Novexx Solutions AP 5.4 User manual

07/15 Rev. 02 USER MANUAL
AP5.4–AP5.6
Product description
Intended Use ................................................. 2
Device types ................................................. 3
Basic ......................................................... 3
Peripheral .................................................. 3
„Basic dispenser“ or
„peripheral dispenser“ ............................... 3
Options .......................................................... 4
Internal Options ......................................... 4
External Options ........................................ 4
Functionality .................................................. 5
AP 5.4/5.6 without dispenser ..................... 5
AP 5.4/5.6 dispenser ................................. 6
Operating controls ......................................... 7
AP 5.4/5.6 “basic” and “peripheral” ............ 7
AP 5.4/5.6 dispenser ................................. 9
Operation panel ....................................... 11
Ports and connections ................................ 13
Warning signs on printer ............................. 15
Operating modes ........................................ 16
Offline mode ............................................ 16
Online mode ............................................ 16
Message mode ........................................ 16
Standalone mode .................................... 17

07/15 Rev. 02 USER MANUAL Intended Use
AP5.4–AP5.6
2
Intended Use
AP 5.4 and AP 5.6 printers are designed for printing label material, using the thermal
or thermal transfer printing process. In addition, the dispenser versions of both printer
types can dispense self-adhesive labels and can rewind the remaining backing paper
(ar alternatively the complete label material). It is possible to use a wide range of label
materials and thermal transfer ribbons. Label stock must be in roll shape or fan-folded.
The label web can optionally be pulled-in from outside the printer through the slots in
the rear side or bottom plate.
Any other use or use going beyond this shall be regarded as abnormal use.
Novexx Solutions assumes no liability for damage due to abnormal use of the printer.

07/15 Rev. 02 USER MANUAL Device types
AP5.4–AP5.6
3
Device types
AP 5.4 and AP 5.6 are available in 4 versions:
Basic
AP 5.4/5.6 equipped with serial, USB and Ethernet interface and SD-card slot. Possi-
ble upgrade to „peripheral“ version.
The following options can be integrated:
• Reflex sensor (top and/or bottom)
• I/O board (signal interface and additional serial interface)
Peripheral
Like the AP 5.4/5.6 basic, but with capability to add the following options:
• External rewinder (for AP 5.4 only)
•Cutter
„Basic dispenser“ or „peripheral dispenser“
AP 5.4/5.6 with additional built-in internal rewinder. In connection with an optional dis-
pensing edge, this printer can also be used as a dispenser. If the dispensing edge is
replaced by a deflection plate, the printed labels are not dispensed, but rewound to-
gether with the backing paper.

07/15 Rev. 02 USER MANUAL Options
AP5.4–AP5.6
4
Options
Internal Options
…should be factory-fitted or installed by a service engineer:
•Reflex Sensor Kit: Light barrier fitting that apart from the transmission sensor, also
contains a reflex sensor.
•Label sensor for short labels. Recommended for label length < 30 mm.
•Internal rewinder kit: To retrofit the internal rewinder; contains the rewinder as well
as the driver board and material guide
•I/O board: RS- 422/485 interface, signal interface
External Options
…do not require any special alterations to the printer:
•Cutter (required printer: AP 5.4/5.6 peripheral)
• AP 5.4 only: (External) rewinder for material rolls with 38 mm (1.5”), 75 mm (3”) or
100 mm (4”) cores (required printer: AP 5.4 peripheral)
•Keyboard for standalone operation
•Foot switch for foot-operated label dispensing
•Dispensing edge (required printer: AP 5.4/5.6 „basic“ or „peripheral“ with internal
rewinder)

