Service Electronics

03/10 Rev. 5.04-01
SERVICE MANUAL
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Service Electronics
Handling boards ............................................ 2
ESD protection .......................................... 2
Handling .................................................... 2
CPU Boards .................................................. 3
Layout without Ethernet ............................ 3
Layout with Ethernet ................................. 4
Connectors ................................................ 5
Output stage board ....................................... 9
Important Notes ......................................... 9
Layout / Connecting .................................. 9
Connectors .............................................. 10
Option Board ............................................... 11
Layout ..................................................... 11
Connectors .............................................. 11
USI Board ................................................... 12
Application notes ..................................... 12
View ........................................................ 13
Connectors .............................................. 13
Signal description (D-Sub 15) ................. 14
Pin assignment internal inputs (CN 300) . 16
Signal description (CN300) ..................... 17
Pin assignment jumper block .................. 17
Block diagram ......................................... 18
Circuit diagrams for signal inputs ............ 19
Circuit diagrams for signal outputs .......... 20
Firmware update ..................................... 22
USI testbox ................................................. 23
Application ............................................... 23
View ........................................................ 23
Connecting the test box .......................... 24
Operation ................................................ 25
Diagram of a USI input ............................ 26
Display 64-xx ...............................................27
Layout ......................................................27
Connector ................................................27
Display DPM/ALX ........................................28
Layout ......................................................28
Connector ................................................28
Power Supplies ...........................................29
Application Notes .....................................29
Retrofitting the ME500 .............................29
NT400 (A1680) ........................................30
ME500 .....................................................31
HME .........................................................32
Printhead Voltages HME & Standard ......33
Characteristics HME power supply ..........34
Settings .......................................................35
Sensor setting ..........................................35
Sensor test ..................................................38
General notes ..........................................38
Sensors on the CPU board (64-xx) ..........39
Sensors on the CPU board (DPM/ALX) ...40
Value table for sensor 0.12
(printhead temp.) .....................................40
Sensors on the output stage boards
(64-xx) ......................................................41
Sensors on the output stage boards
(ALX/DPM) ...............................................41
Options ........................................................42
Installing a Memory Extension .................42
Installing the Option Board ......................44
Installing a Realtime Clock ......................45
Attaching locking clips for flat strap plugs 46
Index ............................................................48
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Handling boards
ESD protection
All the boards described in the following are fitted, among other things, with
large-scale integrated circuits. Voltage impulses caused by static charging
from people or objects can easily destroy the circuits.
When handling boards, ensure that the electronics cannot be damaged by
static charging or discharging.
¯ CAUTION! Place the printer on an earthed underlay before opening it.
¯ CAUTION! Earth your body with an ESD protective armband or by using
another suitable means. If suitable ESD protection is not available, touch an
earthed object, e.g. a radiator, before touching a board.
¯ CAUTION! Only place boards on an earthed underlay.
Handling
The conductor lines on modern multilayer boards are very thin. Bending the
boards can therefore easily break the conductor lines.
¯ CAUTION! Avoid bending the boards.
¯ CAUTION! Avoid using excessive force when removing and installing the
boards.
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
CPU Boards
JP301 Function
Boot from U303 BootPROM
Boot from system flash
(default)
Layout without Ethernet
JP502 Function
/503
+5V at Centronics pin 35
+ 5V at Centronics pin 18
Default
Sockel für 8bit
Boot-PROM
(U303)
SO-DIMM 144 socket for
memory extension
(U201)
CAUTION - Only for production purposes! JTAG
interface (CN402)
RTC socket
(U701)
Power supply USI board
(CN1301)
(CN1005)
JP1101/ Function
1102
Constant LED current at
dispensing edge sensor
Constant LED current at
Ø-sensor Disp.-Rewinder
Pulsed LED current at dispensing edge sensor & at
Ø-sensor Disp.-Rewinder
Display Data cable peripheral
(CN902) (I2C bus) (CN1003)
Sensor dispensing
edge (CN1101)
Ø-sensor dispenser
rewinder (DDS)
(CN1102)
CF card slot
(CN801)
Feed roller sensor
(DPM/PEM/ALX=TS,
64-xx Dispenser=DTS) (CN1103)
Material end sensor
(MS) (CN1104)
Punch sensor (PS)
(CN1105)
Reflex sensor (RS)
(CN1106)
Fullsize sensor (FSS)
(CN1107)
Centronics
(CN501)
Singlestart sensor
(SSS) (CN1108)
Cover sensor (COS)
(CN1109)
Power supply
(CN1004)
Internal scaner
(CN1006)
RS232 (CN601)
Motor output stage
(I2C bus) (CN1001)
Option board
(CN602)
JP601 Function
/602
RS422/485 termination: RxD
RS422/485 termination: TxD
RS232, no RS422/485 termination
(default)
CAUTION - Only for production purposes!
H8-PRG-Adapter (CN1002)
Printhead (CN901)
JP102 Function
1-2
8bit boot bus width (for
U303 Boot-PROM)
2-3
CAUTION - Line termination in RS485-mode:
2-wire-interface: close either JP601 or JP602!
4-wire-interface: close JP601 and JP602!
16bit boot bus width
(default)
L CAUTION Only for production
purposes!
JP1004 Function
H8: RX1 RS232 level
H8: RX1 TTL level (default)
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Layout with Ethernet
JP502 Function
/503
+5V at Centronics pin 35
+ 5V at Centronics pin 18
Default
JP301 Function
Boot from U303 BootPROM
Boot from system flash
(default)
Sockel für 8bit
Boot-PROM
(U303)
SO-DIMM 144 socket for
memory extension
(U201)
CAUTION - Only for production purposes! JTAG
interface (CN402)
RTC socket
(U701)
Power supply USI board
(CN1301)
(CN1005)
JP1101/ Function
1102
Constant LED current at
dispensing edge sensor
Constant LED current at
Ø-sensor Disp.-Rewinder
Pulsed LED current at dispensing edge sensor & at
Ø-sensor Disp.-Rewinder
Display Data cable peripheral
(CN902) (I2C bus) (CN1003)
Sensor dispensing
edge (CN1101)
Ø-sensor dispenser
rewinder (DDS)
(CN1102)
CF card slot
(CN801)
Feed roller sensor
(DPM/PEM/ALX=TS,
64-xx Dispenser=DTS) (CN1103)
Material end sensor
(MS) (CN1104)
Ethernet 10/100
Base T
(CN1501)
Punch sensor (PS)
(CN1105)
Reflex sensor (RS)
(CN1106)
Fullsize sensor (FSS)
(CN1107)
Centronics
(CN501)
Singlestart sensor
(SSS) (CN1108)
Cover sensor (COS)
(CN1109)
Power supply
(CN1004)
Internal scaner
(CN1006)
RS232 (CN601)
Motor output stage
(I2C bus) (CN1001)
Option board
(CN602)
JP601 Function
/602
RS422/485 termination: RxD
RS422/485 termination: TxD
RS232, no RS422/485 termination
(default)
CAUTION - Only for production purposes!
H8-PRG-Adapter (CN1002)
Printhead (CN901)
JP102 Function
1-2
8bit boot bus width (for
U303 Boot-PROM)
2-3
CAUTION - Line termination in RS485-mode:
2-wire-interface: close either JP601 or JP602!
