Service Electronics
Contents
1. 28 UTERE RO 28 RD 28 Power Supplies 29 Application Notes 29 Retrofitting the nun 29 INT AOU ATGBO cese esae 30 31 EE T TT TT 32 Printhead Voltages HME amp Standard 33 Characteristics HME power supply 34 zei 35 Sensor Sethin d SENSON LESE 2 eniro 38 General NOTES anne 38 Sensors on the CPU board 64 xx 39 Sensors on the CPU board DPM ALX 40 Value table for sensor 0 12 printhead temp 40 Sensors on the output stage boards 41 Sensors on the output stage boards FE OBL EE NR MN NEN DENS 41 VODIONS NE RETE 42 Installing a Memory Extension 42 Installing the Option Board 44 Installing a Realtime Clock 45 Attaching locking clips for flat strap plugs 46 INGEX t 48 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Handling boards ESD protection All the boards described in the following are fitted among other things with large scale integrated circuits Voltage impulses caused by static charging from people or objects can easily destroy the circuits When handling boards ensure that the electronics cannot b2. F E P i I TRE he Linum 3 Plug the memory module into the slot U201 as illustrated fig 3 The memory module is coded by a dent fig 3 Make sure that the memory modu le fits into the slot as illustrated Continued overleaf REV 1 0 L 50 DI CT ad m Me SoMa TTS im eee ee rrr rere Ji jn iif hm Wri LIIS Re E EEE EE a YAT a biy 4 ekrlid d ee ae o 2 4645 nm Lj LL LJ of i NE 24 IE Se Ll L Big p em WEIL p 175 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Plug in the memory module under an angle of about 20 fig 1 4 Press the memory module towards the CPU board fig 2 until it snaps autibly into the lateral clips fig 3 cicles 5 Reinstall the CPU board into the printer The new memory capacity is indicated when the printer is powered up Memory 40 MB with 32MB memory extension respectively Memory 72 MB with 64 MB memory extension n RASA AIO s SUNG S Mn iG32D La m E ADU 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Installing the Option Board 1 Requires 64 xx DPM PeM or ALX 92x with CPU board no A2292 or A229
3. gt O1 lt PO Pin Function 1 GND 1 2 5 V 2 3 GND 3 D Output stage boards connection Pin Function 5V OV 38V OV 52V OV E USI board optional 2 Connections at the NT400 OP OIN 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 1 On off mm GND 2 GND ME 00 G USI board optional e The ME500 replaces the NT400 since Pin Function 01 2008 4 yo4ya TI e Operation with dust filter is admissible Part 5 GND 2 number of the dust filter kit see spare parts catalog Mounting instructions for the dust filter kit see topic section Service Mechanics N chapter Assembling accessories H Output stage boards connection mM Pin Function Wait at least 15s between switching off and 1 52V 1 on again 5 GND 2 A Remote on off 3 28V i m 64 xx bridge the connector using a jumper 4 GND 5 Pin Function 5 48V 6 6 B CPU board connection control signals Pin Function 1 NMI 1 2 I2C detect 2 3 SCL 4 SDA 5 5 PG 6 6 n a 7 T n a 8 8 n a 9 9 GND C CPU board connection supply voltage Logic 3 Power supply ME500 Pin Function 1 GND 1 2 45V 2 3 GND 3 D Ground connection im The cable end must be screwed to the printer housing E Printhead connection Pin Function n 1 20 28 V
4. OP GO 6 Connections at the HME 03 10 Rev 5 04 01 Checking the headvoltage SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Printhead Voltages HME amp Standard 2 3 2 30 2 2 2 s sS SEs SE s B B dec X2 Zo Zo 8 8 a gt AD A gt AH A gt AD A gt 1000 21 40 11190 23 30 1 1380 25 05 1570 26 68 1010 21 50 11200 23 39 11390 25 14 1580 26 77 1020 21 61 1210 23 49 1400 25 23 1590 26 85 1030 21 71 1220 23 58 1410 25 31 1600 26 93 1040 21 81 1230 23 68 1420 25 40 1610 27 01 1050 21 92 1620 27 10 1060 22 02 1630 27 18 1070 22 12 1640 27 26 1080 22 22 1650 27 34 1090 22 32 1660 27 42 1100 22 42 1670 27 50 1110 22 52 1680 27 58 1120 22 62 1690 27 66 1130 22 72 1700 27 74 1140 22 81 1710 27 82 1150 22 91 1720 27 90 1160 23 01 1730 27 98 1170 23 11 1180 23 20 Tab 1 The table shows the voltages which the power supply should provide if it is con nected to a printhead with the respective resistance The values are valid for both Standard and HME power supply Proceed as follows to check the printhead voltage 1 Find out the printhead resistance The printhead resistance can be found written on the printhead or by calling the parameter Given that the resistance value is typed in correctly 2 Measure the printhead voltage
5. i dms nh LLL EN T rio ie 1 0 d ar Hin me v iB L 1 ee S e a Flachbandkabel u Ribbon cable USI V2 T1 F873 tai a Her Clef ee uu a amr Fass NER RS 5 if di Apz isn fax FEF iz 4 um cc UC u a d pae ca Pin 1 CN300 Anschluss interne USI Eing nge Connector internal USI Inputs ms Sat Sm iu be oo 100 1 T 20167 Fig 15 Pin 1 is the first in direction of the ribbon cable the writing CN300 Pin 1 be found beside the pins on the USI board The D Sub15 socket at the testbox has the same pin assignment as the D Sub socket of the USI Plug the system control into this socket and connect the testbox to the USI as described above in order to monitor the 4 USI in puts 03 10 Rev 5 04 01 LEDs Internal inputs SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Operation After powering on the printer the LEDs on the testbox show the current levels of the USI outputs with the following meaning LED off USI output High LED on USI output Low The supply voltage LEDs indicate LED off Voltage not applied LED on Voltage applied Each pressing of a key or switch pulls the respective input level down to Low with the LED on the key or switch
6. m 03 10 Rev 5 04 01 SERVICE MANUAL 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Service Electronics Handling boards 2 ESD protection 2 NAC HDI 2 OPU Layout without Ethernet 3 Layout with Ethernet 4 Fe einen 5 Output stage board 9 Important Notes 9 Layout Connecting 9 10 Option Board 11 nee een 11 1 5 rz VUE PU EUM 11 Ni isle 12 Application notes 12 Is 13 Maret UT 13 Signal description D Sub 15 14 Pin assignment internal inputs CN 300 16 Signal description CN 300 17 Pin assignment jumper block 17 BOSK OKI rear 18 Circuit diagrams for signal inputs 19 Circuit diagrams for signal outputs 20 Firmware update ee 22 d 23 Application bait as 23 Lou RM REIR E EP 23 Connecting the test box 24 hatt mo RO 25 Diagram of a USI input 26 Display 64 XX 27 27 MM PN 27 Display DPM ALX
