Novexx Solutions 64- series Bedienungsanleitung

06/15 Rev. 03 SERVICE MANUAL

64-xx

Fault location

Error sources ................................................ 2

Notes about fault location .......................... 2

Data transmission ..................................... 2

Operation panel ......................................... 2

Gap detection ............................................ 3

Material transport ...................................... 3

Ribbon, ribbon guide ................................. 4

Print/Feed roller ......................................... 4

Position of the print image ......................... 5

Print quality ............................................... 5

Cut function, cutter .................................... 6

Plug-in card ............................................... 7

Reading out diagnosis data ...........................8

General notes ............................................8

Storing diagnosis data ...............................8

Reading out via serial interface .................9

Storing on memory card ..........................11

01/13 Rev. 5.08-01 SERVICE MANUAL Fault location

64-xx Error sources

Error sources

Notes about fault location

Status reports should be printed to check the mechanical and electronic function ca-

pabilities – provided that no obvious no defects are evident.

Data transmission

Operation panel

Problem Possible cause Solution

No or damaged data

Faulty connection Check interface cable

Wrong interface selected Check, if INTERF. PARAM. > EASYPLUGINTERPR>

Interface is set correctly

Parameter setting incorrect

Check parameters (Baud rate, parity, stop bits,

number of data bits, data synch. - only for serial in-

terface)

Faulty cable assignment Change or replace cable pin assignment, see to-

pic section Service Electronics 

Incorrect handshake Set parameter (only for serial interface)

Selection Select standard character set

Plug on board loose Check and if necessary plug in again

Board defect Check and if necessary replace board

Admissible cable length

exceeded Do not exceed cable length

[Tab. 1] Faults possibly caused by bad data transmission.

Problem Possible cause Solution

Display blank, but back-

ground light on or

Random frozen display

Random strange

characters displayed

Operation panel does not

match the CPU board.

Operation panel was replaced

by a new one and connected

to a CPU board with change

index below -05 (e. g. A1159-

04)

Replace CPU board. Required change index: at

least -05, see Spare Parts Catalog 

Display dark

Plug connector loose Check and if necessary plug in again

Operation panel defect Check and if necessary replace display

CPU board defect Check and if necessary replace CPU board

Button function faulty

Plug connector loose Check and if necessary plug in again

Buttons defect Check and if necessary replace operation panel

CPU board defect Check and if necessary replace CPU board

[Tab. 2] Possible faults at the display.

01/13 Rev. 5.08-01 SERVICE MANUAL Fault location

64-xx Error sources

Gap detection

Sensortest instruction : see topic section „Electronics“, paragraph „Sensor test“.

Material transport

Problem Possible cause Solution

Unfounded materialend

message

Gap detection not pos-

sible

Position of photoelectric

switch not exact enough Correct position of photoelectric switch

Photoelectric switch defect Check with SERVICE FUNCTION > Sensor test, if

necessary replace

Photoelectric switches set in-

correctly

Use SYSTEM PARAMETER > Sens. punch-LS to alter

sensitivity

False sensor type selected Select "Punched" or "Reflex" using parameter SY-

STEM PARAMETER > Light sens. type

Print position shifted in

or against print direction

Gap position not recognised

consistently due to gap con-

tour

Correct sensor zero line using parameter PRINT

PARAMETER > Punch offset

[Tab. 3] Possible faults, caused by bad gap detection.

Problem Possible cause Solution

Material skew during in-

feed

Unfavourable position of fricti-

on rollers Check and if necessary shift to side

No transport

Unfavourable position of fricti-

on rollers Check and if necessary push on material

Setting value of the contact

spring Check and if necessary correct

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 blokked Check and if necessary loosen

Bouncer arm blocked Check and if necessary loosen

Material shifts Material guide set incorrectly Check and if necessary set

No material transport

Pressure roller set incorrectly Check and if necessary set

Drive belt defective Check and if necessary replace belt

Stepper motor defective Check and if necessary replace motor

Motordriver board defective Check and if necessary replace board

Motor noise (audibly

louder than normal)

Material/ribbon jam

Check if material or ribbon jam occured in feed rol-

ler area. If necessary, clear rollers.