07/15 Rev. 02 USER MANUAL Functionality
AP5.4–AP5.6
5
Functionality
AP 5.4/5.6 without dispenser
[1] Material and foil path inside the AP 5.4/AP 5.6.
APrinthead
BFoil unwind mandrel
CFoil rewind mandrel
DMaterial unwinder
EPrint roller
The label printers AP 5.4 and AP 5.6 only differ in the print width. The functionality is
the same for both printers.
The printing principle is based on the thermal printhead [1A]. The core piece of the
printhead, the thermal edge, consists of a row of dot elements, which can be controlled
and heated separately. Each heated dot element leaves a black dot on the label ma-
terial.
With thermo printing, the black dot results from the reaction of the thermosensitive la-
bel material. With thermo transfer printing, the black colour is transferred from the ther-
motransfer foil to the label material.
In order to add the dot lines to an image, the label material has to be passed under-
neath the printhead during printing. This material feeding is accomplished by the print
roller [1E], which is motor driven. By moving the label material, it is unwound from the
label roll [1C].
When using thermotransfer printing, the thermotransfer foil is fed together with the la-
bel material underneath the printhead. The foil position is between label material and
printhead, the colour side facing the label material. The full foil roll is plugged on the
foil unwinder [1B]. After passing the printhead, the used foil is wound onto the foil re-
winder [1C], which is motor driven. If the foil roll is completely rewound, a new roll has
to be inserted.
Material end and foil end are detected by sensors and are displayed on the operation
panel (optionally by a sound signal).
The label beginning is detected by a light transmission sensor with punched label ma-
terial and by a reflex sensor (option) with endless material.
1
2
3
4
5
60
A
B
CC
E

07/15 Rev. 02 USER MANUAL Functionality
AP5.4–AP5.6
6
AP 5.4/5.6 dispenser
The AP 5.4/5.6 dispenser allows freshly printed labels to be dispensed (via the dis-
pensing edge) or rewound in the printer enclosure (via the defelector).
• When used as a dispenser, the label material is drawn around the dispensing edge
and only the backing paper is rewound.
• When used as a rewinder, the printed label is guided across a baffle plate and re-
wound together with the backing paper.
The electronic components in the rewinder control the tensile force on the release pa-
per so that the same force is applied for all winding diameters. This is controlled inde-
pendently of the material width and printing speed. The controller can be set
automatically or manually depending on the settings in the parameter menu.
The manual setting is only necessary in special cases and may only be performed
by qualified, authorised service personnel.
After switching on the printer, the rewinder is initialised and the backing paper is tight-
ened.
Once a print job is received, the printer searches for the first label start marking at re-
duced printing speed. To do this, the label material is moved by at least the distance
between the label sensor and the printhead (70 mm). This distance is used by the re-
winder controller to calculate the diameter of the previously 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 70 mm. 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 message ap-
pears 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 dispensed re-
mains hanging on the dispensing edge (set dispensing position). The printer waits
until the label is removed before moving the next empty label beneath the print-
head and then printing and dispensing it.
•Dispenser mode with foot switch:
Pressing the foot switch releases the label for printing and dispensing. Afterwards,
the next empty label is positioned beneath the printhead.
See topic section (De)activating the dispensing edge , page 9.

07/15 Rev. 02 USER MANUAL Operating controls
AP5.4–AP5.6
7
Operating controls
AP 5.4/5.6 “basic” and “peripheral”
[2] Outside view of AP 5.4/5.6 “peripheral”.
AControl panel
LCD screen; 4 buttons; displays operating status of printer; allows parameter
menu settings.
BConnection for additional devices:
(Only to AP 5.4/5.6 “peripheral”). This is where the optional cutter or rewinder
(AP 5.4 only) is connected.
CFront cover:
Open this to insert material and the ribbon.
A
B
C

07/15 Rev. 02 USER MANUAL Operating controls
AP5.4–AP5.6
8
[3] Operating controls of AP 5.4/5.6.
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 (AP 5.4 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 material/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

07/15 Rev. 02 USER MANUAL Operating controls
AP5.4–AP5.6
9
AP 5.4/5.6 dispenser
AP 5.4/5.6 “basic” or
“peripheral” dispenser
[4] Additional operating controls on AP 5.4/5.6 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
E
F

07/15 Rev. 02 USER MANUAL Operating controls
AP5.4–AP5.6
10
AP 5.4/5.6 “basic” or
“peripheral” dispenser
in rewinder mode
[5] Additional operating controls of AP 5.4/5.6 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