4-wire-interface: close JP601 and JP602!
16bit boot bus width
(default)
CAUTION - Only for production
purposes!
JP1004 Function
H8: RX1 RS232 level
H8: RX1 TTL level (default)
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Connectors
Picture
I2C Motordr. Bus
Comp.
Type on
Diagram board
CN1001 3M
25146002
PRG Adapter
CN1002 3M
25146002
I2C-Bus
CN1003 PANCON
MLSS
100-04
Power supply
CN1004 PANCON
MLSS
100-09
USI
CN1005 3M
25146002
Type at
cable
Pin assignment on board
1 - CLK_0
3 - CLK_2
5 - CLK_4
7 - CLK_6
9 - SCL
11 - EX_RES\
13 - n.c.
1 - VCC 5V
3 - n.c.
5 - EX_RES\
7 - SCL
9 - SDA
11 - VCC 5V
13 - TX1_232
2 - CLK_1
4 - CLK_3
6 - CLK_5
8 - CLK_7
10 - SDA
12 - H8_IRQ4\
14 - GND
2 - MD2
4 - RX1
6 -TX1
810 - PRGRES\
12 - GND
14 - RX1_232
1 - SDA
2 - SCL
3 - EX_RES\
4 - CLK_7
1 - H8_NMI
2 - ICS
3 - PS_ISK
4 - PS_I/O
5 - ASENSOR_0
6 - KA
7 - KD
8 - KS
9 - n.c.
2 - EX_RES\
4 - AI_IRQ\
6 - H8_IRQ4\
8 - SCL
10 - SDA
12 - TX1
14 - APFS
1 - VCC 5V
3 - VCC 5V
5 - VCC 5V
7 - GND
9 - GND
11 - RX1
13 - GND
Scanner
Tab. 1:
CN1006 Hirose
DF1124DP-2V
Connector description CPU board
2 - GND
4 - n.c.
6 - H8_PA0
8 - n.c.
10 - GND
12 - n.c.
14 - n.c.
16 - n.c.
18 - n.c.
20 - n.c.
22 - n.c.
24 - n.c.
1 - VCC 5V
3 - FRAME 1
5 - n.c.
7 - n.c.
9 - H8_IRQ5\
11 - H8_PB84
13 - n.c.
15 - R1 IN
17 - T1 0UT
19 - n.c.
21 - n.c.
23 - GND
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Picture
Comp.
Type on Type at
Diagram board
cable
Sensor dispensing CN1101 PANCON
edge
MLSS
100-04
Ø-sens. rewinder
Sens. feed roller
Material end S.
Punch Sensor
Reflex Sensor
Fullsize Sensor
Singlestart sens.
CN1102 PANCON
MLSS
100-04
CN1103 PANCON
MLSS
100-04
CN1104 PANCON
MLSS
100-04
CN1105 PANCON
MLSS
100-04
CN1106 PANCON
MLSS
100-04
CN1107 PANCON
MLSS
100-04
CN1108 PANCON
MLSS
100-04
Tab. 1: (Continued) Connector description CPU board
Pin assignment on board
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
1 - Anode
2 - Cathode
3 - Collector
4 - Emitter
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Picture
Cover switch
Comp.
Type on Type at
Diagram board
cable
CN1109 PANCON
MLSS
100-02
Ethernet
CN1501 RJ 45
Centronics
CN501
IEEE
1284 B
36pin
RS232/422/485
CN601
DSub9-F
Pin assignment on board
1 - Signal cover switch
2 - GND
1 - TD+
2 - TD3 - RD+
4 - Termination
5 - Termination
6 - RD7 - Termination
8 - Termination
36 - SELECT_IN\
35 - VCC 5V (JP503 geschl.)
34 - n.c.
33 - GND
32 - FAULT\
31 - INIT\
30 - GND
29 - GND
28 - GND
27 - GND
26 - GND
25 - GND
24 - GND
23 - GND
22 - GND
21 - GND
20 - GND
19 - GND
18 - VCC 5V (JP502 geschl.)
17 - n.c.
16 - n.c.
15 - n.c.
14 - AUTO_FEED\
13 - SELECT
12 - PAPER END
11 - BUSY\
10 - ACK\
9 - LPT_D7
8 - LPT_D6
7 - LPT_D5
6 - LPT_D4
5 - LPT_D3
4 - LPT_D2
3 - LPT_D1
2 - LPT_D0
1 - STROBE\
RS232
9 - (RI)
8 - CTS
7 - RTS
6 - (DSR)
RS422/485
5 - GND
4 - (DTR)
3 - TxD
2 - RxD
1 - (CD)
9 - n.c.
8 - Tx+
7 - Rx+
6 - n.c.
L
CAUTION! RS232 pin assignment
looked at from „PC point of view“!
(Printer = DCE)
Option board
CN602
3M
25206002
Tab. 1: (Continued) Connector description CPU board
20 - RESET
18 - VCC 3V3
16 - KBDCLK
14 - ON_2
12 - RS232_2\
10 - GND
8 - RTS_2\
6 - DTR_2\
4 - DSR_2\
2 - SOUT_2
19 - GND
17 - KBDDAT
15 - DXEN_2
13 - RXEN_2
11 - RI_2\
9 - VCC 5V
7 - CTS_2\
5 - GND
3 - SIN_2
1 - DCD_2\
5 - GND
4 - n.c.
3 - Rx2 - Tx1 - n.c.
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Picture
Printhead
Display
Comp.
Type on
Diagram board
CN901 3M
25206002
CN902
Type at
cable
3M
25206002
Tab. 1: (Continued) Connector description CPU board
Pin assignment on board
1 - HVCC
3 - GND
5 - HDATA 1
7 - HCLK
9 - HLCH
11 - HBE 0
13 - HSTB 2/HDATA 3
15 - HCONT 2
17 - HCONT 4
19 - HDATA 4
1 - ON/OFF\
3 - CUT\
5 - FEED\
7 - PROG\
9-E
11 - RS
13 - R_W\
15 - ERROR
17 - RESET
19 - GND
2 - HVCC
4 - GND
6 - HDATA 2
8 - GND
10 - GND
12 - HSTB 1
14 - HCONT 1
16 - HCONT 3
18 - HCONT 5
20 - HTHM 1
2 - D0
4 - D1
6 - D2
8 - D3
10 - D4
12 - D5
14 - D6
16 - D7
18 - RESET
20 - GND
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Output stage board
Important Notes
¯ Please keep in mind the following points, when you replace or check an out•
•
put stage board:
PIC version:
The PIC must carry a label with the writing "M04A V3 C73"!
Jumper setting:
The jumper setting must match the motor which is ought to be driven by the
output stage!
Layout / Connecting
Jumper
J6
J1
J7
J6
J1
J7
J6
J1
J7
J6
J1
J7
J6
J1
J7
Function
Options motor (e.g.
cutter, ext. rewinder,
dispenser: release
motor)
Printhead motor
Sensor (J4)
Optional: additional
sensor (J8)
Ribbon motor
Feed motor
Motor (J3)
Dispenser motor
ALX 92x / 64xx Dispenser)
Power supply
(J12)
Output stage for
Feed motor
Ribbon motor
Printhead motor
Options motor
Dispenser motor
[1]
Control lines, coming
from the CPU board
(J2)
Marker at
motor cable
FM
RM
HM
OM
WM
Marker at
sensor cable
no sensor
RS
HS
OS
no sensor
By setting the jumpers, you prepare the output stage board for application with the motor
you intend to drive (tab. left side). Connecting the cables: Identify the right motor or sensor cable by its marker on the cable sleeve (tab. below).
