Service manual

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09/09 Rev. 5.02-02 SERVICE MANUAL

AP 4.4 – AP 5.4 – AP 7.t

Service Electronics

Handling Boards ........................................... 2

ESD protection .......................................... 2

Handling .................................................... 2

CPU Boards .................................................. 3

AP 5.4 Layout ............................................ 3

AP 7.t Layout ............................................. 4

AP 4.4 Layout ............................................ 5

Connectors ................................................ 6

Lithium Battery ........................................ 10

Output Stage Stepper Motor ....................... 11

Layout ..................................................... 11

Connectors .............................................. 11

Output Stage Brushless Motor (AP5.4) ...... 13

Notes ....................................................... 13

Layout ..................................................... 13

Connectors .............................................. 14

I/O Board ..................................................... 15

Requirements .......................................... 15

Layout ..................................................... 15

Connectors .............................................. 15

Application ............................................... 17

Setting the Interface Parameters ............ 18

Input/Output Signals ................................ 19

Testing the Signal Interface .................... 21

Testing the Serial Interface ..................... 21

Display Board ..............................................22

Layout ......................................................22

Connectors ..............................................22

Power Supply ..............................................23

Layout ......................................................23

Connectors ..............................................23

Specifications ...........................................24

Sensor settings ............................................25

Setting sensors (AP 4.4/AP 5.4) ...............25

Setting sensors (AP 7.t) ...........................28

Setting the material end sensor ...............32

Sensor test ..................................................33

General notes ..........................................33

Sensors on the CPU board

(AP 4.4/AP 5.4) .........................................33

Sensors on the CPU board (AP 7.t) .........35

Sensors on the stepper motor output stage

board (AP 5.4) ..........................................36

Sensors on the stepper motor output stage

board (AP 7.t) ...........................................37

Sensors on the BLDC motor output stage

board (AP 5.4) ..........................................37

Sensors on the I/O board: ........................38

Summary of content (38 pages)

