Novexx Solutions ALX 73 Series User manual

07/15 Rev. 05 SERVICE MANUAL
ALX 73x
Dispenser (LMA) status messages
Status messages on the dispenser ............... 2
Error messages ......................................... 2
Warnings ................................................... 2
General software errors ............................ 3
Reference status messages - dispenser ....... 4
List of warnings ......................................... 4
List of error messages ............................... 5

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Status messages on the dispenser
Error messages
When an error occurs, the dispenser stops immediately and shows an error
message on the control panel.
Error messages are based on the following outline:
To delete an error message:
1. Rectify the cause of the fault. For further details see section List of error
messages on page 5.
2. Press the key to delete the message.
Error messages that are not described below can only be rectified by qualified
service personnel.
If an error that is not described here occurs:
1. Press the key to delete the message.
2. Switch off the device, wait for 30 seconds and switch it on again.
Warnings
Warnings refer to states less critical than error messages.
Labelling operation is not interrupted by a warning.
Warnings may occur in dispensing mode or in online settings mode.
Warnings are based on the following outline:
While a warning is being displayed, the "Warning" signal output is
active.
Status num: 5144 a
Rewinder init b
a) 5144 = The status number. This number is an easy
way to identify the message.
b) "Rewinder init" = Status text; brief description of the
error.
ONLINE
Material warning a
a) "Material warning" = brief description depending on
what triggered the warning.

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Reset warnings A warning is displayed until…
•the cause of the warning has disappeared
or
•the warning has been reset
Warnings can only be reset in online mode. If the warning occurs in online
setting mode or standalone mode, the user must switch to online mode before
resetting the warning.
To reset a warning in online mode:
Press the key.
It is also possible to reset warnings with
Easy-Plug command #!CLRW.
If several warnings are active simultaneously, the warning with the highest
priority is displayed first. When it has been confirmed the next one is displayed,
and so forth.
General software errors
Errors in the firmware can never be completely ruled out. Such errors are de-
scribed in the error directory as "General software errors". They can only be
corrected by the manufacturer.
If errors which are described in the error directory as "General software errors" repea-
tedly occur, please notify the manufacturer, quoting the error number and the circum-
stances in which the error occurred.

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Reference status messages - dispenser
List of warnings
Productstartwarn New start signal during the dispensing cycle. The contour of the product is resulting
in multiple start signals.
Activate LABEL SETUP > Product length.
Several missing labels on the label belt; unable to compensate for the gap.
Check the label material.
PMA warning The printer (PMA) has stopped or an error has occurred on the printer.
The warning shows up before the error message „PMA not ready“, 5153 on page 11.
Check the printer.
Material low (Internal OD sensor) critical material roll diameter reached.
Prepare for material change
APSF speed warn. The speed of the conveyor belt has exceeded the maximum speed of the
dispenser.
Reduce the speed of the conveyor belt.
OD sensor warn. (External OD sensor) critical material roll diameter reached.
Prepare for material change
Toomany products Each product triggers more than one start signal.
Activate LABEL SETUP > Product length.
Verify, if there are other causes which trigger start signals (e.g. reflections). If yes,
eliminate those causes.
Too many products are between product sensor and dispensing edge (>64). The
buffer for product start signals is about to overflow.
Move the product sensor closer to the dispensing edge.
The resolution of the rotary encoder is set wrong.
Verify, if the conveyor speed matches the speed which is displayed on the operator
panel. If not, correct the resolution setting of the rotary encoder.
Int. mod. synch Although communication between printer and dispenser has been interrupted,
labels can currently still be dispensed from the buffer loop.
Check the connection line; see status message 5068 auf Seite HIDDEN.
Module speed The printer is printing too slowly. Start signals must therefore be left out.
Increase the print speed or reduce the dispensing speed/dispensing rate.
Foil low Critical foil roll diameter at the printer reached.
Prepare for foil roll change