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Connectors
Picture
Comp. Type on board
Diagr.
J4
PANCON
MLAS 100-04
Type at cable
Pin assignment on
board
AMP 643813-4 oder
AUK MK-04H
1-A
2 - K (GND)
3-C
4 - E (GND)
J3
PANCON
MLAS 100-04
AMP 643813-4 oder
AUK MK-04H
1-A
2 - A\
M
J2
Wieson
2120-14RS5
3-B
4 - B\
11 - Reset\
9 - I2C-SCL
1 - Clock 0
MOLEX 70450
Version b
10 - I2C-SDA
14 - GND
J12
Tab. 2:
AMP 640389-6
Connectors on the output stage board.
AMP 0-644465-6
MTA 156 18 AWG
1 - 5V
2 - GND
3 - n.c.
4 - GND
5 - 38..54V
6 - GND
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Option Board
Layout
PS/2 keyboard
(CN103)
L
CAUTION! The maximum output current of the PS/2 interface
is 500mA at 25°C!
A self-resetting fuse interrupts the current in case of over load.
CPU board
(CN104)
JP102 Function
RS422/485 termination: TxD
COM2
(CN101)
RS232, no RS422/485 termination (default)
JP101 Function
RS422/485 termination: RxD
L
CAUTION! Line termination in RS485-mode:
2-wire-interface: close either JP101 or JP102!
4-wire-interface: close JP101 and JP102!
RS232, no RS422/485 term.
(default)
Connectors
Picture
RS232/422/485
Comp.
Diagr.
CN101
Type on Type at Pin assignment on board
board
cable
RS232
DSub9-F DSub9-M
5 - GND
4 - DTR
3 - RxD
2 - TxD
1 - DCD
9 - n.c.
8 - RTS
7 - CTS
6 - DSR
Tastatur
CN 103
PS/2
PS/2
2 - n.c.
1 - Data
CPU-Platine
CN104
Fig. 2:
Kabel ist
an Platine
angelötet
Connectors on the option board
2 - SOUT 2
4 - n.c.
6 - n.c.
8 - RTS 2\
10 - GND
12 - RS232_2\
14 - ON_2
16 - KBDCLK
18 - n.c.
20 - RESET
RS422/485
9 - n.c.
8 - Tx+
7 - Rx+
6 - n.c.
4 - + 5V
6 - n.c.
3 - GND
5 - Clock
1 - n.c.
3 - SIN 2
5 - GND
7 - CTS_2\
9 - VCC 5V
11 - n.c.
13 - RXEN 2
15 - DXEN 2
17 - KBDDAT
19 - GND
5 - GND
4 - n.c.
3 - Rx2 - Tx1 - n.c.
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
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.
USI-equipped machines can for example control applicators or scanners.
The input signals can be used to trigger the print-dispense-process. The output 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
¯ DPM, PEM, PM 3000, ALX 92x: USI and AI (Applicator Interface) can not be
built into the same device.
Version
¯ The functionality described in this section is only then fully available, if USI
board, Controller and printer firmware match the following versions:
y USI board: At least A2345-04 or a later version, which can be recognized by
a higher index (-05, -06, …). The version number can be found on a label attached to the board [3B, C].
y USI controller: At least V2-T1-F873 or a later version, which can be
recognized by the V-section of the version number (V3-, V4-, …). The version
number is written on a label attached to the controller [3A].
y Printer firmware: 4.12 (is displayed after powering on the printer).
Connection type
NPN
Signal voltage
optionally 5 or 24 V
A
C
[3]
At those places, you find the version designations on the USI board.
B
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
View
SPS (optional)
USI board version
number (here: -04)
Micro controller version
number (here: V2)
USI signals
(VB200)
CPU board
(CN101)
JP8
Power supply
(CN100)
Function
5V internal voltage supply active on
Pin2/DB-15
5V external voltage supply on Pin 2/
DB-15
Connector for internal USI inputs
(CN 300)
Connectors
Picture
Comp.
Diagr.
CN100
CN101
Tab. 3:
Connectors on the USI board.
Type on Type at
board
cable
AMP
640457-4
Cable is
soldered
to the
board
Pin assignment on board
1 - EXT 24V
2 - n.c.
3 - n.c.
4 - EXT GND
2 - EX_RES\
4 - AI_IRQ\
6 - H8_IRQ4\
8 - SCL
10 - SDA
12 - n.c.
14 - APSF
1 - VCC +5V
3 - VCC +5V
5 - VCC +5V
7 - GND
9 - GND
11 - n. c.
13 - GND
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Picture
Comp.
Diagr.
CN300
Type on
board
Type at
cable
Pin assignment on board
1 - OD control material
2 - Applicator homeposition error
3 - Applicator touchdown error
4 - SPS ready/error
5 - GND
VB200
15 - MACHINE STATUS\
14 - DATA_RDY\
13 - RIBBON_OUT\
12 - MEDIA_OUT\
11 - PRINT_END\
10 - ERROR\
9 - WARNING
8 - GND_EXT
7 - 24V_EXT
6 - REPRINT\
5 - PAUSE\
4 - FEED\
3 - START_PRINT\
2 - 5V_EXT
1 - GND_EXT
Tab. 3: (Continued) Connectors on the USI board.
Signal description (D-Sub 15)
Pin Signal
Signal
type
Ground
1
GND_EXT
2
5V_EXT
3
START_PRINT\ In
4
FEED\
In
5
PAUSE\
In
Tab. 4:
Voltage
supply
Function
Ground contact
JP8 connected: Internal 5 V source can be used via the wire for external
sensors.
• JP8 clear: Wire can be used for an external 5 V source.
The machine starts printing depending on the setting of parameter DP INTERFACE > Start print mode.
Preconditions: Printjob is available (DATA RDY\ low), printer is in
online mode, no error messages.
Feeding of the label material as long as the signal is low. Minimum feed quantity: 1 label. The display shows „USI feed“ during
feeding.
Preconditions for feeding:
• Offline mode, printing has been stopped or the printer is in USI-paused mode.
• Online mode and no print job loaded.
A high-low-transition switches the printer into the USI-paused
mode.
A further high-low-transition switches the printer back into the online mode.
If parameter DP INTERFACE > Start print mode is set to Level high active
or Level low active, any activating of the PAUSE\ signal stops the
printing after the current label.
Features:
• „USI Pause“ is displayed
• ERROR\ is activ (low)
• If a print job is available: DATA RDY\ is inactive (high)
• Start print signals are suppressed
• Reprint requests are proceeded after switching into online mode.
• Precondition: START PRINT\ inactive (high).
•
Signal designations and functions of the USI interface.
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Pin Signal
Signal
type
In
6
REPRINT\
7
24V_EXT
8
GND_EXT
Voltage
supply
Ground
9
WARNING
Out
10 ERROR\
Out
11 PRINT_END\
Out
11 HOME_POS\
Out
Function
The last printed label is being reprinted as long as REPRINT\ is
low.
Minimum reprint quantity: 1 label.
Preconditions:
• The label which is ought to be reprinted, must be ready printed and dispensed.
