Applies to the following machines: ALX 924 ALX 924 AI
Contents
1. 27 Dust filter at the DPM PEM B 28 Filter liner A 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x ALX m The dust filter is an optional accessory Tool Screwdriver 1 Turn the screw 29A by a quarter turn Re move the cover 29B 2 Replace the liner part number for 5 liners A2581 3 Reassemble the filter housing cover Turn the screw 29A by a quarter turn 30 Filter housing removed 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x ALX 92x Al Pro Fuse replacement Tool Screwdriver medium size Fuse type T2AH 250 V Article number A8676 WARNING The device operates using mains voltage Touching electrically live parts may expose you to hazardous electrical currents and may lead to burns The device can only be completely disconnected by unplugging both power cables Switch off the device and unplug both power cables before removing the fuse insert 1 Switch off the device Remove both power plugs 2 Remove the fuse insert 31A to the left of the power connector 3 Remove the fuse 32A from the insert and replace it by a new one 32 Fuse insert removed 09 09 Rev 5 03 02 USER SERVICE MANUAL DPM Gen 2 3 PEM ALX 92x Gen 2 3 Technical Data Device types USC rrrnrrnnnrrnnrnnnnrnnnrnnnnnnnnnnnnnn 2 Ambient conditions 0062. PEM ALX 92x Gen 2 3 09 09 Rev 5 03 02 ALX 92x 380 5 4 5 412 7 6 309 60 205 8 4 5 238 0 6 167 50 206 4 5 la 153 50 gt l 260 6 A v m Q kem gt m wy v LL TER FS 305 75 d 5 Dimensions of the ALX 92x L version Dimensioned drawings of the ALX 92x in DXF format Autocad can be found on the Documentation CD in directory Dimensional Drawings Weight Machine Weight DPM PEM 45 17kg DPM PEM 6 18kg ALX 924 925 35kg ALX 926 39kg ALX 924 925 Al Pro 38kg Tab 2 Weights of DPM PEM and ALX 92x 09 09 Rev 5 03 02 USER SERVICE MANUAL DPM Gen 2 3 PEM ALX 92x Gen 2 3 Machine Weight ALX 926 Al Pro 42kg Tab 2 Weights of DPM PEM and ALX 92x Technical Data 09 09 Rev 5 03 02 Print technology Print head Resolution Print speed Print width USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Performance data Thermal direct printing thermal trans
3. 2 line 32 figure illuminated LCD display 5mm character height e DPM Gen 3 PEM ALX92x Gen 3 5 key control panel graphical 128 x 32 Dot illuminated LCD display Definition of parameters using menu or Easy Plug commands Status messages Test functions Printouts for parameter settings adding logo and font line and bar code library Print tests test routines for memory and sensors interface test Display of error reports on the display continuation of print jobs without label loss Ribbon roll nearly used up Checks the printhead on defective dots automatically or manually 09 09 Rev 5 03 02 CE TUV GS EMV FCC USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Test certificates The devices conform with the following EC directives e EMC Low voltage For details refer to the EC Declaration of conformity T V GS test certificate Tested safety according to EN 60950 00 The EMC test was made according to the following norms EN 55022 Class A EN 55024 e EN 61000 3 2 e EN 61000 3 3 e EN 61000 6 2 m The norm EN 55022 prescribes the following warning note to be included in the operation manual for devices of class A Warning This is class A equipment This equipment may cause radio distur bances if it is used in a living area in those cases can be demanded of the manufacturer to carry out appropriate measures m FCC Regulat
4. General Notes The unit consisting of the thermal head 2A and thermal head holder 2C will henceforth be referred to as the printhead 1 CAUTION The position of the A N thermal head on the thermal head holder is set at the factory with optical aids gt For this reason always completely replace misaligned printheads and if 1 Printhead necessary send them in for resetting CAUTION Electrostatic discharges DE or contact with sharps edges can damage the printhead a gt Protect the printhead from electrostatic discharges when performing maintenance work or cleaning Avoid touching the thermal edge 2B printhead with bare hands as much as possible Do not allow sharp objects to 2 Printhead side view come into contact with the termal A Thermal head B Thermal edge edge C Thermal head holder If you do not have any professional ESD pro tection equipment ESD wristband ESD shoes place one hand on an earthed object near to you e g tap or radiator before touching the device to discharge any static charge your body may be carrying 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Cleaning the printhead WARNING During operation the printhead can become hot Care should be taken when touch ing the printhead Impurities such as lint and colour particles from the thermal transfer ribbon may collect on the printhead duri
5. ALX 92x Inserting ribbon WARNING A N Rotating parts can trap items and draw them in When working on the printer do not wear loose jewellery long sleeves long hair and similar gt Close the devices cover before printing During operation the printhead can become hot Be careful when touching the printhead m Skip this section if you intend to print directly onto thermal material O For information on choosing a suitable thermal transfer ribbon refer to section Selecting the printing material on page 4 Removing spent ribbon CAUTION If the diameter of the A N ribbon wound on the take up roll becomes too great the machine s operation will be impaired Always remove a used ribbon before inserting a new ribbon roll Assuming spent ribbon has gathered on the rewinding mandrel 1 Remove the roll of used ribbon from the rewinding mandrel 2 Pull the empty ribbon core off the unwind ing mandrel and put it on the rewinding mandrel 3 Put the ribbon roll on the unwinding mandrel 4 Insert the ribbon as described in the fol lowing 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Inserting a new ribbon roll 1 Open the hood 2 Putthe ribbon roll on the lower right ribbon mandrel 15C Put an empty take up roll on the upper left ribbon mandrel m The ribbon must unwind anti clockwise Only valid for ribbon rolls which have the coloured side facing inw
6. chapter Replacing the printhead D on page 68 10 The printhead resistance can be found on a label on the printhead itself Checking the print head Both DPM PEM and ALX 92x are equipped with a test function which tests the functionality of every single dot dot check There are two different modes of operation with three different possibilities to start a dot check Dot check modes Call by Automatic execution after powering on or in ee pau To activate the automatic refer to parameter SYSTEM gt Autom dot chec Automatic dot check Easy Plug Add an optional D to the obligatory ER command gt ERD to trigger a dot check at the end of the print job OE Se are ence ee and the location of the defective dots Parameter Percheckon demand Dot check with ee a ryker sell which visualizes the test result Parameter PR In Off line mode by pressing the Apply Feed buttons Equals the call by parameter Head dot test but without the status report Defective dots are displayed by status messages Tab 1 Starting a dot check 05 09 Rev 5 02 01 USER MANUAL DPM PEM ALX 92x Display message Display of a detected defective dot Status 5103 Dot defective If all dots are faultless no display message ap pears lf the status message appears the current print job is stopped Duration All five ways of dot checking test the entire printhead width Therefore the test pr