7. 10 without material typical 7 11 255 with material 0 09 Cover Hood switch 0 Hood closed 255 Hood opened 0 12 H Temp Printhead temp sensor 105 to 235 Displayed value drops when the printhead temp rises see Tab 7 Tab 6 Test conditions for sensors connected to the CPU board Value table for sensor 0 12 printhead temp Sensor value 235 230 225 220 215 210 205 200 195 190 Printhead temp 12 9 17 8 22 1 26 0 29 5 32 7 35 8 38 7 41 4 44 0 Tab 7 Sensor values of the print head temperature sensor no 0 12 The lower the displayed value is the higher is the print head temperature Sensor value 180 175 1170 165 160 155 150 145 140 135 Printhead temp 49 1 151 5 53 9 56 3 58 6 60 9 63 2 65 5 67 8 70 2 Tab 8 Tab 7 continued Sensor value 120 110 105 Printhead temp 77 3 82 3 84 9 Tab 9 Tab 8 continued 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Sensors on the output stage boards 64 xx Sensor Description Typical Value Condition name Foil Foil sensor Sensor above a hole in the oscilla tor disc light barrier clear 254 Sensor covered 3 01 Head Light barrier at the prin 0 Printhead in economy position thead raising mechanism raised 254 Printhead in print position lowered 4 01 Option Sensor for options appli gt 10 Light barrier covered cation for cutter external rewinder or
8. AMP 643813 4 oder AUK MK 04H MOLEX 70450 Version b AMP 0 644465 6 MTA 156 18 AWG 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Option Board P5 2 keyboard i L CAUTION The maximum output current of the P S 2 interface CN103 N Is 500mA at 25 C A self resetting fuse interrupts the current in case of over load CPU board CN 104 ou RS 422 485 termination TxD CN 101 RS 232 RS 422 485 termination default CAUTION Line termination in RS 485 mode 2 wire interface close either J P 101 or J P 102 4 wire interface close J P 101 and 102 Picture Typeat Pin assignment on board cable RS232 422 485 DSub9 M RS 422 485 9 8 Tx 7 RXx 6 4 5V ones 6 n c 1 Data 3 GND 5 Clock Kabel ist an Platine angelotet EL Fig 2 Connectors on the option board 03 10 Rev 5 04 01 USI Board Utilization Compatibility Version Connection type Signal voltage SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Application notes The USI Universal Signal Interface is an optional interface for all machine types listed in the headline of this page USI equipped machines can for example control applicators or scanners The input signals can be used to trigger the print dispense process The out put lines signal the operating status e g materi
9. E m g m m H8 NH NH NH EH NH DO D1 D2 D3 D4 D5 D6 D7 VCC 5V GND Tab 8 Connectors on the 64 xx display board 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Display DPM ALX Layout CPU board CON 101 Power supply CON 102 Connector CON10 3M in 1 2520 FEED 7 PROG 6002UB ELE 13 LCD RWY 15 ERROR 17 VCC 5V 19 GND 2 D0 4 01 6 02 8 03 10 04 12 05 14 06 16 07 18 VCC 5V 20 GND Tab 9 Connectors on the DPM PEM ALX display board 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Power Supplies WARNING N The outputs of the power supplies are energy hazard Touching the output connectors with the machine switched on can cause exposure to hazar dous electrical currents and may lead to burns Switch off the machine before touching the power supply Application Notes The following two types of power supplies are applied Printer Power supply 64 04 05 06 Up to 01 2008 NT400 Since 01 2008 ME500 64 08 DPM ALX 92x HME Tab 10 Application of the two power supply types For article numbers refer to the Spare Part Catalog D Retrofitting the ME500 CAUTION N If the power supply NT400 is replaced by a ME500 the printer firmware must possibly be updated e he printer will not print with a not matching firmware e A faulty updated patch c
10. lighting up The LEDs on the keys also light up if the level of the corresponging input at the D Sub15 socket Is pulled to Low monitoring This can e g be done by a connected system control or light barrier Even with a system control connected can the USI inputs be activated by pressing the appropriate key set up operation With the testbox being connected to the USI merely by the D Sub15 connec tor the following functions are available Displaying the USI output levels Simulation and monitoring of the 4 USI inputs START PRINT REPRINT PAUSE und FEED Survey of the voltage supply with 5 V and 24 V Additionally the internal USI inputs can be simulated if the 5 pin connector strip is plugged into CN300 on the USI board see Fig 15 PLC ready fault PLC ERROR Applicator fault touch down TOUCH DOWN ERROR Applicator fault home position HOME POS ERROR OD control material MATERIAL LOW Tab 6 The switch designations right column which are printed on the testbox differ slightly from the signal designations left column Befor starting the simulation the following parameter settings are required Interface type USI applicator DP INTERFACE Material signal Enabled Internal inputs Enabled Tab 7 Parameter settings which should be done before starting the simulation m The internal inputs are high active what means that the switches PLC ER ROR TOUCH DOWN ERROR or HOME POS ERRO
11. supply voltages 5 V on pin 2 and 24 V on pin 8 are provided by the USI The output current is limited Maximum current per output line 50 mA all output currents together may not exceed 700 mA Netzteil USI board USI Platine Power Supply 24V JP8 5V Pin2 OV 5V OV Pin1 8 Kabel Cable A2059 24V Pin7 OV Pin1 8 10 USI in the state of delivery The voltage cable is connected JP 8 is closed 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 External supply CAUTION N In previous versions of this document the external voltage supply of the USI was described External voltage supply without external current limiting elements is no longer permitted risk of fire In case of applications that externally supply voltages a current limiting element must be provided by the system integrator Examples of suitable current limiting elements in the supply circuit are e Poly fuse with UL 1434 approval 24 VDC 0 65 mA Ug 30V 5 0 65 mA Ug 6 V e Micro fuse according to IEC EN 60127 24 VDC T 630 mA L 250 V 5 VDC 630 mA L 250 V a Due to an update of EN 60950 1 03 10 Rev 5 04 01 Version check Exchanging the controller 1 2 Open the rear hood SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Firmware update The firmware of the U