PAGE 1
09/09 Rev. 5.02-02 SERVICE MANUAL AP 4.4 – AP 5.4 – AP 7.t Service Electronics Handling Boards ........................................... 2 ESD protection .......................................... 2 Handling .................................................... 2 CPU Boards .................................................. 3 AP 5.4 Layout ............................................ 3 AP 7.t Layout ............................................. 4 AP 4.4 Layout ............................................
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Handling Boards ESD protection CAUTION! - The boards can be destroyed by static discharge! « Before opening the printer, place it on a grounded surface. « Earth your body using an ESD bracelet or other suitable means, before touching a board. If no suitable ESD protection is available, touch an earthed object, e.g. a heating radiator, before touching a board. « Only place boards on earthed surfaces.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Platinen AP 4.4 – AP 5.4 – AP 7.t CPU Boards AP 5.4 Layout RFID module or internal scanner (CN904) Power supply (CN701) Check LED motor voltage, yellow (D20) Feed motor (CN601) Keyboard (CN502) Control lines to the motor driver boards for peripherals (Cutter, ext. Rewinder, int.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Platinen AP 4.4 – AP 5.4 – AP 7.t AP 7.t Layout RFID module or internal scanner (CN904) Power supply (CN701) Check LED motor voltage, yellow (D20) Foil motor (CN601) Keyboard (CN502) Control lines to the motor driver boards for peripherals (Cutter, ext.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Platinen AP 4.4 – AP 5.4 – AP 7.t AP 4.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Connectors Function / Picture Circ. Diagr. JTAG/DEBUG CN 301 2x12pin 1.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Function / Picture Circ. Diagr.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Function / Picture Circ. Diagr.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Function / Picture Circ. Diagr.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Lithium Battery The CPU board used in the AP 5.4 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. ¯ The battery is not rechargeable! ¯ The battery must be UL-listed! Battery type Panasonic CR2032 or an equivalent battery type. WARNING! Danger of explosion if battery is incorrectly replaced.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Output Stage Stepper Motor Layout Peripheral sensor (J4) (D-Sub cable harness) Optional: additional sensor (J8) J6 J1 J7 Peripheral motor (AP 5.4/AP 7.t) Feed motor (AP 7.t) Printhead liftmotor (AP 7.t) External feed motor (AP 7.t) Power supply (J12) Control lines, coming from the CPU board (J2) Peripheral motor (J3) (D-Sub cable harness) Connectors Picture Circ. Diagr.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Picture Circ. Diagr. Type on board Type at cable J12 AMP 640389-6 AMP 0-644465-6 MTA 156 18 AWG Pin assignment on board 1 - 5V 2 - GND 3 - n.b. 4 - GND 5 - 38..
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Output Stage Brushless Motor (AP 5.4) Notes • • Firmware Version BLDC = brushless direct current Application: AP 5.4 with internal rewinder Printer BLDC 3.33 6 [Tab. 2] Required firmware version for the BLDC output stage. Checking the driver firmware version: « Call PRINT INFO > Service status. Section „Peripheraldriver“ on the printout lists all mounted output stage boards with the installed firmware versions.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Connectors Picture Circ. Diagr.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t I/O Board Requirements • • Printer: AP 5.4, AP 7.t Printer firmware version: 2.31 or higher Layout I/O signals similar to USI (CN201) CPU board (CN102) RS-232/422/485 (CN101) Connectors Picture Conn. # Type on board Type at cable Pin assignment on board CN102 JST B18B-PHDSS JST PHDR-18VS CN201 DSub15-F JST JAY-15S-1A3A DSub15-M CN101 DSub9-F DSub9-M See [Tab. 3] and [Tab. 4].
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t ¯ CAUTION - Pin assignment from „PC point of view“ (printer = DCE)! RS 232 Pin Signal name (host) Signal direction from I/O board 1 DCD Short with DTR and DSR 2 RxD Out 3 TxD In 4 DTR Short with DCD and DSR 5 GND Ground 6 DSR Short with DTR and DCD 7 RTS In 8 CTS Out 9 (RI) Not connected [Tab. 3] RS 422/485 Signal direction from I/O board 1 Not connected 2 Rx- Out 3 Tx- In 4 Term.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Application The I/O board may be used for 3 different applications: • 2nd RS 232 interface: The I/O board provides a RS 232 interface, which can be applied additionally to the one on the CPU board. The 2nd interface can e.g. be used to connect a bar code scanner. • 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.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Setting the Interface Parameters With an I/O board mounted, the following additional menus appear in the printer menu: • INTERF. PARAM. > COM2 PORT Contains all parameters required to configure the serial interface. • I/O BOARD Contains all parameters required to configure the signal interface. Menu Parameter Setting INTERF. PARAM. > COM2 PORT Baud rate 9600 No.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Input/Output Signals Internal supply The I/O board provides a galvanically decoupled 5 V source. External electronics, powered from this source, must not consume more than 0.5 W (5 V / 100 mA). ¯ Maximum admissible output current: 100 mA External supply The I/O board outputs may be powered by an external source from 5 V to 24 V (pin 7).
