Novexx Solutions 64- series User manual

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 1
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Service - Boards
General notes ..................................................2
Handling boards...........................................2
Assignment boards - devices ......................2
CPU board.......................................................3
Layout ..........................................................3
Connecting the board ..................................5
Adjusting the sensors ..................................5
Connections / settings (64-xx).....................6
Connections / settings (DPM)......................7
Output stage board..........................................8
General notes ..............................................8
Layout ..........................................................8
Jumper settings............................................9
Connecting motor / sensor ..........................9
Sensor setting............................................10
Functionality test........................................10
Connections / settings (64-xx)...................12
Connections / settings (64-xx Dispenser) .13
Connections / settings (DPM) ...................14
USI board ......................................................15
Board versions...........................................15
Layout ........................................................15
Connecting the board ................................16
Jumper settings .........................................16
Index..............................................................17

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 2
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
General notes
Handling boards
ESD protection All the boards described in the following are fitted, among other things, with
large-scale integrated circuits. Voltage impulses caused by static charging
from people or objects can easily destroy the circuits.

When handling boards, ensure that the electronics cannot be damaged by
static charging or discharging.

Place the printer on an earthed underlay before opening it.

Earth your body with an ESD protective armband or by using another
suitable means. If suitable ESD protection is not available, touch an
earthed object, e.g. a radiator, before touching a board.

Only place boards on an earthed underlay.
Handling The conductor lines on modern multilayer boards are very thin. Bending the
boards can therefore easily break the conductor lines.

Avoid bending the boards.

Avoid using excessive force when removing and installing the boards.
Assignment boards - devices
Device CPU board Output stage
board(s)
USI board
64-xx / Chess x

3
64-xx Dispenser M /
Chess x Dispenser M

5
64-xx Dispenser A /
Chess x Dispenser A

5

ALX 924 / Novexx
PA-146

4

DPM

3

Tab. 1: Overview of the boards which are installed by the manufacturer as a standard in 64
bit devices. 64-xx and "64-xx Dispenser M" printers can optionally be retrofitted
with the USI board. The digits in the middle of the table show the number of
installed output stages.

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 3
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
GND CN3
CN2
CN14
CN16
CON1
CON2
CN13
CN12
CN8
CN7
CON4
P4
P5
CN17
CN15
TP5
TP6
CN9
P6
TP4
JP1
CN18
CN20
CN6
P3
CN5
CN10
CN11
CPU board
Layout
JP4
JP9
JP10

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 4
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
ID Designation/Function
CN2 Connector operating panel
CN3 Connector power supply
CN5 (only 64-xx Dispenser) Connector limit sensor
for backing paper rewinder
CN6 Connector feed roller sensor (only DPM /
ALX 924 / 64-xx Dispenser)
CN7 Connector material end sensor
CN8 Connector gap sensor
CN9 Connector reflex sensor
CN10 Connector full-size sensor
CN11 Connector single start
CN12 Connector hood switch
CN13 Connector data cable power supply
CN14 Connector data cable output stage
CN15 (only TT4) Connector scanner
CN16 Connector printhead cable
CN17 Programming adapter H8
CN18 Connector D-Sub cable harness (4 wires)
CN20 (only DPM / ALX 924) Connection USI board
CON1 Parallel interface (Centronics)
CON2 Serial interface (RS232 / RS485)
CON4 Slot for Compact Flash Card
P3 Pot. 3 Setting feed roller sensor (only DPM /
A.)
P4 Pot. 4 Setting material end sensor
P5 Pot. 5 Setting punch sensor
P6 Pot. 6 Setting reflex sensor
TP4 Test point reflex sensor
TP5 Test point punch sensor
TP6 Test point material end sensor
GND Earth contact
JP1 Enables Boot Loader overwriting
JP4 5 V supply for printserver at CON1, pin 35
JP9 5 V supply for printserver at CON1, pin 18

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 5
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Connecting the board

