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Service Electronics (Gen. 3)

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1. 27 Simplyfied diagram of a USI input 03 10 Rev 5 04 03 I O Board Requirements Applications SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Application notes m The I O board can not be mounted into a PM 3000 Device firmware version 5 00 or above The I O board may be used for 2 different applications e 20d RS 232 interface The I O board provides a RS 232 interface which can be applied additionally to the one on the CPU board The 2 interface can e g be used to connect a bar code scanner e RS 422 485 interface lf there is a long distance between host and printer RS 485 or RS 422 is sometimes used instead of RS 232 or Centronics This is often realized in in dustrial plants where galvanic isolation is required to avoid ground loops m The two serial interface types cannot be used at the same time View Wu Way 0 a O SUPERWORLD SWIDSSHEHLSM aoe eas a 28 I O board A8258 A CN 201 Not yet supported B CN 101 RS 232 422 485 C CN 101 Connection CPU board connect there to CN 501 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connectors B RS 232 m Pin assignment looked at from PC point of view Device DCE Pin Signalname Signal direction at the 5 host I O board 9 A 1 DCD Short with DTR amp DSR 8 2 R
2. Na arm ene titte 3 E3 FE IE kur T Phu l om E As re m Mae AA 123 THP T co i nr DG Ja ELI A6619 02 MAM DAR i g f aww of Fu UU ni im FT 533 Dolphin Main Logic me p na eas y 4 z s S d 2 i9 S z gt s s i gt i e S gt pa R ldd 15 s r st i iigh z 2 e ae c Mg Maar wee m ten en gt ve a amp z kur Zd Fr ar n x etae oterom ar As f om we ma Wua uns Ip Mii DENNISON A6621 01 PCB Serial No 06050013 00 0A 44 05 00 13 li mm 1a 331 HNHH wsk INT DE OG AES com a mm ts hh th Mine 62 eS may a F 1 CPU board A6621 CAUTION A N If replacing the CPU board mind the following to avoid malfunctioning gt Only operate printers with a board index of 05 with a firmware version of 6 33 or higher a CPU boards with index 05 were built in starting with serial number 082566 0911 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics A A 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Battery for realtime clock Lithium 3V CR2032 m Check the battery regularly and replace it if necessary e o m WARNING Danger of explosion if the battery is incorrectly replaced Read a
3. chapter Rear hood ALX m For operation with an Al the connection cable may have to be replaced before as sembling the sensor see chapter Connec ting the OD sensor to Al D on page 43 2 Fix OD bracket 39A and cable clamp 39B to the base plate with a M4 hexagon socket screw and shim 40 m Insert aluminium disc 40A between brack et and base plate m Attach cable clamp to the marked point on the cable m Ensure sufficient distance is retained be tween the light barrier sensor cable and the material guide plate 3 Ensure that the holding plate has the characteristics described in 41 m The threaded holes 41A for the wing screw are only implemented from the fol lowing delivery date serial number ALX 924 05 2002 ALX 925 05 2002 ALX 926 0358610204 ALX926 39 Fixing the OD check system A Bracket B Cable clamp C M4 hexagon socket screw 40 Sequence of assembly on the OD bracket A Aluminium disc B Bracket C Cable clamp D Disc E Screw 41 The material roller holding plate must have the following characteristics A Threaded holes B Counter bore material unwinder axle must be fixed with a countersunk screw 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 m The holding plate with threaded holes and counter bore can be ordered under the or de
4. 4 IF a Galvanically separated H Output stage boards connection Pin Function 5 2 V GND 28 V GND 48 V GND OourWN 0 O1 OIN fr Cole Vi Latah 35 Connections at the ME500 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 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 L 1 On off gt 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 B Ground connection eld a t 2 m The cable end must be screwed to the 2 GND_24V 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 O1 A GO PO oOoONOOIPOD co AN 36 Power supply HME oO N OOA GUIN CONOR ON 1 GND 1 2 5 V 2 3 GND 3 F Output stage boards connection Pin Function 5V G
5. Set x so that y matches the range of 230 255 Typical x values with this setting are 200 with 64 xx 155 with DPM PEM PM 3000 ALS 92x Position the label material with an area without reflex mark over the reflex LS The measured value should now match the range of 25 100 and lie at least 100 digits below the value measured with reflex mark If y doesn t match this range modify the x value by pressing the Apply or Feed button Press the online button to save the setting By doing so the reflex sensor is ready set 03 10 Rev 5 04 03 Fullsize LS SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Now the settings of the Fullsize sensor are displayed Sensor adjust x Fullsz y x setting value of the LED current y value measured by the sensor m The Fullsize LS is an option If the printer is not equipped with a Fullsize LS skip this section by pressing the online button 1 Insert some backing paper of standard label material with the labels peeled off to check the sensor measurement m The material sample must be big enough to cover the LS 2 Set x so that y matches the range of 25 70 3 Insert standard self adhesive material paper label on backing paper into the printer m y should count at least 100 digits higher than the y value measured with bare backing paper 4 If y doesnt match this range modify th
6. Tab 2 Test conditions for sensors connected to the CPU board Value table for sensor 0 12 printhead temp Sensor value 935 12 9 230 225 17 8 22 1 220 215 210 205 200 195 190 185 26 0 29 5 32 35 8 38 7 41 4 44 0 46 6 Printhead temp Tab 3 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 49 1 175 170 165 160 155 150 145 140 135 130 91 5 53 9 56 3 58 6 60 9 63 2 655 67 8 70 2 72 9 Printhead temp Tab 4 tab 3 continued Sensor value 120 110 105 77 3 82 3 84 9 Printhead temp Tab 5 tab 4 continued 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Sensors output stage boards 64 xx Sensor Sensor Description Typical Value Condition name 2 01 Foil Foil sensor 0 Sensor above a hole in the oscil lator disc light barrier clear 254 Sensor covered 3 01 Head Light barrier at the print 0 Printhead in economy position head raising mechanism raised 254 Printhead in print position lowered 4 01 Option Sensor for options ap gt 10 Light barrier covered plication for cutter exter nal rewinder or release motor sensor at the 64 xx dispenser lt 10 Light barrier clear Tab 6 Testbedingungen f r Sensoren die an eine der Endstufen Platinen angeschlossen werden Sensors output s
7. B JP 100 Jumper connected 5V at pin 35 C JP 101 Jumper connected 5V at pin 18 D FFC Flat Flex Cable connection to CPU board A6621 connect there to CN 1301 5 ee 2 de a 5 Mounting position of the board The silver coloured contacts E at the FFC cable must show to the right when connecting it see arrow 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Pin assignment SELECT IN gt 5V JP 100 geschl n b GND FAULT INIT SELECT GND PAPER END GND GND GND GND GND GND GND GND GND GND GND m N U A UIO N OO WHO 1 1 1 1 1 1 1 1 STROBE 6 Pin assignment of the Centronics jack IEEE 1284 B CF daughter board Application notes CF CompactFlash This board is for optional equipement of the device with a second slot for CF cards the first slot is standard on the CPU board im This board can not be mounted into a PM 3000 Requirements e CPU board A6621 e Device firmware version 5 00 or above e List of suitable CF cards see Plug in card manual topic section Card types CompactFlash card View 7 CF daughter board A6624 A CF card slot B Plug in contacts for CPU board connection connect there to CN 1301 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connecting Tool Cross
