Service Electronics
Contents
1. 04 10 Rev 5 05 00 SERVICE MANUAL AP 5 4 AP 5 6 Service Electronics Handling Boards occcccccocccnncccoccnnccnnnccnnnnnos 2 Operation Panel nccccccoccccccccncccncccnoncnnnnnanonnnos 22 ESD protection ccccccccoccnncccnoccnnnnnoncnnnonaness 2 CONNECTIONS c occcccccoccnnncccoccnncononenncnnnnnonnnnnos 22 ACIDO iaa 2 We TECH EE 23 CPU DOA W 3 OI OWNS escindida 23 CONNECTIONS c coocccccncnccnnccnonnnnnonnnnnnnnnnancnnnnos 3 Specifications cccccccccccncccconcncccnanonnnonons 24 T E 5 Interface for peripheral devices 25 Sensor Connections ceee 6 Sensor Settings scr 26 Lithium Battery o s 7 Setting SENSOTS EE 26 Output stage board for stepper motor 9 Setting the material end sensor 30 Connections settings oocccccccccoonnonos 9 EE OSU e 31 Output stage board for brushless motor 10 General notes 31 O o 10 Sensors on the CPU board aa nnnnn0aannnn qe Connections Settings o ccccoccnccoocnos 11 Sensors on the stepper motor output stage VOD coseno 12 GE 33 Connections Settings c ccecessereeeeere 12 Sensors on the BLDC motor output stage ADDliCation oossoo 12 E 33 Pin assignment serial interface 13 Sensors on the I O board 34 Pin assignment signal interface 15 Setting the Interface Parameters 17 Circuit diagrams for signal inputs 18 Circuit diagrams for signal output2. Pin assignment serial interface O N 0 0 NO Ff Ol 13 Pinout RS 232 im CAUTION Pin assignment viewed at from PC printer DCE Pin Signal Signal direction from l O board 1 DCD Short with DTR and DSR 2 RxD Out 3 TxD In 4 DTR Short with DCD and DSR 5 GND Masse 6 DSR Short with DTR and DCD 7 RTS In 8 CTS Out 9 RI Not connected Tab 3 Pin assignment RS 232 04 10 Rev 5 05 00 RS 422 485 RS 422 485 termination RS 485 2 wire connection O N 0 0 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 ANO FO 14 Pinout RS 422 485 m CAUTION Pin assignment viewed at from PC printer DCE Pin Signal Signal direction from l O board 1 Not connected 2 Rx Out BRA 4 Term Termination 110 Ohm 5 GND Ground 6 Term Termination 110 Ohm 7 Tx In 8 Rx Out 9 Notconnected gt Tab 4 Pin assignment RS 422 485 At the ast printer at the RS 422 485 line connect the following pins inside of the cable connector e Pins 3 and 4 Tx e Pins 6 and 7 Tx At each printer on the bus line connect the following pins inside of the cable connector e Pins 2 and 3 Tx Rx e Pins 7 and 8 Tx Rx 04 10 Rev 5 05 00 SERVICE MANUAL AP 5 4 AP 5 6 Service Electronics Pin assignment signal interface SV_EXT 2 10 ERROR START PRINT 3 di 11 PRINT END FEED 4 dl 12 GN
3. CN403 USB device CN402 USB intern host device CN401 USB host CN101 SD card slot AAJP301 302 Jumper set on JP301 micromonitor Jumper set on JP302 Yamon zl OD O VUOZS lt P PFAGC lt C lt N lt xg AB CN902 Foot switch see Foot switch connector on page 5 AC D1210 Display supply voltage yellow 5 V green 45 V AD D1202 1203 Display supply voltage red 3 3 V green 45 V AE D1204 Display supply voltage yellow 5 V 04 10 Rev 5 05 00 Overview interfaces Foot switch connector USB host connector USB device connector SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 AF D301 302 Display only for factory internal use Interfaces 2 External interfaces at the CPU board at AP 5 4 5 6 Foot switch connector USB host connector USB device connector Serial interface RS 232 Ethernet interface Im DO D P m Interfaces 2F and 2G see chapter E A Platine auf Seite 16 I 3 Connection diagram of the 1 4 3 point jack for foot switch connection Pin Signal 1 Vee 2 Data 3 Data 4 GND Pin Signal 1 N C 2 Data 3 Data 4 GND 04 10 Rev 5 05 00 Serial interface RS 232 Ethernet interface SERVICE MANUAL AP 5 4 AP 5 6 Service Electronics Suitable cable for PC connection USB cable A B article number A5799 O N Oo 0 Pin Signal 1 CD RxD TxD DTR G
4. gt Mettre au r but les batteries conform ment aux instructions du fabricant The CPU board used in the AP 5 4 5 6 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 Characteristic Value Nominal voltage 3V Nominal capacity 220 mAh Continous standard load 0 2A Operating temperature 30bis 60 C Max abnormal charging current 5 0 mA Tab 2 Battery type CR2032 specifications and 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 equipe ment terminal clean using a dry cloth m Ensure that dust and other foreign substances will not cause shorting between the poles nm 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 4 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 4 Correct battery polarity Reassemble the rear hood Reconnect the printer to the mains and switch it on Set time and date SYSTEM PARAMETER gt Realtime clock 04 10 Rev 5 05 00 SERVICE MAN
