Novexx Solutions ALX 92 Series User manual

04/09 Rev. 5.02-01 SERVICE MANUAL
DPM – PEM – ALX92x
Fault Location
Error sources ................................................ 2
Notes about fault location .......................... 2
Data transmission ..................................... 2
Display ...................................................... 2
Gap detection ............................................ 3
Material transport ...................................... 3
Ribbon, ribbon guide ................................. 3
Feed roller, print roller ............................... 4
Position of the print image .........................4
Print quality ............................................... 5
Transport unit ............................................ 5
Plug-in card ............................................... 5
Reading out diagnosis data ...........................6
Reading out via serial interface .................7
Storing on CF card .....................................9

04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
2
Error sources
Notes about fault location
Status reports should be printed to check the mechanical and electronic function
capabilities – provided that no obvious no defects are evident.
Data transmission
Display
Problem Possible cause Solution
No or damaged data
Faulty data cable Check, if the right data cable is applied
Wrong interface selected Check,ifINTERF.PARAM.>EASYPLUGINTERPR>
Interface is set correctly
Setting of transmission
parameters incorrect
Check, if the transmission parameters forthe
selected interface are set correctly (not for
Centronics)
Faulty pin assignment of
the data cable Change or replace cable pin assignment, see topic section Service Electronics 
Incorrect handshake si-
gnals Check parameter setting (only for serial inter- face)
Selection Select standard character set
CPU board defective Check and if necessary replace CPU board
Permitted cable length
exceeded Do not exceed cable length
[Tab. 1] Possible faults caused by data transmission.
Problem Possible cause Solution
Display blank, but
background light on
or
Random frozen
display or
Random strange
characters displayed
Operation panel does not
match the CPU board.
Operation panel was repla-
ced by a new one and con-
nected to a CPU board with
change index below -05 (e.
g. A1159-04)
Replace CPU board. Required change index:
at least -05, see topic section „Spare Parts“
Display dark Plug connector loose Check and if necessary plug in again Display defect Check and if necessary replace display
CPU board defective Check and if necessary replace mainboard
Button function faulty
Plug connector loose Check and if necessary plug in again
Buttons defective Check and if necessary replace buttons or
display board
CPU board defective Check and if necessary replace mainboard
[Tab. 2] Possible faults at the display

04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
3
Gap detection
See topic section „Electronics Gen. 3“, chapter Sensor test / on page 57.
Material transport
Ribbon, ribbon guide
Problem Possible cause Solution
Gap detection not
possible
Photoelectric switch
defective Check with SERVICE FUNCTION> Sensor test, if necessary replace the photoelectric switch
Photoelectric switches set
incorrectly Use SYSTEM PARAMETER >Sens. punch-LS to al- ter sensitivity
False photoelectric switch
selected Select "Punched" or "Reflex" using SYSTEM PARAMETER > Light sens. type
Print position shifted
in or against print di-
rection
Gap position not re-
cognised consistently due
to gap contour
Correct photoelectric switch zero line using
PRINT PARAMETERS > Punch offset
[Tab. 3] Possible faults caused by the gap detection
Problem Possible cause Solution
No feed function
Stepper motor plug loose Check and if necessary plug in
Stepper motor defective Check and if necessary replace motor
CPU board defective Check and if necessary replace mainboard
Feed button defective Check and if necessary replace display board
Jolted print image Material unwinder blocked Check and if necessary loosen
Material shifts Material guide set
incorrectly Check and if necessary set
(ALX92x) Backing
paper rewinder runs
continuously or never
runs Rewinder control needs
adjustment
Adjust the rewinder control, see topic section
„Electronics Gen. 3“ , chapter Settings on
page 51.
(ALX92x) Backing
paper tears off
(ALX92x) Backing
paper rewinder initia-
lizeswhenclosingthe
hood.
The rewinder dancer positi-
on was changed, while the
hood was opened.
Don´t move the rewinder dancer arm, while
the front hood is open.
[Tab. 4] Possible faults caused by material transport
Problem Possible cause Solution
Unfounded ribbon
end message Ribbon unwind mandrel is not turned Fix core to mandrel (spring plate), shift spring plate if the thread has stripped.
Photoelectric switch
defective Check and if necessary replace (see also pa- rameter SERVICE FUNCTIONS> Sensor test)
Ribbon is not being
rolled up Ribbon core slips through Fix core to mandrel (spring plate), shift spring
plate if the thread has stripped.
Toothed belt defective Check and if necessary replace the belt
[Tab. 5] Possible faults caused by the ribbon guiding

