safety rules and instructions either written or referred to in this manual apply to the installation,
the usage and the maintenance of both the applicator- and the printer components within
AG4000T systems. They do however not replace any safety instruction published in separate
Godex ZX1000(X)i user- and service manuals, and must be considered complementary to
those instead. Therefore, personnel working with AG4000T systems must be familiar with the
safety instructions stated in the applicable Godex printer manuals as well.
3.2 Following the instructions in this operating manual
A thorough knowledge of basic safety instructions and safety regulations is an essential
prerequisite for using this device in accordance with safety requirements, while ensuring its
fault- free operation. This operating manual, and in particular the safety instructions contained
herein, must be adhered to by any personnel using the device. All relevant standards and
regulations pertaining to the prevention of accidents and injuries relevant to the device
installation site must also be adhered to.
3.3 Possible device handling risks
The device was manufactured in accordance with relevant technical requirements and
internationally recognized safety and technical standards. However, situations might still arise
during the use of the device that could pose a risk to the health and/or lives of operators
and/or third parties, or cause damage to the device and/or other property.
The device may only be used:
 In accordance with the purpose for which it was manufactured
 If it is free of any defects in terms of safety and technical requirements.
Any defects that could potentially compromise safety must be rectified immediately.
3.4 Environmental conditions of the device operation
 Operation ambient temperature within the range of 5 °C to 40 °C (41 °F to 104 °F)
 Storage and transport temperature: -20 °C to 55 °C (-4 °F to 131 °F); the device can
withstand temperatures of up to 64 °C (149 °F) for a period of up to 24 hours
 Operation ambient non-condensing relative air humidity within the range of 20% to 85%
RH
 Storage ambient non-condensing relative air humidity within the range of 20% to 85%
RH

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3.5 Occupational health and safety rules
The device contains moving parts that can pose a risk to the operator unless the safety rules
are adhered to. In order to prevent a potential injury, read the following safety rules carefully:
 Only persons trained in operating the device and acquainted with associated risks
should be authorized to enter the space where the device is installed.
 A safe distance from the application plate must be maintained when the device is
being connected to a source of compressed air and/or when it is being switched on
or off, as the device may begin to move unexpectedly.
 Crumpled and/or detached labels may only be removed when pressurized air is not
being supplied to the device or if the device has moved into an error mode.
 An error or pause mode must be invoked before print material is replaced in the device.
3.6 Safety instructions
 When working with the device the operator must adhere to all relevant generally
binding safety regulations as specified in the labor code of his/her country and in other
legal safety regulations that may apply.
 The device’s keeper must ensure the performance of regular maintenance. Routine
maintenance must be carried out by properly trained and authorized personnel. Failure
to do so could result in device failure or injury and may breach health and safety laws.
 The device may only be operated by properly trained and authorized personnel.
 The device may only be used for those purposes for which it is technically fit in
accordance with the terms and conditions specified by the manufacturer, while the
structure, design and technical condition must comply with the relevant safety
regulations.
 The device’s operator must perform a visual inspection of the device regularly, along
with regular basic maintenance and servicing.
 Should there be a discovery of any defect and/or damage that might compromise
operating safety and/or the operation of the printer that cannot be rectified on the
spot, the device must not be brought into operation / must be switched off
immediately, and the defect must be reported to the device’s keeper and other
relevant persons.
 The legibility of safety signs, symbols and notices on the device must be maintained at
all times. In the event of damage and/or illegibility, any such signs must be restored by
the device’s keeper to their original condition.

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3.7 Never:
 Connect the device to a source of electric power if any of the protective parts (electric
component covers, safety labelling and/or safety elements of the device) have been
removed and/or damaged.
 Modify the mechanical design and/or electrical circuitry of the device in any way.
 Perform any maintenance tasks before the device has been secured in its off state and
the device has been disconnected from the main power.
3.8 Applied harmonized standards and the safe use of electrical
appliances
 AG4000T Print & Apply systems are class I electrical devices in terms of the necessary
protection against electric shock in accordance with harmonized standard EN 61140,
ed. 2 and hence also meet generally acknowledged standards such as, but non only
CE, meaning that all non-live conductive parts are mutually conductively connected
and are further connected to the protective earth conductor of the printer’s power
supply. Other harmonized standards that have been applied, are EN 60439-3,
applicable to low-voltage switch gear and EN ISO 12100 regarding the safety of
machinery.
 Connection to the power network supply must be made in compliance with the
requirements specified in regulations and technical standards valid and applicable in
the country of operation.
 Any work on the device may only be performed by persons who are duly qualified
according to the legislative code of the country where the device is installed (1) and
who has been acquainted to the necessary extent with the device (2).
 The keeper of the device is obliged to secure the performance of inspections of the
electrical device in prescribed intervals and to do so in accordance with the legislation
regarding such inspections applicable in the country of operation.
 The device may not be dismantled.
 If shielded data cables are used with the device, they must comply with international
standards governing devices producing electromagnetic radiation. The utilized data
cables must be completely shielded. The use of shielded data cables is necessary in
order to prevent the production and/or reception of electromagnetic noise. Using non-
shielded data cables may result in electromagnetic radiation exceeding permitted
limits.