7. i 20 Setting the label sensor A Dial B Adjustment wheel Materialmuster Sample 8533 100 A AVERY 21 Measuring the punch position A 06 06 Rev 3 05 01 OPERATING MANUAL ALX 92x Adjustment button for printhead pressure The material width and or material thickness influence the pressure applied by the thermal transfer printhead on the print roller There are three possible settings for pressure 23 Setting for thin narrow material ll Setting for material of medium width thickness III Setting for thick broad material Setting The red adjustment knob 22A 23 is located above the ribbon roller in the front plate and can be adjusted with a coin or large screwdriver To set medium pressure turn the arrow 23A to position ll until it slots gently into place To set a higher pressure turn the arrow to position Ill until it slots gently into place CAUTION Failure to set for the A N correct pressure causes the printhead to wear down more quickly and leads thus to a shorter service life Always select the lightest possible pressure necessary to produce an acceptable print result gt Excessive pressure can lead to the premature wearout of the printhead Factory settings Setting l for thin narrow material Setup 23 A Adjustment knob for the printhead pressure 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX
8. 1 Turn thumb screw 3A loose and swivel guide rod 3B aside 2 Push the material roll onto the unwinder 3C with the appropriate adapter rings The material roll should turn in an anti clockwise direction when unwinding 3 Swivel guide rod to the unwinder axle as illustrated 3 and shift it close to the mate rial roll Tighten the thumb screw again i f e Fl a 3 ALX92x with half used up label roll 4 Lay the material around deflection rollers 4A and dancer arm 4B A O Continued overleaf o A 2 4 Threading the label material around deflection rollers A and dancer arm B 06 06 Rev 3 05 01 OPERATING MANUAL ALX 92x 5 Open the front cover 6 Set the material guide to the width of the label material To do this loosen the thumb screw 5A at the front material guide shift the material guide 5B crossways to the feed direction and tighten thumb screw again m The label material should slide easily between the material guides Press the opener 6A to raise the contact rollers 6B Push the beginning of the label material through underneath the con tact rollers and the print head 8 Position the contact rollers while pressing down the opener 7 m Both contact rollers should press down the material symmetrically O Continued overleaf 5 Adjusting the material guide B l r 7 Positioning the contact rollers Set
9. 92x Dispensing edge By inclining the dispensing edge the dispensing position can be fine adjusted without having to change the machine position 1 Undo the screws 24B on both of the side mounting plates Access the screws from beneath Tool 2 5 mm Allen key 2 Turn the dispensing edge 24A to the desired position 3 Tighten the screws 24 Long dispensing edge option feed roller disassembled for better viewing Dispenser parameters Set the following parameters prior to first operating the machine Determines sequence of the printer dispenser process normal 1 1 mode batch mode or true 1 1 mode Dispensed label Dispense position Pa Setting the adhesive edge with which the label after dispensing adheres to the backing paper 25 Dispensing edge Setting the trigger signal source for the TETERE printer dispenser process foot switch sensor or USI 25 Dispensing position home position shown schematically O For details on how to set parameters refer to Information on printouts and parameters in the Using the Parameter Menu section 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Material Parameters Using the following parameters you can tell the device which kind of labelling material is supposed to be processed Sets material type punched or endless Sets material length measured from label start to label start that is label length plus one gap lengt
10. Technical Data Optional Universal Signal Interface USI 24 V signal voltage m The USI board can not be installed if an Al board is already installed Optional Applicator Interface Al Controls nearly every applicator type m The Al board can not be installed if an USI board is already installed Connection for remote operation panel Mini DIN 6 RS 485 Optional Connection for Avery applicators via USI SPS or Al Pin assignments can be found in topic section Electronics Electronics DPM Gen 2 ALX 92x Gen 2 m This section counts for machines which are equipped with CPU boards A2292 or A2293 64 Bit IDT MIPS 16 MB extendable to max 80 MB 2MB Slot for CompactFlash cards T1 up to 128 MB Optional Electronics DPM Gen 3 PEM ALX 92x Gen 3 m This section counts for machines which are equipped with CPU board A6621 32 Bit AMD MIPS 64 MB 4 MB e 1 Slot for CompactFlash cards I II standard 1 Slot for CompactFlash cards I II optional e 1 Slot for SD MMC cards standard is not supported yet Standard External Sensors Connection to USI or Al m Only for ALX 92x Connection to USI 09 09 Rev 5 03 02 Operation panel Settings Test printouts Test functions Error reports Warnings Dot check USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Operation e DPM Gen 2 ALX92x Gen 2 4 key control panel
11. Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 DPM 6 Consider the following critical points when building a rewinding unit for the DPM e The rewinder must be fast enough to rewind the backing paper tight even when printing at high speeds e There must always be a light tension on the backing paper ALX 926 Material width in mm up to 184 160 130 100 max print speed s given a 4 core 10 10 12 12 max print speed s given a 3 core 8 9 10 12 max print speed s given a 1 5 core 7 9 10 12 Tab 11 Maximum print speed for material rolls with 300mm outer diameter depending on the material width as well as the core diameter Material width in mm up to 160 130 104 80 55 max print speed s 12 12 12 12 12 max print speed s with activated ribbon autoeconomy function 10 10 12 12 12 Tab 12 Maximum print speed for foil rolls with 600m length depending on the material width Material width in mm up to 160 130 104 80 55 max print speed s 10 10 12 12 12 max print speed s with activated ribbon autoeconomy function 6 6 8 10 10 Tab 13 Maximum print speed for foil rolls with 1000m length depending on the material width CAUTION Disregarding the following notes may cause the machine to work unproper Do not heat up more than 50 of the print head dots at a time This me ans that lines which are running crossways to the p
12. position 1 1 0 mm 300 Distance punch printing position Punch position Printing position 2 I I I I I I I I I I I I I I Punch a Printing direction I I I I I 7 Impression accuracy in printing direction depending on the printing position 1 1 and 100 printable Non printable areas Z00521E cdr Label 1 mm from the front label edge 1st edge in feed direction e 1 mm from the left band border right border in feed direction Easy Plug Line Printer Hex Dump e 17 Fixfonts including OCR A and OCR B e 3 scalable fonts Truetype fonts are supported Scaling in X Y direction up to factor 16 Rotation Resident fonts bar codes lines and graphics 0 90 180 270 degrees e Truetype fonts 0 to 359 9 degrees 09 09 Rev 5 03 02 Bar codes 2 dimensional bar codes GS1 Databar amp CC bar codes USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Codabar Code 128 A B C Code 128 Code 128 UPS Code 128 pharmacy ITF Code 2 5 matrix MSI Code 2 5 interleaved EAN 13 add on 2 Code 2 5 5 line EAN 13 add on 5 Code 2 5 interleaved ratio 1 3 EAN 128 Code 2 5 matrix ratio 1 2 5 Postcode guide and identity code Code 2 5 matrix ratio 1 3 UPC A Code 39 UPC E Code 39 extended Code 93 Code 39 ratio 2 5 1 Code 39 ratio 3 1 All bar codes scalable in 30 different w
