Avery Dennison ALX 720 User manual

Service Manual
ALX 720
Release 11/2003 Page 1 Adjustment
Adjustment 720
Contents
1 HOUSING 3
1.1 Important notes 3
2 CONNECTIONS 4
2.1 Important notes 4
2.2 Main connector 4
2.3 Transformer 5
2.4 Fan 5
2.5 Fuses 6
2.6 Printer serial interface 6
3 SENSORS 7
3.1 Overview Sensors 7
3.2 Full size label sensor 8
3.3 Loop sensor 9
3.4 Sensor head position 10
3.5 Foil end sensor 10
3.6 Sensor material end 11
4 SERVICE INFORMATION 12
4.1 Factory setting 12
4.2 Reset of service counter 12
4.3 Increment service counter 13
5 SOFTWARE-UPDATE 14
5.1 General update information 14
5.2 Program-Download (new board) 15
5.3 Program-Download (new version) 16
PRINT MODULE 17
Disassembly print module 17
6.2 Feed roller 18
6.3 Pressure unit 19
6.4 Print head 20
6.4.1 General 20
6.4.2 Print head voltage 20
6.4.3 Other parameter print head 20
6.4.4 Disassembly print head 21
6.4.5 Position print head 22
6.4.6 Pressure print head 23
6.4.7 Adjustment print head 24
6.4.8 Print head axle and zero alignment 24
6.4.9 Adjustment head lift 27
6.4.10 Further adjustments 29
7 MATERIAL GUIDE 30
7.1 Material end sensor 30
8 FOIL MOVEMENT 31
8.1 Foil unwind axle 31
8.2 Foil rewind axle 32
8.3 Foil zero line adjustment 33
8.4 Foil core break 34
8.5 Foil guiding 34
8.6 Foil rewind axle 35

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8.7 Foil end sensor 37
Foil saving 38
8.9 Sensor head position 38
9 MECHANICAL SETTINGS 39
9.1 Unwind brake, dancer arm driven (Option) 39
9.2 Dancer arm 40
9.3 Rewind, drive belt 40
9.4 Adjustment of the pressure roller 40
9.5 Foam roller at the dispensing edge 40
9.6 Adjustment of the label web 41
9.7 Paper brake 41
10 FULLSIZE LABEL SENSOR 42
10.1 Assemble Option 42
10.1.1 Change position of pressure lever 42
10.1.2 Mount full size sensor 42
10.2 Adjustment of the sensor 46
10.3 Check Sensor 47

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1 Housing
1.1 Important notes
♦Open of the cover is only allowed authorised technical personal!
♦The machine is to switch off and the line connector has to be removed before opening the
cover. Attention! Inside the machine is high dangerous voltage.
Housing parts
1 Front pane (Front cover with front pane and
border)
2 Arm
3 Rear cover
4 Clamp
The front cover (1) could be opened. During open
they should be closed.
The machine is mounted at the arm (2).
Clamps (4) and standings could be delivered on
request.
3
2
1
4

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1 2 4
3 4
2 Connections
2.1 Important notes
♦Open of the cover is only allowed authorised technical personal!
♦The machine is to switch off and the line connector has to be removed before opening the
cover. Attention! Inside the machine is high dangerous voltage.
2.2 Main connector
The connections to the mains is done with a com-
bined unit with following functions
1Line connector,
2Main switch,
3Line filter,
4Voltage selector and fuse holder
Voltage selector and fuse holder is one part used for
both functions. Select the correct supply voltage.
Connection of the transformer:
1 Earth yellow/green
2 240 V black
3 100 V green
4 115 V brown
5 230 V blue
7 Null red
Before switch on be sure that the line voltage and
the selected voltage on the line filter are identical.
The line filter prevents that there is any electrical in-
fluence from outside to the machine or that the ma-
chine disturbs other machines (EMI).
7
1
2
3
4
5