5. LED current Default 112 The right value is the sensor value read back here 17 3 Insert some white paper Increase or decrease the control value until the read back value matches the range of 8 20 best 10 Remove the white paper to verify the read back value It should match the range of 50 160 Insert some black paper to verify the read back value It should match the range of 190 255 7 Press the Online button to save the setting 8 Press the Esc button to exit the parameter By doing so the reflex sensor is set m Setting only for AP 5 4 5 6 dispenser with optional punch sensor for short labels For further information about this punch sensor see topic section Service Mechanics paragraph Punch sensor for short labels 1 N Start the printer in production mode and call parameter Press the Online button repeatedly until the following is displayed Sensor Adjust 140 opitn 1 7 The eft value is the control value for the LED current Default 140 The right value is the sensor value read back here 7 3 Remove any material from the label sensor fork 4 Increase or decrease the control value by pressing the Feed or Cut button until the read back value is in the range of 8 20 best at 13 15 Insert some standard material backing paper labels peeled off to verify the read back value The read back value should match the range of 30 90 Insert some
6. mandrel by hand and watch the read back val ue Sensor uncovered the value should match the range 5 7 Sensor covered the value should match the range 220 255 If the value doesn t match this range modify the control value by pressing the Cut or Feed button 4 Press the Online button to save the setting 5 Press the Esc button to exit the parameter With this the ribbon sensor is set Start the printer in production mode and call parameter Press the Online button repeatedly until the following is displayed Sensor Adjust 128 Head 236 The eft value is the control value for the LED current Default 128 The right value is the sensor value read back here 236 Open and close the pressure lever by hand and watch the read back value Pressure lever open the value should match the range 5 7 Pressure lever closed the value should match the range 220 255 Press the Online button to save the setting 5 Press the Esc button to exit the parameter By doing so the printhead sensor is set 04 10 Rev 5 05 00 Reflex sensor Punch sensor for Short labels SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 m Setting only for AP 5 4 5 6 with optional reflex mark label sensor 1 Start the printer in production mode and call parameter Press the Online button repeatedly until the following is displayed Sensor Adjust 112 Reflex 17 The eft value is the control value for the
7. standard self adhesive material paper label on backing pa per to verify the read back value The read back value should match the range of 100 220 and it must be more than 50 best 100 digits higher than the value measured with bare backing paper 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 If the value doesn t match this range modify the control value by pressing the Cut or Feed button 7 Press the Online button to save the setting 8 Press the Esc button to exit the parameter With this the punch sensor is set 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Setting the material end sensor This printer type is equipped with a single light sensor which is designed to de tect both punches and material end The sensor must be able to detect three different states No material e Only backing paper e Backing paper label face The parameter can set the limit between be ing recognized as only backing paper or as material end 4 m Before you even think about changing the setting of this parameter make sure that the sensor is correctly adjusted See chapter Setting sensors on page 26 Proceed as follows to set the materialend sensor 1 Call parameter Matend adjust yyy Level xx 2 Take the label material out of the sensor fork 3 Set the value xx to 20 by pressing the Cut Feed buttons All measured values below the set lim