• Printer is in online mode.
If 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.
Precondition: START PRINT\ inactive (high).
Voltage supply for external sensors
Ground contact
Ribbon low warning:
The signal is activated (high), if
a) DP INTERFACE > Ribbon signal = activated and
b) The ribbon stock is below the threshold value, which is set in parameter
SYSTEM PARAMETER > Ribbon warning.
After changing the ribbon roll, the signal will be inactivated after a short time.
• The signal is activated (high), if
a) DP INTERFACE > Material signal = activated and
b) The label material stock is below the threshold, which is set by positioning
the light barrier
After changing the material roll, the signal will be inactivated.
The WARNING output is only then inactivated (low), if ribbon and
material both are available in a sufficient amount. If one of both
rolls falls below the threshold value, the output switches activ
(high).
In practice, the more or less eccentric running material roll will
trigger the material warning repeatedly, until the roll diameter
falls below a certain tolerance zone.
This signal is only a warning, what means that the printing goes
on.
This output is activated (low) during every status which keeps the
printer from printing:
USI-pause mode, stopped mode, offline mode, hood open, 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)!
The manner in which this output is switched depends on the setting of parameter DP INTERFACE > End print mode.
Difference to older versions of printer firmware (below 2.46): The
output is now also activated as long as labels are fed.
Limitation: This functionality is not available in Batch mode!
Printer operation with LTSI applicator (with PLC version 5.0 and
higher): Applicator is in home position (upper limit position)
•
Tab. 4: (Continued) Signal designations and functions of the USI interface.
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Pin Signal
Signal
type
Out
12 MEDIA_OUT\
13 RIBBON_OUT\ Out
14 DATA_RDY\
Out
15 MACHINE
STATUS\
Out
Function
Low in case of material end. Additionally activated are:
• ERROR\
• MACHINE STATUS\
Low in case of ribbon end. Additionally activated are:
• ERROR\
• MACHINE STATUS\
This signal is activated (low), if the printer has finished image processing and is ready to start printing.
The signal is inactivated, if
• the print job is done, or
• the printer is switched to stopped mode, offline mode or USI-pause mode.
This output is activated (low), if the printing has been interrupted
by a disturbance or an error. Examples are: Pressure roll open,
hood open, ribbon- or material end error, start print error or
another fault that avoids printing.
The output is also activated during the initialization of the printer.
In comparison to ERROR\, MACHINE STATUS\ is not low if the
printer has been switched to offline or pause mode.
Printer operation with LTSI applicator (with PLC version 5.0 and
higher): No function
Tab. 4: (Continued) Signal designations and functions of the USI interface.
Pin assignment internal inputs (CN 300)
The following parameter settings are required to make the internal inputs
useable:
PLC
For usage with PLC:
•
•
OD sensor
DP INTERFACE > Interface type = USI Applicator
DP INTERFACE > Internal inputs = Enabled
For useage with „OD sensor material“:
•
•
DP INTERFACE > Material signal = Enabled
DP INTERFACE > Internal inputs = Enabled
If PLC and „OD sensor material“ are ought to be used, all three parameter
settings have to be done.
¯ To all four inputs applies: The input is inactivated if it is connected to ground
potential!
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Signal description (CN300)
Pin Signal
1
OD control
material
2
Applicator
fault home
position
Applicator
fault touch
down
PLC ready /
fault
GND
3
4
5
Signal
type
In
Function
To be applied to the OD control material option.
The signal WARNING at pin 9 of the DB 15 is switched activ, if
• Parameter DP INTERFACE > Material Signal = Activated and
• the input is high
If one of the inputs is high or makes a low-high-transition, the appropriate status message is displayed at the printer. Additionally, the
outputs ERROR\ and MACHINE STATUS\ will be activated (low).
In
In
In
Ground
GND potential of the internal inputs
[Tab. 5] Signal designations and functions of the internal inputs
Pin assignment jumper block
Each signal of the D-Sub connector can be interrupted separately at the jumper block.
¯ The voltage and ground wires are through-connected and cannot be interrupted (see Fig. 4)!
GND
MACHINE STATUS\
REPRINT\
24 V
DATA RDY\
RIBBON OUT\
PAUSE\
MEDIA OUT\
FEED\
PRINT END\
START PRINT\
5V
GND
WARNING
ERROR\
APPLICATOR MODE
[4]
Pin assignment jumper block
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Block diagram
USI Block Diagram
SPS Connectors
CN300
MUX
7
6
5
4
GND
SPS Ready\ /Error
Touch Down Error
Home Pos. Error
Material Low
Pin 5
Pin 4 internal Inputs
Pin 3
only
Pin 2
Pin 1
USI Connector
[5]
USI logic
USI Controller
Engine Controller
Sub-D 15
3
2
1
0
Block diagram of the USI
Start Print\
Feed\
Pause\
Reprint\
Ribbon Low
Error\
Print End\
Media Out\
Ribbon Out\
Data Ready\
Machine Status\
Applicator Mode
GND
5V
GND
24V
JP303
JP302
JP301
JP300
JP204
JP203
JP205
JP206
JP200
JP201
JP202
CN200
CN201
CN202
CN204
CN203
Start Print\
Feed\
Pause\
Reprint\
Ribbon Low
Error\
Print End\
Media Out\
Ribbon Out\
Data Ready\
Machine Status\
GND
5V
GND
24V
Pin 3
Pin 4
Pin 5
Pin 6
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
Pin 15
Pin 1
Pin 2
Pin 8
Pin 7
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Circuit diagrams for signal inputs
[6]
Timing waveform of
input signals
Main circuit for signal inputs (NPN) at the USI interface (here: connecting a start sensor).
The following criteria must be matched by the input signals of the USI:
¯ Only one signal at a time may be switched active!
¯ 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
Start Print
(Puls mode falling edge)
min. 10ms
Feed
min. 10ms
Reprint
min. 10ms
min. 10ms
Pause
print 1 label
min. 10ms
print 1 label
imprinting of the
previous label must
be finished!
min. 10ms
Pause-mode on
start feeding
labels
print 1 label
Pause-mode off
stop feeding
labels
min. 10ms
min. 10ms
min. 10ms
min. 10ms
min. 10ms
reprint last label
(if not disabled)
imprinting of the previous
label must be finished!
min. 10ms
min. 10ms
Start Print
(Puls mode both edges)
min. 10ms
Feed
min. 10ms
min. 10ms
Reprint
min. 10ms
min. 10ms
Pause
print 1 label
imprinting of the
previous label must
print 1 label
be finished!
imprinting of the
Pause-mode on
previous label must
be finished!
print 1 label
[7]
start feeding
labels
stop feeding
labels
Store to reprint last label
(if reprint functionality is
enabled)
No reprint because of
Pause-mode!
Pause-mode off
reprint last label!
Examples of timing waveform for the USI inputs.
print 1 label
imprinting of the
previous label must
be finished!
reprint last label
(if not disabled)
imprinting of the
previous label must
be finished!
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Start Print
Feed
Reprint
min. 10ms
min. 10ms
Pause
[8]
Signal timing - to be met.
Circuit diagrams for signal outputs
5V
24 V
Load
USI board
47k
Output
Controller
[9]
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:
¯ Maximum current per output line: 50 mA; all output currents together may not
exceed 700 mA.