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Disassembly / Mounting line filter
1. Remove line cable
2. Loose both screws the line filter is fastened.
3. Disconnect the cable to the transformer and the earth connection to the front plate.
4. Remove and replace the line filter.
♦At mounting the new line filter, check the correct connection of the earth cable and
the mounting of the protective cover!
2.3 Transformer
The wires of the transformer has to be connected to:
28 V / 12 A grey Motor control printer
45 V / 5 A violet Motor control dispenser
24 V / 3 A white CPU board dispenser
Disassembly / Mounting
1. Open cover
2. Remove transformer cables. This means
connections to the transformer and to the
electronic. (Details see diagrams).
3. Loose mounting screw (1 Allen screw).
4. Remove and replace transformer.
Tools
♦Allen key 5 mm
2.4 Fan
For stable operation independent of the ambient temperature a fan is installed.
Disassembly / Mounting
1. Loose screws of fan (1) and grill (2)
mounted on the side plate.
2. Disconnect fan cable from connector CN35
on the I/O-board.
3. Change parts.
1
12

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2.5 Fuses
For protection of the electronic standard 5x20mm fuses are in use.
¯In case of changing a fuse use only the recommended value. Inserting
fuses with a wrong value can destroy the machine.
Function Value Standard Manufacturer
Designation
Line fuse 8,0 A slowblow
100/115 V IEC 60127-2/V Wickmann 181
Line fuse 6,3 A slowblow
230/240 V IEC 60127-2/V Wickmann 181
I/O board, F1 10 A slowblow
I/O board, F2 1 A slowblow
2.6 Printer serial interface
For the PC-connection the machine is supported with a RS232 port.
Disassembly
1. Disconnect CN12 on the CPU-board.
2. Loose 2 screws fasten the serial connector.
3. If necessary replace cable and connector.
¯On the CPU-board a connector (CN11) for the parallel Centronics Inter-
face is also available. This port is only for downloading a new software.

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3 Sensors
3.1 Overview Sensors
Sensors are used to detect the status of the machine.
Sensor Function Location Comment
Label sensor (Full
size)
OTHR/SCHK/Pxxx
Detection of label edge also
end of label Print module Nothing to open, full width
Loop sensor
OTHR/SCHK/Rxxx Detection of dancer arm position in printer loop At dancer arm, inside
Position print head
OTHR/SCHK/Hxx Detection of print head po- sition for foil saving Print module, at slotted disk lift mechanic
Foil end sensor
OTHR/SCHK/Fxx Detection of foil movement Print module, slotted disk foil unwind
Material end sensor
OTHR/SCHK/Mxx Detection of end of mate- rial, protection of print head Print module, inner label guide Replace with material guide
All sensors’ could be checked for correct function and the electrical pa-
rameter can be adjusted.
More info A survey of all check functions you will find in the chapter "Info-print
outs and parameter" (Parameter OTHR/SCHK) in the user manual.
The adjustment is described in the chapter
"Service boards" (I/O-boards) in this document.
¯During adjustment of sensor’s take care
that no other light sources have influence to the sensor! Eventual
covers the sensor’s during the adjustment procedure.

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3.2 Full size label sensor
Function The label sensor measure the correct label length and detect the start of
a new label. The position of the sensor could be set nearly of the whole
label width. So the sensor can be used for different labels (shape,
transparency, position and shape of gap).
Location The label sensor is located in front of the print unit and could be easy
adjusted.
P
6
P
5
P7
P
8
P9
P4
CN14
CN13
CN17
CN10
CN16
P1
CN12
CN15
P2
CN18
CN23 CN26
CN35
CN33
CN34
CN32 CN30
CN31
CN9