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Loop empty The buffer loop of the linear dancer arm is empty. Currently, there is no label avail-
able from the loop.
The dancer arm has moved out of the control position. The warning precedes the
warning „LDU lower limit“, see error 5069 on page 8. The warning has the same
causes as the error message.
Tandem Synch. Communication between master and slave machine is not working.
The warning can for example show up shortly after switching the machine on, when
the communication between the machines is not yet established. If the communication
is still established within 5 minutes after the warning showed up, the warning will dis-
appear, otherwise, after the 5 minutes are over, the error message „Tandemsynch.init“
will appear, see 5147 on page 10. The warning has the same causes as the error
message.
List of error messages
1007 Command incorr.
Unknown interface command at data interface.
Check the command that was sent to the data interface as necessary.
1272 #!A wrong Number
Error in command „#!A..“. The value entered for the parameter is outside of the per-
mitted range (0 to 31).
Enter a value within the permitted range.
1276 #!P wrong Number
Error in command „#!P..“. The value entered for the parameter is outside of the per-
mitted range (0 to 31).
Enter a value within the permitted range.
1285 #-comm. incorr.
Error in a command "#!..". The letter entered is not valid.
Enter a valid letter.
1401 Para value wrong
A not defined parameter value was sent. The error occurs for example, if a product
profile was called with a wrong number (Easy-Plug command #!PC).
Correct the sent parameter values.
3000 RS232 Overrun
RS232 interface receive error at COM1 (Overrun).
Press the -key to acknowledge.
3001 RS232 Parity
RS232 interface receive error COM1 (Parity).
Press the -key to acknowledge.
Check setting in labeller's function menu: (INTERFACE PARA. > COM1 PORT > Parity)
and on host computer.

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3002 RS232 Frame
RS232 interface receive error COM1 (Frame).
Press the -key to acknowledge.
Check the setting in the labeller’s function menu: (INTERFACE PARA. > COM1 PORT >
Baud rate and in the menu INTERFACE PARA. > COM1 PORT > Stop Bits) as well as on the
host computer.
3011 Send buffer full
The send buffer is full. This error can occur when the status of the labeller was queried
several times (#!Xn), but the response was not read out.
Ensure that status response is read out.
5000 Bus device
This message appears in most cases as the first of a series of two or three mes-
sages that more closely limit the source of the error.
Unable to access device on the I2C bus.
Delete the message after pressing the key.
Switch off the machine, wait for 30 seconds and switch it on again.
If the error message occurs repeatedly, call in a service technicians.
5001 No gap found
No punches were found
The label sensor has not found any label gap or punch.
Material end (if no roll diameter sensor is activated).
Insert material.
The limit value for missing labels has been exceeded (LABEL SETUP > Miss. label tol.).
Check the label material.
Label type is not set correctly (MASCHINEN SETUP > Label sens. type).
Check/change setting.
The label length is not set correctly (LABEL SETUP > Label pitch).
Check/change setting.
Label sensor is dirty.
Clean the label sensor.
Label sensor is not in the correct position.
Check/change the position of the label sensor.
Label sensor is not correctly connected.
Check whether the label sensor is plugged into the correct connection.
Label sensor is faulty.
Replace the label sensor.
Rotary encoder is not correctly connected.
Check/change the rotary encoder settings.
In all cases: Press the key to confirm the error message.

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5002 Material end
Material end (if the internal OD sensor is connected and activated).
Insert a new label roll.
Internal OD sensor is not connected, but is activated.
To deactivate the internal OD sensor: MASCHINEN SETUP > Mat. Ende Fehler = „Off".
5009 Start error
Refers to the standard start sensor input (M12).
The device received another start signal while applying a label.
Prerequisite: MACHINE SETUP > Start error stop is set to “on” .
Check the operation of the labeller; increase distance between products if required.
Set MACHINE SETUP > Start error stop to “off”.
5019 Startsig. overrun
Too high start signal frequency caused start signal buffer overflow.
Possible causes:
Distance between product sensor and dispensing edge is too high.
Decrease distance between product sensor and dispensing edge.
Products and product distance are too small.
Increase product distance.
Dispensing speed is too high.
Decrease dispensing/conveyor speed.
5020 I2C Timeout 16
Timeout error while communicating via the I2C Bus with device No. 16 (EE-ROM,
contains manufacturing data).
Switch the machine off, wait 30 seconds and switch it back on.
Replace EEPROM
If the error message appears repeatedly:
Contact the manufacturer.
5021 I2C Conf. 16
Confirmation error while communicating via the I2C Bus with device No. 16
(EEPROM, contains manufacturing data).
5022 I2C Busy 16
Error while communicating via the I2C Bus with device No. 16 (EEPROM, contains
manufacturing data). Device constantly transmitting “busy” message.
5024 I2C BER 16
Error while communicating via the I2C Bus with device No. 16 (EEPROM, contains
manufacturing data).
5030 MotorProtectFeed
Dust filter fleece dirty. This will cause the machine to overheat.
Replace the dust filter fleece. Allow the machine to cool off.