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Ouput signals • • • ERROR MACHINE STATUS PRINT END 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. • • • • Internal supply: V5-24 V = 4.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t 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.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Display Board Layout CPU board Connectors Picture Circ. Diagr.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Specifications Power • • Maximum continuous average output power: 196 W. Peak power: 276 W. ¯ Peak must not last longer than 30 ms. ¯ Limitation of peaks per minute: max. 3. Voltage range [6] Output Range Max. Min. +45 V +5% -10% +47.25 V +40.5 V +24 V ±3% +24.72 V +23.28 V +5 V ±5% +5.25 V +4.75 V Output voltage ranges.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensor settings Setting sensors (AP 4.4/AP 5.4) The following cases require the sensor or all sensors to be set newly: • • • Punch sensor A sensor was replaced The CPU board was replaced A punch sensor fork with additional reflex sensor was mounted (only possible with AP 5.4). 1. Start the printer in production mode and call parameter SERVICE FUNCTION > Sensor Adjust.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Ribbon sensor 1. Start the printer in production mode and call parameter SERVICE FUNCTION > Sensor Adjust. 2. Press the Online button repeatedly, until the following is displayed: Sensor Adjust 128 Foil 6 The left value is the control value for the LED current (Default: 128). The right value is the sensor value read back (here: 6). 3. Turn the ribbon unwinding mandrel by hand and watch the read back value.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Reflex sensor ¯ Setting only for AP 5.4 with optional reflex mark label sensor! 1. Start the printer in production mode and call parameter SERVICE FUNCTION > Sensor Adjust. 2. Press the Online button repeatedly, until the following is displayed: Sensor Adjust 112 Reflex 17 The left value is the control value for the LED current (Default: 112). The right value is the sensor value read back (here: 17). 3.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t 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. Setting sensors (AP 7.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensor Adjust 128 Foil 6 The left value is the control value for the LED current (Default: 128). The right value is the sensor value read back (here: 6). 1. Turn the ribbon unwinding mandrel by hand and watch the read back value. Sensor uncovered: the value should match the range 5..7. Sensor covered: the value should match the range 220..255.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t 3. Remove the white paper to verify the read back value. It should match the range of 50..160. ¯ Proceed the preceding step only if the printer doesn´t have a top side reflex sensor. 4. Insert some black paper to verify the read back value. It should match the range of 190..255. ¯ The paper stripe must be pulled tight while the setting is checked, similar to the conditions during printing operation.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t ¯ Because this is a switch, not a light barrier, the function can only be checked. Settings are not possible. Left value: 128 (stays unchanged) Right value: – 0 (cover closed) – 220…255 (cover opened) 6. Open and close the front cover of the printer and watch the read back value. 7. Press the Cut+Online+Feed buttons simultaneously to save the settings and to restart the printer.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Setting the material end sensor These printer types are equipped with a single light sensor which is designed to detect both, punches and material end. The sensor must be able to detect three different states: • • • No material Only backing paper Backing paper + label face The parameter SERVICE FUNCTION > Matend adjust can set the limit between being recognized as „only backing paper“ or as „material end“ [4].
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensor test General notes « Activating the sensor test: call parameter SERVICE FUNCTION > Sensor test. By means of the sensor test, you can check the function of each sensor: Sensor test 0.01 Punch Sensor # [5] 11 Sensor name Value Display after calling „Sensor test“. Digital sensors • Some sensors work digitally, what means that they don´t provide a value range, but the two values „1“ or „0“.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensor Sensor # name Connector # Typical value Condition 0.04 CN 908 0.05 Reflex Optn. 1 CN 909 7-30 White material over sensor 30-180 No material 180-255 Black material over sensor 0-255 analogous Reserved for special functions Punch sensor for short labels: a) 0.06 Optn. 2 CN 910 0.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensors on the CPU board (AP 7.t) ¯ If the printer is equipped with both reflex sensors (top and bottom), the following must be taken into account: – The sensor value of the open sensor („No material“) can not be read back. – The label material applied for setting purposes must in any case be lighttight. If any light shines through, light-tight material (e.g. cardboard) must be layed under the label material.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensor Sensor # name 0.10 0.11 Connector # Typical value Condition M-Supp CN 701 Start 0 No motor supply voltage 255 Motor supply voltage o.k. CN 803/804 0 Start signal low (IN1) 255 0.12 0.13 [Tab. 9] O Foil H (°C) calculated value Value calculated out of 0.07 Start signal high 0 Foil diameter unknown appr. 35-80 Foil diameter in mm appr. 25-70 Temperature at printhead in °C b) (Cont.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensors on the stepper motor output stage board (AP 7.t) Sensor Sensor # name Connector # Typical value Condition 1.01 Option J4 -- Without function 1.02 Option J8 -- Without function 3.01 Headlift J4 <=10 Printhead sensor open >=220 Printhead sensor covered Without function 3.02 Option J8 -- 4.01 Peri. 1 J4 255 4.02 Peri.
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09/09 Rev. 5.02-02 SERVICE MANUAL Service Electronics AP 4.4 – AP 5.4 – AP 7.t Sensors on the I/O board: Sensor Sensor # name Connector # Typical value Condition 15.01 CN 803/804 0 Start signal activated 1 Default start signal a) 0 Feed signal activated 1 Default feed signal 0 Pause signal activated 15.02 15.03 15.04 15.