8. activated and b The ribbon stock is below the threshold value which is set in parameter After changing the ribbon roll the signal will be inactivated after a short time Material end warning The signal is activated high if a activated and b The label material stock is below the threshold which is set by posi tioning 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 will trigger the material warning repeatedly until the roll diameter falls below a certain tol erance zone This signal is only a warning what means that the printing goes on Tab 4 Cont Signal designations and functions of the USI interface 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Pin Signal Function 10 ERROR This output is activated low during every status which keeps the printer Output from printing USI pause mode stopped mode offline mode cover open material 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 11 PRINT _END Th
9. allen key Size 5 socket wrench Preparing the USI board Disconnect and dismantle the USI board Unplug the PLC cable plug 54A 3 Unscrew board plate 54B Preparing the cable for the light barrier sensor Thread the sensor cable leads through the opening in the housing Lead the board plate mounted on the sensor cable through the opening in the housing rotating it slightly For photos see chapter Preparing the light barrier sensor cable on page 45 up Steps 6 7 and 8 The contact spring 55C 56B must engage in the cutout 55D 56A in the plug housing Insert the brown lead as shown 55 into the 30 pin PLC connection cable plug Insert the blue lead as shown 56 into the 5 pin PLC connection cable bushing housing 54 Dismantled USI board the PLC connection cable A is connected 55 Insert the brown sensor cable lead A in the PLC connec tion cable plug B The contact spring C must engage in the cutout D 56 Insert the blue sensor cable lead 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 8 9 58 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Insert the black lead as shown 57 also into the 5 pin PLC connection cable bushing housing Connecting the sensor cable Connect both PLC connection cables 58A B to the USI board TTT TD PLC connection cable plugged into the USI board ALX RH A 5
10. line of the scale are printed exactly on the label edge If this is not the case proceed step 6 6 Measure the distance between the black squares and the label front edge Put the value into Repeat steps 5 and 6 until the black squares exactly flush the label front edge Compensating 1 Print a feedadjust label call l impression mis 2 Measure the distance between leading label edge and Start of meas line alignment 3 Identify the deviation from the target value 10 mm and type it in under m Positive values shift the print image against feed direction negative values shift it in feed direction 4 Print feedadjust label and check it If necessary repeat steps 2 and 3 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 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 f the 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 e 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 f
11. lt an 03 10 Rev 5 04 03 SERVICE MANUAL 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Service Electronics Gen 3 Handling BoardS un 1 ESD protection nennen 1 FRANC ee 1 Setting the imprint position 2 CPU Board ee 3 VEN ee ee 3 LIMUM BAUGIV EEE EL ri Data interfaces at the mounting plate 8 Sensor Connections ee 9 Centronics daughter board 10 Application notes ccccccsssccseeeeseeeesees 10 N ee 10 PiN ZESI HIER soa ssnnncasonrntonsaneacns een snaneans 11 CF daughter board cccccceeeeceeeeseeeeeeaeees 11 Application notes sure 11 VEN EEE NA A ESE A AA A 11 COMMS CHG nee ee 12 Operation panel boards ccccsseeeeeeeeees 13 Application notes cccccccssseessseeeseeeeees 13 N nee 13 Output stage board 2222u002snseennenneenen 14 Application notes uu22u4u022nne nenne een 14 TO ee a een 14 AIO OOM asnasan arinen naaa 15 WSO serae a E R 16 Application notes nennen 16 Ny E E A AE NEE PE ES 17 ONE sirrenrirrrise sa 18 Signals at the D Sub 15 connector 18 Application of the internal inputs at CN 300 nee eae ee ee ene ere rt 21 Signal description of the internal inputs at eine 21 Pin assignment jumper block 22 ER LISTEN aeneseneueeenieee 22 Circuit diagrams for signal inputs 23 Circuit diagrams for signal outputs 24 Replaci
12. pin plug B 30 pin plug Mounting the USI board See topic section Service Mechanics D chapter Mounting the USI board 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Settings Material end Label sensors m The button designations mentioned in this description count for DPM PEM PM 3000 or ALX 92x For 64 xx printers please press the Cut button instead of the Apply button LS LS means light sensor 1 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 2 Press the following buttons one after the other Apply Online Feed Apply 3x Online 3 Call Material end LS This text is displayed Sensor adjust x Matend y x setting value of the LED current y value measured by the sensor The measurement is interpreted by the electronics as follows y lt 128 No material inserted y 128 Material inserted m The higher the setting value the lower is the measured value 1 Remove the label material from the LS 2 Sety to approx 100 using the Apply or Feed buttons Typical x values with this setting are 95 with 64 xx 55 with DPM PEM PM 3000 ALS 92x 3 Insert some backing paper y must rise now to a value clearly above 128 at least 138 mm If y is below 138 Increase the setting without material step by step until the value w
13. positions The value range must be at least 130 Valuerange XXX Endpos XXRestpos If the value range is less than 130 the dancer arm sensor must be set newly see next section 3 To leave the menu press the Esc button repeatedly 03 10 Rev 5 04 03 Setting the sensor Taking over the 4 setting SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Preconditions Rear hood is dismantled Backing paper is removed from the rewinder m During the setting make sure that no extraneous light is falling on the dancer arm sensor 3B XXX DE End pos Rest pos xxx 90 Center pos 2 Setting positions of the rewinder dancer arm schematic ALX LH Call Rewinder adjust Resting pos XXX Move the dancer arm from the rest position over the center position to the end position While doing so watch the value xxx Check ifthe values match the scheme pictured in 2 If the values don t match the scheme Set the potentiometer 3A so that xxx in the center position is at least 90 increments higher and in the end position at least 130 increments higher than the value in the rest position 3 Setting potentiometer A of the dancer arm sensor B Move the dancer arm to the rest position 2 again Press the Apply button Rewinder adjust Center pos XXX Move the dancer arm to the center position dancer arm verti