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Connector cable between CPU board and motor driver board not connected or
faulty.
Check whether the cable is connected correctly.
Check the cable.
Motor driver board overheated or faulty
Switch off the machine, wait for 30 seconds and switch it on again.
If the error message occurs repeatedly:
Replace the motor driver board.
5031 MotorProtectRew.
Dust filter fleece dirty. This will cause the machine to overheat.
Replace the dust filter fleece. Allow the machine to cool off.
Connector cable between CPU board and motor driver board not connected or
faulty.
Check whether the cable is connected correctly.
Check the cable.
Motor driver board overheated or faulty
Switch off the machine, wait for 30 seconds and switch it on again.
If the error message occurs repeatedly:
Replace the motor driver board.
5064 Rewinder full
The critical roll diameter on the backing paper rewinder is reached (settable by
MASCHINEN SETUP > Rewinder full)
Empty the unwinder.
5067 L.DancArm Sensor
Linear dancer lever sensor
Bad connection to the dancer lever sensor.
Sensor cable is not connected.
Connect the sensor cable.
Sensor cable is faulty.
(Service) Check the sensor cable and if necessary replace it.
5068 Int. mod. synch
Communication between printer and dispenser has been interrupted.
The printer is switched off.
Switch on printer
The connector cable between printer and dispenser is damaged or not connected.
Check the connector cable between printer and dispenser and replace it, if neces-
sary.
5069 LDU lower limit
The linear dancer lever has reached the lower limit stop.
Dispensing speed and/or dispensing rate are too high relative to the print speed.
Increase the print speed
Reduce dispensing speed

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Reduce the dispensing rate (number of labels dispensed per unit of time)
Linear dancer lever sensor is not connected.
(Service) Check the sensor cable.
Sensor cable of the linear dancer lever sensor is faulty.
(Service) Replace sensor cable.
5070 LDU upper limit
The linear dancer lever has reached the upper limit stop. This causes the printer to
stop.
The material ribbon is torn.
Insert new label material.
If this error occurs repeatedly reduce the spring tension of the linear dancer arm.
Linear dancer lever sensor is not connected.
Check the sensor cable.
Sensor cable of the linear dancer lever sensor is faulty.
Replace sensor cable.
5073 APSF direction
The rotary encoder belonging to the APSF steering has recognized a wrong rota-
tion direction for a transportation stretch of at least 100 mm.
Check the conveyor direction.
Check the connection of the rotary encoder.
5111 OD sensor error
Regards the external OD sensor. The material roll diameter has reached the critical
value (required setting: MASCHINEN SETUP > Ext. OD sensor = „Error“). The label material
will soon be gone.
Prepare to insert a new material roll
5140 Rewinder control
During problem-free operation the rewinder dancer lever moves only minimally
around the "control position". This is the position the dancer lever assumes after
the machine is initialised.
The dancer lever is moved by the effect of a force from outside the control position.
Press the key.
The dancer lever controller is then reinitialised. The dancer lever moves back to the
control position.
Example: feed motor blocked; the backing paper is not moved quickly enough; this
causes the dancer lever to be drawn upward.
Example: tearing of the backing paper; the dancer lever moves back down by spring
force.
5142 Dancer home pos.
Homeposition of the rewinder dancer arm could not be found.
Check, if the sensor board of the dancer arm is connected properly.
Replace the sensor board.

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5143 Rewinder stop
The rewinder dancer lever is no longer able to move. Therefore the rewinder motor is
switched to a powerless state.
This can be selectively used to insert a new label roll because the rewinder can
easily be turned when the motor is switched off.
The dancer lever was held at the upper limit stop for longer than two seconds.
Press the key to confirm the error message.
5144 Rewinder Init
The message has a couple of possible causes:
No label material inserted.
Insert material.
Rewinder sensors are not or not properly connected.
Check the connection. Connect the sensors properly.
Sensor board position is faulty.
Correct the position of the sensor board.
Sensor defective.
Exchange the sensor board.
5145 Rewinder full
The maximum permissible diameter of the rewinder roll has been reached.
Remove wound backing paper
Press the key to confirm the error message.
This error can only occur if the end of a new label roll has been pasted onto a
backing paper that is already wound around the rewinder.
5147 Tandemsynch.init
Initialization of tandem synchronisation
This message can only occur in tandem
operation mode at the master machine.
Communication between master and slave machine is not working.
Check the tandem interface cable (cable present and correctly connected?).
Check the settings on both machines.
5148 Tandemsynch.init
Initialization of tandem synchronisation
This message can only occur in tandem
operation mode at the slave machine.
Communication between master and slave machine is not working.
Check the tandem interface cable (cable present and correctly connected?).
Check the settings on both machines.
5151 Applic. interf.
Applicator interface is missing or not connected.
Connect and/or install applicator interface.

