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Service Mechanics

1. Clips A on the frame B of the DPM rear hood 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Blower DPM Tools e 2 5mm allen key Size 7 open ended wrench Dismantling 1 Open rear hood see above 2 Disconnect blower cable from USI board and power supply 3 Remove the 2 screws 10A Remove blower Assembl y i 9 Blower for the DPM The cable has two plugs for connec To assemble the device follow the steps in ing to the power supply and the USI the reverse order Make sure to Electronics Gen 2 m connect the blower in accordance with the illustration 11 A Power supply d gt 144 oe I 144 184 i 06 t ees ote p E U TE R gt ooooo ood p 9009009 0 B 9809 0 ooooo 9g serene 10 Fastening the blower to the rear hood Blower 11 Connecting scheme for the blower in DPM and PEM 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Rear hood ALX The rear hood of the ALX 92x consists of two identical plastic parts Tools Allen key 3 mm Dismantling Remove four screws on each half of the housing 12A 13A Pull the housing parts straight off towards the back m
2. a 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Service Mechanics Safety Instructions eee ee e ee 3 PIT 40 General Notes eee 4 Fl 41 Illustrations and Descriptions seer eee 4 Foil tensioner oiiire 41 Paon S ee A Print module orren 42 Key Combinations sese eee ee eee e 5 Feed motor DPM ALX see 42 Ne 5 Feed motor PEM sese 43 Preventative maintenance eee ee ee e D Brake roller version overview ee 44 Performance Interval ee D Brake roller type 1 DPM ALX 45 NN T 6 Brake roller type 2 DPM ALX 47 Replacing wear parts eee 6 Setting the braking torque see eee e e 51 Visual inspection sg 6 Print roller DPM ALA sistcnsarstenmieecevanane de Performance test sse eee ee eee 7 Print roler PEN sevsessosmmsameimune 53 HOUSING EE 8 Print roller drive belt PEM sees 54 FN 8 Toothed belt for feed roller DPM ALX 54 Front hood JER 9 Feed roller drive belt PEM 55 DPM rear hood c ccccceccccsccccscecescecescees 9 Feed roller DPM ALX eese 55 TT eee 11 Feed roller PEM cecce 56 Meal MOOG TALK serat grts aieiai 12 Dispenging edje secerneren 57 ONE ES EE n 12 Guiding profile 58 Dust filter ALX sccssccscectacctcdgvenvaccesaglecvacins 13 Pressure roller Un eee e eee eee 59 ag 81010 Ee ETER 14 Pressure roller PEM 60 Material transport ee eee eee ee eee 15 Material guide sss 62 TET ALAN svsersesvsdesssne 15 Material end SENSOr e cceseeccceceeeseeeeeeees
3. oooo000 00 88990909 8 989 8 9 p 0909 0 B 9909 0 172 Connecting scheme USI to CPU board A6621 in ALX 92x 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x CPU board ALX Tools 2 and 3 mm allen keys Disassembly Assembly 1 Remove rear hood O See paragraph Rear hood ALX on page 12 2 Remove the USI board O See paragraph US board ALX on page 80 3 Disconnect all cables from the CPU board 173 Fastening points arrows at the CPU board 174A mj gt 4 Remove fastening screws 175A from side panel 5 Remove screws 173 arrows from the board 6 Carefully remove the board 3 B e L var 175 Fastening screws A of the CPU board at the side panel 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order Make sure to m Check any new board before mounting Circuit board version Jumper settings m The type and number of cables to be at tached depend on the machine s specifica tions Complete connection list see topic section Electronics Gen 3 chapter CPU board Connectors on the CPU boards A229
4. 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Guiding profile Tools Allen key 3 mm Dismantling Undo the screws 113B 2 Pull the guiding profile 114A out to the side 4 Sap RE sies gt 5 4 gt N N Ao G L C 1 7 r E Eme dj 23 2 Bee f i d f K 113 A Guiding profile B Fastening screws Assembly To assemble the device follow the steps in the reverse order Do the following m Push the guiding profile nut 115A over the cylindrical moulding on the sensor fit ting 115B PEALL ETE T E Wail j 5 120 115 110 105 100 95 90 amp 116 Cylindrical moulding circled on the sensor fitting m The steel pin 115C must engage in 115 When assembling push the guiding profile nut A over the the corresponding hole cylindrical moulding B on the sensor fitting 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Pressure roller unit The pressure rollers 117C press the label material onto the brake roller The unit includes the axle 117B with the two pres sure rollers and a lever at each end of the axle Tools e Small screwdriver Locking ring grippers Dismantling DPM ALX 1 Open the rear hood O See paragraph Housing on page 8 2 Disassemble the feed motor O See paragraph Feed motor DPM ALX on page 42 3 Remove the braking mechanism from the brake roller axle O See
5. access to special service parameters Tab 1 Special startup key combinations for authorised service technicians Service Data The status printout Service status lists the printer s main service data Some of the counters contained in this function are incremented automatical ly for example the running time of the printhead Other counters such as the number of printhead replacements need to be incremented manually by the service technician This is done by using the appropriate parameter Tab 2 m Complete counter reset Call up Parameter Service Increment service calls counter Head exchange Increment head number counter Roller exchange Increment feed roller no counter Cutter exchange Increment cutter number counter Serv data reset Reset all counters to their initial value SERVICE FUNCTION Tab 2 These parameters increment the relevant counters for the info printout Service Status 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Preventative maintenance Performance interval Preventative maintenance should be carried out annually or after 250 km printhead running time m Printhead runtime Call parameter Cleaning In general Cleaning according to the user manual topic section Maintenance and Cleaning Electronic parts Remove accumulated dirt A m WARNING observe ESD safety measures Dust filter gt f present clea
6. Print contrast STEM PARAMETER t contrast 9 Printhead SYSTEM PARAMETER resistance Head resistance Printhead temperature compensation 5 Temp reduction Tab 3 Electronic printhead settings a Oder im Online Modus Prog Taste Mechanical settings Adjusting the printhead position Adjusting the printhead contact pressure Adjusting the printhead gap Tab 4 Mechanic printhead settings YSTEM PARAMETER gt When required Blackening of the printout is too low depends on material foil combination After each printhead exchange Label layout with huge areas of blackening and smearing of tiny structures see user manual topic section Advanced Applications paragraph Printing with temperature compensation on page 2 When required After printhead exchange if the printout is considerably worse see paragraph Adjusting the printhead position on page 75 After removal of the printhead contact pressure lever see paragraph Adjusting the printhead contact pressure on page 76 After removal of the printhead motor see paragraph Adjusting the printhead gap on page 72 05 10 Rev 5 04 03 1 SERVICE MANUAL DPM PEM ALX 92x Replacing the printhead Dismantling Switch off the machine and unplug it 2 Disconnect the printhead cable 146B 2 units 3 Undo the wingscrews 146A and take off the print head 147 Assembly To assemble
7. 2 Pull out the print roller 101 A Ty C i J T ka K mill y D or Hine Y N k a ril Ji ae si Aa SJ j j 100 A Print roller B Locking plate 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Print roller PEM Tools e 2mm allen key Dismantling 1 Remove the locking plate 91A 2 Loosen both set screws 103A at the print roller coupling 3 Pull the print roller out of the coupling 104A and remove it from the bearing plate 104B Assembly To assemble the device follow the steps in the reverse order Ensure that m One of the set screws presses against the flattening of the print roller axle 104 Removing the print roller 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Print roller drive belt PEM Tools 2 and 5 mm allen keys Dismantling 1 Dismantle belt tightener 95A and roll 95B N Remove print roller See paragraph Print roller PEM on page 53 Remove toothed belt Toothed belt for feed roller DPM ALX Tools Size 7 and 8 socket wrenches 2 mm allen key Small screwdriver Dismantling Dismantle the feed motor See paragraph Feed motor DPM ALX on page 42 Dismantle the braking mechanism including the washer disc from the brake roller See paragraph Brake roller type 1 DPM ALX on page 45 Remove locking ring 106B and take off the lever 10
8. L N d E Pes P o KS L P 4 C s J YA W i a JE Hi 4 Front hood seen from below and to the side Assembly A Hood switch gt To assemble the device follow the steps in B Mounting plate for Sub D connection C Front hood fastening screw the reverse order DPM rear hood Before dismantling the rear hood the po wer supply USI board and CPU board con nected to the rear hood must be removed Tools e Torx screwdriver size 20 Allen key 2 5 mm Dismantling 1 Remove two screws on the top and bottom of the rear hood 5A 6A and three on the lateral part 5B O continued on the next page 5 DPM rear hood 6 Underside of front hood 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Open rear hood 7 m To do this carefully pull the entire rear hood back as shown and at the same time open up the right hand lateral part Remove the power supply Refer to paragraph Power supply DPM PEM on page 92 Remove the USI board Refer to paragraph US board DPM PEM on page 84 Remove the CPU board Refer to paragraph CPU board DPM PEM on page 86 Undo the fastening screws from the nine clips 8A on the rear hood frame 8B Take off the rear hood m Lift the frame carefully over the in nards of the DPM Assembly To assemble the device follow the steps in the reverse order 8
9. RH Connector key position B 19 0 1 H meJ 2x 2 50 212 70 207 Sizes and positions of drilling holes for the connector mounting tng 208 Connector locked with a second nut arrows on each side 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 5 Connect the internal cable to connector CN 701 on the CPU board 209A Attach respectively close the rear hood gt Plug in the remote operator panel Switch on the machine EEE 209 Connector A for the remote operator panel on the CPU board A6621 CN 701 8 Operate the machine using the remote operator panel Print a service status print Service Status out saes The service printout must show the firm vanen ov tl ware versions of both operator panels eae 210A Aps na Kop Strobes Anz Irar CAUTION sd Sid 29 min Manipulating both operator panels si ve conti Pacey multaneously can cause mal functions Sipe Always use only one operator panel at rear amo a time to operate the machine Using Boara Teter meea both operator panels alternately is ad a m ISS ble Remote Disp Vers GAUTION se Koplandsiufa Wa T3 Perlpherie Endetule va TA If the connection ca
