ITW Diagraph PA/6000 User manual

PA/4600
PA/4600
PRINTER - APPLICATOR
PRINTER - APPLICATOR
PA/6000
PA/6000
4600-010
Revision G

Diagraph - an ITW Company PA/4600 & PA/6000 User Manual
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.
© 2008 Illinois Tool Works Inc. All rights reserved.
Printed in the United States of America

Diagraph - an ITW Company PA/4600 & PA/6000 User Manual
Introduction Page 2
Introduction
1.0 Introduction
1.1 The PA/4600 and PA/6000 Printer - Applicators
The PA/4600 and PA/6000 are sixth generation, next label out, print and apply systems 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 preventative 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.

Diagraph - an ITW Company PA/4600 & PA/6000 User Manual
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 PA/4600 and PA/6000 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 PA/4600 & PA/6000 User Manual
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 90 lbs (41 kg ) (includes yoke, no stand)
Accuracy ±0.06 in. ( ±1.6 mm )
Certifications Œ, CSA, FCC approved, ETL Listed (UL 60950)
Supply Roll Capacity
PA/4600
PA/6000
13 in. ( 330.2 mm )
14 in. ( 355.6 mm )
Label Length 0.5 in. ( 12.7 mm ) Min. to 22.0 in. ( 558.8 mm ) Max.
Label Width 0.5 in. ( 12.7 mm ) Min. to 4.0 in. ( 101.6 mm ) Max.
Product Rate
PA/4600
PA/6000
50 PPM Max.
110 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 - Tamp System
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 PA/4600 & PA/6000 User Manual
Introduction Page 5
Introduction
1.6 System Dimensions
31in.
23in.
25in.

Diagraph - an ITW Company PA/4600 & PA/6000 User Manual
System Modules Page 6
System Modules
2.0 System Modules
2.1 Mechanical SubSystem
Unwind P/N: 4600-605
Rewind P/N: 4600-606
Tamp Pad P/N: 4600-610 Width x Length
Theunwindisdesignedtocapturesupply
rollsupto14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
printer,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printerandthecolumnonthe
furthestendofthelabel(fromtheprinter)
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.

Diagraph - an ITW Company PA/4600 & PA/6000 User Manual
System Modules Page 7
System Modules
Stand P/N: 6160-329
2.2 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PA/
4600orPA/6000,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printer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.

Diagraph - an ITW Company PA/4600 & PA/6000 User Manual
System Modules Page 8
System Modules
Inlet Filter/Regulator/Shutoff P/N: 4600-705
2.3 Electrical SubSystem
MCA III P/N: 4600-300
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 Page 9
System Modules
Printer P/N: 4600-800 PA/4600 Models Only
Rewind Motor P/N: 4600-503
Power Supply P/N: 4600-521
TheonlyprinterselectionforthePA/4600is
theSATOLt408.TheLt408isamedium‐
dutyprintenginethatsharesthesameformat
languageandcommandsasthevenerable
SATO8485Se.TheLt408iscapableofusing
eitheraribbonforthermaltransferprinting
ordirectthermal.Whenusingaribbon,the
printerwillaccepteitherface‐in(SATO‐
style)orface‐out(Zebra‐style)ribbon.When
changingfromoneribbontypetoanother,
theLt408featuresadjustableheatsettings
selectablethroughtheuserinterfaceorthe
labelformat.
TheLt408iscapableofprintingupto6
inchespersecond,andhasanoptionfora
real‐timeclock/calendar.
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.