8. D y PAUSE 5 di 13 GND REPRIN 5VTO24V A oe 8 15 MACHINE STATUS GND 8 15 Pin assignment signal interface Signal Description 5V_EXT 5 V supply voltage for external sensors Condition s for activating START_PRINT Start signal for printing All of the following conditions Input Setable by e Online mode e Printjob prevailing No error message FEED Feeding of the label material as long One ofthe following conditions Input as the signal is kept low Onlne mode Minimum feed length 1 label e Printer is stopped Display 1 O Board Feed Paice moded Or All of the following conditions e Online mode e No printjob loaded PAUSE A high low change switches the prin START _PRINT is high Input ter to the pause mode Another high low change switches the printer back into online mode If the parameter is set to Level high active or Level low active activating the pau se mode stops the printer after the currently printed label Display LO Board Pause ERROR is activated START _PRINT Signals are discri minated Tab 5 Signals at the signal interface 04 10 Rev 5 05 00 Signal REPRINT Input SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Description Condition s for activating The printing of the last printed label is AU of the following conditions repeated as long as REPRINT is Online mode kept low Minimum number of reprinted MARA MI HON la
9. ND DSR RTS CTS 9 RI AAA 2 N O A 0 CO NIO O1 AJ OJIN Pin 9 supplies 5 V 170 mA if JP701 is set Suitable cable for PC connection D Sub 9 1 1 plug jack extension cable article number A1207 Pin Signal 1 TD 2 2 TD S 3 RD j 4 Termination 5 Termination 6 RD 7 Termination 8 Termination LED Meaning Green Lights high transmission rate 100 Mbit s Yellow Lights printer is connected to network Flashes network trafic Tab 1 Signal LEDs at Ethernet connector Setting of the transmission rate by autonegotiation Sensor connections Schematic diagram for connectors CN905 to CN909 on the CPU board sch NO Pin Belegung Se 1 Anode Kathode Kollektor I 2 3 4 Emitter 04 10 Rev 5 05 00 A Battery type Specifications Battery replacement SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Lithium Battery WARNING Danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended by the ma nufacturer Take care of the correct polarity when replacing the battery gt Discard used batteries according to the manufacturer s instructions AVERTISSEMENT II y a danger d explosion s il y a remplacement incorrect de la batterie gt Remplacer uniquement avec une batterie du m me type ou d un type re commend par le constructeur
10. NUAL Service Electronics AP 5 4 AP 5 6 Connections settings St kee ee a S i iren fe Y P P i y d d mJ IIe oo 4 a a mn a cl B 1 De 9 Connections on the BLDC output stage board A4034 A Connection D Sub cable harness sensor of the peripheral device CN 101 m Only used in AP 5 4 5 6 basic dispenser 10 Connection diagram sensor B Jumper J101 102 103 11 Jumpers J101 and J102 connected C Connection rewinder motor CN 102 D Connection CPU board CN 103 E Connection power supply CN 104 04 10 Rev 5 05 00 O board SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Connections settings ng En TIELET S A 131 1 0 BO0A Sa ww d 7 5020 cory 1020 pord DD E E SW105S05EHISM e s3454141 NE b i a m i b d s J ilr a a Di HT Fi z i BAL E e E i CO A F 7 ER d j a De e D rend F Ji EIES aij EI ge laa E H sch F 3 CA qe Y CG d r TE Je IHN ra CH lt HIN E e ET E e AER aj E 5 d SOM re Sr e WI Er Fal E E T per pera e pa F 105 mitit a ttErOn SITT e d acia S a ER h y SEA BG dl IR SO i a esl CH if E Re SI VS E guan zl 12 Connec
11. Power Fail Temp Sense GND 5V 22 Pin assignment connection CPU board C Connection for printhead 23 Pin assignment printhead connection 04 10 Rev 5 05 00 Power Voltage range Current range SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Specifications e Maximum continuous average output power 196 W e Peak power 276 W m Peak must not last longer than 30 ms m Limitation of peaks per minute max 3 Output Range Max Min 5 45 V 47 25VW 40 5V 10 24 V 3 24 72V 23 28V 5 V 5 5 25 V 4 75 V Tab 9 Output voltage ranges m Precondition to be able to measure the output voltages correctly is that a minimum output current of 0 3 A is drawn from the 5 V output minimal load This is e g reached by connecting the CPU board to the power supply m At the 24 V and 45 V outputs no minimum output current is required to measure the voltages correctly Output Min Typical Peak 45 V OA 2A 2 8A 24V OA 3 8A 7A 5V O3JA 3 0A 4 0A Tab 10 Output current ranges m The 24 V output provides a continuous current of 6A for 10s in typical op eration Im Without a minimum load at the 5 V output the voltage at 24 V and 45 V sup ply should not be higher than 28 V and 50 V respectively 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Interface for peripheral devices This interface is only available at AP 5 4 5 6