10. Service Mechanics DPM PEM ALX 92x Print module Feed motor DPM ALX Tools e 4mm allen key e Torx screwdriver size 20 Dismantling 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Disconnect the cable from the feed motor 78A 3 Loosen screw 78B on the belt tightener 4 Undo screws 3 screws 78C and remove the motor Assembly To assemble the device follow the steps in the reverse order Make sure to m Ensure that the motor connection faces up and to the left If the cable has been replaced m Attach the motor cable to plug J3 79A on the feed motor output stage board m Make sure the output stage board has the correct jumper setting 79B O For more details on this point see topic sec tion Service Electronics Output stage board m Relay and attach the cable making sure that it does not touch any moving parts 78 Feed motor A ALX RH K hlk rper 7 Cooling element Platine Board 79 Slot A for the feed motor on the feed motor output stage board marking J3 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Feed motor PEM Tools 5 mm allen key Dismantling 1 Open the rear hood O See paragraph Housing on page 8 2 Disconnect the cable from the feed motor 80A 3 Loosen screw 80B on the belt tightener 4 Unscrew the four motor flange screws 80
11. Set the sensor O See topic section Electronics Gen 3 section Settings 34 Connection of the dancer arm sensor A at the rewinder output stage 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Backing paper rewinder ALX Tools 2 5 and 3mm allen keys e Size 17 open ended wrench Dismaniling the drive belt 1 Take off the winder guide plate 35A To do this unscrew the two screws 35B 2 Dismantle the dancer lever or unhook the spring and move the dancer lever out to the side O Read paragraph Backing paper dancer le ver ALX on page 19 3 Remove screws 35C and take off the belt cover 4 Loosen screw 36A on the belt tightener Take off the belt Setting belt tension At optimal tension the toothed belt deflexi on may be 2 2 5 mm by a load of 3N The load must be positioned centrally between the two lock washers Centrical operating 3N force Deflexion 2 2 5 mm Measured value by 7 5 8 0 testing with the gauge 37 Measuring the belt tension ALX LH A Messger t Artikelnr A6822 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Completely dismantle the winder 5 Dismantle the ALX rear hood O See paragraph Rear hood ALX on page 12 6 Unscrew nut 38A The nut can be acces sed from below between power supply and base plate
12. The side panel with the electrical con nections is not connected with the plastic part m Remove the lateral part with the blower 12B carefully The side panel remains on the plastic part Disconnect the blower ca ble Blower ALX The blower is attached to the side panel 12B and is removed along with this half of the housing Tools Medium size cross head screwdriver Size 7 socket wrench Dismantling Remove rear hood To do this disconnect the blower cable m YOu only need to dismantle the half of the housing that contains the blower Unscrew the blower from the side panel 2 Screws Assembly To assemble the device follow the steps in the reverse order Make sure to nn connect the blower in accordance with the illustration 14 13 Bottom fastening screws A o o o o o o o o o a o o o o o o S D D D D D D S o o o o o o o o o o o o o o o o o o a D D o 14 Connect the blower to the power supply Ej o 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x ALX 92x power supply can be equipped with an optional dust filter 15 article no A6206 Tools e 3mm hex socket screwdriver e Medium size screwdriver Dust filter ALX i For especially dusty installation sites the a E Assembly 1 Puta filter liner 15C into the filter housing 15B 2 Press the filter housing onto the filter fram
13. f Gn page 30 52 Locking c Pee r ribbon unwinding an 4 Measure and note how deep the nut 53B circled and cap 53A are screwed on to the treaded rod m This step saves having to set the bra mnnt king torque after mounting the foil mandrel HUN 53 Note how deep the nut B and cap A are screwed on to the threaded rod circle i ON SJ 7921 H 5 Unscrew nut 54B 1 d 4 PR O Continued overleaf 54 Type 3 ribbon brake 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Service Mechanics 55 Type 2 ribbon brake RH Disassembly 6 Turn the threaded rod by the red hexago nal head out of the cap 55A and pull it out of the ribbon mandrel 7 Remove the retaining ring 55B from the brake lever Unmount the brake rod 55D from the brake lever 8 Remove all parts from the unwinding man drel Before removing the friction clutch 55E loosen both set screws 55F 9 Push the ribbon mandrel through to the opposite side m If necessary force the ribbon mandrel out by tapping it lightly with the plastic hammer Assembly To assemble the device follow the steps in the reverse order m Slightly grease the disk 55G arrow at its innner diameter before mounting it m Set the distance between cap and ribbon mandrel 55X to 5 5mm 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x The distance X is crucial
14. for the max seta ble brake torque of the unwinder The table shows only reference values which can differ from printer to printer Possibly some shim disks must be added or removed to exactly obtain the required brake torque m Screw the cap and nut onto the threaded rod till they reach the depth noted earlier m After the assembly set the braking torque O See paragraph Seiting braking torque on page 37 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Ribbon end sensor O For details on testing the sensor see topic section Service Electronics Settings Sensor test Tools 3mm allen key Dismantling 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Disconnect the cable from the sensor 56A 3 Remove screw 56B and take off the sen Sor Assembly To assemble the device follow the steps in the reverse order If the cable has been replaced m Attach the sensor to plug 57A on the foil motor output stage board m Make sure the output stage board has the correct jumper setting 57B O For more details on this point see topic section Service Electronics Output stage board m Relay and attach the cable making sure that it does not touch any moving parts lt N 56 Foil sensor Platine Board K hlk rper Cooling element 57 Slot A for the foil sensor on the
15. mm Fit spring balance 97A onto the material Strip Pull on the spring balance until the mate rial moves Read off the traction Setting maximum braking torque Screw in the threaded rod until the spring is maximally tensioned Measure the brake force Compare mea sured value with the values on the table If the measured value is too high insert shim washers 98A 99 arrow and mea sure again Repeat steps 2 and 3 until the measured value is in the permissible range see table m Small parts kit with the required shim rings 1 article number A9249 Setting minimal braking torque Screw the threaded rod out until the spring is completely slack Measure brake force and compare with the table If the brake force is too low continue screwing on the threaded rod and repeat measurement Screw on the self locking nut up to the cap Device EE 10 4N 14 N Fmin dY N 4 1 N DPM 4 5 ALX 924 925 DPM 6 ALX 926 Tab 2 Tractive forces for setting the breaking torque m 97 Measuring the break force A Spring balance 98 Insert shim washers 4x8x1 A to set the maximum braking torque DIE aN EN 99 Position of the shim rings arrow at type 2 brake rollers 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Print roller DPM ALX Tools 2mm allen key Dismantling 1 Remove locking plate 100B
16. roller type 1 DPM ALX Tools e Size 7 and 8 socket wrenches e 2mm allen key e Small screwdriver Dismantling Unhook and remove the brake spring 86A 2 Loosen the screw at the belt tightener 86B Unscrew nut 87G At the same time brace the threaded rod with the red hexa gonal head 85 arrow at the other end of the rod Screw the threaded rod out of the cap 87F Remove parts 87F C from the brake rol ler axle Undo the set screws 2 screws on the washer disc 87B Remove the washer disc and the lock was her 87A from the brake roller axle O Continued overleaf 86 Type 1 brake mechanism at the brake roller A Brake spring B belt tightener mo 87 A Free running lock washer B Washer disc C Spring D Plastic disc E Tension disc F Cap G Nut 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 8 Remove the locking ring 88A 9 Remove locking plate 89A 10 Press in lever 89B and pull out the brake roller 89C along with the bearings Assembly To assemble the device follow the steps in the reverse order Do the following m Insert a shim ring 0 5mm thick both in front and behind the t belt pulley 90A m Set a space of 0 3 mm between the t belt pulley and the washer disc 90B fee ler gauge 89 Brake roller C on the printhead side of the machine ALX RH m Mount the parts onto the b
17. screw 139B underneath the punch sensor thumb wheel 139A 5 Pull out the punch sensor assy 140A 137 A Cylindrical moulding on the sensor fitting B Groove on the guiding profile lt T 138 A Connection cable punch reflex sensor PEM LH 139 Fixing screw B of the punch sensor assy View from the bottom side 140 Pulling out the punch sensor assy A PEM LH 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly PEM To assemble the device follow the steps in the reverse order Make sure to p Fix the sensor onto the belt as shown 141 The right hand edge of the clip 141C points to 123 m Connect the punch sensor to the con nectors CN 1105 and CN 1106 on the CPU board 142 or 143 m Relay and attach the cable making sure that it does not touch any moving parts o lt a 3 U U ilii HELE ET a dL p VZ T L L IBU 155 BU 45 40 5 120 115 110 105 100 95 90 amp Ek 142 Slots of the label sensors on the CPU boards A2292 and A2293 Electronics Gen 2 A Slot of the light transmission sensor cable marking PS CN 1105 B Slot of the reflex sensor cable marking RS CN 1106 p 143 Slots of the label s