14. reprint functionality is reprint last label print 1 label print 1 label eh a Pause mode on stopfeeding enabled s or previous abel must pining othe be finished labels ee be finished be finished 18 Examples of timing waveform for the USI inputs 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Start Print De VE GE Reprint min 10ms min 10ms Pause 19 Signal timing to be met Circuit diagrams for signal outputs 47k Output u Controller 20 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 supply voltages 5 V on pin 2 and 24 V on pin 8 are provided by the USI The output current is limited mm Maximum current per output line 50 mA all output currents together may not exceed 700 mA Netzteil USI board USI Platine Power Supply Pin 2 Pin 1 8 Kabel Cable A2059 Pin 7 Pin 1 8 Z0119 cdr 21 USI in the state of delivery The voltage cable is connected JP 8 is closed 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 External supply CAUTION A N In previous versions of this document the external voltage supply of the USI was described External voltage supply without external curren
15. the label roll is full it interrupts the light beam between the sensor 38A and the reflector 38B in the sensor unit As soon as the label roll is unwound to a cer tain diameter the light beam can reach the reflector The light barrier sensor then sends a signal to the USI which then acti vates a warning signal to a signal output The critical diameter is set by moving the bracket 38C which is fastened at the bot tom to the ALX base plate m A Switching range of around 1 2 m material length may arise due to the label roll mov ing as it is being unrolled i e the light bar rier sensor and thus the WARNING signal may be activated several times within this range System requirements Operation at USI e ALX 92x e OD sensor assy for USI A3523 e USI Version 4 A2345 04 24 V with USI Controller V2 T1 F873 e Printer firmware version 2 46 or higher See chapter Assembling the OD sensor L on page 41 and chapter Connecting the OD sensor to USI D on page 44 Operation at Al e ALX 92x e OD sensor assy for Al A5293 See chapter Assembling the OD sensor L on page 41 and chapter Connecting the OD sensor to Al D on page 43 38 ALX 92x RH with OD control A Sensor B Reflector C Bracket 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Assembling the OD sensor 1 Remove rear hood see topic section Service Mechanics
16. ALX 92x Gen 3 Characteristics HME power supply Inputs Characteristic Value Range of input voltage 100 240 VAC Admissible range of deviation 88 264VAC Frequency range 50 60Hz Admissible range of frequency 47 63Hz 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 Ipeak t lt 10s Pulsed output current 40A lous 50 ED t lt 0 5ms Tolerance 2 5 5 10 5 10 Tab 3 Characteristics of the output voltages m The total power of the outputs 2 and 4 may not exceed 250W m 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 at110VAC max 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 volt age Therefore there can be drawn a maximum current of 4A AC at 230V and 1A AC at 110V from the power supply 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 OD control sensor ALX OD control short for outside diameter control of the label roll Function When
17. CN 1108 Singlestart sensor Cable marking SSS Pin assignment see chapter Sensor connections on page 9 CN 1110 Connection for auxiliary sensor reserved Pin assignment see chapter Sensor connections on page 9 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Q CN 1109 Cover switch Cable marking COS Pin Signal 1 Signal cover switch i he 2 GND R CN301 Connection data cable power supply S CN702 Internal connection RS 485 operating panel Pin Signal Pin Signal 1 5 V 4 GND 123456 gt Axe 5 Xs n 3 Rx 6 Ix T CN 701 Connection external RS 485 operating panel Pin assignment see CN 702 S U CN 503 Connectioin motor output stages I C bus Pin Signal Pin Signal 1 Matmotor CLK 8 GND l 2 Foilmotor_CLK 9 Ext_SCL 3 3 Matmotor CW CCW 10 Ext SDA gt A Foilmotor CW CCW 11 FPGA nReset 5 PWM_ Ctrl 12 V5 MTIF 11 6 Perimotor CLK 13 GND 7 Rewinder_ Ctrl 14 GND V CN 1002 Connection printhead KCE W CN 1001 Connection printhead KCE high resolution reserved X CN 1000 Connection printhead KPA Y JP 101 JP 102 JTAG jumper e Only for factory internal use e Default setting JP 101 connected JP 102 open Z JP 300 JP 301 Software debug jumper e Only for factory internal use e Default setting both jumpers open AA D 301 Software debug LED Only for factory internal use AB D 300 So
18. Displaying the index number Sticker on the board 13B C e USI controller At least V6 T36 or a later version with a higher V number Displaying the version Sticker on the microcontroller 13A Parameter menu SERVICE DATA gt gt MODULE FW VERS gt USI interface m Controller version older than V6 T36 Update is only possible by exchanging the controller see chapter Replacing the controller on page 25 m Controller version V6 T36 or higher Update can be done by loading new firmware same procedure as for printer firmware update see topic section Firmware Requirement printer firmware of at least version 5 30 is installed 03 10 Rev 5 04 03 Connection type Signal voltage USI signals VB 200 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 e Printer firmware 5 0 or higher Displaying the firmware version Parameter menu SERVICE DATA gt gt MODULE FW VERS gt System version During powering up the printer NPN optionally 5 or 24V View SPS optional USI board index number Micro controller version here 04 number here V2 USI V2 T1 F873 N Py CPU board d Li AA i Hey cmo seed Connector for in Function Power supply ater mp 5V internal voltage supply active on CN 100 Pin2 DB 15 5V external voltage supply on Pin 2 15 14 USI board A2345 03 10 Rev 5 04 03 SERVICE MANUAL Service Electroni
19. ND n b GND 48 V GND OoourkWN Oo OP OIN 37 Connections at the HME 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Printhead Voltages HME amp Standard Printhead resi rinth Voltage rinth Voltage rinth Voltage rinth Voltage stance Ohm Printhead resi stance Ohm Printhead resi stance Ohm P V P V Printhead resi P V stance Ohm h oO oO oO h eb 00 O NO O1 oO O1 1570 1580 1590 1600 1610 1620 1630 1640 1650 1660 1670 1680 1690 1700 1710 1720 1730 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 Checking the head Proceed as follows to check the printhead voltage voltage 1 Find out the printhead resistance m 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 at the power supply with a voltmeter and compare the result with the value in the table m Maximum admissible deviation 0 2V 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000
20. RVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connecting the OD sensor to USI Wire colour Function Brown 24 V A Blue GND Black K Tab 6 Pin assignment at the OD sensor cable Also see topic section Electronics_ chap ter USI board Tools e 2mm allen key e Size 5 socket wrench Preparing the USI board Disconnect and dismantle the USI board 46 2 Disconnect the third connected jumper 46C from the jumper strip 3 Unscrew board plate 46A To do this unscrew the two screws 46B 1 DURET Er Pi i IPTE i ie T ERS ae LIS ZIETFIR wi Te mas t i 46 USI board 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Preparing the light barrier sensor cable m Steps 4 5 and 6 The contact springs 47A 48A must engage in the bushing housing cutouts 47B 48B 4 Insert the brown lead of the light barrier sensor cable into the 4 pin bushing housing as shown 47 5 Insert the blue lead of the light barrier sensor cable into one of the 1 pin bushing housings as shown 48 6 Insert the black lead of the light barrier sensor cable into the other 1 pin bushing socket in the same way 7 Thread the light barrier sensor cable leads 49A through the opening in the housing 8 Lead the board plate mounted on the light b
