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Novexx Solutions XLP 504 Service Manual

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SERVICE MANUAL
XLP 504 / XLP 506
Label printer
Edition 9 - 5/2018 - Translation of original version

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Summary of Contents for Novexx Solutions XLP 504

  • Page 1 SERVICE MANUAL XLP 504 / XLP 506 Label printer Edition 9 - 5/2018 - Translation of original version...

  • Page 3: Table Of Contents

    XLP 504 / XLP 506 Service manual Content Please note General notes Validity of this manual and required compliance How information is represented Notes about service work Special key combinations Serial numbers Factory Settings Servicing data For your safety Intended use...
  • Page 4 Handling Boards ESD protection Handling CPU board Connections Interfaces Sensor connections Lithium Battery Output stage board M4A for stepper motor Connections, settings XLP 504: Output stage board M5A for stepper motor Application notes Connections, settings Jumper settings Pin assignments 05/2018 Content...
  • Page 5 I/O-board Connections, settings Application Setting the Interface Parameters Signal interface Serial interfaces Operation panel Connections XLP 504: Power switch for 600 dpi print head Notes Connections / LEDs Power supply Connections Specifications Interface for peripheral devices Sensor test General notes...
  • Page 6 XLP 504 / XLP 506 Service manual Gap detection -219 Material transport -220 Ribbon, ribbon guide -220 Print roller -220 Position of the print image -221 Print quality -221 External memory media -222 Cut function, cutter -222 Reading out diagnostic data...
  • Page 7 XLP 504 / XLP 506 Service manual Please note GENERAL NOTES Validity of this manual and required compliance Contents The complete operating manual for the label printers XLP 504 and XLP 506 consists of the following parts: Manual Target group Medium Availability...
  • Page 8 How information is represented Abbreviations of printer names XLP 50x = XLP 504/XLP 506 (description counts for both printer types) Text sections, which only count for one of the two printer types, are preceded by the printer name in brackets.

  • Page 9: Please Note -7

    The serial number can be found on the rating plate of the machine as illustrated below [1]. Rating plate of an XLP 504. The printer bears the serial number 106378. 05/2018 | 08...

  • Page 10: Factory Settings -10

    XLP 504 / XLP 506 Service manual Factory Settings At the factory, all of the parameters are set to device-specific default values. These factory settings System > Factory settings can be restored at any time by executing = „Factory defaults“.

  • Page 11: For Your Safety -11

    FOR YOUR SAFETY Intended use The label printers XLP 504 and XLP 506 are designed for printing label material, using the thermal or thermal transfer printing process. In addition, the dispenser version of the two printers can dis- pense self-adhesive labels and can rewind the remaining backing paper (ar alternatively the com- plete label material).
  • Page 12 XLP 504 / XLP 506 Service manual Protection against injuries by electrical current • Only operate the printer using the system voltage indicated on the nameplate! • Only connect the printer to a grounded power socket fitted to authorized standards! •...
  • Page 13 Warning notes on the printer provide important information for the operating personnel.  Do not remove warning notes.  Replace missing or illegible warning notes. Warning notes on the XLP 504. Warning note Meaning Article no. The ´Pinch point´ warning note warns you of the danger po- sed by the machine´s rotating parts;...

  • Page 14: Technical Data

    Technical Data TECHNICAL DATA Dimensions Measures (XLP 504) 275 x 266 x 463 mm (H x W x D) (XLP 506) 275 x 336 x 463 mm (H x W x D) (266) (463) Dimensions of the XLP 504 (H=Height, W=Width, D=Depth).
  • Page 15 XLP 504 / XLP 506 Service manual • Print head characteristics: Resolution Resolution Printspeed Printspeed Max. printwidth Printer (Dot/mm) (dpi) (mm/s) (inch/s) (mm) 50-254 2-10 XLP 504 11.8 50-200 105.7 23.6 50-150 105.6 50-200 XLP 506 11.8 50-150 CAUTION! Hazard of malfunction of the power supply and restart of the printer (XLP 506).
  • Page 16 XLP 504 / XLP 506 Service manual Fonts • 17 Fixsize fonts , including OCR-A and OCR-B • 3 scalable fonts (Speedo fonts) • Truetype fonts are supported (also Unicode) • Optionally can Truetype, Speedo and Fixsize fonts be stored on SD card Modifying Fonts •...
  • Page 17 XLP 504 / XLP 506 Service manual  Those values are empirical for typical applications with common label stock / foil combinations. Since the deflection of the print position strongly depends on the applied label stock / foil combina- tion, it can turn out higher if unfavorable combinations are used.

  • Page 18: Label Stock -18

    [Tab. 6] Overview label length. Max. print length  on page 15. (XLP 504) For label length less than 35 mm, the optional label sensor for short labels is recommended Gap size Gap size between the labels on the backing material: •...

  • Page 19: Thermotransfer Ribbon -19

    Corresponds for example to 450 m standard ribbon type Novexx 4903 Generally counts: The thermal transfer ribbon must overlap the label 2 mm on each side. For labels width > max. print width count the foil width: (XLP 504) 110 mm, (XLP 506) 172 mm. Connections, device data...