12. UAL Service Electronics AP 5 4 AP 5 6 Output stage board for stepper motor Connections settings 5 Connections at the output stage board A2742 Connection for D Sub harness sensor of the peripheral device cable marking SENSOR 1 J4 6 Connection diagram sensor Jumper J6 J1 J7 Caution Fig 5 doesn t show the correct jumper set ting 7 Jumper J6 geschlossen Connection for D Sub harness motor of the peripheral device cable mark ing MOTOR J3 8 Connection diagram motor Connection CPU board J2 Connection power supply J12 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Output stage board for brushless motor Notes BLDC brushless direct current e Application AP 5 4 with internal rewinder Firmware version e Drucker Firmware mind 3 34 e Treiber Firmware Endstufe mind 6 Checking the firmware gt Call version Section Peripheraldriver on the printout lists all mounted output stage boards with the installed firmware versions Updating firmware Updating the driver firmware is done the same way as with the printer firmware See topic section Firmware gt The following files are required BLDC_Vx BAT resp BLDCAP54Vx S3B tor firmware version x gt CAUTION Don t load the older firmware version 1 onto the new version 2 04 10 Rev 5 05 00 SERVICE MA
13. bels 1 If REPRINT is activated while the printer is in pause mode PAUSE the reprint is executed only when the pause mode is cancelled 5VTO24V_EXT 5 24 V supply voltage for external sensors ERROR Low if the printer is not ready to print One of the following conditions Output High during the initialization of the e Pause mode printer e Printing stopped e Offline mode e Material end e No punch detected PRINT END Setable by Output See parameter description MACHINE STATUS Setable by Info Printouts and Parameters DO Output Tab 5 Signals at the signal interface 04 10 Rev 5 05 00 SERVICE MANUAL AP 5 4 AP 5 6 Service Electronics Setting the Interface Parameters With an I O board mounted the following additional menus appear in the print er menu the serial interface contains all parameters required to configure contains all parameters required to configure the signal interface Menu Parameter Setting Baud rate 9600 No of data bits 8 Parity None Stop Bits 1 Data synch RTS CTS Serial Port Mode RS232 External signal Singlestart Reprint function Enabled Start delay 0 0mm Start print mode Pulse falling Reprint signal Enabled Feed Standard Pause input Standard Error output Print error Error polarity Level low active Status output Print job ready Status polarity Level low active End print mode Tab 6 Recom
14. cted to the CPU board AP 4 4 AP 5 4 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Sensor Sensor Connector Typical name value Condition 0 12 O Foil calculated 0 Foil diameter unknown value appr 35 80 Foil diameter in mm walle calcu Temperature at printhead 0 13 H C latedoutof appr 25 70 A H in C 0 07 Tab 11 Cont Sensor test conditions for sensors which are connected to the CPU board AP 4 4 AP 5 4 Sensors on the stepper motor output stage board E SES Conn Periph ES Condition name value Dispen 4 01 Peri 1 J4 sing edge 0 ee edge light arrier open sensor Dispensing edge light 255 barrier covered Cutter lt 10 Cutter in end position 055 Cutter not in end posi tion Ena 0 255 Dancer arm position Rewinder Tab 12 Sensor test conditions for sensors which are connected to the output stage board Sensors on the BLDC motor output stage board m Only valid for AP 5 4 5 6 basic dispenser what means that the dispens ing edge sensor is connected to the BLDC output stage board SET SES Connector Typical Condition name value 0 Dispensing edge light barrier open 8 01 Rew S J4 Dispensing edge light barrier 255 covered 8 02 O Rew 0 of the backing paper rewin calculated der roll is not known Value ca 35 of the backing paper rewin 120 der roll in milimeters Tab 13 Sensor test conditions for sensors