21. arrier sensor cable 49B through the opening in the housing rotating it slightly 9 Screw the plate board 50A onto the housing 2 screws m The photo 50 shows assembly on a RH machine On LH machines the plate board is mounted rotated through 180x Continued overleaf 47 Insert the spring contact into the 4 pin bushing housing A 48 Insert the spring contact into the 1 pin bushing housing 49 Insert the board plate into the side panel through the open ing 50 Screw on the board plate ALX RH 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connecting the light barrier sensor cable 10 Connect the three leads to the USI board 51 52 m Push the plugs onto the pins as far as they will go 51 Insert the leads A on the USI board Mounting the USI board 11 Screw the USI board onto the board plate 53 12 Connect the ribbon cable 53A and 2 pin cable 53B and the USI board 53 Mount the USI board 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connecting the OD sensor to USI with applicator PLC In ALX 92x with PLC control for applica tors the cable leads for the light barrier sensor are attached to a different location than that described in the previous section Tools 2mm
22. arting the simulation the following parameter settings are required Menu Parameter Setting 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 ERROR 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 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 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 m 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 N Controller USI Testbox Kunden steuerung Customer control 3 R GND Ext GND
23. assignment on diagr board J4 PANCON AMP 643813 4 or er MLAS 100 04 AUK MK 04H 2 K J3 PANCON AMP 643813 4 or MLAS 100 04 AUK MK 04H J2 Wieson MOLEX 70450 2120 14RS5 Version b J12 AMP 640389 6 AMP 0 644465 6 5V MTA 156 18 AWG DuPwvr Awa D gt OO gt Tab 2 Connections on the output stage board 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 USI Board Application notes Utilization The USI Universal Signal Interface is an optional interface for all machine types listed in the headline of this page USl 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 material 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 Compatibility m DPM ALX 92x USI and Al Applicator Interface can not be built into the same device A Jo feed e z Te N li o Pm i B C Li 13 Version designations on the USI board Version m The functionality described in this section is only then fully available if USI board Controller and printer firmware match the following requirements e USI board At least A2062 08 5 V USI or A2345 09 24 V USI or with a higher index number
24. been switched to offline or pause mode m 64 xx with LTSI applicator mounted with PLC version 5 0 and higher MACHINE STATUS is not available Tab 4 Cont Signal designations and functions of the USI interface 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Application of the internal inputs at CN 300 The following parameter settings are required to make the internal inputs useable PLC For usage with PLC USI Applicator Enabled OD sensor For useage with OD sensor material Enabled Enabled lf 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 Signal description of the internal inputs at CN300 Pin Signal Signal Function type 1 OD control In 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 Activated and the input is high 2 Applicator In fault home iti cakes If one of the inputs is high or makes a low high transition the ap 3 Applicator In propriate status message Is displayed at the printer Additionally fault touch the outputs ERROR and MACHINE STATUS will be activated down low 4 PLC ready In fault GND Ground GND potential of the internal inputs Tab 5 Signal d
25. boards ALX DPM PENI EEE EEG AEEA 58 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Handling Boards ESD protection CAUTION The boards can be destroyed by static discharge Before opening the printer place it on a grounded surface Earth your body using an ESD bracelet or other suitable means before touching a board If no suitable ESD protection is available touch an earthed object e g a heating radiator before touching a board Only place boards on earthed surfaces Handling CAUTION The conducting tracks on the boards are very thin If a board A N is bent or warped the conducting tracks can easily crack Avoid bending or warping boards Avoid the use of excessive force when removing or inserting boards 03 10 Rev 5 04 03 Preconditions SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Setting the imprint position When printing on very long labels it may happen that the imprint position has to be set To do this proceed as follows 0 mm Fu voraus e Erforderliches Etikettenmaterial Mindestl nge 100 mm ideal sind 200 mm e Drucker befindet sich im Produktions Modus 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 CPU Board View fer f ayy d b
26. c Pin Function 1 GND 1 2 5V 2 3 GND 3 D Output stage boards connection Pin Function 5V OV 38 V OV Oo OP OIN OourkWN 52V OV 33 Connections at the NT400 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 ME500 e The ME500 replaces the NT400 since 01 2008 e Retrofitting printers with Gen 3 electronics is possible without further modifications e Operation with dust filter is admissible Part number of the dust filter kit see spare parts catalog Mounting instructions for the dust filter kit see topic section Service Mechanics D chapter Assembling accessories m Wait at least 15s between switching off and on again A Remote on off m 64 xx bridge the connector using a jumper Pin Function 1 On off 2 GND B CPU board connection control signals Pin Function 4 2 Bl 1 NMI 1 2 l2C detect 2 3 SCL 4 SDA 5 5 PG 6 6 n a 7 n a 8 8 n a 9 9 GND C CPU board connection supply voltage Logic Pin Function 1 GND 1 2 5 V 2 3 GND 3 D Ground connection up The cable end must be screwed to the printer housing E Printhead connection Pin Function u 20 28 V 20 28 V 20 28 V 20 28 V GND GND GND GND CONOR WD oO N OO A OIN F Operation indicator G USI board optional Pin Function p 1 24 V 2 GND_24V
27. cal 2 and hold it there Press the Online button Restart the device The sensor is ready set If the required values are not successfully setable the sensor board must be replaced A See topic section Mechanics section Material transport Dancer lever sensor 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Adjusting the imprint position Printing on especially long labels may require under certain circumstances that the imprint position has to be adjusted Do this in the following way Prerequisites 0 mm Foot first e Required label material minimum length 100 mm best are 200 mm e Printer is in production mode Compensating 1 Insert recommended label material Print a feedadjust label call length misalign ment AB C D E l TTT TTT 180 measured length se wu JO Pu Feed adjust 100 SOW JO URIS Z 4 Feedadjust label with printed on measure scale C and calculation scheme D 2 Measure the distance between the two marks Start of meas 4B and End of meas 4E 3 Put the measured distance into the calculation scheme 180 measuredLength 100 of Feedadjust 180 4 Calculate Feedadjust Put the result into the following parameter 5 Print another feedadjust label Check if the black squares 4A or the first