04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
4
Feed roller, print roller
See User Manual, topic section Maintenance and cleaning .
Position of the print image
Ribbon tears during
printing process Printhead temperature is too high
Check setting of print contrast (press Prog.
button in on-line mode or parameter
PRINT PARAMETER > Printcontrast) and if neces-
sary correct.
Problem Possible cause Solution
[Tab. 5] Possible faults caused by the ribbon guiding
Feature Possible cause Solution
Wear High running performance replace roller
Thermal bar contact too
high check and if necessary correct
Pressurerollerdoesnotrun
on material check and if necessary set
Material deposits clean (roller cleaner)
Ink residue Ribbon prints directly on
feed roller clean and prevent direct printing on roller (roller cleaner)
Deformation Printing directly on feed rol-
ler avoid direct printing
High running performance replace roller
Power setting too high for
bar
check print contrast setting (press Prog. but-
ton in on-line mode or parameter
PRINT PARAMETER > Print contrast) and if neces-
sary correct.
Damage by operator replace roller and draw attention to proper
care
[Tab. 6] Faults, which can occur at the print and/or feed roller.
Problem Possible cause Solution
Print position shifted
in or against print di-
rection
Incorrect parameter setting Check parameter PRINT PARAMETER> Y-Print offset or Easy Plug command (#Jx), if neces-
sary correct
Gap position is recognised
incorrectly due to gap con-
tour
Correct sensor zero line with parameter
PRINT PARAMETER> Gap offset
Material unrolling blocked
or too sluggish Check and if necessary correct
Material guide set too
narrowly Check and if necessary set
Pressure rollers positioned
incorrectly or not at all Check and if necessary set
Print shifted at right
angles to document Material guide not set correctly Check and if necessary set
[Tab. 7] Unsatisfactory print position and the possible reasons.

04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
5
Print quality
Transport unit
Plug-in card
Problem Possible cause Solution
Print faded
Printhead dirty or defective Clean or replace thermal bar, see topic
section Maintenance 
Printhead setting incorrect Check settings (e.g. print contrast, print head
resistance) and alter if necessary
Ribbon and material not
aligned Check ribbon type and material type, if nec. alter
Ribbon possibly super-
imposed Insert new ribbon
Poor or uneven print Print roller damaged or
soiled Check and if necessary clean or replace roller
Feed in order but no
print image
Printhead setting too low
Check setting print contrast (press Prog. but-
ton in on-line mode or parameter
PRINT PARAMETER> Print contrast) and if nec.
correct.
Ribbon inserted incorrectly
(colour side) Check and if necessary correct
Printhead not fixed to
bracket Fix thumb screw
Printhead defective Check printhead and if necessary replace it
Printhead cable not or in-
correctly plugged in Check and if necessary plug in again
CPU board defective Check and if necessary replace mainboard
[Tab. 8] Unsatisfactory print quality and the possible reasons
Feature Possible cause Solution
No material transport Pressure rollers set in-
correctly Check and if necessary set
Drive belt defect Check and if necessary replace belt
Stepper motor defect Check and if necessary replace motor
Board defect Check and if necessary replace board
[Tab. 9] Faults, which can occur at the transport unit.
Problem Possible cause Solution
Plug-in card is not
recognised
Contacts dirty Check and if necessary replace
Card defective Check and if necessary replace
Card type does not corre-
spond to approved type Check and if necessary replace
[Tab. 10] Possible problems with plug-in cards