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Sensor Connector Adjustment condition Pot Value /
Test point Para meter Display value
Label sensor CN15 without material in label
sensor Pot. P7 7 Pxxx 7
(Full size) with material >7
Adjustment Without Material in the label sensor (only backing paper):
For adjustment select the function OTHR/SCHK/Pxxx and turn the po-
tentiometer P7 (I/O-board) to get the display value P7.
With material (label) in the label sensor:
A display value of >P7 should be shown.
3.3 Loop sensor
Function The sensor measure the position of the dancer arm. Is the label loop not
filled, so the dancer arm is not in the home position, the printer starts
printing. If the loop is nearly empty a signal is generated to inhibit the
dispenser.
Location The loop sensor is mounted inside the machine at the dancer arm.
Sensor Connector Adjustment condition Pot Value / Test
point Para meter Display value
Loop sensor
CN13 Dancer arm in home posi- tion Pot. P5 LH: 85 RH: 65 Rxxx LH: 85 RH: 65
Dancer arm at end posi-
tion <240 ca. 150
¯Before starting the adjustment be sure that the white wedge angle is
mechanical correct adjusted. In the home position of the dancer arm the
thick part of the wedge angle should be positioned in the sensor.
Adjustment Loop sensor in home:
For adjustment select the function OTHR/SCHK/Rxxx and turn the Po-
tentiometer P5 (I/O-board) until the value R85 is shown for a left hand
machine or R65 for a right hand machine.
Loop sensor in end position:
The value should so high as possible but not higher than R240.
¯The values itself are not important, but the
difference between the home and the end value should be so high as
possible.
¯The trigger points SW01 (Start of print)
and SW02 (Inhibit signal for dispenser) has to be set in the sub menu
SYSP.

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3.4 Sensor head position
Function This sensor is used to check the actual position of the print head. Dur-
ing printing the print head is pressed against the label: For foil saving
the print head is lifted
Location The sensor is mounted on the slotted disk of the foil save motor.
Sensor Connector Adjustment condition Poti Value / Test
point Para meter Display value
Sensor head
position CN12 Sensor in
g
ap of slotted
disk (head lifted) Pot. P4 < 0,6 V an TP CN32 Hxx 0
Disk inside sensor
(print head down) >2,5 V an TP CN32 15
Adjustment Gap of disk in the sensor:
For adjustment select the function OTHR/SCHK/Hxx and set the Poten-
tiometer P4 (I/O-board) to a value of <0,6 V at the test point CN32. The
display value has to be H0 (Null).
Disk inside sensor:
A display value of H15 is shown.
3.5 Foil end sensor
Function The foil end sensor controls the movement of the foil. During foil move-
ment the slotted disk turns and produce a signal. A missing signals indi-
cates end of foil or that the foil is broken.
Location The sensor is mounted at the foil unwind inside the machine.
Sensor Connector Adjustment condition Poti Value / Test
point Para meter Display value
Foil end sensor CN16 Gap of slotted disk in
sensor Pot. P8 < 0,6 V at TP CN34 Fxx 0
Sensor covered >2,5 V at
TP CN34 15
Adjustment Gap of slotted disk in sensor:
Use the function OTHR/SCHK/Fxx to adjust Potentiometer P8 (I/O-
board) to a value <0,6 V at test point CN34. The display value has to be
F0 (Null).
Sensor covered:
A value of F15 is shown if the disk covers the sensor.

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3.6 Sensor material end
Function The material end sensor controls the presence of label material and
detects also broken label web. The print process is immediately stopped
if a failure is recognised.
Location The sensor is mounted in the inner material guide of the print module.
Sensor Connector Adjustment condition Pot Value / Test
point Para meter Display value
Sensor material
end CN9 without material Pot. P1 < 0,6 V at TP CN30 Mxx 0
with material >2,5 V at
TP CN30 15
Adjustment No material in the sensor:
Select the function OTHR/SCHK/Mxx. Set Potentiometer P1 (I/O-board)
to <0,6 V at test point CN30. The display value has to be M0 (Null).
Material in the sensor:
The display shows M15.

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4 Service information
4.1 Factory setting
In case of loading new software or if the machine doesn’t work correctly
for any reason all parameter should be reset to factory programmed
values. This can be done by calling the function OTHR/FACT.
For details see the description in the user manual.
4.2 Reset of service counter
After replacement of the CPU-board all service counter has to be reset
to zero. The service counter are shown on service report (STA3).
Reset the service counter in the following way:
Reset 1. Rest the printer by pressing simultaneously the keys FEED + NEXT +
ON/OFF.
Display: Version number, than blinking INIT.
2. During INIT blinks, press the ON/OFF-key. Display: CODE.
3. Press the following keys in this order:
FEED
NEXT)
ON/OFF
ON/OFF
FEED
NEXT)
Display: OFF (if ON appears, press the ON/OFF-key. Display: OFF:)
4. Select parameter OTHR/NULL. Display: YES?
5. Execute the reset by quitting the question YES? with the ON/OFF-key.
To cancel the reset program press the FEED or the NEXT key. The re-
set procedure could only done once. If you try to repeat the message
ST59.
6. Key in the last 4 digit of the serial machine number.
7. Press the ON/OFF-key to validate the input or cancel the function by
pressing the FEED or NEXT key.
8. The printer restarts.