64-xx dispenser processing

narrow label material in ther-

mal direct mode.

Set SYSTEM PARAMETER > Transport Mode to

„Dual motors“.

[Tab. 4] Possible faults, caused by material transport.

01/13 Rev. 5.08-01 SERVICE MANUAL Fault location

64-xx Error sources

Ribbon, ribbon guide

Print/Feed roller

Maintenance and cleaning 

Problem Possible cause Solution

Unfounded ribbon end

message

Ribbon unwind mandrel is not

turned

Fix core to mandrel (spring plate), shift spring pla-

te if the thread has stripped

Ribbon sensor defective Check and if necessary replace (see also SERVICE

FUNCTIONS > Sensor test)

Ribbon produces folds Friction of ribbon unwinding

set incorrectly Check and adjust friction

Ribbon is not being rol-

led up

Friction of ribbon winding set

incorrectly Check and adjust friction

Drive belt defective Check and if necessary replace

Ribbon is wrapped

around transport roll

Friction of ribbon winding up

set incorrectly Check and if necessary adjust

Drive belt defective Check and if necessary replace

Ribbon tears during

printing process Temperature too high

Check print contrast setting (press Prog button in

online mode or call PRINT PARAMETER >

Print contrast) and if necessary correct

[Tab. 5] Possible faults caused by the ribbon transport.

Problem Possible cause Solution

Wear

High running performance Replace roller

Thermal bar contact too high Check and if necessary correct

Pressure roller does not run 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 print roller Avoid direct printing

High running performance Replace roller

Printhead power setting too

high

Check print contrast setting (press Prog button in

online mode or call PRINT PARAMETER >

Print contrast) and if necessary correct

Damage by operator Replace roller and draw attention to proper care

[Tab. 6] Possible faults at the print/feed rollers.

01/13 Rev. 5.08-01 SERVICE MANUAL Fault location

64-xx Error sources

Position of the print image

Print quality

Problem Possible cause Solution

Print position shifted in

or against print direction

Incorrect parameter setting Check PRINT PARAMETER > Y-Print offset or Easy

Plug command (#Jx), if necessary correct

Gap position is recognised in-

correctly due to gap contour

Correct sensor zero line with PRINT PARAMETER >

Gap offset

Material unrolling blokked or

too sluggish Check and if necessary correct

Material guide set too narrow Check and if necessary set

Pressure rollers positioned in-

correctly 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

Thermo print bar not in zero

position Check and if necessary set

[Tab. 7] Unsatisfactory print position and the possible reasons.

Problem Possible cause Solution

Print faded

Thermal bar at the printhead

dirty or defective

Clean or replace printhead, see user manual, see

topic section Maintenance 

Printhead setting incorrect Check settings (e.g. print contrast, print head resi-

stance) and alter if necessary

Relative position of thermal

bar to feed roller not correct Check mechanical setting and if necessary alter

Printhead contact pressure set

incorrectly

Check setting and if necessary adjust, see topic

section Mechanics 

Ribbon and material not alig-

ned

Check ribbon type and material type, if necessary

alter

Ribbon possibly super-

imposed Insert new ribbon roll

Poor or uneven print Feed roller damaged or soiled Check and if necessary clean or replace print rol-

ler

[Tab. 8] Unsatisfactory print quality and the possible reasons.

01/13 Rev. 5.08-01 SERVICE MANUAL Fault location

64-xx Error sources

Cut function, cutter

Feed in order but no

print image

Printhead power setting too

low

Check print contrast setting (press Prog button in

online mode or call PRINT PARAMETER >

Print contrast) and if necessary correct

Ribbon inserted incorrectly

(colour side) Check and if necessary system no.

Printhead does not move into

print position

Check printhead lift mechanics and if necessary

set, see topic section Mechanics 

Printhead not fixed to contact

axle fix thumb screw in print position

Printhead defective Check printhead and if necessary replace, see to-

pic section Maintenance 

Printhead cable not or incor-

rectly plugged in Check and if necessary plug in again

CPU board defective Check and if necessary replace

Problem Possible cause Solution

[Tab. 8] Unsatisfactory print quality and the possible reasons.