Connect the CPU board as illustrated:
Fig. 1: Right half of the CPU board.
Adjusting the sensors
Adjust the sensors as follows:
1. Call the parameter SERVICE FUNCTIONS/ Sensor test. Use the Feed
button to select the relevant Sensor No.
2. Assure, that the concerned light barrier (LS) is free (not covered).
3. Alter the setting of the potentiometer, until the greyed value in the table
appears on the display. Read the value for:
– punch- and reflex sensor on the printer control panel.
– material end sensor on the display of a voltmeter applied at measuring
point TP6 (GND =Frontal pins of all connectors on top of the power
supply).
Sensor Sensor No. Setting condition Value Pot. Test point Voltage
Pressure roller LS 0.03 closed/open 0/255 only functional check
Material end LS 0.04 LS free 0 P4 TP6 0,2 V
Punch LS 0.05 LS free 7P5
Reflex LS 0.06 White material 9P6
Full-Size-LS 0.07 LS free 10 P7
Hood switch 0.09 closed/open 0/255 only functional check

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 6
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Connections / settings (64-xx)
:
CPU-board 64 Bit
A1159
Compact flash card
Keyboard
Centronics
RS 232
CN3
CN4CN5CN6CN7CN8CN9CN10CN11
CN
12
P1P2P3P4P5P6P7P8
CN15
CN17
CN18 CN13
CN14 CN16
Optional
Rewinder backing
paper (RWS, A1912)
Switch release lever
(PRS, 99809)
Material end sensor
(MS) (A1194)
Punch sensor (PS)
(A1194)
Reflex sensor (RS)
(A1179)
Full-Size (FSS)
(A1816)
Single Start (SSS,
A1863)
Hood switch (COS)
(A1186)
Optional
(Scanner)
Power supply
(Data cable
A1180)
H8 Flash-
programming
plug
Cable harness
sub-D plug
(A1191)
Output stage
(Data cable
A1181)
Print head
(A1182
A1244)
Power supply
(Voltage cable
A1176)
Pot. P5
LS free
Display
7
Pot. P4
LS free
Display
0
TP6
0.2 V
LS covered 255 > 2.5 V
LS covered > 7
Z00492e.cdr
CN2
CN1
CN20
Display
(A1175)
USI board
(Data cable
A2057)

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 7
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Connections / settings (DPM)
:
CPU-board 64 Bit
A1159
Compact flash card
Keyboard
Centronics
RS 232
CN3
CN4CN5CN6CN7CN8CN9CN10CN11
CN
12
P1P2P3P4P5P6P7P8
CN15
CN17
CN18 CN13
CN14 CN16
Optional
Optional
Pressure roller
sensor (PRS, A1107)
Material end sensor
(MS) (A1150)
Punch sensor (PS)
(A1132)
Reflexsensor (RS)
Hood switch (COS)
(A1106)
Power supply
(Data cable
A1074)
H8 Flash-
programming
plug
Output stage
(Data cable
A1793)
Print head
(Data cable
A1157)
Power supply
(Voltage cable
A1073)
Pot. P5
LS free
Display
7
Pot. P4
LS free
Display
0
TP6
0.2 V
LS covered 255 > 2.5 V
LS covered > 7
Z00492ae.cdr
CN2
CN1
CN20
Display
(A1055)
USI board
(Data cable
A2057)

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 8
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Output stage board
General notes
There are two different versions of the output stage boare in circulation
(see ). T he newer board doesn´t require any setting of the sensor by
potentiometer any more. Therefore, the pots are missing in the newer
layo ut (=disti nguishi ng f eature).

Please keep in mind the following points, when you replace or check an
output stage board:

PIC version:
The PIC must carry a label with the writing "M04A V3 C73"!

Jumper setting:
The jumper setting must match the motor which is ought to be driven by the
output stage!

See paragraph Jumper settings on page 9.

(only older board layout) Sensor setting:
The sensor current must amount 25 mA!