15. current 100 mA m External electronics powered from this source must not consume more than 0 5W 04 10 Rev 5 05 00 External supply Fuses SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 External supply Vs o4y 5 to 24 V at lt 600 mA The I O board outputs may be powered by an external source from 5 V to 24 V pin 7 m Maximum admissible output current 200 mA The fuses used on the I O board are polymeric positive temperature coefficient resistors If they trip they don t blow and after cooling down they work again They don t need to be replaced 04 10 Rev 5 05 00 Application of the testbox Notes SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Testing the Signal Interface The USI testbox was designed for use with the USI interface the big brother of the I O board matching the 64 bit printer family But it can also be applied to the I O board if the following is taken into account Not all of the output signals on the USI board are also available on the I O board The pins of not available signals are grounded on the I O board The following signal lamps for outputs are therefore always lighting on the testbox e RIBBON OUT e MEDIA OUT e WARNING Those inputs are not available on the I O board e PLC ERROR e TOUCH DOWN SENSOR e HOME POS ERROR e MATERIAL LOW e Simulating inputs e Checking outputs e Monitoring of drive signals sent by the system control e Aid for sett
16. e following Values be tween 10 and 220 mean that the sensor is poorly set dirty or close to the end of its life Digital values Some sensors work digitally what means that they don t provide a value range but the two values 1 or 0 04 10 Rev 5 05 00 Sensors on the CPU board SERVICE MANUAL Service Electronics Sensor Sensor Typical Condition value 0 01 8 20 No material in light barrier 30 90 Only backing paper in light barrier 140 255 Label material in light barrier 0 02 4 8 Light barrier open 220 255 Light barrier covered 0 03 4 8 Light barrier open 220 255 Light barrier covered 0 04 7 30 White material over sensor 30 180 No material 180 255 Black material over sensor 0 255 Reserved for special 0 05 analogous functions Punch sensor for short labels 8 20 No material in light barrier 30 90 Only backing paper in light barrier 140 255 Label material in light barrier 0 06 Optn 2 CN910 ee Reserved analogous 0 07 Hiem CN901 903 EI 109 Printheadis very hot appr 141 Normal printhead 255 temperature Power supply tempera 0 08 P Temp CN701 ture depends on the PS type i No 5V supply for print 0 09 H Supp CN901 903 0 Beer i 5V supply for printhead o k 0 10 M Supp CN701 0 No motor supply voltage 1 Motor supply voltage o k 0 11 0 Start signal low IN1 1 Start signal high Tab 11 Sensor test conditions for sensors which are conne
17. he sensor value read back The more light the sensor receives the less is the read back value 2 Remove any material from the label sensor fork 3 Increase or decrease the control value by pressing the Feed or Cut button until the read back value is in the range of 8 20 best at 13 15 4 Insert some standard material backing paper labels peeled off to verify the read back value m Glossy side up m The backing paper must cover the light barrier The read back value should match the range of 40 90 5 Insert some standard self adhesive material paper label on backing pa per to verify the read back value The read back value should match the range of 100 220 and it must be more than 50 best 100 digits higher than the value measured with bare backing paper If the value doesn t match this range modify the control value by pressing the Cut or Feed button 6 Press the Online button to save the setting 7 Press the Esc button to exit the parameter With this the punch sensor is set 04 10 Rev 5 05 00 Ribbon sensor Printhead sensor SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Start the printer in production mode and call parameter Press the Online button repeatedly until the following is displayed Sensor Adjust 128 Foil 6 The eft value is the control value for the LED current Default 128 The right value is the sensor value read back here 6 Turn the ribbon unwinding
18. ing up the machine The polarity of the testbox is low active therefore rules m Inputs are pulled low when the push button is pressed m Outputs are low when the LED lights 18 Left side The USI testbox A2739 Right side Connection cable A2842 Both parts are required for the application 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Operation panel Connections al top Ek CF Ga n Saul P a LLL Edd Hey p a Por Bh j kO ESF T ri ra ra Di 1 7 hall ZE d ABR deer d Mag re Bai oat 0804 0199 CIE Ee A7149 on na d pola y H eg D Sr imma i f re y PP ee oe OL L S d ef finer i sp D LH NIR e 8 i h P Ka i i p i la konnnnnns d L IK pg a re E ie ai k DE e al Gr a d S r a ma j T i IK Bit dm SA ld ee iF a ee d p 88 an ty iol al S ke j o EN q q i y Y a i d i il j Pa jii ET de A i 7 D FT 1 Pre MHL ana al 2 19 Operation panel board A7149 A Connection programming adapter only for factory internal use B Connection CPU board C Connection I C bus reserved 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Power supply Connections A SS e 20 Power supply A3958 A Connections for output stage boards 21 Pin assignment connections for output stage boards B Connection for CPU board