18. the device follow the steps in the reverse order Make sure to do the fol lowing m After mounting a new printhead it is es sential to enter the printhead resistance with the parameter SYSTEM PARAMETERS gt ead resistance Read off the resistance value from the label on the printhead 148A 146 Detach the printhead cable 148 Label A at the printhead Service Mechanics 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Replacing the printhead cable Dismantling 1 Disconnect cable 2 units from the print head see above 2 Open DPM or dismantle ALX the rear hood 3 Pull the end of the cable line printhead side through the opening in the base plate 147A 4 Undo the cable fastenings 5 Detach the cable from the power supply and CPU board Assembly To assemble the device follow the steps in the reverse order Make sure to m Connect the cable as shown 149 m Relay and attach the cable making sure that it does not touch any moving parts m Reattach the securing clamps O For details on the connections to the power supply and CPU board see topic section Electronics Gen 2 or E
19. timing disc Don t undertighten it this would cause the timing disc to rotate on the motor axle Press the Online button Press Escape twice 157 Pressure tool A applied side view aO 158 Timing disc on head lifting motor dismantled A Notch in the timing disc 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Adjusting the printhead position In this chapter Printhead position means the position of the printhead 159A at the printhead bracket 159B in printing direc tion The printhead position is factory adjusted and hasn t to be changed in most of the ap plications Changing the printhead position is only re commended if the following is the case e A spare part printhead was installed The printout is considerably worse than be fore regarding blackening and contrast m During the adjustment no other settings may be changed which influence the prin ting quality m For test printouts use parameter Tool Allen key 1 5 mm Adjustment 1 Print a sample label Loosen all screws 160A and 160B Turn inthe set screws 160C turn Tighten the screws 160B Print a sample label and evaluate it oo e Oy If the printout became better Repeat steps 2 to 5 until the printout is good enough or until it is worsening again If the printout became worse Repeat steps 2 to 5 but turn the set screws out step by step
20. until the printout is good enough or until it is worsening again If the printout is good enough gt Tighten all screws 160A and 160B m Secure the screws 160B with locking var nish 160 Adjusting the printhead position by rotating the set screws C 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Adjusting the printhead contact pressure Tools Spring balance 0 to 50 N Part number 93665 00 0 Size 7 open ended wrench Coupling piece allows the spring balance to be hooked onto the end of the threaded bolt Adjusting Set the setting knob to the lowest pressure one line Turn the connecting link on the head motor until the head lifting mechanism s pressure arm is pointing into the recess in the con necting link printhead lowered position Screw the coupling piece onto the bolt 161B 4 Unscrew the locknuts 161A 5 Hook the spring balance onto the coupling piece and pull on it until the balance shows 8 N At the same time tighten the locknuts against the axle 161C until they lock 161 Adjusting knob with printhead lifting mechanism 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Printhead lifting mechanism ak ONO Printhead pressure setting knob The printhead press on unit is used to en sure that the printhead presses on the print roller at a defined and consistent ra
21. 0Hz Measurement using a fish balance From 04 2008 on the cam at the belt tigh tener provides a grooved pin 68 arrow at which the fish balance can be hooked in Tool Fish balance 10N Article no 93665 02 Proceeding Pull at the grooved pin with the pulling force indicated below Tighten the screw at the belt tightener Set point 5 6N 68 Measuring the belt tension with a fish balance 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Setting braking torque The braking torques of the foil mandrels can be set by turning the red hexagon on each mandrel Turn clockwise to increase the torque The traction exerted on the foil is in propor tion to the winding unwinding torque To set the braking torque measure the trac tion with a spring balance Tools Spring balance 50 N 69 Procedure 1 Put an empty cardboard sleeve onto the foil mandrel 2 Wrap foil a few times round the cardboard sleeve Fix the end of the foil to the backing paper 3 Twist the other end of the foil together and Knot it into a loop 4 Hook the spring balance 69 into the foil loop and pull on it until the foil mandrel turns slowly and steady 70 Read off the traction m While pulling at the rewinding mandrel it is essential to keep the foil feed roller blocked m The pulling force may vary within the indi cated tolerances Tab 1 5 If necessa
22. 2 and A2293 see topic section Electronics Gen 2 chapter CPU board 176 Connectors on CPU board A6621 Electronics Gen 3 A Power supply 5 V B USI or Al C Power supply 24 V D Rotary encoder E Backing paper rewinder sensor F Feed roller sensor G Material end sensor H Light transmission label sensor I Cover switch J Power supply data cable K Operator panel L Motor output stages data cable M Printhead N Centronics interface 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x USI board DPM PEM Tools 2mm allen key Dismantling 1 Open the rear hood O See paragraph DPM rear hood on page 9 2 Disconnect all cables from the board 3 Unscrew the circuit board from the back casing 2 screws 178A TELE ATT oe TUULE TT alU vzs og SLAOTIATEIS JON 81 1 VAD 04 KH 0 THOS osv S INA gr A N A 179 Mounted position of the USI board A DPM LH 45 855 inv YAE La L sE E EEE T N Te E T ae sss litt e gt aa be B nmi Bid ee or a gt ea on om inte r gt 3 p m N Y vr L S Z v NLU EEG U lt i gt 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order Make sure t
23. 4 03 SERVICE MANUAL DPM PEM ALX 92x Operator panel board sese eee 89 Power supply ALX sse eee 90 Power supply DPM PEM 92 Remote operator panel eee eee 94 Prerequisites ET AR 94 Assembly of internal cable ALX 92x 94 Assembly of internal cable DPM PEM 95 Wall mounting the remote operator panel 97 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Safety Instructions WARNING A N The machine operates using mains voltage Touching electrically live parts can cause exposure to hazardous electrical currents and may lead to burns Only authorised service technicians are permitted to disassemble the housing gt Before disassembling housing components turn off the machine and unplug the power cable m The machine can only be completely disconnected by unplugging the power cable m The ALX 92x Al Pro is equipped with two power cables To completely disconnect this machine both power cables must be unplugged gt f the machine needs to be powered up for repairs or testing after the hou sing has been disassembled never touch electrically live parts This also applies to low voltage parts gt Never open the housing of the power supply Faulty power supplies should always be replaced not repaired gt After switching off the printer wait at least 1 minute before touching any electric contacts at the power supply gt Ensure that the
24. 64 Deflection rollers ALX vnez snata nrp 15 Punch Sensor ceeeessesecerceereereeereenreereeeee 65 Material dancer lever ALX serere 16 Printhead se 68 Contact pressure axle at drawing roller 17 General TASS EE 68 Contact axle Sensor eee ee 18 Overview of printhead settings 69 Backing paper dancer lever ALX 19 Replacing the printhead cccceece 70 Dancer lever sensor ALX se 19 Replacing the printhead cable 71 Backing paper rewinder ALX 20 Printhead adjustment sss eee ee ee ee e 72 Rewinder motor ALX sse 21 Adjusting the printhead gap 0 72 Foll tansport Se 22 Adjusting the printhead position 75 IES Tn NOTES sana ceannacagnecanganmnanuaaeienceses 22 Adjusting the printhead contact pressure 76 Version Overview eee eee e eee 23 Printhead lifting mechanism esse eee ee 77 Ribbon unwinding mandrel type 2 24 Printhead pressure setting Knob Zi Ribbon unwinding mandrel type 3 27 Printhead lift Sensor css eee ee ee 78 Ribbon end sensor sse eee eee stenen 30 Sa T BU Ribbon rewinding mandrel type 1 2 31 USI board ALX seende 80 Ribbon rewinding mandrel type 3 33 GFU Bord ALA sasmsemmennismii 82 Setting belt tension eee ee ee 36 USI board DPM PEM see 84 Setting braking torque see eee ee 37 CPU board DPM PEM arez eysan 86 Stepper motor output stages sese ee 88 05 10 Rev 5 0
25. 6A Take off the toothed belt Assembly To assemble the device follow the steps in the reverse order 105 Print roller drive belt of the PEM LH A belt tightener B Roll 106 The lever A in front of the belt must be removed 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Feed roller drive belt PEM Dismantling 1 Dismantle drive belt from the print roller O See paragraph Print roller drive belt PEM on page 54 2 Disassemble the feed motor O See paragraph Feed motor PEM on page 43 3 Take out the belt 97A Assembly To assemble the device follow the steps in the reverse order Ensure that m Turn the belt tightener clockwise to tigh ten the belt 107 Feed roller drive belt A Feed roller DPM ALX Tools 6mm allen key e Screwdriver medium Dismantling 1 Disassemble the feed motor O See paragraph Feed motor DPM ALX on page 42 2 Undo the set screws 2 screws on the lock washer 106C Take off the lock was her 3 Remove the locking ring from the axle 4 Undo the mounting axle To do this push the lever 108A downwards 5 Remove locking plate 108B Pull out the feed roller 108C along with 108 A Mounting axle lever B Locking plate Mees C Feed roller Assembly To assemble the device follow the steps in the reverse order 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics
26. C and remove the motor Assembly To assemble the device follow the steps in the reverse order Ensure that nn The motor connection faces towards the left O You will find details for connecting the mo 81 A Feed motor tor to the output stage board in the previous B belt tightener eect on p g p C Screws on the motor flange 4 fastening screws Replacing the toothed belt disk on the motor 1 Undo the set screws 2 screws 81A on the toothed belt t belt disk 2 Remove the t belt disk m If necessary heat the t belt disk before hand with hot air Assembly 3 Ensure a 1 mm gap between motor and t belt disk using the clearance gauge 81B 4 Secure and tighten the set screws with thread locking adhesive Loctite 243 82 Assembly of the new toothed belt disk m Fit the t belt disk in such a way that one poole B Clearance gauge 1 mm of the set screws presses on the flattening at the motor shaft SERVICE MANUAL Service Mechanics 05 10 Rev 5 04 03 DPM PEM ALX 92x Brake roller version overview O Parts kit for retrofitting from type 1 to type 2 E e A9138 LH k f A s A9239 RH c y 1e e oo am Mnd pp W dii 83 Type 1 of the brake mechanics with wrap around spring A 84 Type 2 of the brake mechanics 05 10 Rev 5 04 03 1 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Brake