13. up to 300 mm s DPM and ALX 92x are both available in a righthand RH as well as a lefthand LH version Distinguishing feature e LH version Printed Labels leave the machine on the lefthand side line of vision towards the display RH version Printed Labels leave the machine on the righthand side line of vision towards the display DPM Dispensing Printing Module DPM Monotone printing on labelling materials for thermal and thermotransfer processes Requires labelling roll material Dispensing of the printed labels e Mounting into the cutout of an appropriate plate PEM Print Engine Module PEM e Same features as the DPM but without label dispensing and backing pa per rewinding function ALX 92x Dispensing printing machine based on the DPM Same features as the DPM with separate labelling material unwind and rewind unit Mounting on a tripod ALX 92x Al Pro contains additionally Applicator Interface Al Pro for a maximum over all output current of 4A Separate power supply for the Applicator Interface 09 09 Rev 5 03 02 Realtime clock USI board Applicator Interface Al Applicator PLC Options board OD control USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Options DPM Gen 2 ALX 92x Gen 2 m This section counts for machines which are equipped with CPU boards A2292 or A2293 To add any production dates to the labe
14. EE oe ee ere ee 2 Interfaces DPM Gen 2 DPM cenisdeeanleavstocsmcoiciermsntniescetanameten 2 ALX92x Gen 2 cece PEM oooeecccseccccesesesesesssceeesssseresteeesteseeteneass 2 Interfaces DPM Gen 3 PEM PEO EE ENE E 2 RE RE E a Options DPM Gen 2 ALX 92x Gen 2 3 eS nag Gen 2 Ont DPM Gen 3 PEM EE SE a Electronics DPM Gen 3 PEM ALX 92x Gen J PE 4 o ALX 92x Gen 3 umesmseunesennsn Technical specifications rrrrarerrrrnrernevnrene 6 External Sensors rrrarerarevnnrnnn Ba sisausarpscannahasasnrsipransieemnneysnenet 6 0 Performance data rrrnnornnrnrnnrrnnnovanennnvennn 8 er er ee sty i a Automatic ribbon economy arrrnnnrrvnnrnn 12 iig ko pr Test certificates rrrrrrnrernrerenens Labelling material ccccsecseeeeeeees 14 Pee Thermotransfer ribbon rrrrrrnrrnnnrnnnrnne 15 ur TT TN sec wo ee os r repr ND Connection device data rarnnnnnannnnnnnnr 16 09 09 Rev 5 03 02 USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Device types use Print width Resolution Print speed RH LH General Notes DPM PEM and ALX 92x are available in two housing widths and three print width max 106 127 or 160 mm Machines with 106 or 127 mm print width come in a narrow housing those with 160 mm print width come in a wider hou sing 300 dpi Machines with 106 127 mm print width up to 400 mm s Machines with 160 mm print width
15. N If huge ribbon rolls run length of 1000m are supposed to be used with activated ribbon economy function there is a hazard of the ribbon tearing off gt Consider the limitations according to Tab 6 and Tab 7 Read Limitations on page 23 for details See Automatic ribbon economy on page 13 for details 09 09 Rev 5 03 02 Ribbon width Dispensing edge Label drive Label web tension Ribbon tension Label sensor adjustments Material unwind Material rewind Protection category Mains voltage Mains frequency Power consumption Input current Operating temp Storage temp Humidity Protection class Noise USER SERVICE MANUAL DPM Gen 2 3 PEM ALX 92x Gen 2 3 Technical Data The ribbon should overlap the label material some milimeters Mechanical features DPM ALX 92x only Adjustable for direct or indirect dispensing mode Forward and backward movement of labelling material for real 1 1 applications and full size print of labels DPM ALX 92x only Easy to adjust patented reliable friction mechanism Adjustable by disc brakes at the unwind and rewind mandrel Mechanical via thumb wheel with position indicator electronical setting via dis play function ALX 92x only Dancer arm for smooth unwinding of labelling material label reel unwind with integrated friction brake ALX 92x only Stepper motor driven rewind mandrel Connection devic
16. PM ALX 92x only Maximum admissible weight of the wound up backing paper 5kg ea A A A B Te ea EEE C gg ene 9 Material measures A Material width B Label width C Label length Materi Machine al width Label length DPM 4 5 16 136 5 1000 DPM 6 16 190 PEM 4 5 16 136 10 1000 PEM 6 16 190 ALX 924 925 16 130 pe 5 1000 ALX 926 16 184 Tab 8 Label measures in mm 09 09 Rev 5 03 02 USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Punch measures 10 Punches and reflex marks at different material types A Punch position B Reflex mark position PEM only C Punch length D Punch width E Reflex mark length F Reflex mark width Item Machine Punch dyder mark 7 4 5 2 80 Position mm 10A 10B 6 2 100 2 100 Length mm all 0 8 14 10C 4 10E Width mm all min 4 10D 12 10F Tab 9 Measures of punches and reflex marks Thermotransfer ribbon Ribbon type The following recommendations are given for thermotransfer ribbons The ribbon reverse must have an anti static and friction reducing coating backcoating Ribbons must be specified for Near Edge Type Print Heads Ribbons should be suitable for print speeds of up to 12 inch sec Ribbon roll Max outer 105mm equals 1000 m Avery 2240 standard ribbon on a 40 2 mm ribbon core Inner 1 25 4mm or 1 6 40 2mm 0 2 with ribbon mandrel adapter CAUTIO
17. USER MANUAL Applies to the following machines ALX 924 ALX 924 Al Pro ALX 925 ALX 925 Al Pro ALX 926 ALX 926 Al Pro Fig ALX 924 left version Shipped version may deviate from the pictures AVE RY DENNISON 06 06 Rev 3 05 01 OPERATING MANUAL ALX 92x Setup Winding pattern 2 mesvadenss dnnamiinesteide 2 Inserting ribbon secsiccicctecetecendetedarcenechacewset couse 11 Selecting the printing material 4 Removing spent ribbon rrranrnnnrnnnrnnnnnnn 11 Thermal transfer direct thermal printing 4 Inserting a new ribbon roll rrannnnnnnnnnn 12 Es TN 4 Settings sc ceteca aan areesiesgeee conden caaiteosesocentacipnen se 13 Thermal transfer ribbon cccceeeeees 5 Ribbon tension EE EE 13 Inserting label material rrrurrnnrrnnrrnnrnnnnnnr 6 Label sensor SEE NER 14 Removing spent backing paper 6 Adjustment button for printhead pressure 15 Removing glue residue EE 6 Dispensing edge rrrrnrnnnnrnrrrrnrrreverervrrrens 16 Inserting a new label roll rvrrnnnnevnnnnnn T Dispenser parameters cccccceseeeeeeees 16 Material Parameters cccccsseeseeees 17 10 gt REN 18 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Winding pattern The winding diagram shows the winding direction of material and ribbon through the ALX 92x gt Follow this basic scheme when inserting changing material and ribbon us Only spec
18. X 92x Print A brake B and feed roller C are accessible from the devices bottom side 12 PEM Print A and feed roller B looked at from the bottom side 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning PEM Pressure roller ND a Remount the printhead into its former posi Reassemble the guiding section and fix it DPM PEM ALX 92x WARNING During operation the printhead can become hot Care should be taken when touch ing the printhead Switch off the device Pull out the mains plug Remove material Remove screw 13A use a3 mm allen key Remove the guiding section 14A to the side If the printhead is neither positioned com pletely to the right nor the left mark the po sition of the printhead on the axle Loosen both wing screws 15A at the print head Remove the printhead 15 from the axle Moisten a dust free cloth with roller cleaner part no 98925 and wipe the pressure roll er with it Gradually rotate the roller until it is completely clean tion with the screw m Make sure to feed the right one of the two guiding noses 16A into the groove at the guiding section 15 Printhead removed from the printhead axle A Wing screws B Pressure roller 16 Guiding noses A at the photoelectric switch fork 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Deflection rolle