19. it that is lt 20 are recognized by the electronics as material end values lying above are recognized as only backing paper m To be able to process transparent label stock the parameter has to be set to zero 255 Me wertbereich Tr germaterial Etikett Auswertebereich f r Stanzen LichtschrankenmeBwerte erkennung MeBwertbereich nur Tragermaterial 20 MeBwertbereich Erkennungsbereich ohne Material 0 fur Materialende 25 The measurement ranges of the combined punch material end sensor schematically illustrated 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Sensor test General notes gt Activating the sensor test call parameter By means of the sensor test you can check the function of each sensor Sensor test 0 01 Punch 11 A B C 26 Display after calling Sensor test A Sensor ID B Sensor name C Value Analog values e 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 e Check the sensor function e g by covering it If the displayed value doesn t change when the sensor is covered it is possibly not connected or defective General rule for all analog 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 th
20. mended parameter default settings Mode3 low pulse For detailed parameter descriptions see topic section Info printouts and Parameters 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Circuit diagrams for signal inputs 5V 24V TT 16 I O board Input circuitry and possible connections to external electronics The input signals are supplied by an internal galvanically decoupled 5 V source mw Maximum admissible input voltages 0 to 24 V Input signal Voltage range Current range Low Vu 0 1 V IL 10 20mA High Vin 40 24 V lu 0 1 mA Tab 7 Characteristics of the input signals 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Circuit diagrams for signal outputs che van Sy VA NGN 0 5 24V Fuse le AS O 424V 424V Fuse i A 24V WN lt ZN co o DN 05 24V 24V HAV o Out o GND 17 1 O board Output driver and possible connections to external electronics The output signals are powered by the internal 5 V source or by an external 5 to 24 V source The output stages provide an active low transistor and also an active high transistor Output signal Voltage range Current Low Vo 0 5 1V lo 200 mA High Vs o4y Von 1 5 2 5V lop zs 200 mA Tab 8 Characteristics of the output signals Internal supply Internal supply Vs o4y 4 5 to 5V at lt 100 mA m Maximum admissible output
21. nder Leen La al keete RL A El E 1 a qr TETA 21607 WOR WIA WOR rren E fi A ree CENA LE Gu MIS D ES TAE Pie CZE Kn d t a Le HI w RR ES E e fie El A EIER a 25 elle Med Mole ale CR Pra mis af E ma aAA P REIS EJEA NI dale pie Mila Weer SS AA e ef lid LME I E Big F Ju a Cir eye a el Ejea ENE Lal EM Li D e Service Electronics 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 e CNxxxx Connector e Dxxxx LED e JPxxx Jumper CN1201 Power supply CN601 Feed motor CN1202 D Sub harness marking POWER CN501 I O board option CN1001 printhead CN602 Motor output stage board s Data line CN702 Operation panel TI O0 mn mm DO D PS CN701 External operation panel CN801 I C bus CN904 Not applied CN905 Label sensor transmissive CN906 Ribbon end sensor CN907 Locking lever sensor CN908 Label sensor reflex bottom CN909 Label sensor reflex top CN910 D Sub harness marking AUX CN901 5 V supply voltage CN503 RFID module option B1801 Battery for realtime clock see chapter Lithium Battery on page 7 CN1101 Ethernet 10 100 Base T see chapter Ethernet interface 2 on page 6 CN703 RS 232 see chapter Serial interface RS 232 L on page 6 JP701 Jumper connects 5 V 170 mA supply voltage to pin 9 atthe RS 232 connector