27. CE MANUAL Service Mechanics DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order E tr m Connect the power supply as shown in the illustration 201 O Further information can be found in the Ty amp 201 Connecting the power supply topic section Service Electronics Power A CPU data gt CN 403 supplies B Remote on off switch C Printhead D CPU supply voltage 5 V gt CN 1401 E USI blower CPU board F CPU supply voltage 24 V gt CN 1400 G Output stages HAI 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Remote operator panel Prerequisites Device with electronics Gen 3 CPU board A6621 Drilling for connector mounting is available Remote operator panel upgrade kit article number A8719 The upgrade kit contains Remote operator panel article number A8293 Internal cable article number A8380 1940 1 Assembly of internal cable 2x 2 50 ALX 92x Tools D e Cross head screwdriver small size e Hex socket wrench size 4 12 70 Assembly 1 Remove the rear hood see paragraph Rear hood ALX on page 12 2 a Drilling hole 204A for connector moun ting is available remove the cap 203 Sizes and positions of drilling holes for the connector mounting b Drilling hole for connector mounting is not available drill the holes accordi
28. DPM PEM ALX 92x Feed roller PEM Tools 2mm allen key Dismantling 1 Dismantle drive belt from the print roller O See paragraph Print roller drive belt PEM on page 54 2 Dismantle drive belt from the print roller O See paragraph Feed roller drive belt PEM on page 55 3 Remove locking plate 109A of the feed roller 4 Open the pressure roll lever 109B 5 Pull out the feed roller 1090 6 Undo the set screws 2 each 110A on the t belt disk Take off the t belt disk Assembly To assemble the device follow the steps in the reverse order Ensure that m The steel bushing 1 1 OB is attached 110 Arrangement of t belt disks on the feed roller axis A Set screws with the collar facing the roller B Collar on the steel bushing m The inner t belt disk fits to the plate 101 with a space of 10 mm m Set screws are secured with thread lok king adhesive Loctite 243 111 Required distance during lock washer mounting 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Dispensing edge The dispensing edge 112A is held at both ends in side panels 112B Tools 2 5mm allen key Dismantling 1 Dismantle the print roller see above 2 Remove holding screws from the side panels 112C one in each Take off the dispensing edge i 112 A Dispensing edge long version from below B Side panel
29. J3 74A on T the foil motor output stage board Kuhlkorper Cooling element A m Make sure the output stage board has the correct jumper setting 74B 7 O For more details on this point see topic sec tion Service Electronics Output stage board m Relay and attach the cable making sure that it does not touch any moving parts 74 Slot A for the foil motor on the output stage board for the foil motor marking J3 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Foil roller Tools Allen key 2 5 mm e Large and medium sized screwdrivers Dismantling 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Undo the retaining screw 75A on the belt tightener Take off the belt 75B 3 Take off the first locking ring 75C the too thed belt pulley 75D and the second lok king ring 75E 4 Pull out the foil roller 76 Assembly To assemble the device follow the steps in the reverse order 76 Pull the foil roller A out Foil tensioner Tools Screwdriver medium Dismantling 1 Unhook spring 77B 2 Remove locking ring 77C 3 Pull out the foil tensioner roller 77A and swivel arm off the axle Assembly To assemble the device follow the steps in the reverse order 77 The foil tensioner consists of the roller A and the swivel arm 05 10 Rev 5 04 03 SERVICE MANUAL
30. M ALX 92x Assembly To assemble the device follow the steps in the reverse order Assure the following m Spacer sleeves behind the rear materi al guide ALX DPM each axle 1x A3629 6 7 mm PEM rear axle 1x A3629 6 7 mm front axle 1x A7650 3 5mm m Tightening torque for setting screw in the inner material guide 20 Nem m PEM front axle Insert a spacer ring on each side between pressure roller wing and bearing plate 128A 129C B 128 Parts arrangement at the front axle PEM LH outer side A Aluminium ring 3 5 mm A7650 B Pressure roller wing C Retaining ring LEG Pe ea e N E Ze PN JE 129 A Inner material guide at a PEM LH feeding module dis mantled B Pressure roller wing C Aluminium ring 3 5 mm A7650 D Aluminium ring 6 7 mm A3629 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Material end sensor The material end sensor recognises when no more material is there and thus protects the printhead from unnecessary wear The error is displayed and the machine stops The light barrier for sensing the end of ma terial 130 circled is located in the internal material guide of the machine The light barrier sensor is attached to the guide and can only be replaced as a complete unit O For details on testing the light barrier sen pet Gaa topic section Service Electronics 130 Material end sensor circled stuc
31. Rewinder motor ALX Tools Torx screwdriver size 20 Dismantling 1 Dismantle the drive belt O See paragraph Backing paper rewinder ALX on page 20 2 Dismantle the ALX rear hood O See paragraph Rear hood ALX on page 12 3 Disconnect the motor cable from the adap ter cable 39D 4 Undo screws 4 screws 39B and remove the motor Assembly To assemble the device follow the steps in the reverse order m The cable comes out of the motor poin ting upwards If the cable has been replaced m Attach the motor cable to plug J3 40A on the winder motor output stage board m Make sure the output stage board has the correct jumper setting 40B O For more details on this point see topic section Service Electronics Output stage board m Relay and attach the cable making sure that it does not touch any moving parts 38 Undo this nut A to completely dismantle the winder ALX RH power supply dismantled FIN H A0GIGG paus Tr HOIOA DNlddajs P X Len E 39 Winder motor C and the related motor driver board A ALX RH Platine Board K hlk rper N ea Cooling element d g Ss 40 Slot A for the winder motor on the winder motor output stage board marking J3 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Service Mechanics Foil transport Important Notes m The components for foil transport are the same for DPM and ALX Lu
32. ard DPM PEM on page 84 Disconnect all cables from the CPU board 183A Remove fastening screws A from side panel Carefully detach the board from its four plug sockets CAUTION Disregard may damage the board Do not bend the board under any circumstances when removing it 6 Remove the board carefully 182 Fastening points arrows at the CPU board lage S_ _ _ _ _ _ SHOR I SURRY SEI a ania mret AOE paa ve yeu tg ews HILE v ZS xP Bn A TI S YST OL TI S gt neo L THs ar s J 184 Mounted position of CPU board A DPM LH Service Mechanics 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order Make sure to m Check any new board before mounting Circuit board version Jumper settings m The type and number of cables to be at tached depend on the machine s specifica tions Complete connection list see topic section Electronics Gen 3 chapter CPU board Connectors on the CPU boards A2292 and A2293 see topic section Electronics Gen 2 chapter CPU board 185 Connections of the CPU board A6621 Electronics Gen 3 A Power supply 5 V B USI or Al C USI Blo
33. ble is longer than 2 5m EMG caused disturbances can occur 210 The service status printout shows the firmware for both gt Only use the factory installed cable pe gt Don T extend the cable 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Wall mounting the remote operator panel Tool Cross head screwdriver medium size Mounting Drill 2 holes according to the drawing beside 211 Open the operator panel housing 4 screws Mount the lower part of the housing using 2 M4 screws Close the operator panel housing 211 Hole distances for wall mounting of the remote operator pa nel
34. bricating plastic parts m All plastic parts pictured below must be greased at the inner diameter 41 arrow before assembling it All other surfaces must be absolutely free of grease A6466 01 V h 41 Plastic parts used for foil transport with the surfaces to be lubricated arrows 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Version Overview 42 Type 2 of ribbon drive A and ribbon brake B Built in until serial number 074315 12 2007 43 Type 3 of ribbon drive A and ribbon brake B Built in starting with serial number 074315 12 2007 Retrofitting kits Part kits for retrofitting from type 2 to type 3 Rewinder Article number A9040 e Unwinder Article number A9017 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Ribbon unwinding mandrel type 2 Tools 2 5 and 2 mm Allen key Size 7 and 8 socket wrenches Plastic hammer Dismantling 1 Pull the cap 44B off the foil mandrel 2 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 3 Measure and note how deep the nut 46B circled and cap 46A are screwed on to the foil mandrel m This step saves having to set the bra king torque after mounting the foil mandrel m This step is unnecessary if the spring 46C is to be replaced sd 45 Foil unwinding mandrel A with rear hood
35. cled and cap 59A are screwed on to the foil mandrel m Doing this saves setting the braking tor que after mounting the foil mandrel ELLE A 63 Before unscrewing the nut B and cap A it is essential to note how deep they are screwed in circled H 7 Eee ie F ja a L L T 0 Ta L RS EN p fe 4 F d ia ua Ta K d s x ign f v ri c r er aie 1 F k B w F L 4 Unscrew nut 64B O Continued overleaf 7 4 7 d a 64 Type 3 ribbon drive 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x A o 65 Type 3 rewinding mandrel RH Disassembly 5 Turn the threaded rod by the red hexago nal head out of the cap 65A and pull it out of the ribbon mandrel 6 Remove all parts from the unwinding man drel Before removing the friction clutch 65E loosen both set screws 65F 7 Push the ribbon mandrel through to the opposite side m f necessary force the ribbon mandrel out by tapping it lightly with the plastic hammer Assembly To assemble the device follow the steps in the reverse order m Slightly grease the disk 65D arrow at its innner diameter before mounting it m Set the distance between cap and ribbon mandrel 65X to the value given in the fol lowing table Device Distance X ALX 924 925 DPM 4 5 6 0mm PEM 4 5 ALX 926 DPM 6 PEM 6 4 2 mm Service Mec