12. the sensor measurement Inserting material means here inserting a material sample into the LS fork m The material sample must be big enough to cover the LS 18 Set the setting value to 155 5 by pressing the Cut or Feed button respectively The measured value should match the range of 12 18 19 Insert standard self adhesive material paper label on backing paper into the printer The value measured now should count at least 100 digits higher than the va lue measured with bare backing paper If the measured value doesn t match this range please modify it by pressing the Cut respectively Feed button 20 Press the online button to save the setting value By doing so the Fullsize LS is ready set 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Sensor test General notes Activating the sensor test call parameter By means of the sensor test you can check the function of each sensor e Ifthe value shown on the printer display exceeds the range given in the chart below the respective sensor is possibly dirty and has to be cleaned blow the dirt off with compressed air Check the function of light barriers by covering it and of micro switches by triggering it If the displayed value doesn t change when the sensor is covered or switched it is possibly or defective e Sensors which are not connected show values about 255 in the sensor test e General rule for
13. xx dispenser only Dispense light barrier 64 xx dispenser only microswitch at the inter nal rewinder 64 xx dispenser only microswitch at the pres sure roller Material end light barrier Punch sensor Optional reflex sensor Optional Full size light barrier Hood switch Printhead temp sensor 255 255 0 0 255 to 10 11 to 255 gt 200 10 bis 20 10 11 to 255 0 255 105 to 235 Test conditions for sensors connected to the CPU board Light barrier covered by a dispensed label Light barrier clear Internal rewinder not full Internal rewinder full Pressure roller closed Pressure roller open Without material light barrier clear With material inserted Without material typical 7 With material Without material approx 253 or opposite of the reflex mark gt 200 With white material Without material With material Hood closed Hood opened Displayed value drops when the printhead temp rises see Tab 7 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Sensors on the CPU board DPM ALX Sensor Description Typical Value Condition name Press Microswitch at the pres Pressure roller closed sure roller on the feed roller not available at PEM 0 Pressure roller open 0 04 Matend Material end light barrier 0 without material light barrier clear 255 with material inserted 0 05 Punch Punch sensor 7 to
14. 002 Printhead CN 901 u L CAUTION Only for production U303 BootPROM purposes y lor p 2 3 16bit boot bus width default H8 RX1 RS 232 level H8 RX1 TTL level de CAUTION Line termination in RS 485 mode fault 2 wire interface close either P 601 or P 602 4 wire interface close J P 601 and 602 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Layout with Ethernet Boot from U303 Boot PROM Constant LED current at Boot from system flash dispensing edge sensor default Constant LED current at Sockel f r 8bit sensor Disp Rewinder Boot PROM Pulsed LED current at dis U 303 CAUTION Only for pro pensing edge sensor amp at duction purposes TAG Q sensor Disp Rewinder interface CN 402 15V at Cen tronics pin 35 u ws ster SO DIMM 144socketfor socket Power supply USI board e e tronics pin 18 me extension U 701 CN1301 CN1005 Default U 201 Display Js cable peripheral CN902 bus CN 1003 Sensor dispensing edge CN 1101 sensor dispenser rewinder DDS CF card slot CN 801 Nee EN on ie 48 CN 1102 50 ET fe Feed roller sensor aA x Ex PEJE hami DPM PEM ALX TS EM erg 64 Dispen EM ee oan E suni a IN C CN 1103 O W Er Material end sensor Base rare XE ptpususuawueddus j T st A
15. 1003 Sensor dispensing edge CN 1101 sensor dispenser rewinder DDS CN 1102 Feed roller sensor DP M P EM ALX TS 64 xx Dispen ser DTS CN 1103 f we LI EH 0000001 66000 555 Tr III 2 N ET iliis Ed Je LELLE rt Meo Be Eo B Avery Denison CF card slot CN 801 i A iz d MIENNE LN QUEE js die e DS Ta iz TU gk aea ta ae ar Lu 1 Duy CLR MM 2172277 e a KELTE r Ton Pig TN e ess Cia wel PRI PENNE n iuueni tendit TM 1223123 LS Yi ritti Cover sensor COS CN 1109 Power supply CN 1004 memento mn sensor Dib Bande cm MET Free MS CN 1104 gb T us me I NISI Punch sensor PS Lo es ie EE CN 1105 o ea d Reflex sensor RS foc ey 17 ELA AREE S ro CN 1106 i 24 tee Fullsize sensor FSS Centronics 8 DE Sy dL E CN 1107 LE ri iere UA sese Singlestart sensor PEN Sm SSS CN 1108 277277227099 D em Internal scaner se N 15 RS 232 CN 601 E sa eu fs CN 1006 5 Y LA 2 ir Ta DE aap Motor output stage bus CN 1001 CAUTION Only for produc tion purposes H8 PRG Adapter CN 1
16. 2 Left side USI testbox A2739 right side connecting cable A2842 Both parts are required for application View Survey of the voltage supply at the D Sub connector of the USI The test box needs 5 V supply voltage a pre PRON out Survey of in and outputs at the D Sub connector of the USI x REPRINT Fast Simulation of the 4 inputs at the D Sub connector of the USI 4 pushbuttons Simulation of the 4 internal inputs at the CN300 connector of the USI from vers 4 on 4 switches Al 0 HOME EEDA ats PIS un EPRE Optional connection of a customer control unit Ben or product sensor monitoring Fig 13 Operating parts and connections of the USI testbox 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Connecting the test box Connect the connecting cable D Sub25 connector to the appropriate socket at the testbox Connect the connecting cable D Sub15 connector to the appropriate socket at the USI Given version 4 of the USI the 5 pin connector of the connection cable can be connected to the internal inputs of the USI Plug the connector strip onto CN300 in Connect the black cord of the connector strip to pin 1 see Fig 14 and Fig 15 Fig 14 The connector strip for connecting the testbox to the internal inputs of the USI The mounting orientation is printed on the cable black on CN300 pin 1
17. 2 20 28 V 3 20 28 V 4 20 28 V 5 GND 6 7 8 GND GND GND 4 Connections at the ME500 F Operation indicator 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 HME G Remote on off e Operation with dust filter is admissible m 64 xx bridge the connector using a jumper e Part number of the dust filter kit see spare Pin Function parts catalog 1 On off 2 e Mounting instructions for the dust filter kit 2 GND see topic section Service Mechanics D H CPU board connection supply voltage only chapter Assembling accessories ALX 92x DPM USI board optional A Applicator Interface connection Pin Function a B Ground connection 24 V mm 2 m The cable end must be screwed to the 2 GND printer housing a galvanically separated C CPU board connection control signals Pin Function NMI I2C detect SCL SDA PG n a n a n a GND D Printhead connection Pin Function 20 28 V 20 28 V 20 28 V 20 28 V GND GND GND GND E CPU board connection supply voltage Logic Pin Function o NO A OIN 5 Power supply N OOA lt 1 GND 1 2 5 V 2 3 GND 3 F Output stage boards connection Pin Function 4 5 V GND n a GND 48 V GND