28. cs 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connectors Picture Comp Typeon Pin assignment on board Diagr board CN100 AMP BE 640457 4 Fezz 1 Ex7 Jay N C 3 N C 4 EXT GND CN101 Cable is 1 VCC 5V Ta 3 VCC 5V soldered 5 VCC 45V ys to the 7 GND FE board a 4 3 GND Les CN300 EJ 1 0OD control material EJ 2 Applicator homeposition error 3 Applicator touchdown error EJ 4 SPS ready error EI 5 GND 15 MACHINE STATUS 6 GND_EXT 7 24V EXT 14 DATA RDY 7 3 6 REPRINT 13 RIBBON OUT 5 PAUSE 12 MEDIA OUT 11 PRINT END 4 FEED 3 START PRINT 10 ERROR 7 9 WARNING 2 5V EXT 1 GND EXT Tab 3 Connectors on the USI board Signals at the D Sub 15 connector Pin Signal Function 1 GND EXT Ground contact 2 5V EXT JP8 connected Internal 5 V source can be used via the wire for external Voltage supply Sensors JP8 clear Wire can be used for an external 5 V source 3 START PRINT The machine starts printing depending on the setting of parameter Input Preconditions Printjob is available DATA RDY low printer is in online mode no error messages 4 FEED Feeding of the label material as long as the signal is low Minimum feed Input 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 mode e Online m
29. e manner in which this output is switched depends on the setting of pa rameter Difference to older versions of printer firmware below 2 46 The output is now also activated as long as labels are fed m Limitation This functionality is not available in Batch mode m 64 xx with LTSI applicator mounted with PLC version 5 0 and higher PRINT END is not available 11 HOME POS m Only valid for 64 xx with LTSI applicator mounted with PLC version 5 0 Output and higher e HOME _POS replaces PRINT END e HOME POS is active if the LTSI is in home position upper limit position 12 MEDIA OUT Low in case of material end Additionally activated are Output e ERROR e MACHINE STATUS 13 RIBBON OUT Low in case of ribbon end Additionally activated are e MACHINE STATUS 14 DATA_RDY This signal is activated low if the printer has finished image processing Output and is ready to start printing The signal is inactivated if e the print job is done or e the printer is switched to stopped mode offline mode or USI pause mode 15 MACHINE This output is activated low if the printing has been interrupted by a dis STATUS turbance or an error Examples are Pressure roll open hood open ribbon Output or material end error start print error or another fault that avoids printing The output is also activated during the initialization of the printer m In comparison to ERROR MACHINE STATUS is not low if the printer has
30. e x value by pressing the Apply or Feed button 5 Press the online button to save the setting By doing so the Fullsize LS is ready set 03 10 Rev 5 04 03 Check setting SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Light sensor rewinder dancer arm ALX The backing paper dancer lever controls the speed at which the back ing paper is unwound The winder rotates fastest when the dancer le ver is in resting position The unwinder rotates more slowly the more the dancer lever is moved out until it comes to a stop in the center position The dancer lever needs the area between the center position and end posi tion when the printer is transporting the label strip backwards approx 90 _ Plastic disk 7 N Stopper NG Stopper Ya Rewinder End position NA Dancer Feed direction S arm 7 gt Rest a Centre position i position Deflection roller gt Backing paper 1 Schematic picture of the rewinder dancer arm at an ALX LH Preconditions Dancer arm is in rest position Backing paper is removed from the rewinder Call SERVICE FUNCTIONS gt Sensor test Press the Apply button repeatedly until the sensor with the ID 5 01 appears Sensor test Xxx LS value 5 01 Option xxx Move the dancer arm from the rest position to the end position spring extended 1 While doing so watch the sensor values in both
31. ed on can cause exposure to hazard ous electrical currents and may lead to burns Switch off the machine before touching the power supply WARNING A N Risk of burn injuries caused by a hot power supply Only operate the power supply if it is built in into the printer housing gt Let the power supply cool down before removing it 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 PEM PM 3000 ALX 92x HME Tab 12 Application of the two power supply types For article numbers refer to the Spare Part Catalog L 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 NT400 Al680 E USI board optional m The NT400 is discontinued since 01 2008 It Pin suneton is replaced by the ME500 see next chapter 1 24V PAm gt GND WARN ING l a galvanically Fire hazard by overheating separated gt This power supply must not be A CPU board connection control signals Pin applied with a dust filter Function NMI ICS ISK I O TK KA KD oOo NO O1 P PO oOoONOOIPOD co B Printhead connection KS GND Pin Function 1 20 28 V 1 2 20 28V 2 3 20 28V 3 4 20 28V 4 5 GND 6 GND 7 7 GND 3 8 GND C CPU board connection supply voltage Logi
32. em 2 Data 3 Data 4 GND 4 Tab 5 Pin assignment of the USB B interface device type B 03 10 Rev 5 04 03 SERVICE MANUAL 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Service Electronics Sensor connections The pin assignment and connection diagram described below applies to the sensor connections H to P in fig 1 yellow marking in 3 Pin Signal 1 Anode 1 ne 2 Cathode 2 Tab 6 Pin assignment and connection dia gram of the sensor connectors 3 Collector 4 Emitter Do TWh allan yosues ak o _ _ gt Zar ee pests posse jie gees qeee jeer bn tee So adhe LLIETIERTTFFTTTETTTTE WM cr eee 3 Right yellow marking sensor connections on the CPU board 03 10 Rev 5 04 03 SERVICE MANUAL 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Service Electronics Centronics daughter board Application notes This board offers the possibility to optionally equip the device with a parallel Centronics interface Requirements m For reasons of limited mounting places this board can not be mounted into a device which is already equipped with the optional I O board up This board can not be mounted into a PM 3000 e CPU board A6621 e Device firmware version 4 12 or higher View E 4 Centronics daughter board A6758 A Centronics jack IEEE 1284 B 36pin
33. esignations and functions of the internal inputs 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Pin assignment jumper block Each signal of the D Sub connector can be interrupted separately at the jumper block m The voltage and ground wires are through connected and cannot be inter rupted 15 GND MACHINE STATUS REPRINT 24V 7 DATA RDY yE RIBBON OUT an PAUSE Een MEDIA OUT m FEED gu PRINT END or START PRINT fr 5V 9 2 GND WARNING ERROR APPLICATOR MODE 15 Pin assignment jumper block Block diagram USI Block Diagram SPS Connectors CN300 GND SPS Ready Error Touch Down Error internal Inputs Home Pos Error only Material Low USI Connector Sub D 15 Start Print Start Print aj fal a ee Fe O O Pause OIP3010 Pause O O Reprint P300 Reprint O T D Ribbon Low Pao Ribbon Low O O Erron OJP2040 Erron O Print End SO Print End 3 7 Media Out ae Media Out fe Ribbon Oufl Ribbon Out LL Data Ready st Data Ready Machine Status OJP2010 Machine Status I Applicator Mode OJP2020 CND OCN2000 GND By OCN2010 BV GND OCN2020 GND Day OCN2040 Day OCN2030 L 16 Block diagram of the USI 03 10 Rev 5 04 03 SERVICE MANUAL Serv