USI board / USI-Platine
Netzteil /
Power Supply
JP8
24 V
0V
5V
5 V Pin 2
0 V Pin 1 / 8
Kabel / Cable
A2059
24 V Pin 7
0 V Pin 1 / 8
[10] USI in the state of delivery: The voltage cable is connected, JP 8 is closed.
Z0119.cdr
Max output current
Main circuit (NPN) for signal outputs at the USI interface.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
External supply
CAUTION
In previous versions of this document, the external voltage supply of the USI
was described.
External voltage supply without external current limiting elements is no
longer permitted (risk of fire) a.
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:
y Poly fuse with UL 1434 approval
24 VDC: Ihold = 0.65 mA; Umin = 30 V
5 VDC: Ihold = 0.65 mA; Umin = 6 V
y 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.
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Firmware update
The firmware of the USI can be updated in the following ways:
•
•
Exchanging the appropriate controller on the USI board (see Fig. 11).
Loading a firmware file (same procedure as for updating the printer firmware).
This procedure requires the following:
– Controller version: V6-T36 or higher
– Printer firmware: version 4.30 or higher
Article number of the controller with the most recent firmware: A3379.
Version check
•
•
Displaying the installed controller version:
Parameter menu: SERVICE DATA > MODULE FW VERS. > USI interface
Status printout PRINT INFO > Service status, entry „Peripheral driver/USI interface“
•
•
Displaying the installed printer firmware:
Parameter menu: SERVICE DATA > MODULE FW VERS. > System version
Status printout PRINT INFO > Printer status

Z0151.cdr
[11] The controller (1) contains the USI firmware.
Exchanging the
controller
1. Switch the printer off, pull out the mains connector.
2. Open the rear hood.
P For details, refer to topic section „General Service“, section „Housing“, chapter „Rear hood“.
3. Take the controller (1) out of the socket.
4. Insert the new controller into the socket.
¯ The dent in the controller housing must show in the pictured direction
(see Fig. 11)!
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03/10 Rev. 5.04-01
SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
USI testbox
Application
Simulating USI inputs
Checking USI outputs
Monitoring of drive signals sent by the system control
Aid for setting up the machine.
Fig. 12: Left side: USI testbox (A2739); right side: connecting cable (A2842). Both parts are
required for application.
View
Connection to the USI
Survey of the voltage supply at the
D-Sub connector of the USI
(The test box needs 5 V supply voltage!)
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
CN300 connector of the USI (from vers. 4 on)
(4 switches)
z0175E.CDR
•
•
•
•
Optional connection of a customer control unit
or product sensor (monitoring)
Fig. 13: Operating parts and connections of the USI testbox.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Connecting the test box
•
•
•
Connect the connecting cable D-Sub25 connector to the appropriate socket
at the testbox.
Connect the connecting cable D-Sub15 connector to the appropriate socket
at the USI.
Given version 4 of the USI, the 5-pin connector of the connection cable can
be connected to the internal inputs of the USI:
Plug the connector strip onto CN300.
•
¯ Connect the black cord of the connector strip to pin 1!
(see Fig. 14 and Fig. 15)
Fig. 14: The connector strip for connecting the testbox to the internal inputs of the USI. The
mounting orientation is printed on the cable: „black on CN300 pin 1“.
Flachbandkabel /
Ribbon cable
z0167.cdr
Pin 1
CN300:
Anschluss interne
USI-Eingänge /
Connector internal
USI-Inputs
Fig. 15: 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 DSub 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.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Operation
LEDs
•
After powering on the printer, the LEDs on the testbox show the current levels
of the USI outputs, with the following meaning:
– LED off: USI output = High
– LED on: USI output = Low
•
The supply voltage LEDs indicate:
– LED off: Voltage not applied
– LED on: Voltage applied
•
Each pressing of a key or switch pulls the respective input level down to Low,
with the LED on the key or switch lighting up.
•
The LEDs on the keys also light up, if the level of the corresponging input at
the D-Sub15 socket is pulled to Low (monitoring). This can e.g. be done by a
connected system control or light barrier.
Even with a system control connected can the USI inputs be activated by
pressing the appropriate key (set-up operation).
Internal inputs
•
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.
•
Additionally, the internal USI-inputs can be simulated, if the 5-pin connector
strip is plugged into CN300 on the USI board (see Fig. 15).
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).
¯ Befor starting the simulation, the following parameter settings are required:
Menu
DP INTERFACE
[Tab. 7]
Parameter
Setting
Interface type
USI applicator
Material signal
Enabled
Internal inputs
Enabled
Parameter settings which should be done before starting the simulation.
¯ The internal inputs are high-active, what means that the switches PLC ERROR, 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 further operated, if the testbox switch is pressed again (error withdrawn, LED
on) and the status message is acknowledged at the printer operating panel.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Internal input „OD control material“ (switch MATERIAL LOW):
Releasing this switch (LED off) switches the WARNING-output of the USI
high. Thus, the WARNING-LED on the testbox goes out. The machine is not
being stopped.
¯ The WARNING-output also shows the close end of ribbon stock; what means
that this ouput can change its level without the MATERIAL LOW switch being
pressed.
Diagram of a USI input
5V
5V/24V
5V
Optokoppler /
Opto-coupler
Controller
USI
Testbox
z0165.cdr
Kundensteuerung /
Customer
control
GND
Fig. 16: Simplyfied diagram of a USI input.
Ext.-GND
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Display 64-xx
Layout
Setting brightness
Setting contrast
CPU board (JP1)
Connector
Comp. Type on
Diagr. board
JP1
Type at
cable
Pin assignment on board
1 - ON/OFF
3 - CUT
5 - FEED
7 - PROG
9 - LCD_E
11- LCD_RS
13 - LCD_RW\
15 - n.c.
17 - VCC 5V
19 - GND
3M
25206002
2 - D0
4 - D1
6 - D2
8 - D3
10 - D4
12 - D5
14 - D6
16 - D7
18 - VCC 5V
20 - GND
[Tab. 8]
Connectors on the 64-xx display board.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Display DPM/ALX
Layout
CPU board
(CON101)
Power supply (CON102)
Connector
Comp.
Diagr.
Type on
board
Type at
cable
Pin assignment on board
1 - ON/OFF
3 - CUT
5 - FEED
7 - PROG
9 - LCD_E
11- LCD_RS
13 - LCD_RW\
15 - ERROR
17 - VCC 5V
19 - GND
CON10 3M
1
25206002UB
2 - D0
4 - D1
6 - D2
8 - D3
10 - D4
12 - D5
14 - D6
16 - D7
18 - VCC 5V
20 - GND
[Tab. 9]
Connectors on the DPM/PEM/ALX display board.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Power Supplies
WARNING!
The outputs of the power supplies are energy hazard. Touching the output
connectors with the machine switched on can cause exposure to hazardous electrical currents and may lead to burns.
« Switch off the machine before touching the power supply.
Application Notes
The following two types of power supplies are applied:
Printer
Power supply
64-04/05/06
Up to 01/2008: NT400
Since 01/2008 ME500
64-08, DPM, ALX 92x
HME
[Tab. 10] Application of the two power supply types.
For article numbers refer to the Spare Part Catalog .