18. 230V and 1A AC at 110V from the power supply 03 10 Rev 5 04 01 Settings LS Material end LS Punch LS SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Sensor setting m The button designations mentioned in this description count only for 64 xx 7 printers With DPM PEM or ALX 92x please press the Apply button instead of the Cut button LS means light sensor Proceed as follows to set the sensors Switch on the printer while you keep the Feed and Prog buttons pressed for approx 5s After the printer has started Enter code is displayed Press the following buttons one after the other Cut Online Feed Cut Online Online Online Call the parameter This text is displayed Sensor adjust 220 Matend 255 The number on the eft side is the setting value of the LED current standard 220 The number on the right side is the value measured by the sensor here 255 The higher the setting value the lower is the measured value Remove the label material from the material end LS The measured value should now change to 0 If not increase the setting value to 220 Decrease the setting value by pressing the Cut button until the measured value changes to 255 64 xx Increase the setting value by 30 DPM PEM ALX 92x Increase the setting value by 5 The measured value changes to 0 Insert some label material The measured value should now be 255 um The
19. 3 installed Option board no A2294 fig 1 Install the Option board as follows 1 Remove the rear hood of the printer 2 Remove the power supply 1 in order to get to the CPU board 3 Remove the cover plate 2 fig 3 4 Set the jumpers on the Option board O Howto read paragraph Option Board on page 11 2 5 Install the Option board instead of the removed cover plate and connect it as illustrated fig 4 6 Reinstall the power supply 7 Close the rear hood 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Installing a Realtime Clock 1 This requires 64 DPM PEM or ALX 92x with a CPU j board no A2292 or A2293 installed Las X PT Upgrade kit realtime clock no A4201 The upgrade kit contains a box with the realtime clock RTC fig 1 and an instal lation guide Install the RTC as follows 1 Remove the CPU board from the printer How to Read topic section Service Me chanics chapter Replacing the boards board 2 Plug the RTC into the socket U701 on the CPU board fig 2 The RTC socket is located in the upper left area of the CPU board fig 2 white circle Hold the RTC in a way that the molded spot is in the lower left corner when plug ging the chip onto the socket figs 3 and 4 The molded spot marks pin 1 3 Reinstall the CPU board into the printer Set
20. Collector Emitter Anode Cathode Collector Emitter em Anode Cathode Collector Emitter co Anode Cathode Collector Emitter al p dius Service Electronics E 2 ar P s 2 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Picture Comp Typeat Pin assignment on board Diagram board cable Cover switch CN1109 PANCON 1 bs MLSS 1 Signal cover switch fO i 100 02 2 GND CN1501 The RD Termination Termination RD SLISPEZI Termination Termination CO CO amp WN I 1 1 SELECT_IN 18 VCC 5V J P 502 geschl VCC 5V 503 geschl GND FAULT AUTO FEED INIT SELECT GND PAPER END GND GND GND GND GND GND GND GND GND GJ OO 1 1 1 1 1 1 1 1 1 STROBE RS 422 485 5 GND eom EDS 3 TxD 7 Ry 2 RxD 6 1 CD us L CAUTION 85232 pin assignment looked at from PC point of view Printer DCE Tab 1 Continued Connector description CPU board 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Picture Comp Typeat Pin assignment on board Diagram board cable Printhead CN901 Tab 1 Continu
21. ND SPS Ready Error Touch Down Error internal Inputs Home Pos Error only Material Low USI Connector Sub D 15 Start Print j T l OJP3030 Start Print gt o Feed CJP3020 Feed O O Pause Pause OJP3010 c A Reprint 023000 Reprint C 7 Ribbon Low Ribbon Low OJP204O 5 Error Erron 2 Print End Print End o Media Ouf CJP20 2 Media Out Ribbon Outi CJP200 Ribbon Out LLI Data Ready 0201 Data Ready Machine Status P20 ex Machine Status Applicator Mode 20 d GND oe GND OCN2010 BV GND OCN2020 GND OCN2030 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Circuit diagrams for signal inputs USI board NPN sensor 1k2 Controller GND 24V 6 Main circuit for signal inputs NPN at the USI interface here connecting a start sensor Timing waveform of The following criteria must be matched by the input signals of the USI input signals Only one signal at a time may be switched active The input signals must switch bounce free min 10ms min 10ms 10ms 10ms min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms Start Print Puls mode falling edge min 10ms Feed min 10ms Reprint min 10ms Pause print 1 labe
22. OME POS SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Signal type Voltage supply Ground Out Function The last printed label is being reprinted as long as REPRINT is low Minimum reprint quantity 1 label Preconditions e The label which is ought to be reprinted must be ready printed and dispen sed e Printer is in online mode Ift a REPRINT is triggered while the printer is in USl pause mode the reprint will be proceeded as soon as the printer is switched back in online mode Precondition START PRINT inactive high Voltage supply for external sensors Ground contact Ribbon low warning The signal is activated high if a DP INTERFACE Ribbon signal activatedand b The ribbon stock is below the threshold value which is set in parameter SYSTEM PARAMETER Ribbon warning After changing the ribbon roll the signal will be inactivated after a shorttime The signal is activated high if a DP INTERFACE Material signal activated and b The label material stock is below the threshold which is setby positioning the light barrier After changing the material roll the signal will be inactivated The WARNING output is only then inactivated low if ribbon and material both are available in a sufficient amount If one of both rolls falls below the threshold value the output switches activ high In practice the more or less eccentric running material roll