34. ftware debug LED Only for factory internal use AC CN 300 Connection Centronics daughter board AD CN 500 Connection RFID read write unit AE CN 1200 Connection Ethernet 10 100 Base T Pin assignment see chapter Data interfaces at the mounting plate on page 8 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 AF D1200 Ethernet status LED LED Meaning Green Continuously lit High transfer rate 100 Mbit s Yellow Continuously lit Device is connected with the network Flashing Communication with network AGCN 703 Serial interface RS 232 Pin assignment see chapter Data interfaces at the mounting plate on page 8 AH LS 300 Audible signal generator Al CN 401 USB interface type A host e Keyboard connection 2A e Inter Connect Port ICP 2B Connection to a dispenser main board e Pin assignment see chapter Data interfaces at the mounting plate on page 8 bsf aay n mocme O 2 Position of the two USB host interfaces AJ CN 402 Internal USB interface host parallel to CN 401 Pin Signal 1 5 V D D 1234 u DEEH 3 D 4 GND AK CN 400 USB interface type B device Pin assignment see chapter Data interfaces at the mounting plate on page 8 AL CN 403 USB interface host reserved Pin assignment see CN 402 AM CN 1300 CF card slot List of suitable CF cards see Plug in card manual D
35. head screwdriver 1 Remove screws 8A Remove cover plate 8B 8 CPU board with mounted cover plate B 2 Lay the left board edge onto the remaining metal angle 9D Press the right side of the board with its contacts 7B into the connector 8C on the CPU board 3 Fix the board to the metal angle using the two screws 10E Additionally fix the board with two screws from the CPU board rear side into the hex bolts at position 10F 10 Fixing the adapter board 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Operation panel boards Application notes Requirements e CPU board A6621 e Device firmware version 4 12 or above View 11 Operation panel boards for 64 xx left A7149 and for DPM PEM ALX right A6626 A Connection programming adapter only for factory internal use B Connection CPU board connect there to CN 701 m Caution compared to electronics 6 06 the article numbers for the cables were changed The valid numbers are 64 xx A7058 DPM PEM PM 3000 A8176 ALX 92x A8177 C Connection I C bus reserved D Connection for fifth button reserved only at board A6626 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Output stage board Application notes m In case of replacing an output stage board keep in m
36. ice Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Circuit diagrams for signal inputs PE mi mm Tu m nme mm m mm mm Sm m m am m m Sm m m m m mm mm m m m m mm m m m mm mm u I USI board l 5V 24 V 24V 7 NPN sensor 1k2 Controller GND 24V 17 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 m Only one signal at a time may be switched active m The input signals must switch bounce free min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms min 10ms F Start Print fi Puls mode falling edge min 10ms _ Reprint min 10ms print 1 label print 1 label Pause mode on Bang 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 min 10ms min 10ms a aa Start Print Puls mode both edges min 10ms Reprint min 10ms print 1 label print 1 label imprinting of the previous label must start feeding Store to reprint last label Pause mode off be finished labels if
37. ind the following points see tab 12 Article number see label on the board PIC version see label on the microcontroller 12G Jumper setting matching the motor View er a PET gt e t m A G m XXXXXXXXXXXX u cre e Oo Oe oat F EN Eu D F E LEEFT r E L a BE 12 Output stage board A2742 A J4 Sensor E J2 Connection CPU board B J8 Optional sensor Data cable C Jumper setting of the motor F J12 Connection power supply type to which the board applies G PIC version D J3 Motor Output stage applies to PIC version Partno Motor Sensor Jumper set cable cable J6 Ji J7 Feed motor ALX MO4AA V3 F73 A6713 FM X X X Feed motor MO4AA V3 F73 A2742 FM X X X Ribbon motor M04A V3 F73 A2742 RM RS X X Printhead motor MO4A V3 F73 A2742 HM HS X X Rewinder Feed motor 64 xx Disp MO4A V3 F73 A2742 DRM X X Options motor 64 xx M04A V3 F73 A2742 OM OS X Options motor PM 3000 M04A V3 F73 A2742 MOTOR SENSOR X Deflection motor 64 xx Dispenser MO4A V3 F73 A2742 DLM DLS X Rewinder motor ALX R04A V4 F876A A3036 WM WS X X Tab 1 Overwiew output stage configurations for the different motors a for Cutter 2000 or Rewinder 2000 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connections Picture Comp Type on board Type at cable Pin
38. ith backing paper shows at least 138 4 Press the online button to save the setting 03 10 Rev 5 04 03 Punch LS Reflex LS SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Now the settings of the punch sensor are displayed Sensor adjust x Punch y x setting value of the LED current y value measured by the sensor Insert some backing paper of standard label material with the labels peeled off to check the sensor measurement m The material sample must be big enough to cover the LS 2 Set x so that y matches the range of 25 40 Typical x values with this setting are 75 with 64 xx 110 with DPM PEM PM 3000 ALS 92x Insert standard self adhesive material paper label on backing paper into the printer m y should now count at least 100 digits higher than the value measured with bare backing paper If y doesn t match this range modify the x value by pressing the Apply or Feed button Press the online button to save the setting By doing so the punch sensor is ready set Now the settings of the reflex sensor are displayed Sensor adjust x Reflex y x setting value of the LED current y value measured by the sensor m The reflex LS is an option If the printer is not equipped with a reflex LS skip this section by pressing the online button Push the reflex mark on the label material over the reflex LS
39. nd dimensions 1 Switch off the printer Disconnect the power cord 2 Take off the rear hood m Prior to installation of the new battery wipe the battery and the equipement terminal clean using a dry cloth m Ensure that dust and other foreign substances will not cause shorting between the poles m When handling batteries wear finger covers or gloves made of rubber cotton etc to protect the battery from dirt 3 Take used battery out of the socket insert the new battery m Take care of the correct polarity see fig right 4 Reassemble the rear hood 5 Reconnect the printer to the mains and switch it on 6 Set time and date 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Data interfaces at the mounting plate A Ethernet Pin Signal BER 1 TD Cc 2 TD 3 RD 4 Termination 5 Termination 6 RD 7 Termination 8 Termination Tab 2 Pin assignment of the Ethernet interface RJ 45 B RS 232 m Pin assignment looked at from PC point of view Device DCE Pin Signal 5 1 4 6 connected 9 4 2 RxD 5 3 TxD 2 5 GND T 7 RTS 8 CTS 9 not used Tab 3 Pin assignment of the RS 232 interface D Sub 9 female ie USBRA Pin Signal y 1 5 V 1234 x 3 Data ETIN 4 GND Tab 4 Pin assignment of the USB A interface host type A D USB B Pin Signal 3 2 1 5V T