Retrofitting the ME500
CAUTION
If the power supply NT400 is replaced by a ME500, the printer firmware
must possibly be updated.
y The printer will not print with a not matching firmware.
y A faulty updated patch causes I2C bus errors and disturbs the printing
operation.
« Check carefully, if a firmware update is required.
« Update the firmware, if this is required, immediately after assembling the
ME500 into the printer.
64-04/05/06 printers with Gen. 2 electronics may be retrofitted with a ME500
power supply, if the printer is updated to the appropriate firmware version.
y Recommended: update to firmware version 4.32
y If an update to firmware v. 4.32 is not possible, different patches for older
firmware versions are available:
Printer firmware
Patch
4.00
h8R_4.00.s3b
4.10 / 4.11 / 4.12
h8R_4.11_4.12.s3b
4.21 / 4.22 / 4.30 / 4.31
h8R_4.22_4.31.s3b
[Tab. 11] Patches for older firmware versions.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
NT400 (A1680)
Pin Function
1
+24 V a
2
GND
¯ The NT400 is discontinued since 01/2008. It
is replaced by the ME500 (see next chapter).
1
2
a) galvanically
separated
WARNING!
Fire hazard by overheating.
«This power supply must not be
applied with a dust filter.
A CPU board connection (control signals)
Pin Function
1
1
NMI
2
2
ICS
3
3
ISK
4
4
I/O
5
5
TK
6
6
KA
7
7
KD
8
8
KS
9
9
GND
B Printhead connection
Pin Function
1
20-28 V
2
20-28 V
3
20-28 V
4
20-28 V
5
GND
6
GND
7
GND
8
GND
1
2
3
4
5
6
7
8
[1]
A
B
C CPU board connection (supply voltage) /
Logic
Pin Function
1
1
GND
2
2
+5 V
3
3
GND
D Output stage boards connection
Pin Function
1
5V
2
0V
3
38 V
4
0V
5
52 V
6
0V
E USI board (optional)
Power supply NT400.
1
2
3
4
5
6
C
D
[2]
Connections at the NT400.
E
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
ME500
y The ME500 replaces the NT400 since
01/2008.
y 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
, chapter „Assembling accessories“.
¯ Wait at least 15 s between switching off and
on again.
A Remote on/off
¯ 64-xx: bridge the connector using a jumper.
Pin Function
1
On/off
2
GND
1
2
G USI board (optional)
Pin Function
1
+24 V a
2
GND
1
2
a) galvanically
separated
H Output stage boards connection
Pin Function
1
5.2 V
2
GND
3
28 V
4
GND
5
48 V
6
GND
1
2
3
4
5
6
B CPU board connection (control signals)
Pin Function
1
1
NMI
2
2
I2C detect
3
3
SCL
4
4
SDA
5
5
PG
6
6
n. a.
7
7
n. a.
8
8
n. a.
9
9
GND
C CPU board connection (supply voltage) /
Logic
Pin Function
1
1
GND
2
2
+5 V
3
3
GND
[3]
A
B
D Ground connection
¯ The cable end must be screwed to the
printer housing.
E Printhead connection
Pin Function
1
20-28 V
2
20-28 V
3
20-28 V
4
20-28 V
5
GND
6
GND
7
GND
8
GND
F Operation indicator
Power supply ME500.
C
1
2
3
4
5
6
7
8
D
[4]
Connections at the ME500.
E
F
G
H
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
HME
G Remote on/off
y Operation with dust filter is admissible.
y Part number of the dust filter kit see spare
parts catalog .
y Mounting instructions for the dust filter kit:
see topic section Service Mechanics ,
chapter „Assembling accessories“.
A Applicator Interface connection
B Ground connection
¯ The cable end must be screwed to the
¯ 64-xx: bridge the connector using a jumper.
Pin Function
1
On/off
2
GND
H CPU board connection (supply voltage, only
ALX 92x/DPM) / USI board (optional)
Pin Function
1
1
+24 V a
2
2
GND
printer housing.
a) galvanically
separated
C CPU board connection (control signals)
Pin Function
1
1
NMI
2
2
I2C detect
3
3
SCL
4
4
SDA
5
5
PG
6
6
n. a.
7
7
n. a.
8
8
n. a.
9
9
GND
D Printhead connection
Pin Function
1
20-28 V
2
20-28 V
3
20-28 V
4
20-28 V
5
GND
6
GND
7
GND
8
GND
A
B
1
2
3
4
5
6
7
8
[5]
Power supply HME.
C
E CPU board connection (supply voltage) /
Logic
Pin Function
1
1
GND
2
2
+5 V
3
3
GND
F Output stage boards connection
Pin Function
1
+5 V
2
GND
3
n. a.
4
GND
5
+48 V
6
GND
1
2
G
D
E
H
1
2
3
4
5
6
F
[6]
Connections at the HME.
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SERVICE MANUAL
Service Electronics
64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Printhead resistance / Ohm
Printh. Voltage /
V
Printhead resistance / Ohm
Printh. Voltage /
V
Printhead resistance / Ohm
Printh. Voltage /
V
Printhead resistance / Ohm
Printh. Voltage /
V
Printhead Voltages HME & Standard
1000
21,40
1190
23,30
1380
25,05
1570
26,68
1010
21,50
1200
23,39
1390
25,14
1580
26,77
1020
21,61
1210
23,49
1400
25,23
1590
26,85
1030
21,71
1220
23,58
1410
25,31
1600
26,93
1040
21,81
1230
23,68
1420
25,40
1610
27,01
1050
21,92
1240
23,77
1430
25,49
1620
27,10
1060
22,02
1250
23,87
1440
25,58
1630
27,18
1070
22,12
1260
23,96
1450
25,66
1640
27,26
1080
22,22
1270
24,05
1460
25,75
1650
27,34
1090
22,32
1280
24,14
1470
25,84
1660
27,42
1100
22,42
1290
24,24
1480
25,92
1670
27,50
1110
22,52
1300
24,33
1490
26,01
1680
27,58
1120
22,62
1310
24,42
1500
26,09
1690
27,66
1130
22,72
1320
24,51
1510
26,18
1700
27,74
1140
22,81
1330
24,60
1520
26,26
1710
27,82
1150
22,91
1340
24,69
1530
26,35
1720
27,90
1160
23,01
1350
24,78
1540
26,43
1730
27,98
1170
23,11
1360
24,87
1550
26,52
1180
23,20
1370
24,96
1560
26,60
[Tab. 1]
Checking the
headvoltage
The table shows the voltages which the power supply should provide, if it is connected to a printhead with the respective resistance. The values are valid for both,
Standard and HME power supply.
Proceed as follows to check the printhead voltage:
1. Find out the printhead resistance.
The printhead resistance can be found written on the printhead or by calling
the parameter SYSTEM PARAMETERS > Head resistance (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.
¯ Maximum admissible deviation: +/- 0.2V!
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Characteristics HME power supply
Inputs
Characteristic
Value
Range of input voltage
100-240VAC
Admissible range of deviation
Frequency range
50-60Hz
Admissible range of frequency
47-63Hz
[Tab. 2]
Outputs
88-264VAC
Characteristics of the input voltages.
Characteristic
Outputs
1
Output voltages (Unom)
2
5V
24V
Setting range
Output currents (Inom)
2.7A
6.3A
10A
Pulsed output current
(Ipuls)
40A
(50% ED;
t<=0.5ms)
[Tab. 3]
4
24V
48V
1.5A
5.2A
20-28V
Max. output currents
(Ipeak)
Tolerance
3
±2.5%
±5%
7.3A
(t<=10s)
±10%
+5% / 10%
Characteristics of the output voltages.