23. R respectively have to be pressed before starting the simulation Releasing one of those switches LED off stops the machine additionally the appropriate status message is displayed The machine can only be fur ther operated if the testbox switch is pressed again error withdrawn LED on and the status message is acknowledged at the printer operating panel 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Internal input OD control material switch MATERIAL LOW Releasing this switch LED off switches the WARNING output of the USI high Thus the WARNING LED on the testbox goes out The machine is not being stopped The WARNING output also shows the close end of ribbon stock what means that this ouput can change its level without the MATERIAL LOW switch being pressed Diagram of a USI input 5V 5V 24V 5V Optokoppler Opto coupler Controller USI Testbox ze Kunden steuerung Customer control i GND Ext GND Fig 16 Simplyfied diagram of a USI input 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Display 64 xx Layout Setting ronness a Setting contrast es Connector JP1 3M 2520 6002 al CPU board J P 1 1 ON OFF 3 CUT 5 FEED 7 PROG 9 LCD E 11 LCD RS 13 LCD RW 15 n c 17 VCC 5V 19 GND m gg m gm BH NH NH NH E
24. S 100 04 CN1004 PANCON MLSS 100 09 ICS PS ISK PS 1 0 ASENSOR 0 KA KD KS ZIG CN 1005 EX RES Al TRQ H8 IRQA SCL SDA TX1 APFS ie 2 3 4 5 6 7 8 9 CN1006 Hirose ee DE11 N C ee 3 FRAME 1 ee 24DP 2V H8 IRQ5 H8 PB84 Tab 1 Connector description CPU board 03 10 Rev 5 04 01 Picture Sensor dispensing unch Sensor E j RET Ah Te oe e i 2i Eu zz d i I Reflex Sensor At 1 En pis i LI Weed E x b Li Yi Fullsize Sensor EL Single ns pg j E j RE Lo S TEM rm Comp Diagram CN1101 CN1102 CN1103 CN1104 CN1105 CN 1106 CN1107 CN 1108 SERVICE MANUAL 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Type at board PANCON MLSS 100 04 PANCON MLSS 100 04 PANCON MLSS 100 04 PANCON MLSS 100 04 PANCON MLSS 100 04 PANCON MLSS 100 04 PANCON MLSS 100 04 PANCON MLSS 100 04 cable Tab 1 Continued Connector description CPU board Pin assignment on board Anode Cathode Collector Emitter Anode Cathode Collector Emitter Anode Cathode Collector Emitter bir Anode Cathode Collector Emitter Enn Anode Cathode
25. SI can be updated in the following ways Exchanging the appropriate controller on the USI board see Fig 11 Loading a firmware file same procedure as for updating the printer firmware This procedure requires the following Controller version V6 T36 or higher Printer firmware version 4 30 or higher Article number of the controller with the most recent firmware A3379 Displaying the installed controller version Parameter menu SERVICE DATA gt MODULE FW VERS gt USI interface Status printout PRINT INFO gt Service status entry Peripheral driver USI interface Displaying the installed printer firmware Parameter menu SERVICE DATA gt MODULE FW VERS gt System version Status printout PRINT INFO Printer status 11 The controller 1 contains the USI firmware Switch the printer off pull out the mains connector For details refer to topic section General Service section Housing chap ter Rear hood 3 Take the controller 1 out of the socket 4 Insert the new controller into the socket m The dent in the controller housing must show in the pictured direction see Fig 11 03 10 Rev 5 04 01 USI testbox z0175E CDR SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Application Simulating USI inputs Checking USI outputs Monitoring of drive signals sent by the system control Aid for setting up the machine Fig 1
26. al or ribbon end so that the machine can be integrated completely into a system The USI comes on a separate board and can be easily retrofitted PM 3000 ALX 92x USI and Al Applicator Interface can not be built into the same device The functionality described in this section is only then fully available if USI board Controller and printer firmware match the following versions e USI board At least A2345 04 or a later version which can be recognized by a higher index 05 06 The version number can be found on a label at tached to the board 3B C e USI controller At least V2 T1 F873 or a later version which can be recognized by the V section of the version number V3 V4 The version number is written on a label attached to the controller SA e Printer firmware 4 12 is displayed after powering on the printer NPN optionally 5 or 24 V v d att TTT TT PY T I usi RT Zen 1777 ize bor TU i p XE nu j Li I TILILA Eu 31 33 597 line TT i a a wu 3 At those places you find the version designations on the USI board 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 View SPS optional USI board version Micro controller version number here 04 number here V2 USI signals TU VB 200 lt LII MITES CPU b
27. all sensor values Full light leads to values lt 10 No light leads to values 220 e To sensors which function as a switch applies the following Values between 10 and 220 mean that the sensor is poorly set dirty or close to the end of its life Sensor test 0 01 Punch 11 Sensor Sensor name Value 1 Display after calling Sensor test E xtraneous light must be avoided when checking the sensors Therefore keep the front cover and the housing cover closed during the sensor test After starting the sensor test the following is displayed Sensor test 0 01 Sensor ID Option Sensor designation 0 01 Option 255 255 Sensor setting Press the Feed or Cut button Apply button with ALX DPM PEM to select the individual sensors if present O For details refer to paragraph Sensor setting on page 35 im f the following message shows up a communication error occured between the CPU board and the motor driver board belonging to the sensor Sensor test No sensor found 03 10 Rev 5 04 01 01 0 02 0 03 0 04 0 05 0 06 0 07 0 09 0 12 Tab 5 a Precondition parameter SYSTEM PARAMETER gt Sens punch LS 3096 Option Option Press Matend Punch Heflex FullSz Cover H Temp SERVICE MANUAL 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Service Electronics Sensors on the CPU board 64 xx Sensor Description Typical Value Condition name 64
