Novexx Solutions 64- series User manual

08/10 Rev. 5.05-01 TECHNICAL MANUAL
64-xx
Mounting the PLC
System Requirements ................................... 2
Printer ........................................................ 2
Applicator .................................................. 2
PLC module .............................................. 2
Assembly ...................................................... 3
Safety ........................................................ 3
Required Tools .......................................... 4
Fitting the Cable Harness .......................... 4
Fitting the PLC .......................................... 4
Connecting the PLC for LTP/LTPV
operation ................................................... 7
Connecting the PLC for LTSI operation .... 8
Appendix ..................................................... 10
Connection Diagram 64-xx ...................... 10
Signal-LEDs at the PLC .......................... 12

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System Requirements
Printer
64-xx dispenser with USI interface board
installed.
PFor details see topic section „Technical Da-
ta“, chapter „System Requirements“.
Applicator
LTSI / LTP / LTPV
PLC module
Component Part number Picture
PLC module for
LTP/LTPV C0823 (LH)
PLC module for
LTSI C0747 (LH)
D-Sub cable har-
ness C0776
Tab. 1: Required components to mount the PLC
into a 64-xx. The PLC module is required
only once; it has to match the applied appli-
cator type.

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Assembly
Safety
WARNING!
This unit operates at mains voltage! Coming into contact with electrically
live components can cause potentially lethal electrical shocks and burns.
«Only authorised technicians are permitted to remove any parts of the
enclosure.
«Before removing any parts of the enclosure, switch off the device and re-
move the mains plug.
If, after removing the enclosure, the device has to be switched on for repair
and testing purposes, observe the following:
«Never touch electrically live components. This also applies to low-voltage
components.
«Only operate the unit when the enclosure is properly installed.
«Never open the enclosure of the power supply. If the power supply is de-
fective, you must replace the entire power supply.
«Ensure that the electrical system is functioning flawlessly.
•Test the electrical system on a regular basis.
•Retighten any loosened connections.
•Immediately replace any damaged lines.
«After assembling, check theprinter according to the regulations relevant in
your country.
CAUTION! - Protect the electronic components against damage from electro-
static discharge.
«Wear protective ESD gear.
«Place the device on an earthed pad before opening it.

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Required Tools
•Philips screwdriver sizes 1 and 3
•Screwdriver of medium size
•Hex socket wrench WAF 4.5
•Allen key 3mm with ball head
•Flat nose pliers
Fitting the Cable Harness
1. Switch off the device and disconnect the
power plug from the power outlet!
2. Remove the rear cover and the left front
housing.
PHow to? - see Service Manual 64-xx, topic
section Service Mechanics, chapter „Hou-
sing“.
3. Disconnect the D-Sub cable harness.
Unscrew the ground strap from the printer
bottom.
4. Unscrew the D-Sub plug from the hou-
sing.
5. Fit the D-Sub plug of the new cable har-
ness to the housing (fig. 1).
Fitting the PLC
1. Remove the fixing screws of the power
supply.
PHow to? - see Service Manual 64-xx, topic
section Service Mechanics, chapter „Con-
nections and Electrics“, „Power Supply“.
¯Leave the angled plate (1) fixed to the po-
wer supply!
2. Disconnect the ground cable (2) and the
plug (3), to be able to move the power sup-
ply farther out of the printer housing.
3. Pull the power supply slightly out of the
printer housing as illustrated (fig. 2 and 3).
PContinued overleaf.
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4. Remove the cable clamp (1) from the prin-
ter bottom (by means of a screwdriver).
Fig. 4 shows the two fixing holes (2) to
which the PLC module is screwed. The
frontal hole was beforehand used to fix the
power supply. The rear hole already bears
a screw which can be used to fix the PLC
module.
5. Unscrew the rear fixing screw out of the
printer bottom.
6. Pull at the wiring harness (3) as illustrated
to make room for the insertion of the PLC
module (fig. 5).
7. Turn the PLC module carefully over the
wiring harness into the printer (fig. 6).
¯The carrier plate of the PLC module must
have contact to both, printer bottom and
partitioning wall!
PContinued overleaf.
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8. Right now is the best moment to connect
the PLC module to the USI board!
PSee paragraph Connecting the PLC for
LTP/LTPV operation on page 7 respective-
ly paragraph Connecting the PLC for LTSI
operation on page 8.
9. Put the power supply in its initial position
and fix it at the angled plate (fig. 7).
Reconnect the cables you unplugged
before.
¯Order of the parts which are fixed by the
screw: cable clamp, PLC module, angled
plate (top down).
10.Screw the rear fixing screw into the PLC
module plate.
¯To do so, hold the screw with some flat
nose pliers and turn it in using the 4mm al-
len key with ball head!
11.Tighten all the fixing screws of power sup-
ply and PLC module.
12.Connect the PLC module as it is shown in
the following paragraphs.
13.Fix the cables by means of the cable
clamps (fig. 8).
14.Reassemble the housing parts.
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Connecting the PLC for LTP/
LTPV operation
PAlso refer to section Connection Diagram
64-xx on page 10.
The cable harness fitted earlier consists of
three cables, labeled VENT, SENS and
MOTOR. Two connectors on the PLC
board are also labeled VENT and SENS
(see figs. 1 and 2).
1. Connect the VENT (4) and SENS (5)
cables, which are part of the cable har-
ness, to the sockets on the PLC board that
bear the same names (fig. 2).
¯Don´t plug in the cable labeled MOTOR!
The plugs (1) and (2) are located on two of
thecablesthatarealreadypluggedintothe
PLC board (fig. 3).
2. Connect plugs (1) and (2) to the USI board
(fig. 4).
¯Plug the plug (1) exactly into the position
shown!
¯When plugging in plug (2), pay attention to
the information on the cable sleeve!
3. Reassemble the housing parts.
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Connecting the PLC for LTSI
operation
PAlso refer to section Connection Diagram
64-xx on page 10.
The cable harness fitted earlier consists of
three cables, labeled VENT, SENS and
MOTOR (fig. 1). Two connectors on the
PLC board are also labeled VENT and
SENS.
1. Connect the VENT (5) and SENS (6)
cables, which are part of the cable har-
ness, to the sockets on the PLC board that
bear the same names (fig. 2).
2. Connect the MOTOR (7) cable, which is
part of the cable harness, to the output
stage board (fig. 2).
The plugs (1), (2) and (3) are located on
two of the cables that are already plugged
into the PLC board (fig. 3).
PContinued overleaf.
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3. Connect the plugs (1) and (2) to the USI
board (fig. 4).
¯Plug the plug (1) exactly into the position
shown!
¯When plugging in plug (2), pay attention to
the information on the cable sleeve!
4. Connect plug (3) to the power supply
(fig. 5).
5. Reassemble the housing parts.
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Appendix
Connection Diagram 64-xx
LTP/LTPV
Fig. 1: Correct connection of the PLC for LTP/LTPV to an 64-xx.
USI1 USI2
SENS
VENT
NAIS
MOTOR
Notto be connected!
USI2
USI1
SENS
VENT
Connection board
Cable harness
LMind the connection
note on the cable sleeve!
PLC Applicator
connector
USI board
Z0206E.cdr/.eps