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3.9 The possible risks of electric shocks if working with the applicator
Despite the application device being manufactured in accordance with relevant technical
regulations pertaining to safety, its technical design cannot preclude all risks that may occur,
especially in the event of careless or negligent behavior during use of the device. The device
must be used with full awareness of the following risks of electric shock:
 Resulting from direct or indirect contact with parts designed to conduct electric current
(live parts), direct or indirect contact during the removal of electric equipment covers,
or direct or indirect contact in the event of damage caused to insulating parts of a
movable power cord;
 Caused by damaged parts of electrical equipment;
 Resulting from a failure to observe instructions regarding equipment connected to the
power mains.
3.10 Configuring the pneumatic unit, safety
Excessive operating pressure may cause:
 Injury by crushing;
 Mechanical damage to parts of the labelling machine.
The equipment manufacturer configures the pneumatic unit of the labelling machine in a
manner that ensures all pneumatically controlled parts of the device (e.g. the piston) can be
stopped by hand without the use of excessive force (max. 150N)
The customer shall bear responsibility for any adjustments that are not made by the equipment
manufacturer prior to delivery.

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4 Contents of delivery - what’s in the box?
4.1 Standard configuration with 250 mm effective stroke
AG4000T systems can have slightly different configurations, however, the installation and
operation of most configurations are identical, we will use an example of standard
configuration of ZX1200i (203 DPI), 250 mm effective stroke AG4000T with standard 100x100mm
applicator head and standard stand to guide you through the installation and make you
familiar with the usage of the AG4000T print & apply solution. Further in this manual you find
an option list.
4.2 Checking the box contents (AG-4000-400001)
Depending on the configuration you have ordered, it can be 2 or more boxes. Please check
whether the boxes and their content has arrived undamaged. If you see any clearly visible
damage on the outer cartons, please demand the courier to make a note about the damage
and sign it before accepting the shippment. §4.2.1 and 4.2.2 will help you to check whether
nothing is missing. Please inform your supplier immediately if anything seems to be wrong.
4.2.1 Box 1: Printer + Accessories
If you have received the printer parts for your AG4000T directly from a Godex subsidiary the
printer box contains the printer components described below here. In case you have
purchased the printer and options through a Godex distributor or dealer you may receive
them in separate boxes. In that case it is also possible the internal rewinder and applicator
interface have been pre- installed.
Due to simplicity, the illustrations below are depicted in different scales.
1x GoDEX ZX1200i 203dpi printer (optional:
ZX1300i 300 dpi printer, ZX1600i 600dpi printer
or ZX1200Xi 203 dpi, ZX1300Xi 300 dpi)
1x GoDEX ZX1000(X)i GPIO interface board,
item no. GP-031-Z2i003-001:
1x GoDEX ZX1000(X)i peeler/rewinder unit, item
no. GP-031-Z21005-000
Pic. 10
Pic. 11
Pic. 12

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Pic. 13
4.2.2 Box 2: Applicator unit components
The package includes:
 1 x AG4000T applicator unit Pic. 13
 1 x AG4000T Base plate Pic. 15
 1 x Dispenser module with air support unit Pic. 14
 1 x Air support regulator valve Pic. 18
 4 x Printer mounting adapter set (cylindrical
adapter, screw, washer) Pic. 16
 2 x screws for dispensing edge Pic. 17
 6 x screws for fixing applicator unit to
the base Pic. 20
 1 x set screw ?? Pic. 19
 1 x alarm beacon set (optional) Pic. 21
Depending on the configuration you have ordered there might be
slightly different contents, please check with your local Godex Partner
Pic. 21
Pic. 15
Pic. 14
Pic. 18
Pic. 16
Pic. 17
Pic. 20
Pic. 19

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4.2.3 Box 3: Stand components
The illustration below show the stand configuration used for this example. Your Particular
application may be different, but the principles are the same.
Pic. 22
In the box you will find assembly kit for the standard stand.
Pic. 23
Pic. 24
Pic. 25