19. ansfer Ribbon 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Inserting label material WARNING e Rotating parts can trap items and A N draw them in When working on the device do not wear loose jewellery long sleeves long hair and similar gt Close the devices cover before printing During operation the printhead can become hot Be careful when touching the printhead Removing spent backing paper The backing paper rewinder can exactly rewind the amount of backing paper remai ning from a material roll with 300 mm dia meter 2A A CAUTION A backing paper roll exceeding the diameter limit can stall and damage the machine Always remove the backing paper from the rewinder if you insert a new material roll Assuming backing paper has gathered on the rewinder 1 Pull out the release button 2B The tensioning mechanism of the rewinder is slackened 2 Remove the rewound backing paper Removing glue residue gt f necessary clean the following compo nents Printhead e Dispensing plate Deflection rollers Drive roller Pressure rollers O Follow the directions provided in topic sec tion Maintenance and Cleaning 2 Removing rewound backing paper oO 1 Rewound backing paper on the ALX 92x A fn A Backing paper roll B Release button 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Inserting a new label roll
20. ards 3 Guide the ribbon end under the ribbon deflection 15B and thread through to the side of the printhead 15A 4 Pull the ribbon under the printhead from the side then unwinding some ribbon smoothen it out 16 5 Draw ribbon upwards and guide it around the ribbon roller 1 7A the ribbon deflec tion roller 1 7B and the strain relief 170 6 Attach the ribbon end to the empty take up roll Winding direction clockwise 18A ea 10 17 A Ribbon roller B Ribbon deflection roll C Strain relief 18 Winding direction of ribbon rewinding mandrel A 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Settings Ribbon tension To achieve an optimal print result the ribbon has to run without creases This is achieved by correctly setting the torque for the rewinding mandrel and the braking torque for the unwinding mandrel The factory settings cover a wide range of different ribbon widths Nevertheless adjustment can be necessary if very narrow or very wide ribbons are being used The braking torque of the ribbon mandrels can be set by adjusting the red hexagonal plastic nuts 19A on the ribbon mandrels Turn clockwise to increase the torque Caps 19B protect the nuts against being adjusted by accident The ribbon must run evenly and free of creases between the mandrels while being fed through The following indications can help you correct the settings The ribbo
21. e best adhesion Unsuitable ribbons can lead to poor printing results O Further information can be found in the topic section echnical data section Label material 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Thermal transfer ribbon The following is recommended for thermal transfer ribbons The back of the ribbon should be coated so that it produces no static or friction Backcoating If this isn t the case the printhead may be damaged by static discharge coming off the ribbon surface The ribbons need to be designed for corner edge printheads Ribbons should be able to handle print speeds of up to 400 mm s 16 ips Size of the ribbon roll The following dimensions need to be checked outside inside diameter of the ribbon roll ribbon width CAUTION Thermal transfer ribbons without these properties can degrade the performance of the printer and the print quality as well as damage the printhead Armor APR 600 Avery part no 2240 600 xxx is a recommended ribbon type m The thermal transfer ribbon should only be slightly wider than the label material If an overly narrow ribbon is used the border of the label material interferes with the printhead which wears it down more quickly If an overly wide ribbon is used creasing may occur in the ribbon This can led to poor printing results For more details on the permissible dimensions of ribbon rolls refer to Technical data Thermal Tr
22. e data 100 240 V AC 60 50 Hz 450W 3 5 1 5A ALX 92x Al Pro e 2 0 1 2 at connection Mains 1 e 1 5 0 7 A at connection Mains 2 Ambient conditions 5 to 35 ALX 926 5 to 30 C 20 to 70 C 45 to 75 non condensing IP 21 70 dB A 09 09 Rev 5 03 02 USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Interfaces DPM Gen 2 ALX 92x Gen 2 m This section counts for machines which are equipped with CPU boards A2292 or A2293 e Parallel interface Centronics Bi directional mode nibble mode conforms with IEEE 1284 Serial interface Com1 RS 232 or RS 485 422 Selectable in the parameter menu Max baud rate 115200 Optional 2 serial interface Com2 RS 232 Max baud rate 115200 Optional Ethernet Interface integrated on CPU board RJ 45 10 100 Base T with TCP IP LPD RawlP printing DHCP HTTPD FTPD SNMP Optional Universal Signal Interface USI Optional Applicator Interface Al controls nearly every available applicator type PS 2 keyboard connector for use in standalone mode and for input of va riable print data optional board Optional Connection for Avery applicators via USI SPS or Al 09 09 Rev 5 03 02 USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Interfaces DPM Gen 3 PEM ALX 92x Gen 3 m This section counts for machines which are equ
23. ectronics Gen 3 chap OD control sensor ALX D on page 42 09 09 Rev 5 03 02 2 CompactFlash slot USI board I O board Applicator Interface Al Applicator PLC Applicators RFID read write unit USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Options DPM Gen 3 PEM ALX 92x Gen 3 m This section counts for machines which are equipped with CPU board A6621 m The optional boards can not be combined arbitrarily Tab 1 Q C Boards O T O V LL LL O lt x O am Centronics no yes yes yes yes I O NO yes yes yes yes USI yes yes no yes yes Al yes yes no yes yes CF yes yes yes yes yes RFID yes yes yes yes yes Tab 1 Compatibility of optional interface boards yes compatible no not compatible Available as option on a separate daughter board See Service Manual topic section Electronics Gen 3 chap CF daughter board on page 11 Universal Signal Interface USI board with 24V signal voltage and 4 inputs as well as 7 outputs A USI test box is available For details refer to the service manual topic section Electronics Gen 3 chap USI Board I 1 on page 16 D Sub 9 jack second serial interface for RS 232 422 485 selectable by parameter setting max baud rate 115200 e D Sub 15 jack providing I O signals similar to the USI For details refer to the service manual topic secti
24. ed material feed on the print module It is necessary to regularly clean the photoelectric switch of material and dust particles The cleaning intervals are dependent on the materials being used Clean the material end photoelectric switch with compressed air compressed air can be or dered in acan as an accessory m Additionally clean it using cleaning fuel and a dust free cloth if it is particularly dirty GR z _ ll i i 25 Material end photoelectric switch A on the inner material feed 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Cleaning the foil path Parts which contact the foil must be cleaned regularly The following intervals should be considered weekly or after 5000 m of foil 26 Parts which may be soiled with foil residue A Ribbon roller B Deflection roller stress relief C Deflectioin axle D Deflection nose at the printhead 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Replacing the dust filter liner CAUTION An exhausted filter liner can cause the power supply to overheat and the device to break down Replace the filter liner regularly at least in monthly intervals DPM PEM Tool Medium size philips screwdriver 1 Remove the screws 27A and the filter housing 27B 2 Replace the liner 28A part number for one liner A2236 3 Remount the filter housing