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5152 Winding direct.
The backing paper was incorrectly fastened on the rewinder core.
Fasten the backing paper on the rewinder as described in the operating manual.
Wrong machine type set (MASCHINEN SETUP > Dispenser type)
"RH" setting on LH machine or vice versa.
5153 PMA not ready
The printer (PMA) is offline or an error has occured.
Check the printer
5200 Home position
The applicator has not reached its home position (upper limit stop) within the assigned
time period. This message can only occur in applicator mode.
No applicator present, but applicator mode is set.
Set SIGNAL INTERFACE > Interface mode to "PLC interface".
Applicator is jammed
Eliminate the obstruction
Compressed air applicator: compressed air supply is interrupted or switched off
Check the compressed air connection and if necessary connect it correctly
Cable not correctly connected.
Check the cable and if necessary connect it correctly.
5201 Touch down
The applicator has not reached its lower end position (touch down) within the assigned
time period. This message can only occur in applicator mode.
No applicator present, but applicator mode is set.
Set SIGNAL INTERFACE > Interface mode to „PLC signals".
Applicator is jammed
Eliminate the obstruction
Compressed air applicator: compressed air supply is interrupted or switched off
Check the compressed air connection and if necessary connect it correctly
Cable not correctly connected.
Check the cable and if necessary connect it correctly.
5203 Touch down sens.
The touch down sensor(s) are/were triggered before the application process was
started.
Check the cable and compressed air connection; connect correctly if necessary.
5204 Appl. Starterror
Refers to the start input at the optional applicator interface.
The device received another start signal while applying a label.
Prerequisite: MACHINE SETUP > Start error stop is set to “on” .
Check the operation of the labeller; increase distance between products if required.
Set “Start error stop” function to “off”.

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5205 Applicator gen.
General software error
Switch the machine off, wait 30 seconds and switch it back on.
See topic section Printer status messages , chapter „General software errors“.
5206 Applicator resp.
A time limit was exceeded while communicating with the applicator interface (AI).
Switch the machine off, then back on again after half a minute.
If the error continues to occur after switching on and off several times, please con-
tact our technical support.
5207, 5208, 5209, 5210 Appl. driver x (x=[1…4])
Short circuit or over-temperature at power output x of the applicator interface (AI).
Check connections.
5212 Vx.x for AI rec
Wrong firmware for applicator interface (AI) installed.
Install AI firmware version x.x.
5250 PLC Out overload
At least one PLC output signal is over-loaded. Possible causes:
Load to big
Reduce load.
Wrong wiring
Correct wiring.
CPU board defective
Replace CPU board.
5251 PLC 24V missing
24V supply for PLC is missing. Possible causes:
24V cabling between power supply and CPU is not available or defective
Check voltage cable; replace if necessary.
Power supply is defective
Replace power supply.
CPU is defective
Replace CPU board.
5252 PLC out disabled
PLC outputs are disabled. Possible causes:
Watchdog timer expired
Firmware error
Switch the machine off, wait 30 seconds and switch it back on.
See General software errors on page 3.
CPU board defective
Replace CPU board.

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5253 24V switched off
24V output of the power supply is switched off. Possible causes:
General firmware error
Switch the machine off, wait 30 seconds and switch it back on.
See General software errors on page 3.
CPU board defective
Replace CPU board.
5500 Unknown
General software error
Switch the machine off, wait 30 seconds and switch it back on.
See topic section Printer status messages , chapter „General software errors“.
6000 Param. incorr.
NOVRAM checksum error.
Press online button to acknowledge error. This resets all parameters to their factory
settings.
6001 NOV. prog. err.
Error programming user memory.
Switch the machine off, wait 30 seconds and switch it back on.
Please contact the manufacturer if the error message appears repeatedly.
6002 New prog. vers.
New firmware has been loaded. The dispenser is reporting by way of this message
that new firmware is present.
Press the online key to confirm.
All parameters are reset to the factory setting.
6003 Memory error
Error allocating user memory.
Switch the machine off, wait 30 seconds and switch it back on.
Please contact the manufacturer if the error message appears repeatedly.
6030 New parameters
New firmware has been loaded, which has caused new functions to be added to
the menu.
Press the online key to confirm.
The system is restarted.
All parameters are set to the factory setting.
6031 Param. checksum
The parameter checksum is incorrect.
6200 Filesystem regis
General software error that can occur when installing file system.
Switch the machine off, wait 30 seconds and switch it back on.