6
04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
Reading out diagnosis data
With the diagnose dump function, device inter-
nal operation states can be read via serial con-
nectionandbesaved inatextfile.Thisway,the
last device internal communication can be cap-
tured and analysed (comparable to the black
box in an airplane).
The function is helpful, if the device got in an
undefined state. This happened for example,
if…
•printing suddenly stops.
•the status message „unmanaged interrupt“
appears on the display.
•the device suddenly doesn´t react on key-
strokes any more.
In those cases, the log file is generated auto-
matically.
There are two ways of storing the log file:
•Reading out via the serial interface and
storing it on the host PC.
•Storing on CF card.
¯Alternatively, the log file can be read out us-
inganotherthantheserialinterfaceorusingthe
debug interface, see Easy-Plug manual,
#!XM command.

7
04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
Reading out via serial interface
Prerequisites
•Firmware (at least):
•Terminal program, e. g. „Hyperterminal“ (is
delivered with Windows operating sys-
tems).
Carrying out
1. Connect the printing device to a PC, using
the serial interface. Set the transfer param-
eters to 115kB, n, 8, 1 (default setting).
2. Start Hyperterminal.
The window „Connection Description“ [1]
opens.
3. Name the new connection [1A]. Click OK.
The window „Connect“ opens.
4. Select the serial port of the PC and click
OK.
Thewindow„COM1Properties“[2]opens(if
COM1 was selected).
5. Set the transfer parameters to
115kB, n, 8, 1 and click OK.
The Hyperterminal main window opens.
6. Open the menu „Transfer“ and click
„Record Text“ [3]. An input window opens.
Enter the file name for the record file and
click „Start“.
7. At the printer operation panel press all four
buttons simultaneously.
This starts data being read out of the print-
ing device and being displayed in the
Hyperterminal main window [4]. At the
same time, the data are saved in the record
file.
8. To stop the transmission, click „Cancel“ in
the menu „Transfer > Record text...“.
Generating further record files:
«Close Hyperterminal and start new.
Version Printing device
3.22 AP4.4 (16MB), AP5.4, AP7.t
4.22 64-xx Gen. 2, DPM, ALX92x
5.02 64-xx Gen. 3, PEM
[1] Enter a name (A) for the new connection.
[2] Set the transfer parameters.
[3] Hyperterminal main window.
A

8
04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
[4] Read out data.
«Send the generated files with a descriptioin
ofthe circumstancesinwhichtheerroroccured
per email to the technical support at Avery Den-
nison.

9
04/09 Rev. 5.02-01 SERVICE MANUAL Fault Location
DPM – PEM – ALX92x
Storing on CF card
Prerequisites
Firmware (at least):
Carrying out
1. Call SERVICE/DIAGNOS. > Diagnosis to CF.
The second line shows the initial 16 charac-
ters of the default file name. The complete
file name is:
„Diagnose AP 5.4 203 Dpi
A429403110613.log“
–AP 5.4 203 Dpi: Printer type and print-
head resolution
–A429403110613: Serial number of the
CPU board; equals the string in
SERVICE DATA > CPU BOARD DATA > Serial
number
2. Press the online button twice to acknowl-
edge and to store the file name.
Typing in a new file name:
1. Press the prog button to dismiss the default
file name.
2. Select each character of the new file name
by pressing the cut/feed buttons and ac-
knowledge it by pressing the online button.
3. Finally press the online button twice to ac-
knowledge and store the file.
¯Alternatively, type in the file name onan op-
tional keyboard connected to the printer and
acknowledge by pressing online.
The log file will be stored in the \LOGFILES di-
rectory on CF card.
Version Printing device
3.31 AP4.4 (16MB), AP5.4, AP7.t
4.31 64-xx Gen. 2, DPM, ALX92x
5.31 64-xx Gen. 3
Diagnosis to CF
Diagnose AP 5.4