36. d sil O See paragraph Rear hood ALX on page 12 2 Disconnect all cables from the board anp lalat 169A wate TER 44 BING ge er R 8999999888 passene vere le se H 5 P T x DL TT ANEAN Muy ay L A vet an Raa pi liti 169 Mounted position A of the USI board 3 Unscrew the circuit board from the side panel 2 screws 170A 170 Fastening A of the USI board to the side panel with cable feedthrough B for the OD control sensor 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order Make sure to m Check any new board before mounting Circuit board version Controller version Jumper setting m Connect the board as shown in the illu stration 171 and 172 You may have to attach additional cables to the board de pending on the machine s specifications e g applicator PLC Al See topic section Electronics Gen 2 or Electronics Gen 3 chapter USI board Power supply 88990909 ooooo0 00 88990909 B 9909 0 p 00000 B 9909 0 171 Connecting scheme USI to CPU boards A2292 and A2293 in ALX 92x Power supply 88990909
37. dismantled B ALX RH 46 Before unscrewing the nut B and cap A it is essential to note how deep they are screwed in circled 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 4 Dismantle the foil sensor by removing screw 47A Remove nut 47B At the same time brace the threaded rod with the red hexagonal head at the other end of the rod gi D gt Turn the threaded rod by the hexagonal head out of the cap 47C and pull it out of the foil mandrel N Remove the cap spring and discs 8 Undo the 2 set screws 48A on the buffer disc Push in the end of the foil mandrel 48B so that the other discs can be taken off m f necessary force the foil mandrel out by tapping it lightly with the plastic hammer 48 Detail of foil unwinding mandrel Nut cap and spring have been removed 10 Screw the nut off the end of the rod 49A oa Gane RH ae 9 ar Remove the lower spring and discs CN S at 11 Pull the rod up and out of the joint 49B 12 Remove the brake lever 49C and the other parts from the foil mandrel 13 Push the foil mandrel through to the oppo site side 49 Foil brake The lower spring has been removed 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order Make sure to do the following up Mount the bu
38. e 15A Turn the screw 15D by a quarter turn bi Li SS I B LS 18 Assembly of the dust filter Mounting 1 Unscrew the 2 screws 16A at the side plate of the ALX 2 Screw the dust filter 15A onto the tapped holes using the screws which came with the filter kit 17 CAUTION An exhausted filter liner x A N can cause the power supply to over heat and the device to break down Replace the filter liner regularly at least in monthly intervals 17 Mounted dust filter A 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Hood switch WARNING The hood switch is there for your safety Putting it out of operation increases the risk of hair jewellery etc being caught Do not disable the hood switch Regularly check that the hood switch is working O Checking the switch see topic section Electronics Gen 2 or Electronics Gen 3 chapter Settings Sensor test Tools Small screwdriver Dismantling 1 Open the front cover 2 Remove the hood switch fastening screws 2 screws 3 Open the rear hood O See paragraph Housing on page 8 4 Undo the cable fastenings 5 Thread the cable end through the opening in the base plate and disconnect from the CPU board marked COS Assembly To assemble the device
39. e roller axle O See paragraph Brake roller type 1 DPM ALX on page 45 3 Remove screw 133A 4 Remove screws 134A 2 screws 5 Carefully pull the light barrier sensor 135A out along with the adjustment wheels and belt 6 Pull the light barrier sensor 136A off the belt 7 Undo the connection cable from the faste ning and disconnect it from the CPU board Assembly DPM ALX To assemble the device follow the steps in the reverse order Make sure to ne Fix the sensor onto the belt as shown 136 The right hand edge of the clip 136C points to 123 O continued on the next page 133 Screw A on the underside of the print module ALX RH with long dispensing edge 134 Fastening screws on the base H ALX RH il 135 Pull the sensor A out carefully TT U JU H UU H d 5 120 15 no 105 100 95 og amp 111181 IL ka ALD 160 155 150 145 40 136 The sensor fitting A is attached to the belt B 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x m Fit the cylindrical moulding 137A into the groove on the guiding profile 137B Dismantling PEM 1 Open the rear hood O See paragraph Housing on page 8 2 Remove the cable straps from the sensor cable 138A and disconnect the cable from the CPU board 3 Remove the guiding profile O See paragraph Guiding profile on page 58 4 Remove the
40. e measured value is higher than the in dicated value Check movability of the bearing Replace the part causing sluggish operation 3 Screw the nut up to the cap without lok king the cap SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 05 10 Rev 5 04 03 Printhead Core Unwinding mandrel Winding mandrel width min N max N min N max N 5 e BT 4 5 6 Tab 1 Minimum and maximum setting values for the traction on the winding and unwinding mandrels Setting the functional brake force With the settings given above the range that can actually be set corresponds to the permissible range for the braking torque gt Screw the threaded rod in until it stops then screw it out again by about 2 rotations 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Foil motor Tools Torx screwdriver size 20 Dismantling 1 Remove the tension disc lock washer and washer disc from the foil winding mandrel 73 O See paragraph Ribbon rewinding mandrel type 1 2 on page 31 2 Undo the fastening screws 73B 4 screws on the motor 73A 3 Disconnect the cable from the motor and take out the motor Assembly To assemble the device follow the steps in the reverse order Make sure to P 73 Foil motor A m Ensure that the motor connection faces up and to the left If the cable has been replaced e m Attach the motor cable to plug
41. electrical system is in perfect condition Check the electrical system on a regular basis Fasten loose connections Replace damaged cables immediately gt Only operate the unit once the housing has been reassembled properly After assembling check the machine according to the regulations which are relevant in your country CAUTION Always make sure the electronic circuitry is protected from elec A N trostatic discharge gt Wear ESD protective gear gt Before opening the machine make sure it is placed on an earthed surface 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x General Notes Illustrations and Descriptions DPM or ALX The following descriptions are largely applicable both to DPM and to ALX 92x The latter will be referred to as ALX below Some sections apply to only one of the two types of machine In such cases the machine type will be shown after the heading in brackets Figures Texts are accompanied by figures where necessary Figures are indicated using figure numbers in Square brackets A capital after a figure number for example 12A refers to a specific section of the figure Serial numbers Some assemblies were subject to one or more constructive changes and can therefore be ordered in several versions The spare parts catalog notes in those cases the serial number or the production month year of the machine which is required to be compatible wit
42. ensors on the CPU board A6621 Electronics Gen 3 A Slot of the light transmission sensor cable marking PS CN 1105 B Slot of the reflex sensor cable marking RS CN 1106 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Printhead General Notes CAUTION Electrostatic discharges or contact with sharps edges can da mage the printhead Protect the printhead from electrosta tic discharges when performing maintenance work or cleaning Avoid touching the thermal edge 145C printhead with bare hands as much as possible Do not allow sharp objects to come into contact with the termal edge Printhead type Corner Edge In this chapter printhead means the as sembly of thermal printhead 144A and printhead bracket 144B The position of the printhead on the prin thead bracket is set ex works using optical aids This setting fits for most of the appli cations In rare cases after replacing the printhead the printing may be worse than before low blackening low contrast In this case a service technician should correct the prin thead position see chapter Adjusting the printhead position on page 46 145 Thermal edge C at the printhead 05 10 Rev 5 04 03 SERVIGE MANUAL Service Mechanics DPM PEM ALX 92x Overview of printhead settings There are electronic and mechanical prin thead settings Electronic Parameter settings
43. er ALX Tools Screwdriver medium 2 5mm hexagon spanner Dismantling Dismantle material unwinder see above Remove locking ring 25B Unhook the spring 25A Pull the damcer lever off the axle To replace the brake lining 25C gt Unscrew the brake lining fastening screw Take out the brake lining Adjusting the dancer lever spring At the dancer lever are two holes 26A B into which the spring can be hooked The recommended position depends on the la bel length and on the print speed Choose the hook in position in a way that the dancer lever never crushes against the outer limit bloc 26C neither with a new la bel roll nor with a nearly empty roll i T GES 25 Upper dancer lever ALX RH Sa gy HA 26 Hook in position of the retaining spring at the dancer lever A Position for use with short labels and low print speed B Position for use with long labels and high print speed 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Contact pressure axle at drawing roller Tools 2 5 and 3mm allen keys Dismantling the pressure roller ALX 924 One pressure roller e ALX 925 926 Two pressure rollers 1 Loosen screw 27A 2 Open the pressure lever 27B 3 Remove screw 27A and take off the pres sure lever 4 Loosen the thumb screw 27C 5 Unscrew the set screws 27D 6 Pull off the pressure roller