28. at the power supply with a voltmeter and compare the result with the value in the table in Maximum admissible deviation 0 2 V 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Characteristics HME power supply Inputs Characteristic Range of input voltage 100 240 VAC Admissible range of deviation 88 264VAC Frequency range 50 60Hz Admissible range of frequency 47 63Hz Tab 2 Characteristics of the input voltages Outputs Characteristic Outputs 1 2 3 4 Output voltages Unom 5V 24V 24V 48V Setting range 20 28V Output currents lhom 2 7A 6 3A 1 5A 5 2A Max output currents 10A 7 3A t lt 10s Pulsed output current 40A Ipuis 50 ED t lt 0 5ms Tolerance 2 5 5 10 5 10 Tab 3 Characteristics of the output voltages in The total power of the outputs 2 and 4 may not exceed 250W Output 2 May only be activated by an I C bus command AC output Characteristic AC output Output voltage max 250V AC Output current at 230VAC max 4A AC Output current at 110VAC 1A AC Tab 4 Characteristics of the AC output The AC output of the HME power supply is internally protected together with the power supply input by one single fuse 6 3A The input current of the HME power supply depends on the application as well as on the mains volta ge Therefore there can be drawn a maximum current of 4A AC at
29. auses I C bus errors and disturbs the printing operation Check carefully if a firmware update is required Update the firmware if this is required immediately after assembling the 500 into the printer 64 04 05 06 printers with Gen 2 electronics may be retrofitted with a ME500 power supply if the printer is updated to the appropriate firmware version e Recommended update to firmware version 4 32 e f an update to firmware v 4 32 is not possible different patches for older firmware versions are available Printer firmware Patch 4 00 h8R 4 00 s3b 4 10 4 11 4 12 h8R 4 11 4 12 s3b 4 21 4 22 4 30 4 31 4 22 4 31 s3b Tab 11 Patches for older firmware versions 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 NT400 A1680 Pin Function gt The NT400 is discontinued since 01 2008 It 1 24V is replaced by the ME500 see next chapter 2 GND a galvanically WARNING separated Fire hazard by overheating gt This power supply must not be applied with a dust filter A CPU board connection control signals Pin Function 1 NMI ICS ISK O TK KA KD KS 9 GND B Printhead connection Pin Function 20 28 V 20 28 V 20 28 V 20 28 V GND GND GND GND C CPU board connection supply voltage Logic O1 lt PO 1 Power supply NT400
30. e damaged by static charging or discharging CAUTION Place the printer on an earthed underlay before opening it CAUTION Earth your body with an ESD protective armband or by using N another suitable means If suitable ESD protection is not available touch an earthed object e g a radiator before touching a board im CAUTION Only place boards an earthed underlay Handling The conductor lines on modern multilayer boards are very thin Bending the boards can therefore easily break the conductor lines mm CAUTION Avoid bending the boards m CAUTION Avoid using excessive force when removing and installing the boards 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 CPU Boards JP301 Function J P 1101 Function Boot from U303 Boot 1102 Layout without Ethernet PROM ee Constant LED current at Boot from system flash dispensing edge sensor default Constant LED current at Sockel f r 8bit e e sensor Disp Rewinder Boot PROM Pulsed LED current at dis U 303 CAUTION Only for pro pensing edge sensor amp at duction purposes TAG Q sensor Disp Rewinder 15V at Cen interface CN 402 tronics pin 35 5V at Cen SO DIMM 144 socketfor socket tronics pin 18 memory extension U 701 Default 0201 Power supply USI board Display Data cable peripheral CN1301 CN1005 l CN902 1 bus CN
31. e of the LED current default 128 The number on the right side is the value measured by the sensor here 176 The reflex LS is an option If your printer is not equipped with a reflex LS skip this section by pressing the online button 13 Push the reflex mark on the label material over the reflex LS 14 Set the setting value to 95 5 The measured value should now match a range of 230 255 15 Position the label material with an area without reflex mark over the reflex LS The measured value should now match the range of 12 48 and lie at least 100 digits below the value measured with reflex mark If the measured value doesn t match this range please modify the setting va lue by pressing the Cut respectively Feed button 16 Press the online button to save this value By doing so the reflex sensor is ready set 03 10 Rev 5 04 01 Fullsize LS SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Now the settings of the Fullsize sensor are displayed Sensor adjust 128 Fullsz 154 The number on the eft side is the setting value of the LED current default 128 The number on the right side is the value measured by the sensor here 154 The Fullsize LS is an option If your printer is not equipped with a reflex LS skip this section by pressing the online button 17 Insert some backing paper of standard label material with the labels peeled off to check
32. ed Connector description CPU board 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Output stage board Important Notes in Please keep in mind the following points when you replace or check an out put stage board PIC version The PIC must carry a label with the writing MO4A V3 C73 Jumper setting The jumper setting must match the motor which is ought to be driven by the output stage Layout Connecting Sensor J 4 2 Optional additional sensor J 8 Feed motor dd _ T mn Em Motor 3 E um J7 e i 6 Dispenser motor I Control lines coming Eu Dis pue CPU board J ee B J2 12 Output stage for Marker at Marker at motor cable sensor cable no sensor RS Printhead motor HS Options motor OM OS Dispenser motor WM no sensor 1 By setting the jumpers you prepare the output stage board for application with the motor you intend to drive tab left side Connecting the cables Identify the right motor or sen sor cable by its marker on the cable sleeve tab below 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Connectors Picture Comp Type on board Diagr J4 PANCON MLAS 100 04 PANCON MLAS 100 04 Wieson 2120 14RS5 AMP 640389 6 Tab 2 Connectors on the output stage board Type at cable Pin assignment on AMP 643813 4 oder AUK MK 04H