25. fer printing Near Edge Type print head high definition fast with integrated temperature control easy to replace 12 Dot mm 300 dpi Machine Print speed Print width DPM 4 PEM 4 50 bis 400 mm s 16inch s 106mm ALX 924 DPM 5 PEM 5 50 bis 400 mm s 16inch s 127mm ALX 925 DPM 6 PEM 6 50 bis 300 mm s 12inch s 160mm ALX 926 Tab 3 Print speed and print with of DPM PEM and ALX92x Unit interval 5 mm s or 1 inch s 0 2 inch s with Easy Plug PR command CAUTION Disregarding the following limitations will have negative effects on the print result and or on the machine function Devices with 6 print width The maximum print speed of 300 mm s can only be used under certain limitations Limiting factors are e Material width Core diameter of the material roll Diameter of the ribbon roll See Tab 12 to Tab 13 If huge ribbon rolls run length of 1000m are supposed to be used with ac tivated ribbon economy function limitations of both print speed and ribbon brake setting must be considered Disregard of those limitations can cause the ribbon to tear off See Tab 6 and Tab 7 09 09 Rev 5 03 02 Pull in force pull out force Punch detection USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 DPM PEM only Pull out force a Pull in force 6 Pull in force schematic mm The maximum difference between p
26. gt Always comply with the safety guidelines for using flammable liq uids gt Do not smoke while servicing the device 1 Moisten a lint free cloth with solvent and wipe the thermal transfer printhead with it 6 Cleaning the printhead with an alcohol based solvent 2 After cleaning return the print head mount ing to its old position and retighten the thumb screws m Press the thumb screw on the tapered edge of the square axle and ensure the ex act positioning of the print head mounting on the axle m Pay attention to the position of the print head in relation to the edge of the label Factory set printhead position Flush against the inner black plastic plug 3 Before switching on the device check whether the printhead cable is still properly connected If this is not the case plug in the cable correctly 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Changing the print head The printhead can only be replaced completely as illustrated 7 WARNING During operation the printhead can become hot Care should be taken when touch ing the printhead Switch off the device Pull out the mains plug Remove material and ribbon pe I Pull out both plugs from the printhead 8 m Wait at least 3 minutes after switching off the device before removing the print head cable from the print head Mark the position of an axially adjusted pr
27. h Setting not relevant for endless material Sets material width O For details on how to set parameters refer to Information on printouts and parameters in the Using the Parameter Menu section 06 06 Rev 3 05 01 Index B D H L Backcoating 5 Braking torque ribbon 13 Direct thermal printing 4 Hexagonal plastic bolt red 13 Inserting ribbon 11 Label material 4 Label sensor setting 14 OPERATING MANUAL Setup ALX 92x R Ribbon mandrels 73 Ribbon slack 13 Ribbon tears 73 Ribbon tension 73 S Setting material parameters 17 Setting the dispenser parameters 16 Setting the label sensor 14 Setting the printhead pressure 15 T Thermal transfer printing 4 Torque ribbon 13 W Wheel for setting label sensor 14 Winding diagram 2 05 09 Rev 5 02 01 USER MANUAL DPM PEM ALX 92x Maintenance amp Cleaning General Notice rarrrarenarennrrnnnrnnannrnnenanennnenne 2 Maintenance by Qualified Personnel 2 EE EE EN 2 Troubleshooting EE 2 Ordering Spare Parts rrrrrnnnrnnnrennrennnenner 3 Note on Cleaning RE 3 Cleaning Agents rrrnnnnnnrnrnnnrrnannnnanennnnene 3 Printhead raronarnnnrnanrnnrnnnrnnnnnnrnannnnnnnnrnanener D General Notes Jr mms 5 Cleaning the printhead cccccceeeeeeee 6 Changing the print head rrareranrornnernnernr 8 Checking the print head erernrernnernnrnre 9 Rubber rollers rrrrernnrnnrnanenannnnennnnna
28. ially trained staff to insert and change the ribbons and material gt po ge Q f gt oO fo N 19 181716 1413 12 11 5 10 1 Material and ribbon path in the ALX 92x left version 06 06 Rev 3 05 01 Names of parts OPERATING MANUAL ALX 92x Adjustment knob for printhead pressure Ribbon rewinding mandrel Ribbon unwinding mandrel Operation panel Deflection roll Material dancer arm Material unwinder Guiding rod Backing paper rewinder Backing paper dancer arm Pressure roller Lever for pressure roller Tab 1 ALX 92x operating parts Setup Feed roller Deflection roll Material guide Opener Brake roller Adjustment wheel for label sensor Print roller Dispensing edge Printhead Ribbon deflection axle Ribbon deflection roller with stress relief Ribbon roller 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Selecting the printing material Direct thermal Thermal transfer Material roughness Printhead temperature Thermal transfer direct thermal printing The ALX 92x can print onto label material using the direct thermal mode or thermal transfer mode Direct thermal printing is done without ribbon The direct thermal process requires label material with a temperature sensitive coating The printout is produced by applying precise bursts of heat to the material under the printhead This changes the colour of the coating Thermal transfer pri
29. idth and in the height Data Matrix Code code according to ECC200 Maxi Code PDF 417 Codablock F Code 49 QR Matrix Code bar codes GS1 Databar 14 Reduced Space Symbology GS1 Databar und Composite Component CC UPC A CC A CC B GS1 Databar 14 truncated UPC E CC A CC B GS1 Databar 14 stacked EAN 13 CC A CC B GS1 Databar 14 stacked omnidirectional EAN 8 CC A CC B GS1 Databar limited GS1 Databar expanded UCC EAN 128 CC A CC B UCC EAN 128 CC C 09 09 Rev 5 03 02 USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Automatic ribbon economy In regular print mode ribbon is fed simultaneously with the labelling material The automatic ribbon economy ribbon saving stops the feeding of the rib bon if there are label areas of a certain size without imprinting As a result rib bon is saved see Fig 8 AT Label Print head moves up Label length do Ul Text ext Te Printout Print head moves dov Z0091E cdr Feed direction 8 Ribbon Foil consumption when printing labels with a small imprinting area and activated automatic ribbon economy Ribbon consumption is slightly higher than the length of the imprinted area The effect of ribbon saving depends on the print speed The reason for this is the up and down movement of the print head as well as the acceleration and slowing down of the ribbon Ge
30. int head 5 Unscrew both wing screws on the printhead until the printhead can be removed from the contact shaft 9 6 To install move the new printhead to the old position and tighten the wing screws Printhead factory setting Flush against the inner black plastic plug m Before doing this make a note of the re sistance value of the print head read off from the print head When placing the print head on the print head mounting ensure that the print head is lying flat m The wing screws must press on the ta pered edge of the square axle m Pay attention to the position of the print head in relation to the edge of the label 7 Plug the printhead cable back into the print head 7 Complete printhead 8 Remove both cables from the printhead Fig DPM gt fra S T le N Ch a 5 ES M cA E gt Ss NG 2 E Mr 9 Remove the wing screws A and remove the printhead Fig DPM 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x 8 The resistance value of every new print head must be entered after putting the print er into operation Use the parameter m The resistance value can be found ona label on the printhead 10 circle CAUTION A N Entering a false resistance can damage the printhead For additional information refer to the service manual topic section Service Mechanics