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6201 File sys. format
Error while formatting RAM disk or compact flash card.
Switch the labeller off, wait 30 seconds and switch it back on. Please contact the
manufacturer if the error message appears repeatedly.
6202 Drive open
Error accessing compact flash card.
Reformat compact flash card; test again to see if you can write to the card.
Test with a different compact flash card
6203 FileSystem close
Error accessing compact flash card.
6204 Disk directory
Working directory cannot be opened.
Press the -key to acknowledge
Check the name of the working directory and that it exists.
6205 Write disk
Error writing to RAM disk or memory card.
Press the -key to acknowledge
6206 Read Disk
Error reading from RAM disk or compact flash card.
Press the -key to acknowledge
6207 No file card
No memory card was found.
Check to see whether a memory card is inserted. If the memory card was not in-
serted until after the machine was switched on: Turn the machine off and on again.
9000 Wrong errornum
General software error
Switch the machine off, wait 30 seconds and switch it back on.
See topic section Printer status messages , chapter „General software errors“.
9001 Software error
General software error
Switch the machine off, wait 30 seconds and switch it back on.
See topic section Printer status messages , chapter „General software errors“.
9007 Bad MAC address
The MAC address is not valid
This error is displayed if the CPU board has a MAC address that lies outside of
the range reserved for Novexx (00.0a.44.xx.xx.xx). In this case the network can-
not be initialised. To be able to work with the network, the CPU board must be pro-
grammed with a MAC address which is valid for Novexx. This can only be carried out
by an authorised servicing technician or at the factory.

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Press the -key to acknowledge the status message.
The labeller boots up, but cannot be operated as part of a network.
Contact technical support.
Replace the CPU board if necessary.
9009 Temporary MAC
Temporary MAC address
This error is displayed if the MAC address of the CPU board has the value
00.0a.44.00.00.00 . In this case, the network can be initialised. This MAC ad-
dress is only used during manufacture of the labeller.
Press the online button to acknowledge the status message. The labeller boots and
the network is operational.
Contact technical support.
Replace the CPU board if necessary.
9011 Bootloader ext.
The applicator interface has no valid (e.g. an incomplete) firmware loaded. This is
the reason, why the device remains in the bootloading status and signalizes this status
message.
Reload the applicator interface firmware.
9015 Network init
Error initialising the network.
Call in network administrator.
9016 DHCP Failed
DHCP has failed. Occurs when the parameter: INTERFACE PARA > NETWORK PARAM
> IP Addressassign is set to DHCP and no IP address can be allocated.
Call in network administrator.
9019 Filename wrong
The entered filename has a length of 0 characters
Change filename.
9020 Param ID incorrect
An invalid parameter ID was used.
Correct parameter ID.
9022 No network link
This status message can only occur if the Ethernet address assignment is set
to DHCP (INTERFACE PARA >NETWORK PARAM. > IP Addressassign).
Network plug not correctly connected.
Check whether the network plug is correctly connected and correct it if necessary.
9025 24V voltage miss
The 24 V output voltage was not detected during system start.
Switch machine off and on again after 30 s. If the message continues to appear,
check power supply.

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9100 Invalid format
Format error in download data, e. g.:
• invalid data format
• invalid checksum
• invalid address
• invalid record type
Check and modify download data.
Restart machine.
9101 Invalid header
Format error in the dowload data header.
Check and modify header of download data.
Restart machine.
9102 Inv. board rev.
Download data is incompatible to the current board revision.
Check and modify download data.
Restart machine.
9103 Invalid firmware
Download data is incompatible to the current board.
Check and modify download data.
Restart machine.
9104 Inv. data size
The size of download data exceeds the predefined size, which is set in the header.
Check and modify download data.
Restart machine.
9107 Flash overflow
Onboard flash memory is full.
Restart machine.
9108 Flash ovf. diag.
The available flash area doesn´t provide enough space for diagnosis information.
Delete flash data blocks.
Reduce max. size of diagnosis information.
9109 Flash ovf. params
The available flash area doesn´t provide enough space to store the activ system
parameters.
Functions are set to factory settings after restart.
9110 Flash write err.
The program flash cannot be accessed for writing.
Reset machine.

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9116 Ser. disp. missing
No (serial) operation panel found for update.
Check machine, if an operation panel is connected.
Download continues after the error message.
9117 Device unknown
Missing device information in the header of the download data.
Check and modify download data.
Restart machine.
9122 Checksum error
Checksum error while loading a firmware file. The checksum of the loaded data
doesn´t match the calculated checksum.
Repeat the download.
If the error continues to occur, the file is probably damaged or corrupted. Check/
exchange the firmware file
9123 Memory unavailable
Error while loading a firmware file. There is not enough free memory available.
Restart machine and repeat the download.