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Pic. 26
Pic. 27
Pic. 28
5 Assembling the system
5.1 Required Tools
• Hex wrenches 4, 5, 6, 8
• Socket wrench 15
• Screwdriver set
• Phillips head screwdriver set
5.2 Assembling the stand
Please review all steps and parts described below here before you start assembling. It will help you
to anticipate on every step to come.
Mount the four round feet to the corners of the 2 longer alloy profiles Pic. 26 - Pic. 28:
Mount the feet on the side of the longer profiles which do not have screw holes Pic. 29
Let the narrow ends of the screw holes face each other on the inside whilst mounting the
feet. Pic. 30
The height of each foot is adjustable individually to level the stand on uneven surfaces Pic.
31
Pic. 29
Pic. 30
Pic. 31

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Close the ends of the alloy profiles with the black plastic covers Pic. 32
Place the shorter alloy profile (the one with holes on two faces in the middle) between the
longer profiles. Make sure the wider ends of the screw holes are on the same side as the feet.
Pic. 33
Firmly connect the three legs with screws Pic. 34 and Pic. 35.
Take the remaining profile (Pic. 36) and mount it firmly with screws onto the central profile:
Pic. 32
Pic. 33
Pic. 34
Pic. 35
Pic. 36
Pic. 37
Pic. 38

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Mount the adapter plate and clamp on the top of the vertical profile.
Mount the cross clamp onto the slide inside positioner (tube with thread and wheel to turn)
and then mount the positioner in to the floor stand:
Mount the tube in to the cross clamp Pic. 46.
At a later stage the end of the tube must be inserted in - and firmly attached to clamp on the
applicator by tightening the screw Pic. 47.
Positioner
Clamp
Pic. 46
Pic. 39
Pic. 40
Pic. 41
Pic. 47
Pic. 42
Pic. 45
Pic. 43
Pic. 44

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5.3 Installing the internal rewinder and GPIO card in the printer
(Does not apply if you ordered preconfigured system)
1. Open the printer door (Pic. 48)
2. Remove the screws (Pic. 48)
3. Remove the plastic panel (Pic. 48)
4. Remove the plastic cap (Pic. 48)
5. Remove the left cover (Pic. 49)
6. Insert the bearing (Pic. 50)
7. Insert the bearing (Pic. 51)
1
2
2
2
4
3
Pic. 48
5
Pic. 49
7
6
Pic. 50
Pic. 51

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Pic. 53
Pic. 55
Pic. 54
Pic. 56
Pic. 57
Steps 8 and 9 are omitted as they are
irrelevant for the AG4000T application.
The panel with label
taken sensor that
comes with the internal
rewinder kit Pic. 52 is not
needed for this
application.
Please continue from
step 10.
10. Install roller kit (Pic. 53)
11. Install backing paper rewind shaft.
(Pic. 53)
12. Install Rewinder full switch (Pic. 53)
13. Connect the switch connector to
the mainboard of the printer (Pic. 53)
14. Remove the motor (Pic. 55)
15. Install 22t gear and retaining ring on
to the motor shaft (Pic. 55)
16. Reinstall the motor back and
tighten the toothed belt (Pic. 55)
17.-18. Install the gear kits. Lubricate
the metal rods/screws that holds the
gears with silicone oil (Pic. 55)
19. Install clutch kit. (Pic. 55). The torque
setting from the factory of the clutch is suitable
for the AG4000T application. In case the torque
setting would need to be adjusted at some
point, please refer to the printer service
manual.
20. Remove the metal cover on the
back side of the printer (Pic. 54 and
Pic. 56)
21. Inspect the jumpers J4, J5, J6 on the
GPIO board (Pic. 57). J4 should be
connected, J5 –pins 2-3 connected,
J6 –pins 2-3 connected. Incorrect
jumper configuration can damage the
device. For more information about the GPIO
board and I/O signals please refer to Annex 1
8
9
10 11
12
13
19 17 18
15
16
16
14
8
9
10 11
12
13
Pic. 52

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22. Connect the GPIO board connector to the printer mainboard
(Pic. 58 and Pic. 59) and install the board (Pic. 60). Fix the board
from the back side of the printer with screws (Pic. 61).
23. Reinstall the left cover (Pic. 62)
24.-25. Open the printer door and reinstall the screws (Pic. 63)
20
21
22
22
Pic. 62
Pic. 63
Pic. 58
Pic. 59
Pic. 60
Pic. 61
23
24
25
25

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5.4 Installing the label dispensing edge
Remove the bottom right cover/panel. (If you needed to complete steps in Paragraph 5, start from Pic.
69)
Pic. 64
Pic. 65
Pic. 66
Pic. 67
Pic. 68
Pic. 69