31. intenance and cleaning is required to ensure that the device op erates safely and provides a high level of performance The frequency with which maintenance checks are required depends on operating and environ mental conditions the length of operation daily and the print media used m n particular the printhead and feed roller need to be checked regularly for paper adhesives and ink residues Cleaning Agents Dirty component Cleaning agent Order number Printhead Cleaning pen 1A 95327 Printhead l Cleaning paper 5030 Print roller and other rubber Roller cleaner 1B 98925 rollers Metal deflection axis or Cleaning fuel guide tube Label remover 90073 Plastic deflection rollers Serra ALX 92x g Common neutral cleaning li External parts quid Tab 1 Recommended cleaning agents CAUTION Keep to the following rules to avoid damaging the device Do not use any cleaning agent that could damage or destroy the resin surface labelling display nameplates electrical components etc Do not use any cleaning agents that are abrasive or damaging to plastics Avoid acid or alkaline solutions 05 09 Rev 5 02 01 USER MANUAL DPM PEM ALX 92x Fla kn ri aa ar hal Lia n i er ep Tia he a se Ty 1 Printhead cleaning pen A and roller cleaner B Maintenance amp Cleaning 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Printhead
32. ions require the following wording for Class A devices WARNING This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equip ment generates uses and can radiate radio frequency energy and if not in stalled and used in accordance with the instruction manual may cause harmful interference to local radio communications Operation of this equip ment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense m C Industry Canada requires the following wording for Class A devices CANADIAN D O C WARNING This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulati ons of the Canadian Department of Communications Le pr sent appareil num rique n met pas de bruits radio lectriques d pas sant les limites applicables aux appareils num riques de la classe A prescri tes dans le R glement sur le brouillage radio lectrique dicte par le minist re des Communications du Canada 09 09 Rev 5 03 02 Limitations Rewinder construction Print speed Printable area A Ambient conditions USER SERVICE MANUAL
33. ipped with CPU board A6621 m The interfaces can not be combined in any way Tab 10 LO O N EE 2 c ae E o lt ae DB o 3 u L O N gt lt x O am Centronics NO yes yes yes yes 2 RS 232 422 no ee Wea ven wes 485 y y y y Signale USI yes yes no yes yes Al yes yes NO yes yes CF zweite yes yes yes yes yes RFID yes yes yes yes yes Tab 10 Combinability of interface boards yes can be combined no can not be combined USB interface USB 1 1 2 USB A host ports 1 USB B device port full speed Serial interface Com1 RS 232 Max baud rate 115200 e Optional 2 serial interface Com RS 232 or RS 485 422 Selectable in the parameter menu Max baud rate 115200 m The 2 serial interface I O board can not be installed if a Centronics daughter board is already installed Parallel interface daughter board Centronics Bi directional mode nibble mode conforms with IEEE 1284 B m The Centronics daughter board can not be installed if an I O board 279 serial interface is already installed Ethernet Interface RJ 45 10 100 Base T with TCP IP LPD RawlP printing DHCP HTTPD FTPD SNMP 09 09 Rev 5 03 02 Processor RAM ROM Plug in cards Realtime clock Processor RAM ROM Plug in cards Realtime clock Start sensor OD sensor USER SERVICE MANUAL DPM Gen 2 3 PEM ALX 92x Gen 2 3
34. l layout e g best off date The real time clock is a standard for DPM and PEM Universal Signal Interface USI board available with 5V or 24 V signal voltage and 4 inputs as well as 7 outputs A USI test box is available For details refer to the service manual topic section Electronics Gen 2 chap US Board 1 on page 12 Programmable applicator interface designed to control nearly all applicator ty pes The Al can be integrated into the ALX 92x For application with the DPM an external applicator box is available For details refer to the service manual topic section Applicator Interface ALX 92x only PLC for control of Avery applicators of the types LTP LTPV LTSI Provides an additional serial interface COM2 and a keyboard connector PS 2 For details refer to the service manual topic section Electronics Gen 2 chap Option Board on page 11 For details about keyboard application read the user manual topic section Advanced Applications chap Standalone Operation on page 8 1 Right OD control mounted ALX 92x only The Outer diameter OD control for the label roll detects early if the machine is going to run out of labelling material how early this happens can be adju sted The application of the OD control requires a USI which provides a warning signal as soon as the roll OD falls below the set value For details refer to the service manual topic section El
35. mechanical or electrical means if safety instructions are not ob served gt Turn off the device and disconnect the power cable prior to cleaning or maintenance work ALX 92x Al Pro Remove both power cables On no account should liquid be allowed to enter the device Do not use any of kind of spray directly on the printer Moisten a cloth with a cleaning agent to clean the device gt Repairs to the printer may only be carried out by a trained service techni cian Troubleshooting If device malfunctions occur analyze the device messages first Please read the relevant chapter contained in this documentation If you are not authorized to carry out a diagnosis and repair of problems please call your technician or authorized service supplier The service person nel have the required information and replacement parts to correctly carry out the repairs 05 09 Rev 5 02 01 A Order Specifications Frequency of Care A USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Ordering Spare Parts CAUTION Using parts that do not meet the manufacturer s high standards may damage the machine Only use original spare parts supplied by the manufacturer The following information is required when ordering spare parts e Model Device serial number Optional device configuration Description and part number of the spare part Number of parts required Note on Cleaning Frequent ma
36. n is slack or in folds or winds on to the rewinding mandrel too loosely 19 Ribbon mandrels on a ALX 92x gt Increase torque braking torque turn red A Ribbon rewinding mandrel without cap hex nut clockwise B Ribbon unwinding mandrel without cap e The ribbon clearly stretches or it tears during printing The ribbon is not being transported adequately gt Decrease torque braking torque turn red hex nut anti clockwise 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x Label sensor The ALX 92x is equipped with a light trans mission sensor for punch recognition Setting the label sensor Turning the red adjustment wheel 20B moves the sensor up to 80 mm 4 5 modules or 100 mm 6 modules across the material A dial 20A displays the value Reading the value Value punch position 2 mm whereby the following applies Punch position Distance of the punch from the inner edge of the material 21A e Value Value on dial set by rotating the red wheel Example Punch centre 11 mm from the left edge subtracting 2 mm gives a value of 9 mm gt To make the setting turn the wheel 20B until the desired value is aligned with the mark 20A m Round labels To ensure in those cases that the label start is correctly identified a punch offset can be preset This may be done by manually setting the printer Parameter or by the appropriate control command