See paragraph Sensor setting on page 10.
Layout
Fig. 2: Newer (top) and older (bottom) layout of the output stage board.

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 9
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Jumper settings
Each of the applied three, four or five printer motors is controlled by a
separate output stage board. The boards only differ from each other in the
jumper setting (Fig. 3:).

Set the jumper.
Motor Jumper
Pos.
Options motor (e.g.
Cutter, Rewinder;
Dispenser Version:
Release motor)
Printhead motor
Ribbon motor
Feed motor
Dispenser motor
(ALX 924 / 64-xx
Dispenser)
Fig. 3: The Jumper position (1) on the board must match the motor.
Connecting motor / sensor
Both, motor and sensor cables are supplied with marked sleeves at their
ends. The markings are abbreviations of the corresponding motor or sensor
designation, respectively.
Fig. 4: Cable marker (FM =feed motor).
Cable marker
Output stage
for... motor sensor
Feed motor FM –
Ribbon motor RM RS
Printhead motor HM HS
Options motor OM OS
Dispenser motor WM –
Tab. 2: Markers at motor and sensor cables.
1

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 10
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Sensor setting

This description is only valid for boards with the older layout (recognizeable
by the two blue pots). T he newer board version doesn´t have to be set!
1. Turn printer off, disconnect the sensor cable from connector "Sensor",
switch printer on.
2. Measure the current with an amperemeter as shown (see Fig. 5:).
3. Turn potentiometer P1 until you measure 25 mA.
Fig. 5: The current between the measuring points A and B must amount to 25 mA. If not,
use P1 to set the current.
4. Switch printer off, connect sensor cable, switch printer on for functionality
test.
Functionality test
1. Call the parameter "SERVICE FUNCTIONS / Sensor test":
Sensor Test
0.04 Matend xxx
xxx =Numeric value
0.04 =Sensor number
2. Press the feed button repeatedly until the appropriate sensor number (see
Tab. 3:) shows up.
Sensor Sensor
no.
R ibbon se nsor 2.01
Printhead sensor 3.01
Options sensor 4.01
Tab. 3: Select in menu "Sensor test" the no. of the sensor which you would like to check.


03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 11
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
3. The numeric value shown on the right hand part of the display, alters, if the
light barrier is covered. Tab. 4: shows the setting rules. Check the values
listed in the table with covered and uncovered light barrier.
Num. value Setting condition
less than 10
(typical: 0)
Light barrier uncovered
more than 10
(typical: 255)
Light barrier covered
Tab. 4: Sensor setting values.

The rewinder output stage requires a different setting procedure and
different values!

Refer to manual "Rewinder 2000", topic section "Connection, Setup,
Service".

For details about the parameter "SERVICE FUNCTIONS / Sensor test"
refer to topic section " Info-printouts and parameters"." .

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 12
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Connections / settings (64-xx)
Output stage boards A1160
Power supply A1680
Cable harness A1189
(Voltage cable to the
output stages)
Cable harness A1191
(Voltage cable D-Sub plug)
Cable harness A1182 / A1244
(Printhead voltage)
Round cable A1176
(Voltage cable to the
CPU board)
Ribbon cable A1180
(Data cable to the
CPU board)
Cable harness A1194
(Motor / sensor)
Cable harness A1191
(SUB-D plug)
Cable harness A1189
(Power supply -
output stage)
Ribbon cable A1181
(CPU - output stage)
Feed motor Ribbon motor Printhead motor Peripheral motor
Sensor
1.2
Sensor
1.1
Motor
Sensor
2.2
Sensor
2.1
Motor
Sensor
3.2
Sensor
3.1
Motor
Sensor
4.2
Sensor
4.1
Motor
OM
OS
HS
RS
CN7 HMRMFM
Pot. P1
A
25 mA
Unplug sensor connector!
Z00491E.cdr