44. ffer disc 50H with the lar ger chamfer pointing outwards m Brake lever 50G Lightly grease the bearing surface between plastic disc and mandrel before assembly with universal grease The brake surfaces between the dics must not be greased Mount the brake lever with the bulge side 51 arrow facing outward m Mount the brake disc 50F with the sharp edge pointing outwards m Foil brake Turn the self locking nut on the end of the rod 50A until it protrudes by 8mm m Screw the cap 50B and nut SOA onto the threaded rod till they reach the depth noted earlier m f a new spring 50C has been moun ted the braking torque must then be set O See paragraph Setting braking torque on page 37 50 Order of parts on the foil unwinding mandrel A Nut B Cap C Spring D Shim washers E Oscillator disc F Brake disc G Brake lever H Buffer disc I Spacer ring D UI 51 Mount the brake lever A with the bulge side arrow facing outward 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Ribbon unwinding mandrel type 3 Tools 2 5 and 2 mm Allen key Size 7 and 8 socket wrenches e Plastic hammer Preparing for dismantling 1 Pull the cap 52B off the foil mandrel 2 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 3 Remove the ribbon end sensor 54A O See paragraph Ribbon end sensor on
45. foil motor output stage board marking J4 05 10 Rev 5 04 03 1 2 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Ribbon rewinding mandrel type 1 2 Tools Size 7 and 8 socket wrenches Allen key 2 mm Plastic hammer Torx screwdriver size 20 Dismantling Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 Pull the cap 58B off the foil mandrel Measure and note how deep the nut 59B circled and cap 59A are screwed on to the foil mandrel m Doing this saves setting the braking tor que after mounting the foil mandrel m This step is unnecessary if the spring 59C is to be replaced Undo the retaining screw on the belt tightener 60A Take off belt 60B Remove nut 60C At the same time brace the threaded rod by the red hexagonal head on the opposite side of the printer Unscrew the threaded rod out of the cap 60D remove the cap Take off the spring brake disc and toothed belt pulley ba F al 3 L ar 7 el tm 7 reg 58 Ribbon rewinding mandrel A with locking cap B 1 ww OE 59 Before unscrewing the nut B and cap A it is essential to note how deep they are screwed in circled c E H al ns K 7 M 7 k pe C h ae Bh i a 60 Ribbon rewinding mandrel with drive highlighted 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 8 Und
46. follow the steps in the reverse order Make sure to m When reattaching the cable make sure it does not touch any moving parts Z Al k a S 19 Hood switch dismantled a AN SDA Mp ONLINE FEED PROG gt 5 A 7 P 3 o u S 20 Hood switch A assembled 21 Slot A of the hood switch on the CPU boards A2292 and A2293 Electronics Gen 2 CN1109 22 Slot A of the hood switch on the CPU boards A6621 Elec tronics Gen 3 CN1109 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Material transport Unwinder ALX Tools Screwdriver medium Dismantling Remove locking ring 23A Move the guide rod to the side and pull the unwinder off the axle For transport the unwinder must be remo ved along with the holding plate gt To do this unscrew the two screws 23B The screws can be accessed through the opening 23C Deflection rollers ALX Tools Screwdriver medium Dismantling Remove the locking ring from the end of the deflection roller axle 24A 2 Pull the roller off the axle 24 Deflection rollers ALX RH 05 10 Rev 5 04 03 lt OE Y SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Material dancer lev
47. h the respective assembly The serial number can be found on the rating plate of the machine as illustra ted below 1 XXXXXXyymm yy year mm month XXXXXX Sequential number 1 Rating plate at an ALX 926 The machine was built 07 2004 and has the sequential number 052773 Factory Settings All of the parameters are set to default values by the manufacturer These vary from model to model The factory settings can be restored at any time using the parameter Default Values Requirements The parameter is set to Stan dard If it is set to User setting the values that were current when User setting was selected are restored O More details on factory settings can be found in the topic section Info Prin touts and Parameters parameter 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Key Combinations Access to certain of the printer s functions should be reserved for authorised service technicians Access to these functions has been restricted In order to access them the operator must restart the printer while pressing a specific key combination for several seconds Key Function Described in combination Cut Prog H8 forced reset Topic Firmware section Load Firmware via Bootloader Feed Prog Provides access to Topic Info Printouts and Parameters special service section Parameter parameters Cut Online H8 forced reset plus see above Feed Prog
48. hanics 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x The distance X is crucial for the max setable brake torque of the rewinder The table shows only reference values which can differ from printer to printer Possibly some shim disks must be added or removed to exactly obtain the required brake torque m Screw the cap and nut onto the threaded rod till they reach the depth noted earlier m After the assembly set the braking torque O See paragraph Seiting braking torque on page 37 Service Mechanics 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Setting belt tension Press the belt tightener against the belt Tighten screw 66A Measure the belt tension using one of the methods described below If necessary repeat steps 1 and 2 until the belt is tightened correctly Measuring using a dial gauge Tool Dial gauge article number A6737 Proceeding Apply the dial gauge so that the measure ment takes place in the centre of the top strand of the belt Press the measurement bolt downwards onto the belt 66 arrow Set point 8 5 Frequency measurement Tool Frequency meter e g from Optibelt see http www optibelt com engl into_messe tt_mini html Proceeding gt Measure the frequency according to the devices user manual m The measurement must be applied at the pictured strand 67 arrow Set point 31
49. hanics DPM PEM ALX 92x 5 Lift the pressure roller Unscrew the locking plate 123A 6 Remove the ball bearing 123B from the pressure roller wing outside direction 7 Remove the pressure roller from the wing 124 Dismantling the pressure roller A Assembly To assemble the device follow the steps in the reverse order Make sure to m Before assembling the pressure axle insert the torsion spring as illustrated in 125 125 Assembling the torsion spring A Long side B Short side 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Material guide The material end sensor is located in the inner material guide 126A Tools e Retaining ring pliers e 2mm allen key Dismantling 1 Undo the set screw on the inner material guide 126A Undo the thumbscrew on the outer material guide 126B 2 Push the outer material guide into the middle of the guide rods 3 For each of the two guide rods spread the front retaining ring and at the same time pull out the guide rod 127 4 Push the inner material guide out over the inner guide rod end ba E DI A 126 A Inner material guide secured with set screw B Outer material guide secured with thumbscrew 127 Spread the retaining ring B and at the same time pull out the rod A A Guide rod B Retaining ring 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PE
50. it at least 1 minute before touching any electric contacts at the power supply Tools 2 5 3mm allen key Dismantling 1 Remove rear hood O See paragraph Rear hood ALX on page 12 2 Detach all cables from the power supply 192 3 Remove screw on the inside of the power supply 193A 4 Unscrew earth contact 194B 5 Remove screws in the side panel 194A 2 screws 6 Remove the power supply 194 Fastening of power supply A to side panel 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order While doing so pay at tention to WARNING A N Hazard caused by dangerous contact voltage gt Attach the ground cable to the ma chine housing gt After assembling check the machi ne according to the regulations which are relevant in your country 195 Ground cable A of the power supply B C DEF G m Connect the power supply as shown in the illustration 196 tt ale TLL m Screw the ground cable 195A to the al M dr E i machine housing assemble the parts in the following order to the threaded bolt 196 Connecting the power supply Serrated lock washer Eyelet 195B Ser A CPU data gt CN 403 rated lock washer Nut B Remote on off switch C Printhead O Further information can be found in the D CPU supply voltage 5 V g
51. k in the rear material Settings Sensor test guide Dismantling 1 Remove the rear hood 2 Disconnect the material end sensor from the CPU board cable marked MS 3 Dismantle the rear material guide O See paragraph Material quide on page 62 4 Pullthe material end sensor cable through the cutout in the base plate Assembly To assemble the device follow the steps in the reverse order Make sure to m Plug the sensor into plug CN 1104 on the CPU board 131A or 132A m Relay and attach the cable making sure that it does not touch any moving parts 131 Slot of the material end sensor A on the CPU boards A2292 and A2293 Electronics Gen 2 CN1104 132 Slot of the material end sensor A on the CPU board A6621 Electronics Gen 3 CN1104 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Punch sensor O For details on testing the light barrier sen sor see topic section Service Electronics Settings Sensor test Tools e 2 5mm allen key Torx screwdriver size 20 Cross head screwdriver small Dismantling 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Take the braking mechanism off the brak
52. lectronics Gen 3 149 Attach the printhead cable to A Power supply B CPU board A2292 or A2293 CN901 Electronics Gen 2 or C CPU board A6621 CN 1002 Electronics Gen 3 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Printhead adjustment Adjusting the printhead gap When the machine is switched on and the foil is in place there should be a gap of bet ween 0 75 and 1 00 mm between the prin thead and the print roller If this is not the case set the printhead gap as follows Tools 2 and 3mm allen keys Pressure tool 150 part number A8288 Preparation 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Set the printhead pressure to the mini mum Insert foil and thin material 4 Call parameter Confirm with Enter Head adjust Press Feed m Do not press the Feed button yet 5 Loosen screw 151A on the pressure arm 6 Undo the clamping screw 152B on the timing disc 152A O continued on the next page U 150 Pressure tool for setting the printhead gap 151 ead pressure arm DPM RH head lifting motor dis mantled J 7s 152 Timing disc A on the head lifting motor ALX RH Service Mechanics 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Setting 7 Turn the connecting link 153A to the lowest position printing position 153 Connecti