37. nerally said With a high print speed less rib bon is saved as with a low print speed Tab 5 Cutting or dispensing applications can additionally deteriorate the effect of rib bon saving Activating ribbon Activate the automatic ribbon economy by selecting parameter saving l Set the minimum distance between two print areas from which on ribbon sa ving should be activated with parameter For detailed information refer to topic section Info printouts and Parameters Minimum length of Consumed ribbon per in deni s alah area oak al 51 2 3 7 1 2 76 3 4 6 1 9 102 4 5 9 3 1 127 5 7 4 4 4 152 6 8 9 5 9 178 7 11 1 7 6 Tab 5 The amount length of consumed ribbon per saving action lifting and lowering of the print head increases with the print speed 09 09 Rev 5 03 02 USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Minimum length of Consumed ribbon per in ke en s gd lake area ap Ada 203 8 14 1 9 5 229 9 17 6 11 3 254 10 21 3 13 6 279 11 25 3 15 9 305 12 30 0 18 5 330 13 34 5 21 2 356 14 39 9 24 2 381 15 45 6 27 3 406 16 51 3 30 5 Tab 5 The amount length of consumed ribbon per saving action lifting and lowering of the print head increases with the print speed CAUTION If huge ribbon rolls run length of 1000m are supposed to be used with activated ribbon economy function there is a hazard of
38. ng printing This can degrade the printed image considerably Noticeable effects Differing contrast on the labels Light stripes in the printing direction m Clean the printhead and the print roller reg ularly and always clean them before inserting a new ribbon When using direct thermal mode always clean them before inserting a new ma terial roll Cleaning the print roller See chapter Rubber rollers on page 11 Preparing the printhead 1 Switch off the device 2 Pull out the mains plug 3 Remove material and ribbon 4 Unscrew the two wing screws 3A until the printhead can be swivelled upwards m Before swivelling the printhead up wards shift it approx 1 cm to the middle of the axle m Mark the printhead position on the axle before moving it Cleaning with a cleaning pen gt Run the pen over the thermal transfer head a few times Cleaning with a cleaning stripe Use the rough side of the cleaning strip 5A to wipe a few times along the thermal edge Press the stripe slightly to the thermal edge while doing so Ms 3 Printhead of a PEM 06 A Thumb screws i ES _ s 4 Cleaning the printhead with a cleaning pen A Thermal edge 5 Druckkopf reinigen mit dem Reinigungsstreifen 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Cleaning with alcohol based solvents WARNING A N Solvents are highly flammable
39. nnnnenn 11 POE f Print roller Luuuansrtmeseseemsman 11 PEM Pressure roller rrranrrnnnrrnnnrnnnre 12 Deflection rollers rrrrrrnrrnnrernrerarennnrvnnnrnn 13 DPM ALX Backing paper deflection 0 EE TE EE RE 13 ALX Material deflection rollers 13 Photoelectric switches rrrarrrnrernrrrnnrnnnnrnn 14 Cleaning the gap photoelectric switch 14 Cleaning the material end photoelectric SL EE 16 Cleaning the foil path rrrrnrrrnrrrarenranennn 17 Replacing the dust filter liner 18 Ba ERE 18 EEE ae T 19 ALX 92x Al Pro Fuse replacement 20 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x General Notice Qualifications Calling for Service Maintenance by Qualified Personnel Regular technical maintenance Is required to ensure that the device is always in operating order Maintenance work should only be carried out by qualified personnel The safe ty reliability and longevity of the device depend on correct maintenance m Persons causing damage as a result of unqualified maintenance repair and care are liable for these costs For reliable maintenance servicing diagnosis and troubleshooting please contact your supplier nearest dealer or another service supplier authorized by the manufacturer Safety WARNING Maintenance and cleaning may result in hazardous situations Accidents can occur by
40. nting is done with thermal transfer ribbon on normal label material The printout is produced by applying precise bursts of heat to the thermal transfer ribbon under the printhead This transfers the colour particles to the label Label material The ALX 92x was developed for printing on self adhesive stock Pay attention to the following factors when selecting label material The roughness of the material surface The printhead temperature required for the colour transfer Size of the material roll The following dimensions need to be checked Outside inside diameter of the material roll and the material width If the material is very rough the printhead will be worn down more quickly than when using a smooth material This is an important aspect of thermal printing With thermal transfer printing this doesn t pose such a problem because you can and indeed should select a ribbon that is wider than the material This means that the printhead is protected over the entire width of the material High printhead temperatures can similarly cause problems The material and the ribbon take longer to cool As a result the print quality may degrade particularly at high print speeds The printhead also wears down more quickly m The printing result is highly dependent on the right combination of label material and thermal transfer ribbon The surface of the label material determines which thermal transfer ribbons produces th
41. ocedure may take from 10 s up to several minutes time the wider the printhead is and the more dots are defective the longer CAUTION Disregard of the A N following may cause the printer firmware to hang up gt Never change the setting of a dot check parameter during a dot check is running Abortion m Only if it really cannot be avoided cancel the dot check by a reset press Feed Cut On line button CAUTION Disregard of the following can destroy single dots of the print head gt Never cancel a dot test by switching off the printer Maintenance amp Cleaning 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Rubber rollers Feed Print roller All rubber rollers contained in the DPM PEM and in the ALX 92x can be cleaned from the bottom side of the machine without any disas sembly The ribbon roller is easily accessible by opening the hood and removing the ribbon 1 Switch off the device 2 Pull out the mains plug 3 Remove material and or ribbon 4 Clean the print roller with a dust free cloth and roller cleaner CAUTION Disregarding the following may damage the roller gt Never use knives or sharp edged objects to clean the rollers m To access the print roller from the front side the printhead can be disassembled Refer to chapter Changing the print head L on page 8 to learn how to do this 11 DPM AL
42. on Electronics Gen 3 chap 0 Board on page 32 Programmable applicator interface designed to control nearly all applicator ty pes The Al can be integrated into the ALX 92x max over all output current 1 A for a higher over all output current of up to 4 choose the ALX 92x Al Pro For application with the DPM an external applicator box is available For details refer to the service manual topic section Applicator Interface ALX 92x only PLC for control of Avery applicators of the types LTP LTPV LTSI Several Applicators is available for operation at the DPM ALX 92x Optional equipment for reading and writing labels with integrated RFID trans ponder 09 09 Rev 5 03 02 Bar code verifier OD control External control panel USB Stick USB Scanner USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Online bar code verifier OLV Checks the readability of the printed bar code and stops the printer in case of a negative result 2 OD control mounted ALX 92x only The Outer diameter OD control for the label roll detects early if the machine is going to run out of labelling material how early this happens can be adju sted The application of the OD control requires a USI which provides a warning signal as soon as the roll OD falls below the set value min firmware 5 31 For details refer to the service manual topic