¯ The total power of the outputs 2 and 4 may not exceed 250W!
¯ Output 2: May only be activated by an I2C-bus-command!
AC output
Characteristic
AC output
Output voltage
max. 250V(AC)
Output current at 230VAC
max. 4A(AC)
Output current at 110VAC
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 voltage. Therefore, there can be drawn a maximum current of 4A(AC) at 230V
and 1A(AC) at 110V from the power supply.
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Settings
Sensor setting
¯ The button designations mentioned in this description count only for 64-xx
LS
printers. With DPM, PEM or ALX 92x, please press the Apply button instead
of the Cut button!
LS means light sensor.
Proceed as follows to set the sensors:
Material-end-LS
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:
Cut, Online, Feed, Cut, Online, Online, Online.
3. Call the parameter SERVICE FUNCTION > Sesor adjust.
This text is displayed:
Sensor adjust
220 Matend 255
The number on the left side is the setting value of the LED current
(standard: 220).
The number on the right side is the value measured by the sensor
(here: 255).
The higher the setting value, the lower is the measured value.
4. Remove the label material from the material-end-LS. The measured value
should now change to 0. If not, increase the setting value to 220.
5. Decrease the setting value by pressing the Cut button, until the measured
value changes to 255.
6. 64-xx: Increase the setting value by 30.
DPM/PEM/ALX 92x: Increase the setting value by 5.
The measured value changes to 0.
Punch LS
7. Insert some label material. The measured value should now be 255.
¯ The punch may not be recognized as material end! If this is the case, adjust
the setting once more!
8. Press the online button to save the setting value.
Now, the settings of the punch sensor are displayed:
Sensor adjust
70 Punch 12
The number on the left side is the setting value of the LED current
(default: 70).
The number on the right side is the value measured by the sensor (here: 12).
9. Insert some backing paper of standard label material (with the labels peeled
off), to check the sensor measurement.
Inserting material means here inserting a material sample into the LS fork.
¯ The material sample must be big enough to cover the LS!
10. Set the setting value to 75 ±5 by pressing the Cut or Feed button
respectively. The measured value should match the range of 11..25.
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11. Insert standard self-adhesive material (paper label on backing paper) into
the printer.
The value measured now should count at least 100 digits higher than the value measured with bare backing paper.
If the measured value doesn´t match this range, please modify it by pressing
the Cut respectively Feed button.
12. Press the online button to save the setting value.
By doing so, the punch sensor is ready set.
Reflex LS
Now, the settings of the reflex sensor are displayed:
Sensor adjust
128 Reflex 176
The number on the left side is the setting value of the LED current
(default: 128).
The number on the right side is the value measured by the sensor
(here: 176).
¯ The reflex LS is an option. If your printer is not equipped with a reflex LS, skip
this section by pressing the online button!
13. Push the reflex mark on the label material over the reflex LS.
14. Set the setting value to 95 ±5. The measured value should now match a
range of 230..255.
15. Position the label material with an area without reflex mark over the
reflex LS. The measured value should now...
– match the range of 12..48 and
– lie at least 100 digits below the value measured with reflex mark.
If the measured value doesn´t match this range, please modify the setting value by pressing the Cut respectively Feed button.
16. Press the online button to save this value.
By doing so, the reflex sensor is ready set.
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Fullsize LS
Now, the settings of the Fullsize sensor are displayed:
Sensor adjust
128 Fullsz 154
The number on the left side is the setting value of the LED current
(default: 128).
The number on the right side is the value measured by the sensor
(here: 154).
¯ The Fullsize LS is an option. If your printer is not equipped with a reflex LS,
skip this section by pressing the online button!
17. Insert some backing paper of standard label material (with the labels peeled
off), to check the sensor measurement.
Inserting material means here inserting a material sample into the LS fork.
¯ The material sample must be big enough to cover the LS!
18. Set the setting value to 155 ±5 by pressing the Cut or Feed button
respectively. The measured value should match the range of 12..18.
19. Insert standard self-adhesive material (paper label on backing paper) into
the printer.
The value measured now should count at least 100 digits higher than the value measured with bare backing paper.
If the measured value doesn´t match this range, please modify it by pressing
the Cut respectively Feed button.
20. Press the online button to save the setting value.
By doing so, the Fullsize LS is ready set.
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Sensor test
General notes
«Activating the sensor test: call parameter SERVICE FUNCTION > Sensor test.
By means of the sensor test, you can check the function of each sensor:
•
If 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).
•
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.
•
•
Sensors which are not connected show values about 255 in the sensor test.
•
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.
General rule for all sensor values:
– Full light leads to values <= 10
– No light leads to values >= 220
Sensor test
0.01 Punch
Sensor #
[1]
11
Sensor name
Value
Display after calling „Sensor test“.
¯Extraneous light must be avoided when checking the sensors. Therefore,
keep the front cover and the housing cover closed during the sensor test.
After starting the sensor test, the following is displayed:
Sensor test
0.01 Option 255
0.01 = Sensor ID, Option = Sensor designation,
255 = Sensor setting
« Press the Feed or Cut button („Apply“ button with ALX/DPM/PEM) to select
the individual sensors (if present).
P For details refer to paragraph Sensor setting on page 35.
¯If 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
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Sensors on the CPU board (64-xx)
Sensor
#
0.01
0.02
Sensor
name
Option
Option
Description
64-xx dispenser only:
Dispense light barrier
64-xx dispenser only:
microswitch at the internal rewinder
0.03
Press
64-xx dispenser only:
microswitch at the pressure roller
0.04
Matend
Material end light barrier
0.05
Punch
Punch sensor
0.06
Reflex
Optional:
reflex sensor a
0.07
FullSz
Optional:
Full size light barrier
0.09
Cover
Hood switch
0.12
H-Temp
Printhead temp. sensor
[Tab. 5]
Typical Value Condition
255
0
255
Light barrier covered by a
dispensed label
Light barrier clear
Internal rewinder not full
0
255
Internal rewinder full
Pressure roller closed
0
0
255
7 to 10
11 to 255
> 200
10 bis 20
10
11 to 255
0
255
105 to 235
Test conditions for sensors connected to the CPU board.
a)Precondition: parameter „SYSTEM PARAMETER > Sens. punch LS“ = 30%
Pressure roller open
Without material (light barrier
clear)
With material inserted
Without material (typical: 7)
With material
Without material (approx. 253) or
opposite of the reflex mark > 200)
With white material
Without material
With material
Hood closed
Hood opened
Displayed value drops when the
printhead temp. rises (see Tab. 7)
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Sensors on the CPU board (DPM/ALX)
Sensor
#
0.03
Sensor
name
Press
Description
0.04
Matend
Material end light barrier
0.05
Punch
Punch sensor
0.09
Cover
Hood switch
0.12
H-Temp
Printhead temp. sensor
[Tab. 6]
Typical Value Condition
Microswitch at the pressure roller on the feed
roller (not available at
PEM)
255
Pressure roller closed
0
0
255
7 to 10
11 to 255
0
255
105 to 235
Pressure roller open
without material (light barrier
clear)
with material inserted
without material (typical: 7)
with material
Hood closed
Hood opened
Displayed value drops when the
printhead temp. rises (see Tab. 7)
Test conditions for sensors connected to the CPU board.