22. peripheral CAUTION A N Connecting non original devices to this interface can damage the printer In the worst case the printer can start to burn Only connect original Avery Dennison peripheral devices to this interface 24 D Sub15 connection for peripheral devices at an AP 5 6 peripheral Pin Signal 1 Emitter 2 GND Collector 2 sensor input signal O Collector 1 sensor input signal Emitter 1 GND 3 A 151413121110 9 5 5V supply voltage 6 7 8 45 V supply voltage Motor A motor voltage Motor A motor voltage 9 LED Kathode 2 light sensor 10 LED Anode 2 light sensor 11 LED Anode 1 light sensor 12 GND supply voltage 13 GND supply voltage 14 Motor B motor voltage 15 Motor B motor voltage 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Sensor settings Setting sensors The following cases require the sensor or all sensors to be set newly e A sensor was replaced e The CPU board was replaced e A punch sensor fork with additional reflex sensor was mounted only pos sible with AP 5 4 Punch sensor 1 Start the printer in production mode and call parameter For more information about production mode refer to the description of parameter The following message shows up Sensor Adjust 140 Punch 16 The eft value is the control value for the LED current Default 140 The right value is t
23. s 19 Testing the Signal Interface 21 04 10 Rev 5 05 00 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 Handling Boards des ESD protection CAUTION The boards can be destroyed by static discharge gt Before opening the printer place it on a grounded surface gt 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 gt Only place boards on earthed surfaces Handling CAUTION The conducting tracks on the boards are very thin If a board is bent or warped the conducting tracks can easily crack Avoid bending or warping boards gt Avoid the use of excessive force when removing or inserting boards 04 10 Rev 5 05 00 CPU board Connections KAS AEN TETANU nono LONA AS Wb AURA Rahs lau A100150 02 PCS Serialo 100148085 700086 0 04 44 07 00 22 ELI ERLELOLLOL UI MITT ttt ee KTKASKERKAOAR DTTOOE AOS LITLE 3 Cc ee a fo wea D iy Jsa EIF m mn 1 CPU board connections A100150 JE a L SERVICE MANUAL AP 5 4 AP 5 6 wii aiii ee T D I d a ci m CR TEER E Lal A arm E KE phe E krme VA KE H D St z i As Mea A AS e Eas F A fn is TTT WE TTT E 31 i SV Ein Er E gt az COTOS ie a AL En Crema Wu
24. tions at the l O board A3926 A Signal interface D Sub 15 CN201 B Connection CPU board CN 102 C RS 232 422 485 D Sub9 CN 101 Application The I O board may be used for 3 different applications e 2nd RS 232 interface The I O board provides a RS 232 interface which can be applied addition ally to the one on the CPU board The 2nd interface can e g be used to connect a bar code scamner e RS 422 485 interface If 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 industrial plants where galvanic isolation is required to avoid ground loops e Signal interface If an applicator is applied with the printer this requires the exchange of control signals between printer and applicator Therefore signals like printing is finished have to be generated by the printer and the printer it self must wait for a signal like start print from the applicator before it starts printing the next label Galvanic isolation is provided for robustness The output signals can also be used to drive signal lamps 04 10 Rev 5 05 00 RS 232 SERVICE MANUAL Service Electronics AP 5 4 AP 5 6 m The two serial interface types cannot be used at the same time mm Signal interface and serial interface can be used at the same time The signals of both interfaces must then be related to the same supply system Same ground potential
25. which are connected to the BLDC motor output stage board 04 10 Rev 5 05 00 SERVICE MANUAL AP 5 4 AP 5 6 Sensors on the I O board Service Electronics Sensor Sensor Connector Typical Condition name value 15 01 Start CN 803 804 0 Start signal activated 1 Default start signal 2 0 Feed signal activated 15 02 Feed CN 804 1 Default feed signal 0 Pause signal activated 15 03 Pause CN804 101 Dynamic signal see T and F 255 Default pause signal 0 Reprint signal aktivated 15 04 Reprt CN 804 SE 1 Default reprint signal 0 APSF signal periodic time lt 1us EES TuS GINGO 1 254 Periodic time in us 255 Periodic time gt 254 us 0 APSF signal periodic time 15 06 T ms CN804 lt 1ms 1 13 Periodic time in ms 205 Invalid value 0 APSF signal frequency lt 6Hz 15 07 F Hz CN804 76 254 Frequency in Hz Frequency more than SE 254 Hz 0 APSF signal frequency lt 100 Hz 15 08 F100Hz CN804 E fol ca 149 Frequency in multiples o 100Hz Tab 14 Sensor test conditions for sensors which are connected to the I O board
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