40. nd take notice of the notes in chapter Lithium Battery on page 7 CN 1401 Connection Power Supply Voltage supply of the board with 5V CN 1400 Connection Power Supply Voltage supply of the board with 24 V CN 504 Connection signal interface USI or applicator interface Al D 1401 LED indicating 24 V supply voltage CN 1100 Connection rotary encoder for automatic speed adaption APSF sensor Pin Signal 1 24 V 2 Impulse B ae n ulmm 3 GND 4 Impulse A CN 501 Connection I O board CN 1101 Connection dispensing edge sensor Cable marking OS Pin assignment see chapter Sensor connections on page 9 CN 1102 Connection backing paper rewinder sensor control Cable marking DDS Pin assignment see chapter Sensor connections on page 9 CN 1103 Connection feed roller sensor DPM PEM PM 3000 ALX Cable marking TS 64 xx Dispenser Cable marking DRS Pin assignment see chapter Sensor connections on page 9 CN 1104 Connection material end sensor Cable marking MS Pin assignment see chapter Sensor connections on page 9 CN 1105 Light transmission label sensor Cable marking PS Pin assignment see chapter Sensor connections on page 9 CN 1106 Reflex label sensor Cable marking RS Pin assignment see chapter Sensor connections on page 9 CN 1107 Fullsize transmission label sensor Cable marking FSS Pin assignment see chapter Sensor connections on page 9
41. ng the controller 25 WSIS SIDOX rs een OE 26 Application notes nennen 26 N ee N 26 Connecting the test box 27 RO RUIN een 28 Diagram of a USI input eee 29 OBOA ee 30 Application notes ae 30 VIEW oo ecccecccececeecceeceececeeseeeteneeeneeeneteneseeenes 30 IE ee 31 Setting the Interface Parameters 33 Testing the Serial Interface 33 Power SUD DIES eu 34 Application Notes wis cniicsvivsniencneucesonmesauii 34 NT400 A1680 cceccceeeeseeeeeeeeeeeeeees 35 NEID see een 36 PIE ee 37 Printhead Voltages HME amp Standard 38 Characteristics HME power supply 39 OD control sensor ALX cecceeeeeeeeee eee 40 PUNO each 40 System requirements cecceceeeseeeeee ease 40 Assembling the OD sensor 41 Connecting the OD sensor to Al 43 Connecting the OD sensor to USI 44 Connecting the OD sensor to USI with applicator PLO ren 47 SONGS ee 49 Material end Label sensors 49 Light sensor rewinder dancer arm ALX 52 Adjusting the imprint position 54 SENSOr TEL een 55 General NCES anni 55 Sensors CPU board 64 XX cccseees 56 Sensors CPU board DPM PEM ALX 57 Value table for sensor 0 12 printhead temp ccccssseeeseeeseeseeeeeees S7 Sensors output stage boards 64 xx 58 Sensors output stage
42. nics 132 03 10 Rev 5 04 03 SERVICE MANUAL 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Service Electronics Setting the Interface Parameters With an I O board mounted the following additional menus appear in the printer menu serial interface contains all parameters required to configure the contains all parameters required to configure the signal interface m The signal interface is not yet supported Menu INTERF PARAM gt COM2 PORT SYSTEM PARAMETER O BOARD Parameter Setting Comment Baud rate 9600 No of data bits 8 Parity None Stop Bits 1 Data synch RTS CTS Serial Port Mode RS 232 External signal Singlestart Reprint function Enabled Start delay 0 0 mm Start print mode Pulse falling Reprint signal Enabled A Feed Standard Pause input Standard Error output Print error a Error polarity Level low active gt Status output Print job ready O Status polarity End print mode Level low active Mode3 low pulse Tab 11 Recommended parameter default settings Testing the Serial Interface See parameter description of Info Printouts amp Parameters N in topic section 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Power Supplies WARNING A N The outputs of the power supplies are energy hazard Touching the output connectors with the machine switch
43. ocket 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 m Connect the black cord of the connector strip to pin 1 see 25 and 26 25 The connector strip for connecting the testbox to the internal inputs of the USI The moun ting orientation is printed on the cable black on CN300 pin 1 fet La aie ols IE m m nr oo mp Ml fy Flachbandkabel Ribbon cable F Th E pt USI V2 T1 F873 77 H lan we co FENNEN Ben u zu de du 2 BEAT 1 j Tm 4 a tn 44 a Se g F th a veve K ER 4 A er me ee SD Shy so he Pin 1 1 i n oo 4 Er at i ue un j h A 0 CNS300 i en a NS Anschluss interne USI Eing nge Connector internal USI Inputs z0167 cdr 26 Pin 1 is the first pin in direction of the ribbon cable the writing CN300 Pin 1 can 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 inputs 03 10 Rev 5 04 03 LEDs Internal inputs SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Operation e After powering on the printer the LEDs on the te
44. ode and no print job loaded Tab 4 Signal designations and functions of the USI interface 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Pin Signal Function 5 PAUSE A high low transition switches the printer into the USI paused mode Input A further high low transition switches the printer back into the online mode If parameter 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 ERROR is activ low e f a print job is available DATA RDY is inactive high e Start print signals are suppressed e Reprint requests are proceeded after switching into online mode e Precondition START PRINT inactive high 6 REPRINT The last printed label is being reprinted as long as REPRINT is low Input Minimum reprint quantity 1 label Preconditions e The label which is ought to be reprinted must be ready printed and dispensed e Printer is in online mode e f a REPRINT is triggered while the printer is in USI pause mode the reprint will be proceeded as soon as the printer is switched back in online mode e Precondition START PRINT inactive high 7 24V EXT Voltage supply for external sensors Voltage supply 8 GND_ EXT Ground contact GND 9 WARNING Ribbon low warning Output The signal is activated high if a
45. oller into the socket m The dent in the controller housing must show in the pictured direction 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 USI testbox Application notes e Simulating USI inputs e Checking USI outputs e Monitoring of drive signals sent by the system control e Aid for setting up the machine 23 Left side USI testbox A2739 right side connecting cable A2842 Both parts are re guired for application Both parts A2843 View Survey of the voltage supply at the D Sub connector of the USI The test box needs 5 V supply voltage ERED STOPPED Survey of in and outputs at the D Sub connector of the USI Simulation of the 4 inputs at the D Sub connector of the USI 4 pushbuttons Simulation of the 4 internal inputs at the aaa eens ee CN300 connector of the USI from vers 4 on pede ERN j 4 switches Optional connection of a customer control unit _ or product sensor monitoring 24 Operating parts and connections of the USI testbox z0175E CDR 03 10 Rev 5 04 03 Connection to internal inputs SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 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 s
46. 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 10 Without material typical 7 11to255 With material 0 06 Reflex Optional gt 200 Without material approx 253 or reflex sensor opposite of the reflex mark gt 200 10 bis 20 With white material 0 07 FullSz Optional 10 Without material Full size light barrier 11to255 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 3 Tab 1 Test conditions for sensors connected to the CPU board a Precondition parameter SYSTEM PARAMETER gt Sens punch LS 30 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Sensors CPU board DPM PEM ALX Sensor Sensor Description Typical Value Condition name 0 03 Press Microswitch at the pres 255 Pressure roller closed sure roller contacting the feed roller 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 10 without material typical 7 11 to 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 3