33. ge e P8 connected Internal 5 V source can be used via the wire for external supply Sensors e jP8clear Wire can be used for an external 5 V source SIART PRINTA The machine starts printing depending on the setting of parame ter DP INTERFACE gt Start print mode Preconditions Printjob is available DATA RDY low printer is in online mode no error messages Feeding of the label material as long as the signal is low Mini mum feed quantity 1 label The display shows USI feed during feeding Preconditions for feeding e Offline mode printing has been stopped or the printer is in USI paused mo de Online mode and no print job loaded PAUSE A high low transition switches the printer into the USI paused mode A further high low transition switches the printer back into the on line mode If parameter DP INTERFACE Startprint mode is set to Level high active or Level low active any activating of the PAUSE signal stops the printing after the current label Features e USI Pause is displayed e 15 activ low e print job is available DATA RDY is inactive high Start print signals are suppressed Reprint requests are proceeded after switching into online mode e Precondition START PRINT inactive high Tab 4 Signal designations and functions of the USI interface 03 10 Rev 5 04 01 Pin Signal 6 REPRINT 7 24N EXT 8 EXT 9 WARNING 10 ERROR PRINT END H
34. l print 1 label Pause mode on Seen Pause mode off print 1 label reprint last label imprinting of the if not disabled previous label must stop feeding imprinting of the previous be finished labels label must be finished min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms 10ms min 10ms LL Start Print Puls mode both edges min 10ms e Feed min 10ms min 10ms Reprint Pause print 1 label print 1 label imprinting of the previous label must start feeding Store to reprint last label Pause mode off reprint last label print 1 label d ee print 1 label imprinting of the be finished if oe functionality is reprint last label imprinting of the previous label must stop feeding enabled previous label must must be finished labels No reprint because of be finished previo be finished 7 Examples of timing waveform for the USI inputs 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Start Print Reprint min 10ms min 10ms Pause 8 Signal timing to be met Circuit diagrams for signal outputs 47k a Output Controller 9 Main circuit NPN for signal outputs at the USI interface Max output current In the state of delivery jumper 8 closed cable A2059 connected the
35. nd into the hole in the plug housing Fig 3 The plug is locked now 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Index A USI board 9 13 AC output 34 L At 12 Locking clips for flat strap plugs 46 B M Block diagram USI 18 Memory Extension Option 42 Centronics 7 Option Board 44 CN300 USI board 24 Options 42 Connectors Options board installation 44 display 64 xx 27 Output current USI 20 display DPM ALX 28 on the CPU board 5 on the USI board 13 on USI board 10 CPU board jumper setting 3 p PIC version on USI board 9 Printhead voltage 33 R Realtime Clock 45 EU i RS 232 422 485 7 eret HS 422 485 termination option board 77 F RTC 45 Firmware USI 22 S H Sensor setting 35 Headvoltage 33 T Termination RS 422 485 option board 11 Internal inputs 16 Testbox 23 Internal inputs USI board 25 Timing waveform USI 19 Internal inputs USI pin assignment 16 U J USI 12 Jumper block USI 17 USI Signal description 14 Jumper on the CPU board 3 V Jumper setting V2 T1 F873 12 on Option board 11 Option board 11
36. oard Su er He CN 101 enh 9 MEC EUN rem pOSPezy APZ ISN 4 ER E 4 Li AT 000 h an oo 0001 SA 16 a Connector for in ternal USI inputs Function Power supply CN 300 5V internal voltage supply active on CN 100 Pin2 DB 15 5 V external voltage supply on P in 2 DB 15 Connectors Picture Typeon Typeat Pin assignment on board board cable AMP 640457 4 N C EXT GND Cable is 2 VCC 5V soldered VCC 95V to the Sel board SI V2 T1 F873 Tab 3 Connectors on the USI board 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Picture Comp Typeat Pin assignment on board board cable EE CN300 ANS 1 OD control material 2 Applicator homeposition error 3 Applicator touchdown error 4 SPS ready error 5 GND E HO a gt e Ut e e uU m oof ur D er c 7 15 MACHINE STATUS 8 GND_EXT E 7 24V EXT 7 14 DATA RDYY 6 REPRINT 13 RIBBON OUT n 5 PAUSE 12 MEDIA OUTl 11 PRINT END non 3 START PRINT 10 ERRORI 9 WARNING LC EAT 1 GND EXT Tab 3 Continued Connectors on the USI board Signal description D Sub 15 Pin Signal Function GND EXT Ground Ground contact 5V EXT Volta
37. on CN 300 Pin Signal Signal Function type OD control To be applied to the OD control material option material The signal WARNING at pin 9 of the DB 15 is switched activ if e Parameter DP INTERFACE gt Material Signal Activated and e the input is high Applicator If one of the inputs is high or makes a low high transition the appro fault home priate status message is displayed at the printer Additionally the position outputs ERROR and MACHINE STATUS will be activated low Applicator fault touch down PLC ready fault GND Ground GND potential of the internal inputs Tab 5 Signal designations and functions of the internal inputs Pin assignment jumper block Each signal of the D Sub connector can be interrupted separately at the jum per block The voltage and ground wires are through connected and cannot be interrup ted see Fig 4 GND MACHINE STATUS REPRINT 24V DATA RDY 4 RIBBON OUT wil PAUSE NN MEDIA OUT S FEED E PRINT END START PRINT 5V GND WARNING ERRORY APPLICATOR MODE 4 Pin assignment jumper block SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 03 10 Rev 5 04 01 Block diagram USI Block Diagram SPS Connectors 5 Block diagram of the USI CN300 G
38. punch may be recognized as material end If this is the case adjust 8 the setting once more Press the online button to save the setting value Now the settings of the punch sensor are displayed Sensor adjust 70 Punch 12 The number on the eft side is the setting value of the LED current default 70 The number on the right side is the value measured by the sensor here 12 Insert some backing paper of standard label material with the labels peeled off to check the sensor measurement Inserting material means here inserting a material sample into the LS fork The material sample must be big enough to cover the LS 10 Set the setting value to 75 5 by pressing the Cut or Feed button respectively The measured value should match the range of 11 25 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 11 Insert standard self adhesive material paper label on backing paper into the printer The value measured now should count at least 100 digits higher than the va lue measured with bare backing paper If the measured value doesn t match this range please modify it by pressing the Cut respectively Feed button 12 Press the online button to save the setting value By doing so the punch sensor is ready set Reflex LS Now the settings of the reflex sensor are displayed Sensor adjust 128 Reflex 176 The number on the eft side is the setting valu