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 13
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Connections / settings (64-xx Dispenser)
Output stage boards A1160
Power Supply A1680
Cable harness A1189
(Voltage cable power supply -
output stage)
Cable harness A1191
(Voltage cable
D-Sub-plug)
Cable harness A1182 / A1244
(Printhead-voltage)
Round cable A1176
(CPU-power supply)
Ribbon cable A1180
(CPU-power supply)
Ribbon cable A1181
(CPU-Output stage)
Feed motor Ribbon motor Head motor Options motor
Sensor
1.2
Sensor
1.1
Motor
Sensor
2.2
Sensor
2.1
Motor
Sensor
3.2
Sensor
3.1
Motor
Sensor
4.2
Sensor
4.1
Motor
HS
RS
HM
RM
FM
Pot. P1
A
25 mA
Unplug sensor cable!
Z00493E.cdr
Dispenser Motor
Sensor
5.2
Sensor
5.1
Motor
OS
OM
Stepper motor 98856
(Release motor)
Fork photoel. switch
96017
WM
Stepper motor 98804
(Dispenser feed)
Cable harness A1189
(CPU-Output stage)
Cable harness A1194
(Motor-Sensor)

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 14
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Connections / settings (DPM)
Power supply
USI board
Voltage cable
(A2059)
Connection Ribbon motor
(A1153)
Z00494E.cdr
Print head
(A1157)
CPU
(Data cable
A1074)
CPU
(Voltage cable
A1073)
Output stage
(Power cable
A1148)
CPU board
(A2057)
Connection
Ribbon sensor
(A1180)
Output stage boards
RM
RS
Conn.
Feed motor
(A1152)
Connection
Head motor
(A1909)
HM
Connection
Head sensor
(A1158)
HS
Pot. P1
A
25 mA
Unplug sensor cable!!
Power supply (Power
Cable A1148)
Connection
Head motor
(A1909)
CPU (Data cable
motor driver A1148)

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 15
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
USI board
Board versions

T his description is o nly f or USI boards matchi ng the f ollowing co nditions
(see Fig. 6:):
– Version of the board: A2345-04.
– Version of the USI controller: V2-T1-F873.
Fig. 6: Version designations on the USI board.
Layout
Fig. 7: Connecting the USI board.
USI signals
Connector for
optional PLC
Data line and
voltage supply
controller
CN300:
Connector internal
USI inputs
Voltage supply
output driver
JP8
z0166E.cdr
Pin 1
0
170.cdr
USI 24 V
A2345-04
USI V2-T1-F873
USI 24 V A2345-04

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 16
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Connecting the board
Internal 
Connect the cable data line and voltage supply (the cable is fixed to the
board) to the CPU board, next to the display cable connector.

Voltage supply : Connect it to the powerpack (24 V galvanic separated from
the voltage supply by data line).

Internal USI inputs: Optional connection of an Avery PLC and "OD sensor
material".

Jumper row: Possibility of connecting an Avery PLC.
External

USI signals : The 7 outputs and 4 inputs of the USI.
Jumper settings
No. Pos. Description
JP8 5 V external voltage supply
5 V internal voltage source active at pin 2 / DB-15 (Default)
Fig. 8: Settings of JP8.

The maximum current in all 5 V and 24 V supply lines may not exceed
700 mA!

Also refer to section "Universal Serial Interface" in topic section
"Interfaces".

03/02 Rev. 2.14-02 SERVICE MANUAL Service - Boards, Page 17
64-xx – CHESS x – DPM – ALX 92x – Novexx PA-1x6
Index
Boards, assignment ......................................2
Boards, handling...........................................2
CPU board
Connecting.................................................5
Layout.........................................................3
Sensor adjust .............................................5
ESD protection..............................................2
Output stage board
-Jumper setting..........................................9
-Layout .....................................................11
-Preparation ...............................................9
-Sensor adjust..........................................10
Static charging..............................................2
USI board
-Jumper settings ......................................15
-Layout .....................................................15