47. or all sensor values Full light leads to values lt 10 No light leads to values gt 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 5 Display after calling Sensor test m Extraneous light must be avoided when checking the sensors Therefore keep the front cover and the housing cover closed during the sensor test Press the Feed or Apply button to select the individual sensors if present e For details refer to chapter Material end Label sensors on page 49 m 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 03 SERVICE MANUAL 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Sensors CPU board 64 xx Service Electronics Sensor Sensor Description Typical Value Condition name 0 01 Option 64 xx dispenser only 255 Light barrier covered by a Dispense light barrier dispensed label 0 Light barrier clear 0 02 Option 64 xx dispenser only 255 Internal rewinder not full microswitch at the inter nal rewinder 0 Internal rewinder full 0 03 Press 64 xx dispenser only 255 Pressure roller closed microswitch at the pres sure roller 0 Pressure roller
48. r number A2794 for fitting onto older ma chines Alternatively the threaded holes and the counter bore can be implemented on the existing plate 4 Screw the OD bracket onto the holding plate with the wing screw and shim 43 gt 5x45 55 12 0 10 M5 2x 7 ZA A A ul Q A Mn 3 50 99 115 87 gt 42 Holding plate dimensions 43 Screw the OD bracket onto the holding plate 03 10 Rev 5 04 03 SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Connecting the OD sensor to Al Plug the D Sub 26 connector 44A to the centre connection machine status at the Al Alternatives An already available OD sensor assy for USI can be modified for use with an Al by doing the following Exchange the shipped cable by the cable A5292 Or gt Connect the D Sub 26 connector to the ca ble according to the table right The Al connector kit A5069 contains connector and housing each 1x D Sub 15 high density 1x D Sub 26 high density 44 OD sensor assy for Al A5293 1x D Sub 44 high density Wire colour Pin at D Sub 26 Function Also see topic section Applicator Brown 14 24V Interface D 23 A Blue 15 GND Black 24 K Tab 5 Pin assignment at the D Sub 26 connector NPN 03 10 Rev 5 04 03 SE
49. stbox show the current levels of the USI outputs with the following meaning LED off USI output High LED on USI output Low e The supply voltage LEDs indicate LED off Voltage not applied LED on Voltage applied e Each pressing of a key or switch pulls the respective input level down to Low with the LED on the key or switch lighting up e 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 e With the testbox being connected to the USI merely by the D Sub15 connector 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 e Additionally the internal USI inputs can be simulated if the 5 pin connector Strip is plugged into CN300 on the USI board 26 Internal USI input Switch 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 m Befor st
50. t 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 Ino d 0 65 MA U min 30 V 5 VDC lhoig 0 65 MA Umin 6 V e Micro fuse according to IEC EN 60127 24 VDC T 630 mA L 250 V 5 VDC T 630 mA L 250 V a Due to an update of EN 60950 1 Replacing the controller A firmware update for controller versions older than V6 T36 can only be done by replacing the controller 22A Article number of the controller with the most recent firmware A3379 Version check Displaying the current controller version SERVICE DATA gt gt MODULE FW VERS gt USI interface US W2 T1 FB73 xa 2 p un ae ai EL E a ag Ju Pd ER hr ECESE hia LEE FE FL 5 h rF en i Ar Felge J d a n i J a E ami iwi r Se J n fari ZN i Ea oer el ii be Fr Re eer j 3 Piel LEE LIE ae r f EE en k Pe j mp i ni J i 6 ill Ah B m F re Wu 1 22 The controller A contains the USI firmware Controller 1 Switch the printer off pull out the mains connector replacement 2 Open the rear hood See topic section Service Mechanics D section Housing chapter Rear hood 3 Take the controller 22A out of the socket 4 Insert the new contr
51. tage boards ALX DPM PEM Sensor Sensor Beschreibung Typische Bedingung ID Name Werte 2 01 Folie Foil sensor 0 Sensor above a hole in the oscil lator disc light barrier clear 254 Sensor covered 3 01 Kopf Light barrier at the print 0 Printhead in economy position head raising mechanism raised 254 Printhead in print position lowered Tab 7 Testbedingungen f r Sensoren die an eine der Endstufen Platinen angeschlossen werden
52. topic section Card types CompactFlash card AN CN 1301 Interface for optional second CF card slot See Abschnitt CF daughter board auf Seite 11 AO CN 101 SD MMC card slot 03 10 Rev 5 04 03 Battery type A A Specifications Battery replacement SERVICE MANUAL Service Electronics 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Lithium Battery The CPU board is equipped with a realtime clock which keeps its setting if the printer is switched off This is done by a lithium battery on the board m The battery is not rechargeable m The battery must be UL listed Panasonic CR2032 or an equivalent battery type WARNING Danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended by the man ufacturer Take care of the correct polarity when replacing the battery Discard used batteries according to the manufacturer s instructions AVERTISSEMENT ll y a danger d explosion s il ya remplacement incorrect de la batterie Remplacer uniquement avec une batterie du m me type ou d un type recommende par le constructeur Mettre au rebut les batteries conform ment aux instructions du fabricant Nominal voltage 3V Nominal capacity 220 mAh Continous standard load 0 2A Operating temperature 30 to 60 C Max abnormal charging current 5 0 mA Tab 1 Battery type CR2032 specifications a
53. xD Out R 3 TxD In 6 1 4 DTR Short with DCD amp DSR 5 GND 6 DSR Short with DCD amp DTR 7 RTS In 8 CTS Out 9 RI Not connected Tab 8 Pin assignment of the RS 232 interface D Sub 9 female B RS 422 485 gt Set to RS 422 or RS 485 m Pin assignment looked at from PC point of view Device DCE Pin Signal name Signal direction at the host I O board 9 j 1 Not connected 8 2 Rx Out 7 2 3 Tx In 6 4 Termination 5 GND 6 Termination 7 TX In 8 Rx Out 9 Not connected Tab 9 Pin assignment at the RS 422 485 interface D Sub female a 110 Ohm RS 422 485 At the ast printer at the RS 422 485 line connect the following pins inside of termination the cable connector e Pins 3 and 4 Tx e Pins 6 and 7 Tx RS 485 2 wire At each printer on the bus line connect the following pins inside of the cable connection connector e Pins 2 and 3 Tx Rx e Pins 7 and 8 Tx Rx 03 10 Rev 5 04 03 C Connection CPU board SERVICE MANUAL 64 xx Gen 3 DPM Gen 3 PEM PM 3000 ALX 92x Gen 3 Pin Signal 1 GND 2 nREPRINT 3 FPGA_U4RX 4 nSTART 5 FPGA _U4TX 6 nFEED 7 GND 8 nPAUSE 9 FPGA U4CTS e i 10 ERROR n 11 FPGA _U4RTS r 12 WARNING 2 gt 13 GND 2 7 14 PRINTEND 15 3 3V 16 5V 17 DXEN 18 RS485_ nRS323 Tab 10 Pin assignment at the CN 101 connector Service Electro

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