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4.3 Increment service counter
¯To have information about the reliability of the machine there are sev-
eral counters available, indicating how often a service was necessary.
The counter should be incremented with every service.
Procedure to increment service counter:
Input 1. Reset printer by simultaneously pressing of FEED+ NEXT + ON/OFF
keys.
Display: Version number, than blinking INIT.
2. During blinking of INIT, press the ON/OFF-keys.
Display: CODE.
3. Display keys in following order:
ON/OFF
ON/OFF
FEED
NEXT
ON/OFF
ON/OFF
Display: OFF.
4. Select parameter OTHR/SERV.
Display: YES?
5. To acknowledge the question YES? press the ON/OFF-key else cancel
the input with the FEED or the NEXT key.
Calling the service function increment the number of services by 1 also
if no other counter was affected.
The service counter you can increment are:
– HEAD
– ROLL
– KNIF (could be used for individual information)
6. Select part you change (ie. HEAD).
Display: actual counter for changed HEAD.
7. Press ON/OFF-key to increment counter.
Display: new blinking value.
8. Press ON/OFF-key again to acknowledge the increment of the counter
(Nothing is done if you press the FEED or NEXT key). Display: HEAD
9. Do the same for other changed parts (ROLL or KNIF)
or
leave the SERV function by pressing the FEED or NEXT key.
After leaving the SERV function the extended code is cleared. To call
the function again you have to reset the machine and enter the code
again.

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5 Software-Update
5.1 General update information
Flash-RAM The machine is supported with a FASH memory. Programming is done
from a computer without any change of parts. The memory contains the
operating program, fonts and bar code.
To update the software you have to do the following steps:
Preparation 1. Connect the Centronics-cable on the parallel port CN11 on the er CPU-
board.
2. Set parameter IFAC/PORT to CENT (= Centronics).
Downloading of software is possible only via the parallel port.
¯Don’t interrupt a started transmission. If
the downloading process was not successfully completed of you can
not start the machine again. In this case you have to replace the FLASH
memory on the CPU-board.
Copy-Instruction Downloading of new software can be done with the COPY instruction
(IBM-PC). You have to select the /B option to prevent that the computer
send additional data to the machine.
Loader The FLASH memory is programmed from the factory with a loader. This
loader handles the reprogramming of the FLASH memory.

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5.2 Program-Download (new board)
This chapter describes the downloading process of a not programmed
board.
After power on a CPU-board the first time the display shows .LDR and
the machine is waiting for the download at the parallel port.
Now you can select the program part you will download:
V55_FONT.LDR: Internal font.
V55_SPD.LDR: Scaleable font.
720.LDR: Operation program (z. B. 720).
The download is finished with the transmission of the file END.LDR.
Example
Complete Download:
copy V55_START.LDR/B lpt1 Start of Flash-Download.
copy V55_FONT.LDR/B lpt1 Transmission of font data
copy V55_SPD.LDR/B lpt1 Transmission of Speedo-Fonts.
copy 720.LDR/B lpt1 Program download.
copy END.LDR/B lpt1 End of Flash-Download.