53. n or replace Replacing wear parts Description Location Toothed belt HTD 315 3M 06 Foil rewinding mandrel belt tightener Foil rewinding mandrel Spring Ribbon tightener Toothed belt HTD 315 3M 09 Feed roller Tab 3 Parts to be replaced as part of preventative maintenance Visual inspection gt Subject all moving parts to a visual inspection gt f any defect is visible replace the affected part 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Performance test Springs Foil mandrels Sensors Blower Dancer levers Rollers Brake pad on material dispenser Material pressure rollers Drawing roller Print roller Printhead Printing head axle Deformations Scoring groove marks Bearing clearance outside the normal range Check values SERVICE FUNCTIONS gt Sensor test Sluggish operation unusual noises Deformations Clearance Wear Damage Sluggishness Function Sluggish Clearance Groove marks Groove marks Carry out dot check SERVICE FUNCTIONS gt Head dot test Clearance Tab 4 Parts to be checked as part of preventative maintenance Service Mechanics If defective Replace spring Replace foil mandrel Clean replace sensor Correct settings Replace blower Replace dancer lever Replace roller Replace brake pad Replace the pressure roller Replace drawing roller Replace print roller If dots are missing in importan
54. ng link A on the mounted head lifting motor ALX RH 8 Clamp 0 1 mm thick material 154C bet ween the connecting link and the pressure arm 154B 154 Connecting link A on the dismantled head lifting motor A Connecting link B Pressure arm C 0 1mm thick material 9 Loosen screw 155A at the head lifting motor Turn the contact spring 155B aside O continued next page 155 Kontaktfeder A an der Druckkopf Andruckachse 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 10 Shift the pressure tool 156A 157A onto 11 the printhead axle m The pressure tool suits for both machi ne types RH and LH Press the lever of the pressure tool 157A downwards to press the pressure arm against the connecting link and reattach the pressure arm fastening screw m Tightening torque 350 Nem m Secure the screw with Loctite 243 12 Bring back the contact spring 155B in its initial position and tighten the screw 13 Press the Feed button Head adjust Sens 3 01 255 14 Turn the timing disc until the notch 158A is at the top 12 o clock 15 Slowly turn the timing disc with the notch to the sensor 153B until the display shows 0 zero Head adjust Sens 3 01 0 16 Carefully retighten the fastening screw on 17 the timing disc m Tightening torque 20 Nem m Don t overtighten the screw this would damage the
55. ng to 203 and 204 3 Hold the connector from inside against the side panel m The connector key 204B must face the built in boards 204 Connector A for the remote operator panel at an ALX 92x side panel RH Connector key position B 4 Push two screws M2x16 from outside through the side panel and the connector holes Mount lock washers and nuts on each of the screws tighten the nuts Lock each nut with a second nut 205 arrows O Continue with step 5 on page 96 205 Connector locked with a second nut arrows on each side 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Assembly of internal cable DPM PEM Tools Cross head screwdriver small size Hex socket wrench size 4 Assembly Open the rear hood see paragraph DPM rear hood on page 9 a Drilling hole 206A for connector moun ting is available remove the cap b Drilling hole for connector mounting is not available drill the holes according to 206 and 207 Hold the connector from inside against the side panel m The connector key 206B must face the bottom of the machine 4 Push two screws M2x16 from outside through the rear hood and the connector holes Mount lock washers and nuts on each of the screws tighten the nuts Lock each nut with a second nut 208 arrows O Continued overleaf 206 Connector A for the remote operator panel at an DPM PEM rear hood
56. o m Check any new board before mounting Circuit board version Controller version Jumper setting m Connect the board as shown in illustra tion 180 or 181 Further cables may have to be attached to the board depen ding on the machine s specifications e g applicator PLC Al O See topic section Electronics Gen 2 or Electronics Gen 3 chapter USI board Power supply ooooo 0090 B p 89900 0 0 800009 0 ooooo 9 B 8900 0 899809 6 3 Blower 180 Connection scheme USI to CPU boards A2292 and A2293 in DPM and PEM CPU Power supply a T T dh JB i ee dk 8 ES C TEETER ee C ni E E J HD H e L i a S J USI D 2 Blower 181 Connection scheme USI to CPU board A6621 in DPM and PEM 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x CPU board DPM PEM Tool 2mm allen key Disassembly Assembly Open the rear hood See paragraph DPM rear hood on page 9 Remove the USI board See paragraph US bo
57. o the 2 set screws on the buffer disc 61F Remove the buffer disc 9 Push the foil mandrel through to the oppo site side m If necessary force the foil mandrel out by tapping it lightly with the plastic hammer Assembly To assemble the device follow the steps in the reverse order Make sure to do the fol lowing m Mount the buffer disc 61F with the lar ger chamfer pointing outwards 61 Order of parts on the foil winding mandrel A Nut m Lightly grease contact surface of the a pring toothed belt pulley 67E before assembly ne m Mount the brake disc 61D with the z Urke PE chamfer pointing outwards G Spacer ring m Screw the cap 61B and nut 61A onto the threaded rod till they reach the depth noted earlier m f a new spring 61C has been moun ted the braking torque must then be set O See paragraph Seiting braking torque on page 37 m Following assembly the belt tension needs to be set see below 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Ribbon rewinding mandrel type 3 Tools Size 7 and 8 socket wrenches Allen key 2 mm Plastic hammer Torx screwdriver size 20 Dismantling 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Pull the cap 58B off the foil mandrel Mon i S 62 Ribbon rewinding mandrel A with locking cap B 3 Measure and note how deep the nut 59B cir
58. ok spring 164E 3 Carefully take out the sensor mount 165 4 Unplug the cable 165A from the sensor and unscrew the screw 165B Remove the sensor Assembly To assemble the device follow the steps in the reverse order Make sure to do the fol lowing um Reattach the spring 164E after as 4 AD f f sembling the mount f 0 m Underneath the motor the mount ser 165 Mount for head lifting light barrier ves as a cable guide Do not trap the cable O continued on the next page 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x m The sensor 166A must reach over the motor timing disc 166B The disc must not drag on the sensor If the cable has been replaced m Attach the sensor to plug J4 167A on the head lifting motor output stage board m Make sure the output stage board has the correct jumper setting 167B O For more details on this point see topic section Service Electronics Output stage board m Relay and attach the cable making sure that it does not touch any moving parts Me 166 A Sensor B Timing disc Platine Board Kuhlkorper Cooling element 167 Slot A for the head lifting sensor on the head lifting sensor output stage board 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Service Mechanics Boards USI board ALX Tools 2mm allen key WW Dismantling 1 Remove rear hoo
59. ot touch any moving parts 29 Switching lug B and light barrier sensor A on the moun ting axle for the drawing roller 30 Slot for the mounting axle sensor A on the CPU boards A2292 and A2293 Electronics Gen 2 CN1103 31 Slot for the mounting axle sensor A on the CPU board A6621 Electronics Gen 3 CN1103 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Backing paper dancer lever ALX Tool 3mm allen key Dismantling 1 Unhook spring 32B 2 Remove screw 32A Take off the dancer lever 32C To replace the roller take off the locking ring 82D f 32 Backing paper dancer lever C Dancer lever sensor ALX Tool 2 mm allen key Dismantling Dismantle the rear hood See paragraph Housing on page 8 Disconnect the cable at the sensor board pP DV Unscrew screws 33B Remove sensor board Assembly Make sure to m Position the sensor board in an way that the sensor 33C does not touch the wedge 33 A Sensor board 33D B Mounting screws C Sensor m Connect the dancer arm sensor to pos D Wedge 34A at the rewinder output stage CAUTION different mounting position in RH and LH machines m
60. out the brake roller 95C along with the bearings 95 Brake roller C on the printhead side of the machine ALX RH 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Assembly To assemble the device follow the steps in the reverse order Do the following m Insert a shim ring 0 5 mm thick both in front and behind the t belt pulley 96A m Set a space of 0 3 mm between the t belt pulley and the friction clutch feeler gauge m Slightly grease the inner diameter of part 96B arrow before mounting it m Set the distance between cap and ribbon mandrel X to the value given in the follo wing table Device Distance X ALX 924 925 DPM 4 5 6 8mm ALX 926 DPM 6 6 4mm The distance X is crucial for the max seta ble brake torque of the rewinder The table shows only reference values which can differ from printer to printer Possibly some shim disks must be added or removed to exactly obtain the required brake torque m After the assembly set the braking torque O See paragraph Setting the braking torque on page 51 Service Mechanics O L SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 05 10 Rev 5 04 03 96 Position of the parts on the brake roller axle 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Setting the braking torque Measuring the break force Insert material strip 97 Material size 110
61. paragraph Brake roller type 1 DPM ALX on page 45 4 Remove locking ring 118B Remove the pressure lever 118A and the spacer sleeve from the axle 5 Remove the locking ring 119B and the red opener 119A from the axle O continued on the next page Z0089 cdr 117 Pressure roller unit Pressure lever with spring B Axle with pressure rollers C Pressure roller TF NES wa sn Mam 118 Pressure lever with the dismantled rear hood feed motor and brake roller mechanism A Pressure lever B Locking ring 119 The opener A is located on the printhead side of the pres sure roller axle 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 6 Thread the axle out back and to the side 120 120 Thread the pressure roller axle A out back and to the si Pressure roller PEM de Unlike the DPM with its two plastic rollers the PEM is equipped with one long sillicone pressure roller 121A Tools e Allen key 2mm e Retaining ring pliers Dismantling 1 Remove retaining washer 121B and ope ner 121C from the end of the pressure axle 2 Remove retaining washer 121D at the inner side of the bearing plate 3 Pull the rear end of the pressure axle 122A out of the bearing plate then remove the axle diagonal as pictured 122 arrow 4 Remove the torsion spring 05 10 Rev 5 04 03 SERVICE MANUAL Service Mec