39. r i Punch sensor PS CN 1501 BR EA ONE oma CN 1105 D o NA Reflex sensor RS uae CN 1106 LINES N rn 4 3 mie Fullsize sensor FSS Centronics MESSEN E Eme ge m N 1107 CN500 MEE oat Ry S inglestart sensor H L T ed om r mutter NN i N 1108 SOT MITIS Le is i c Za M gt gt u 44 E ue T MES wee Cover sensor COS CN 1109 z Power supply mS UO Bee CN 1004 Internal scaner CN 1006 RS 232 CN 601 4 Motor output stage a p 0 bus CN 1001 CAUTION Only for produc tion purposes H8 PRG Adapter CN 1002 Option board CN 602 Printhead CN 901 RS 422 485 termination R xD abit boot bus width for CAUTION only 4 RS 422 485 termination TxD 0303 Boot PROM purposes 16bit boot bus width RS 232 no RS 422 485 termination default H8 RX1 RS 232 level default H8 RX1 TTL level de CAUTION Line termination in RS 485 mode fault 2 wire interface close either P 601 or J P 602 4 wire interface close J P 601 and J P 602 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Connectors Picture Comp Typeat Pin assignment on board Diagram board cable I2C Motordr Bus CN1001 CN 1002 CN1003 PANCON MLS
40. release mo tor sensor at the 64 xx dispenser lt 10 Light barrier clear Tab 10 Testbedingungen fur Sensoren die an eine der Endstufen Platinen angeschlossen werden Sensors on the output stage boards ALX DPM Sensor Beschreibung Typische Bedingung Name Werte 2 01 Folie Foil sensor 0 Sensor above a hole in the oscilla tor disc light barrier clear 254 Sensor covered 3 01 Kopf Light barrier at the prin 0 Printhead in economy position thead raising mechanism raised 254 Printhead in print position lowered Tab 11 Testbedingungen f r Sensoren die an eine der Endstufen Platinen angeschlossen werden 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Options Installing a Memory Extension Requirements 64 xx DPM PEM or ALX 92x with CPU board no A2292 or A2293 installed Upgrade kit for 32MB memory extension no A4413 or Upgrade kit for 64MB memory extension no A4414 The upgrade kit contains a bag with the memory module fig 1 and an installation guide Installation Proceed as follows to install the memory module 1 Remove the CPU board from the printer How to Read topic section Service Me chanics chapter Replacing the boards board 2 Take the memory module out of the bag The slot for the memory module is located in the upper third of the CPU board fig 2 white circle ET n EM cres
41. ting the RTC 1 Call the parameter SYSTEM PARAMETERS gt Realtime clock e Realtime clock af dd mm yyyy hh mm D Shows up on the display E CNN di BEB st in nem j Miel en E With dd day mm month yyyy year hh hour mm minute 2 Key in date and time Cut ALX DPM PEM Apply moves the cursor Feed changes the setting and Online saves it iinit d Q 4 LIE Ine o M a ES a xt E u l 12 2 T T E n ol IL TD 42292 00 03 10 Rev 5 04 01 SERVICE MANUAL 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Attaching locking clips for flat strap plugs An unfavourable combination of installation position and load may loosen the on board flat strap plugs inside of the ALX 92x and DPM PEM An appropriate countermeasure are the follwing locking clips A5386 14pin A5387 20pin Those clips must be attached to all flat strap plugs inside of ALX 92x and DPM PEM machines m Exception Flat strap plug at the printhead To attach the clips Hang the clip 1 into the hole in the plug housing 2 Fig 1 2 Use the tweezers to pull the clip end over the plug Fig 2 O Continued overleaf SE Tweezers or flat pliers Service Electronics 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 3 Snap the clip e
42. will trigger the material warning repeatedly until the roll diameter falls below a certain tolerance zone This signal is only a warning what means that the printing goes on This output is activated low during every status which keeps the printer from printing USI pause mode stopped mode offline mode hood open ma terial end no punch recognized pressure roller open ribbon end and other failures which avoid printing During the initialization of the printer the output is inactive high The manner in which this output is switched depends on the set 1 ting of parameter DP INTERFACE End print mode Difference to older versions of printer firmware below 2 46 The output is now also activated as long as labels are fed Limitation This functionality is not available in Batch mode Printer operation with LTSI applicator with PLC version 5 0 and higher Applicator is in home position upper limit position Tab 4 Continued Signal designations and functions of the USI interface 03 10 Rev 5 04 01 MEDIA OUn RIBBON OUn DATA RDY MACHINE STATUS SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Function Low in case of material end Additionally activated are ERROR MACHINE STATUS Low in case of ribbon end Additionally activated are e ERROR MACHINE STATUS This signal is activated low if the printer has finished image pro cessing and is read
43. y to start printing The signal is inactivated if e the print job is done the printer is switched to stopped mode offline mode or USI pause mode This output is activated low if the printing has been interrupted by a disturbance or an error Examples are Pressure roll open hood open ribbon or material end error start print error or another fault that avoids printing The output is also activated during the initialization of the printer In comparison to ERROR MACHINE STATUS is not low if the printer has been switched to offline or pause mode Printer operation with LTSI applicator with PLC version 5 0 and higher No function Tab 4 Continued Signal designations and functions of the USI interface PLC OD sensor Pin assignment internal inputs CN 300 The following parameter settings are required to make the internal inputs useable For usage with PLC DP INTERFACE gt Interface type USI Applicator DP INTERFACE Internal inputs Enabled For useage with OD sensor material DP INTERFACE Material signal 2 Enabled DP INTERFACE gt Internal inputs Enabled If PLC and OD sensor material are ought to be used all three parameter settings have to be done m To all four inputs applies The input is inactivated if it is connected to ground potential 03 10 Rev 5 04 01 SERVICE MANUAL Service Electronics 64 xx Gen 2 DPM Gen 2 ALX 92x Gen 2 Signal descripti
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