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5.3 Program-Download (new version)
This chapter descriptes the download of a new program to the machine.
1. Switch on the machine and set the parameter IFAC/PORT to CENT (=
Centronics).
2. Transfer the file START.LDR in Online-Mode.
This activates the internal loader and the display shows .LDR. The ma-
chine is awaiting data on the parallel port.
Now with the different batch files one of following parts could be send:
V55_FONT.LDR: Internal Font.
V55_SPD.LDR: Scaleable font.
720.LDR: program (z. B. 720).
The loader is closed with sending the file END.LDR.
Beispiele
Complete Download:
copy START.LDR/B lpt1 Call the LDR-Mode.
copy V55_FONT.LDR/B lpt1 Transfer fonts.
copy V55_SPD.LDR/B lpt1 Send Speedo-Fonts.
copy 720.LDR/B lpt1 720 Program.
copy END.LDR/B lpt1 Exit Flash-Download.
Programm-Download:
copy START.LDR/B lpt1 Call the LDR-Mode
copy 720.LDR/B lpt1 720 Program.
copy END.LDR/B lpt1 Exit Flash-Download.
Font-Download:
copy START.LDR/B lpt1 Call the LDR-Mode
copy V55_FONT.LDR/B lpt1 Transfer fonts.
copy V55_SPD.LDR/B lpt1 Send Speedo-Fonts.
copy END.LDR/B lpt1 Exit Flash-Download.

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6 Print module
6.1 Disassembly print module
Construction print module
Built to the cast-metal case (1) are following
parts:
– feed unit
– material guiding
– foil unwind
– foil rewind
– foil transport
– additional components.
¯The print module can be removed com-
pletely from the printer!
Disassembly print module
1. Remove cover.
2. Remove the foil guiding (2) on the foil un-
wind and rewind axle (1 hexagonal screw)
3. Loosen knurled screw (3) to untie the
thermal print head.
4. Loosen ground connection from cast metal
case to steel body..
5. Untie the screws fixing the print module to
the body (7 hexagonal screws).
6. Move print module backwards - swing out
of the way the board carrier (slightly).
Tooling
•hexagonal socket 3 mm
•hexagonal socket 2 mm
•cross recessed head size 1
1
Print
m
odule
2
3

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6.2 Feed roller
Disassembly
1. Loosen feed stepper motor and remove ( 3
self locking hex nut’s).
2. Remove toothed belt
3. Loosen and open print head (knurled
screw).
4. Remove lock washer (1) from gear and
loosen gear (2) from feed axle - remove
gear (small screw driver)
5. Remove tab washer (3) on the outside (2
hexagonal screws)
6. Remove feed roller (4) to the outside
Assembly
1. Assemble feed roller (1 and 2)
2. Mount tab washer, assemble gear and fix
with lock washer
3. Check free run of roller
Tooling
•hex socket wrench SW 7
•hexagonal socket 2,5 mm
•screw driver medium size
1
2
3
4

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6.3 Pressure unit
The pressure roller is responsible for the mate-
rial transport in the printer section. The both
rollers are moveable on the axle.
By pressing the lever you can open the pres-
sure unit to feed in or pull out material.
Disassembly
1. Unhook spring (3) to freeze the pressure
from the unit.
2. Remove outer lock washer (4).
3. Dismount lock washer (2) inside.
4. Pull out square axle (1).
5. Remove pressure roller if necessary .
Mounting
1. Insert square axle.
2. Mount lock washer outside and inside.
3. Hook spring.
4. Position pressure roller.
Tool
– Tongs for lock washer
– Small tongs
3
2
4
1

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6.4 Print head
¯The print head is a sensitive component, especially against electrostatic
discharge! Be aware - before touching the thermal head - that you
remove static electricity from your body. As well if the print head is
disassembled.
6.4.1 General
Type of print head A near edge type is used.
The connection from the I/O-board is done with two cables.
The print head has to be adjusted electrical and mechanical.
Adjustment Electrical settings:
– Maximal value for supply voltage (Adjust HV99)
– Maximal value for print energy (Adjust HVxx during operation)
– Resistance of dots (HRES)
Mechanical adjustment:
– Position of print head
– Adjustment of pressure print head
– Print head pressure (User selection)
– Adjustment print head parallelism (Factory)
– Adjustment print head lift position
6.4.2 Print head voltage
¯A wrong adjustment (too high voltage) of the supply voltage for the print
head destroys the print head or reduces the lifetime!
1.Select Online-Mode
2.Press simultaneously FEED+NEXT.
3.Set HV99.
4.Adjust head voltage measured on test point I/O-board CN29 with Poten-
tiometer R25 to +25,5 V.
6.4.3 Other parameter print head
The setting of the print energy during operation see the user manual
Parameter HVxx.
The input of the resistance is described in the user manual, Parameter
HRES.