62. rake roller axle in the order shown 90 m Mount washer disc 90B with the lar ger chamfer pointing outwards m Mount tension disc 90D with the chamfer pointing outwards m Lubrication The surface between the discs 90B D must be free of grease m Insert two 1mm thick discs between the spring 90E and the cap 90F 90 A Overrunning t belt pulley B Washer disc C Tension disc D Plastic disc E Spring F Cap G Nut 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Brake roller type 2 DPM ALX Tools Size 7 and 8 socket wrenches e 2mm allen key e Small screwdriver Dismantling 1 Loosen the screw at the belt tightener 92A 2 Unscrew nut 92C At the same time brace the threaded rod with the red hexa gonal head 91 arrow at the other end of the rod 3 Screw the threaded rod out of the cap 92B and pull it out or the brake roller 4 Remove all parts 93 from the brake roller axle Before removing the friction clutch 93A loosen both set screws 93B 5 Remove the t belt pulley 93C from the brake roller axle hl O Continued overleaf 92 Type 2 brake machanics at the brake roller 93 Type 2 brake mechanics part positions 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x 6 Remove the retaining ring 94A 7 Remove locking plate 95A 8 Press in lever 95B and pull
63. ry increase or lower the brake force by turning the red hexagon on the foil mandrel Screw in the threaded rod turn the red hexagon clockwise Screw out the threaded rod turn the red hexagon anti clockwise O Continued overleaf 69 Spring balance 50 N part no 93665 00 0 Folie P Ribbon Foliendorn 9 Ribbon mandrel Pappkern vA Cardboard sleeve p Federwaage Fish balance Z0030 cdr 70 Determine the traction needed for winding or unwinding with a spring balance 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Setting the maximum brake force 1 Screw in the threaded rod until it stops 2 Measure the brake force as described above If the value measured is lower than the specified range gt insert additional shim washers 71 72 and repeat steps 1 and 2 If the value measured is higher than the range given r ai gt Remove shim washers 71 72 and repeat 71 Position of the shim disks at type 2 unwinders steps 1 and 2 m Small parts kit with the required shim rings article number A9249 Setting the minimum brake force 1 Screw the threaded rod out until the spring is just slack 2 Measure the brake force The measured force is lower than the indi cated value Screw in the threaded rod a couple of turns and repeat step 2 l 72 Position of the shim disks at type 3unwinders Th
64. s Assembling the pressure roller To assemble the device follow the steps in the reverse order Make sure to m Lock the set screws 27D with locking varnish Loctite 243 m Tighten set screws 27D until the alu minium block is easily movable but has mi nimal game on the axle Dismantling the mounting axle 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Unscrew the screws 28A from the switch plate Take off the switch plate 28B 3 Pull out the axle from the opposite side 28 Mounting axle with switching lug B DPM LH 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Contact axle sensor O For details on testing the light barrier see topic section Service Electronics Set tings Sensor test Tools 3mm allen key Dismantling Open DPM or dismantle ALX the rear hood See paragraph Housing on page 8 Undo the mounting axle As a result the switching lug 29C swings out of the light barrier sensor 29A Undo the screw 29B on the light barrier sensor Disconnect the cable from the board of the light barrier sensor Assembly To assemble the device follow the steps in the reverse order If the cable has been replaced m Plug the light barrier sensor into plug CN 1103 on the CPU board 30A or 31A m Relay and attach the cable making sure that it does n
65. stage board DPM LH A Head lifting motor B Foil motor C Feed motor 188 The ALX contains an additional output stage A for the rewind motor B 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Operator panel board Dismantling 1 Open the front cover 2 Carefully remove the front part of the ope rator panel housing 189A This does not require tools 3 Detach the display board Assembly To assemble the device follow the steps in the reverse order m f the connection cable has been replaced plug the cable onto the CPU board as illu strated in 190 and 191 O For more information about boards see to pic section Electronics Gen 2 or Electronics Gen 3 chapter Operator panel 189 Opening the operator panel x Ca PEEEEEEE 190 Connecting scheme operator panel to CPU boards A2292 and A2293 Electronics Gen 2 d ma 8 191 Connecting scheme operator panel to CPU board A6621 Electronics Gen 3 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Power supply ALX WARNING Hazard caused by dangerous contact voltage gt After switching off the printer wa
66. t CN 1401 topic section Service Electronics Power E USI Al basic supplies F CPU supply voltage 24 V gt CN 1400 G Blower H Output stages I Alpro 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Power supply DPM PEM WARNING A N Hazard caused by dangerous contact voltage gt After switching off the printer wait at least 1 minute before touching any electric contacts at the power supply Tools e 2 5 3mm allen key e Small medium cross head screwdriver e Side cutting pliers Dismantling 1 Open the rear hood O See paragraph DPM rear hood on page 9 2 Detach all cables from the power supply Open the cable clamps 198A and sepa rate the cable ties r a I p f IN 4 4 198 Detach the cable from the fastenings arrows 3 Remove screws 2x A 2x B 2x C on the outside of the rear hood 199A C LH version us RH version The both screws 199A are fixed at a mounting bracket 200A in side the DPM PEM Unscrew them 200B from this bracket oO aN gt jul Ge Scene TT eee lele 2 G SS I S B VEI AEG 199 Fastening of power supply A B C to side panel 200 Fixing the power supply with the bracket A Iiii 4 Take out the power supply 05 10 Rev 5 04 03 SERVI
67. t areas replace the printing head Adjust bearing or replace bearing bush 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Housing The DPM housing consists of the parts shown in the illustrations 1 The front and rear hoods each consist of several sheet metal components connected with hinges 8 The hinges are welded so the sheet metal components can not be taken apart 1 The DPM housing is made up of three parts A DPM rear hood B DPM front hood C Front screen part of the front hood The ALX has the same front hood as the DPM but a different rear hood 2A 2 The ALX has a different rear hood Front screen A ALX rear hood B DPM front hood Tools Medium size cross head screwdriver Dismantling Open up the front hood 2 Undo recessed head screws 3A 10 screws Take off the front hood Assembly To assemble the device follow the steps in the reverse order 3 Open front hood 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Front hood Tools 3 pe vi F IN Ese e Torx screwdriver T20 20 cm long Small screwdriver Allen key 2 5 mm apply ONLINE FEED PROG Dismantling 1 Open up the front hood 4 2 Unscrew hood switch 4A m If there is a Sub D applicator unscrew the plug board 4B 3 Undo Torx screws 4C 7 screws Take off the front hood A ber L E L E j
68. te This pressure must be adjusted for diffe rent material widths and or material strengths See operating instructions topic section Setup Setting printhead pressure A spring loaded thrust pad 162A on the adjusting knob 162B engages at the selec ted position and prevents the pressure from being changed accidentally Tools Size 7 open ended wrench Retaining ring pliers Dismantling Open DPM or dismantle ALX the rear hood See Housing Unhook the spring 163B at the lower end Unscrew nuts 163C Remove the grip screw 163D Remove the adjusting knob on the prin thead side of the base plate 162 The printhead pressure is set with this adjusting knob B 163 Adjusting knob A with printhead lifting mechanism 05 10 Rev 5 04 03 SERVICE MANUAL Service Mechanics DPM PEM ALX 92x Printhead lift sensor O For details on testing the sensor see topic section Service Electronics Settings Sensor test The light barrier 164A is fastened to the head lifting motor 164D with a mount 164B It is advisable to dismantle the mount along with the light barrier Tools e Torx screwdriver size 20 2 5mm allen key Dismantling 1 Undo the two fastening screws 164C on the inner side of the motor to which the mount 164B is attached m Do not undo the two external screws If the head lifting motor is detached the printhead gap must be reset 2 Unho
69. wer Power supply 24 V D Rotary encoder E Backing paper rewinder sensor F Feed roller sensor G Material end sensor H Light transmission label sensor I Cover switch J Power supply data cable K Operator panel L Motor output stages data cable M Printhead N Centronics interface 05 10 Rev 5 04 03 SERVICE MANUAL DPM PEM ALX 92x Service Mechanics Stepper motor output stages Each of the three end stage circuit boards 186 controls one of the three stepper mo tors Each board forms a unit with a cooling element 186A The cooling elements are each attached to the DPM base plate with two screws Motor board allocation 187 Foil motor 187B Head motor 187A Feed motor 187C Tools e 3mm Allen key e Torx screwdriver size 15 machines built until 6 2006 Dismantling 1 Open DPM or dismantle ALX the rear hood O See paragraph Housing on page 8 2 Disconnect the cable from the board 3 Undo the fastening screws 2 screws on the board cooling element Remove the board 187 Stepper motors and the corresponding output stages Assembly To assemble the device follow the steps in the reverse order Make sure to m Check any new output stage board be fore mounting Circuit board version PIC version Jumper setting must be appropriate for the motor Further information can be found in the to pic section Service Electronics Output

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