Value table for sensor 0.12 (printhead temp.)
Sensor value
Printhead temp.
[Tab. 7]
230
17,8
225
22,1
220
26,0
215
29,5
210
32,7
205
35,8
200
38,7
195
41,4
190
44,0
185
46,6
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
Printhead temp.
[Tab. 8]
235
12,9
180
49,1
175
51,5
170
53,9
165
56,3
160
58,6
155
60,9
150
63,2
Tab. 7 continued
Sensor value
Printhead temp.
[Tab. 9]
Tab. 8 continued
120
77,3
110
82,3
105
84,9
145
65,5
140
67,8
135
70,2
130
72,5
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Sensors on the output stage boards (64-xx)
Sensor
#
2.01
3.01
Sensor
name
Foil
Head
Description
Foil sensor
Light barrier at the printhead raising mechanism
Typical Value Condition
0
>10
Sensor above a hole in the oscillator disc (light barrier clear)
Sensor covered
Printhead in economy position
(raised)
Printhead in print position
(lowered)
Light barrier covered
<10
Light barrier clear
254
0
254
4.01
Option
[Tab. 10]
Sensor for options (application for cutter, external
rewinder or release motor sensor at the 64-xx
dispenser)
Testbedingungen für Sensoren, die an eine der Endstufen-Platinen angeschlossen werden.
Sensors on the output stage boards (ALX/DPM)
Sensor
ID
SensorName
Beschreibung
2.01
Folie
Foil sensor
3.01
Kopf
Light barrier at the printhead raising mechanism
Typische
Werte
0
254
0
254
[Tab. 11]
Bedingung
Sensor above a hole in the oscillator disc (light barrier clear)
Sensor covered
Printhead in economy position
(raised)
Printhead in print position
(lowered)
Testbedingungen für Sensoren, die an eine der Endstufen-Platinen angeschlossen werden.
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Options
1
Installing a Memory Extension
Requirements
•
•
•
64-xx, DPM, PEM or ALX 92x with CPU
board no. A2292 or A2293 installed
Upgrade kit for 32MB memory extension
no. A4413 or
Upgrade kit for 64MB memory extension
no. A4414
The upgrade kit contains a bag with the
memory module (fig. 1) and an installation
guide.
2
Installation
Proceed as follows to install the memory
module:
1. Remove the CPU board from the printer.
P How to? - Read topic section „Service Mechanics“, chapter „Replacing the boards“,
„CPU board“.
2. Take the memory module out of the bag.
The slot for the memory module is located
in the upper third of the CPU board (fig. 2,
white circle).
3. Plug the memory module into the slot
(U201) as illustrated (fig. 3).
¯ The memory module is coded by a dent
(fig. 3). Make sure, that the memory module fits into the slot as illustrated!
Continued overleaf
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¯ Plug in the memory module under an angle
1
of about 20° (fig. 1)!
4. Press the memory module towards the
CPU board (fig. 2), until it snaps autibly
into the lateral clips (fig. 3, cicles).
5. Reinstall the CPU board into the printer.
The new memory capacity is indicated
when the printer is powered up:
Memory: 40 MB
with 32MB memory extension, respectively
Memory: 72 MB
2
with 64MB memory extension.
3
Service Electronics
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Installing the Option Board
•
•
1
Requires:
64-xx, DPM, PeM or ALX 92x with CPU
board no. A2292 or A2293 installed.
Option board no. A2294 (fig. 1).
Install the Option board as follows:
1. Remove the rear hood of the printer.
2. Remove the power supply (1) in order to
get to the CPU board.
3. Remove the cover plate (2) (fig. 3).
4. Set the jumpers on the Option board.
P How to? - read paragraph Option Board on
page 11.
2
5. Install the Option board instead of the
removed cover plate and connect it as
illustrated (fig. 4).
6. Reinstall the power supply.
7. Close the rear hood.
™
3
š
4
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Installing a Realtime Clock
•
•
1
This requires:
64-xx, DPM, PEM or ALX 92x with a CPU
board no. A2292 or A2293 installed
Upgrade kit realtime clock no. A4201
The upgrade kit contains a box with the
realtime clock (RTC) (fig. 1) and an installation guide.
Install the RTC as follows:
1. Remove the CPU board from the printer.
P How to? - Read topic section „Service Mechanics“, chapter „Replacing the boards“,
„CPU board“.
2
2. Plug the RTC into the socket U701 on the
CPU board (fig. 2).
The RTC socket is located in the upper left
area of the CPU board (fig. 2, white circle).
¯ Hold the RTC in a way, that the molded
spot is in the lower left corner, when plugging the chip onto the socket (figs. 3 and 4)!
The molded spot marks pin 1.
3. Reinstall the CPU board into the printer.
Setting the RTC
1. Call the parameter SYSTEM PARAMETERS >
Realtime clock.
3
Realtime clock
dd.mm.yyyy hh:mm
...shows up on the display.
With dd=day, mm=month, yyyy=year,
hh=hour, mm=minute.
2. Key in date and time: Cut (ALX/DPM/PEM:
Apply) moves the cursor, Feed changes
the setting and Online saves it.
4
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64-xx Gen. 2 – DPM Gen. 2 – ALX 92x Gen. 2
Attaching locking clips for flat
strap plugs
# Tweezers or flat pliers
An unfavourable combination of installation
position and load may loosen the on board
flat strap plugs inside of the ALX 92x and
DPM/PEM.
™
An appropriate countermeasure are the
follwing locking clips:
•
•
A5386 (14pin)
A5387 (20pin)
Those clips must be attached to all flat
strap plugs inside of ALX 92x and DPM/
PEM machines.
¯ Exception: Flat strap plug at the printhead.
To attach the clips:
1. Hang the clip (1) into the hole in the plug
housing (2) (Fig. 1).
1
™
š
2. Use the tweezers to pull the clip end over
the plug (Fig. 2).
P Continued overleaf.
2
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3. Snap the clip end into the hole in the plug
housing (Fig. 3).
The plug is locked now.
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Index
- USI board 9, 13
A
AC output 34
At 12
B
Block diagram USI 18
C
Centronics 7
CN300, USI board 24
Connectors
- display 64-xx 27
- display DPM/ALX 28
- on the CPU board 5
- on the USI board 13
- on USI board 10
CPU board, jumper setting 3
E
Ethernet 7
F
Firmware, USI 22
H
Headvoltage 33
I
Internal inputs 16
Internal inputs, USI board 25
Internal inputs, USI, pin assignment 16
J
Jumper block, USI 17
Jumper on the CPU board 3
Jumper setting
- on Option board 11
- Option board 11
L
Locking clips for flat strap plugs 46
M
Memory Extension Option 42
O
Option Board 44
Options 42
Options board, installation 44
Output current USI 20
P
PIC version, on USI board 9
Printhead voltage 33
R
Realtime Clock 45
RS 232/422/485 7
RS 422/485 termination, option board 11
RTC 45
S
Sensor setting 35
T
Termination, RS 422/485, option board 11
Testbox 23
Timing waveform, USI 19
U
USI 12
USI Signal description 14
V
V2-T1-F873 12