43. r access to the gap photoelectric switch 1 Switch off the device Pull out the mains plug 20 Mounting bolts A of the guiding section Fig DPM 2 3 Remove material 4 Unscrew both screws 20A using a 3 mm allen key m At the PEM there is only one fixing screw to remove 5 Slide out the guiding section 21B to the side Continued overleaf 21 Sliding out the guiding section B Fig DPM 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x 6 Clean the gap photoelectric switch with compressed air compressed air can be or dered in acan as an accessory 22 m Additionally clean it using cleaning fuel and a dust free cloth if it is particularly dirty gt 22 Blow compressed air at this point arrow to clean the pho toelectric switch 7 Assembly Feed the right one of the two cy lindrical shapes 24B into the groove at the guiding profile Both steel pins 23A must fit into the holes 24A Replace the screws and tighten them 23 Guiding section disassembled A Steel pins 24 Printmodule DPM A Holes into which the steel pins must fit Fig DPM B Cylindrical shapes at the gap photoelectric switch 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Cleaning the material end photoe lectric switch The material end photoelectric switch 25A is located on the inner r
44. rinting direction may only cover half of the maximum print width The other half of the label may not be printed on in this area Those lines may not exceed a line width of 3mm The ALX 926 may only be operated ata mains voltage of 220 V or higher The operating temperature may not exceed 30 C
45. rs DPM ALX Backing paper deflection roller Clean the material deflection roller if it is dirty with residues of adhesive labels or something similar 1 Switch off the device 2 Pull out the mains plug 3 Remove material 4 Screw out the thumb screw 17B and take off the locking plate 170 Pull the deflecting roller 18A off its axle on 6 Clean the deflecting roller using cleaning fuel or adhesive removing solvent depend ing on the degree of pollution 7 Put the deflecting roller back on the axle apply locking plate and thumb screw ALX Material deflection rollers All of the material deflection rollers 19A at the ALX 92x should be cleaned regularly in order to not disturb material feeding and with it the print ing quality gt Wipe the rollers with a clean cloth and cleaning fuel 17 Backing paper deflection roller at the DPMs printing module A Deflection roller B Thumb screw C Locking plate 18 Pull off the deflection roller A O 4 x 19 Material deflection rollers A at the ALX 92x z gt A 05 09 Rev 5 02 01 USER MANUAL Maintenance amp Cleaning DPM PEM ALX 92x Photoelectric switches The photoelectric switches must be cleaned of material and dust particles at regular intervals depending on the materials used Cleaning the gap photoelectric Switch Dismantle the guiding section first to get prop e
46. section Electronics Gen 3 chap OD control sensor ALX D on page 42 3 External control panel An external control panel can be connected in addition to the integrated control panel An external control panel is useful if the standard control panel is diffi cult to access due to the position in which the unit is installed All types of USB mass storage class devices connected to the USB host port are supported Those are e g USB sticks min firmware 5 31 USB scanner can be operated at one of the USB host ports Scanned data is interpreted as keyboard input min firmware 5 31 09 09 Rev 5 03 02 USER SERVICE MANUAL DPM Gen 2 3 PEM ALX 92x Gen 2 3 Technical Data Technical specifications Dimensions DPM PEM 261 4 6 245 5 221 7 ra 207 4 4 5 265 0 223 000 OPL 6808908 OO ere 4 Dimensions of the DPM as L version The PEM has the same measures Dimensioned drawings of the DPM PEM in DXF format Autocad can be found on the Documentation CD in directory Dimensional Drawings USER SERVICE MANUAL Technical Data DPM Gen 2 3
47. the ribbon tearing off gt Consider the limitations according to Tab 6 and Tab 7 Ribbon type 2240 600 Ribbon width 030 055 080 104 max print speed inch s 12 12 12 12 max print speed with ribbon economy activated inch s 12 12 12 12 Release the ribbon brake turns 12 8 6 6 Tab 6 Limitations for ribbon type 2240 600 depending on the ribbon width Ribbon type 2240 1000 Ribbon width 030 051 080 102 max print speed inch s 12 12 12 12 max print speed with ribbon economy activated inch s 12 10 9 6 Release the ribbon brake turns 12 8 6 6 Tab 7 Limitations for ribbon type 2240 1000 depending on the ribbon width For details on setting the ribbon brake refer to the user manual topic section Setup paragraph Settings Ribbon tautness 09 09 Rev 5 03 02 Material types Material roll Backing Paper Material measures USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 Labelling material DPM ALX 92x All common self adhesive labelling materials suitable for printing in thermal direct and thermal transfer process e PEM All common cardboard and self adhesive labelling materials suita ble for printing in thermal direct and thermal transfer process ALX 92x only Max outer 300 mm Inner 1 5 88mm with adapter rings 3 76mm or 4 102mm Maximum admissible roll weight 12kg D
48. ull in and pull out force may be 9N m The pulling forces in the label web must be applied evenly Example The unwinder brakes with 10 N Then the rewinder may pull with a force in the range of 1 to 9N given that the backing paper is strong enough not to tear off e DPM ALX 92x Self initializing light through sensor for punched label material e PEM Self initializing combination sensor which can detect punches as well as reflex marks on the material bottom side Module Light through sen ee width sor Setting 4 5 2 80 mm 2 80 mm range 6 2 100 mm 2 100 mm Tab 4 Setting ranges for punch and reflex sensors a Only with PEM material bottom side b Measured lay edge to sensor center Punch position and size see Punch measures on page 16 09 09 Rev 5 03 02 Impression accuracy Output modes Interpreter Character sets Character modification USER SERVICE MANUAL Technical Data DPM Gen 2 3 PEM ALX 92x Gen 2 3 In printing y direction The impression accuracy depends on the print position With the printout starting directly at the punch position the accuracy is 0 5 mm A distance between punch that is label start and print position will add 1 of this distance to the accuracy fault see fig 7 X direction 0 5 mm Max misalignment at printing position 2 2 5 mm Max misalignment of the printing position Max misalignment at f printing
49. up 06 06 Rev 3 05 01 OPERATING MANUAL Setup 9 Peel labels off the backing paper for a stretch of appr 50 cm 8 10 Open the pressure roller lever 9A by pressing it downwards 11 Pull the backing paper backwards under neath the printing module and insert it as illustrated 9 12 ALX 925 926 Loosen the two thumb screws 10B at the spring suspended blocks Position the spring suspended blocks 10A in a way that the contact rolls press symmetrically on the backing paper Retighten the thumb screws ALX 924 Loosen the thumb screw 10B Position the spring suspended block 10A in a way that the contact roll presses in the middle on the backing paper Retighten the thumb screw 13 Tighten the backing paper backwards and close the lever 11 ALX 92x 8 Peeling some labels off 9 Threading the backing paper underneath the printing module 11 Closing the pessure roller lever 06 06 Rev 3 05 01 OPERATING MANUAL Setup ALX 92x 14 Thread the backing paper around dancer arm 12A and deflection roller as illus trated 12 15 Pull out the release button 12B A 16 Insert the end of the backing paper into the rewinder as illustrated 13 17 Push in the locking knob 18 Turn the rewinder manually anti clockwise until the backing paper is tightened 14 14 Tightening the backing paper 06 06 Rev 3 05 01 OPERATING MANUAL Setup
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