Problem Possible cause Solution

No cutter function

Plug connector loose Check and if necessary plug in firmly

Cutter function not activated Set SYSTEM PARAMETER > Periph. device to "Cutter"

Sensor defective Check and if necessary replace switch

Stepper motor or output stage

board defective Check and if necessary replace

Material is only partially

cut or not at all

Setting of cutter position Check photoelectric switch or position of oscillator

disc and if necessary correct

Cutter blunt or dirty Check and if necessary clean or replace. Don´t cut

self-adhesive endless material.

Material problem Only use approved materials

Cut next to recognised

gap Gap detection Check setting for parameter PRINT PARAMETER >

Cut position and if necessary correct

Cut offset to impression Cutter position incorrect Check and if necessary set

Material moves above

or under cutter

Unwinding too sluggish, roll

weighs too much Check and if necessary set

Cutter cuts twice Double cut programmed Check setting of double cut function

(PRINT PARAMETER > Double cut)

[Tab. 9] Possible problems caused by a cutter (if applied).

01/13 Rev. 5.08-01 SERVICE MANUAL Fault location

64-xx Error sources

Plug-in card

Problem Possible cause Solution

Plug-in cards are not re-

cognised

Contacts dirty Check and if necessary replace

Card not initialised Check and if necessary initialise

Card defective Check and if necessary replace

Card type does not corre-

spond to approved type Check and if necessary replace card

[Tab. 10] Possible faults caused by plug-in cards.

06/15 Rev. 03 SERVICE MANUAL Fault location

64-xx Reading out diagnosis data

Reading out diagnosis data

General notes

For diagnosis purpose, the printer offers the possibility

to generate diagnosis data and to store it in the internal

flash memory. This way, the last device internal com-

munication can be captured and analysed (comparable

to the black box in an airplane). The functin is very help-

ful to detect the cause of malfunctions.

DD = diagnosis dump

The flash memory can keep 2-3 DDs stored. If ad-

ditional DDs are stored, older ones will drop out of

memory.

DDs stay in the flash memory, even if the printer is

switched off.

Storing diagnosis data

Automatically

DDs are stored automatically, if the printer got in an un-

defined state. This happened for example, if…

• printing suddenly stops.

• the status message „unmanaged interrupt“ appears

on the display.

• the printer suddenly doesn´t react on keystrokes

any more.

Manually

DDs can be stored manually at any time during normal

operation:

Press all 4 keys on the operation panel simultane-

ously.

Generating a log file

To be able to have a look at the diagnosis data for fault

analysis, the data has to be stored into a text file (log

file)

There are two ways of storing the log file:

• Reading out via the serial interface and storing it on

the host PC, see chapter Reading out via serial in-

terface on page 8.

• Storing on memory card, see chapter Storing on

memory card on page 10.

Alternatively, the log file can be read out using an-

other than the serial interface or using the debug inter-

face, see Easy-Plug manual, #!XM command.

06/15 Rev. 03 SERVICE MANUAL Fault location

64-xx Reading out diagnosis data

Reading out via serial interface

Prerequisites

• Firmware (at least):

• Terminal program, e. g. „Hyperterminal“ (is deliv-

ered with Windows operating systems).

Carrying out

1. Connect the printing device to a PC, using the serial

interface. Set the transfer parameters to 115 kB, 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.

The window „COM1 Properties“ [2] opens (if COM1

was selected).

5. Set the transfer parameters to

115 kB, 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 printing device

and being displayed in the Hyperterminal main win-

dow [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.

Printer Vers.

AP 4.4 (16 MB), AP 5.4 red, AP 7.t 3.22

AP 5.4 black, AP 5.6 3.34

64-xx, DPM, PEM, ALX 92x

(each Gen. 2) 4.22

64-xx, DPM, PEM, ALX 92x

(each Gen. 3) 5.02

[1] Enter a name (A) for the new connection.

[2] Set the transfer parameters.

[3] Hyperterminal main window.

06/15 Rev. 03 SERVICE MANUAL Fault location

64-xx Reading out diagnosis data

[4] Read out data.

Send the generated files with a description of the cir-

cumstances in which the error occured per email to the

technical support at Novexx Solutions.

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