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LTSI
Fig. 2: Correct connection of the PLC for LTSI to an 64-xx.
USI1 USI2
SENS
VENT
NAIS
MOTOR C0896
USI2
USI1
SENS
VENT D-Sub cable harness
Connection
power supply
Motor
output
stage
LMind the connection
note on the cable sleeve!!
PLC Applicator
connector
USI board
Z0208E.cdr/.eps
Jumper:
On = 400mm-Applicator
Off = 200mm-Applicator

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Signal-LEDs at the PLC
Fig. 3: Control elements at the PLC.
Operationmode
switch Must be set to RUN for normal operation.
PLC status
LEDs
Input LEDs A lighting LED indicates that a signal is active at the respective input. The in-
puts work analogous to the printer USI with low-active signals. Thus, a
lighting-up LED shows a GND signal at the input.
Input X0-X7
Output Y0-Y7
Operation mode switch
PLC status LEDs
LED Meaning
RUN PLC is switched to run mode (the program is running)
PROG PLC is switched to program mode
ERROR Lights or is blinking: indicates a PLC error
Tab. 1: Bedeutung der SPS-Status-LEDs.

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Input assignment:
Output LEDs A lighting LED indicates that a signal is active at the respective output. The
outputs work analogous to the printer USI with low-active signals. Thus, a
lighting-up LED shows a GND signal at the output.
Output assignment:
LED LTSI / LTP / LTPV
X0 Touchdown sensor:
On = No touchdown signal
X1 Home position sensor:
On = Applicator is not in home position
X2 Product sensor:
On = Product detected
X3 Print_End signal coming from USI:
On = Printing / feeding is active
X4 Error signal coming from USI
On = Printer set to Stop/Offline
X5 Machine status signal coming from USI
On = Printer is in error mode
X6 Applicator mode signal coming from USI:
On = „After print“ mode
Off = „After start signal“ mode
X7 Signal coming from the jumper on the
board (which is part of the whole PLC mo-
dule):
Off = 200mm Applicator
On = 400mm Applicator
Tab. 2: PLC input-LED assignment.
LED LTSI LTP / LTPV
Y0 Motor clock signal:
lights up during any motor
movement
Cylinder valve:
On = Cylinder piston moves
down
Y1 •Print_End signal at the
15-pin output connector
of the USI (analogous to
the USI description)
•Starting with program
version 5.0a:
Display of the applicator
home position:
On = Applicator in home
position
•Print_End signal at the
15-pin output connector
of the USI (analogous
USI description)
•Additionally, the support
air valve is triggered:
On = Support air is blo-
wing (during the feeding)
Tab. 3: PLC output-LED assignment.

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Y2 Motor direction:
On = Down movement Vacuum valve: On = Vacuum switched on
(from feed start until appli-
cation)
Y3 Error signal to the 15-pin output connector at the USI (ana-
logous to the USI description)
Y4 Start_Print signal to the USI:
On = Label printing is enabled
Y5 SPS ready signal to the USI:
On = SPS enabled without error and in RUN mode
Y6 Touchdown error signal to the USI:
On = No touchdown error occured
Y7 Homeposition error signal to the USI:
On = No homeposition error occured
a. The program version can be read on a label on the PLC housing.
LED LTSI LTP / LTPV
Tab. 3: PLC output-LED assignment.