  • Page 20: Specifications For Dispenser -20

    XLP 504 / XLP 506 Service manual Specifications for dispenser Speed, while the rewinding-Ø is calculated: 75 mm/s (3“/s) Speed, while the material is fed back: 75 mm/s (3“/s) Distance dispensing edge - print zero line: 25 mm Distance punch sensor - print zero line: 71 mm Max.
  • Page 21 XLP 504 / XLP 506 Service manual 300 dpi printhead Print speed Limitations mm/s Inch/s 51/76 Max. admissible print contrast: 120% Max. admissible print contrast at print width > 100 mm: 105% Max. admissible print width at print contrast > 105%: 100 mm Max.

  • Page 22: Service Mechanics

    XLP 504 / XLP 506 Service manual Service Mechanics HOUSING COMPONENTS Overview Housing components of the XLP 50x: A Rear hood B Rear bottom housing C Front hood D Flange cover E Front bottom housing F Plug cover G Front left housing...

  • Page 23: Front Hood -23

    XLP 504 / XLP 506 Service manual Front hood Tools Torx screwdriver, size 20 Removing 1. Remove the 4 bolts [7A].  Hold the front hood while doing so. 2. Remove the front hood. Perform the installation in the reverse order to the re- moval.

  • Page 24: Front Left Housing -24

    XLP 504 / XLP 506 Service manual Front left housing Tools • Torx screwdriver, size 20 • Open-ended spanner, size 7 Removing 1. Remove the rear hood. See chapter Rear hood on page 23. 2. If any: Unplug the connector of the option from the D-Sub connector.

  • Page 25: Bottom Housing Sections Front/Rear Side -25

    XLP 504 / XLP 506 Service manual Bottom housing sections front/rear side Tools Torx screwdriver, size 15 Removing 1. Remove screw [12A] respectively [12B] at the rele- vant housing section. 2. Lightly pull the housing section outwards and care- fully lift it upwards [13A].

  • Page 26: Xlp 504: Ribbon Mandrels -26

    XLP 504 / XLP 506 Service manual XLP 504: RIBBON MANDRELS Exploded drawings [14] Ribbon unwinding mandrel [15] Ribbon rewinding mandrel 05/2018 | 03 Service Mechanics...
  • Page 27 XLP 504 / XLP 506 Service manual Replacing the ribbon core adapters The ribbon core adapters ensure that the ribbon roll holds firmly on the unwind or rewind mandrel. Each rib- bon mandrel carries two adapters [16C+D], the inner one [16D] being additionally equipped with a clamp spring.
  • Page 28 XLP 504 / XLP 506 Service manual Ribbon unwinding mandrel Replacing Tools • Torx screwdriver, size 10 • Open-ended spanner, size 8 • Allen key 2.0 mm Removing 1. Remove the rear hood, see chapter Rear hood  on page 23.
  • Page 29 XLP 504 / XLP 506 Service manual Replacing the ribbon end sensor Checking the ribbon end sensor: See chapter Sensors on the CPU board on page 95. Tools • Torx screwdriver, size 10 • Side cutters Removing 1. Remove screw [22A], take off the sensor [22B].
  • Page 30 XLP 504 / XLP 506 Service manual Ribbon rewinding mandrel Replacing Tools • Torx screwdriver, size 20 • Open-ended spanner, size 8 • Allen key 2.0 mm Removing 1. Removing the rear hood, see chapter Rear hood on page 23.

  • Page 31: Setting The Braking Torque -31

    XLP 504 / XLP 506 Service manual Setting the braking torque Tools • Open-ended spanner, size 8 • Spring balance 10 N The following adjustment instructions apply to both rib- bon mandrels; the figures display the ribbon unwinding mandrel. 1. Push a cardboard sleeve on the ribbon mandrel.

  • Page 32: Xlp 506: Ribbon Mandrels -32

    XLP 504 / XLP 506 Service manual XLP 506: RIBBON MANDRELS Exploded drawings [30] Ribbon unwinding mandrel [31] Ribbon rewinding mandrel 05/2018 | 03 Service Mechanics...

  • Page 33: Replacing The Ribbon Core Adapters -33

    XLP 504 / XLP 506 Service manual Replacing the ribbon core adapters The ribbon core adapters ensure that the ribbon roll holds firmly on the unwind or rewind mandrel. Each rib- bon mandrel carries two different adapters [16C+D], the inner one [16D] being additionally equipped with a clamp spring.

  • Page 34: Ribbon Unwinding Mandrel -34

    XLP 504 / XLP 506 Service manual Ribbon unwinding mandrel Replacing Tools • Torx screwdriver, size 10 • Open-ended spanner, size 8 • Allen key 2.0 mm Removing 1. Remove the rear hood, see chapter Rear hood  on page 23.
  • Page 35 XLP 504 / XLP 506 Service manual 7. Remove all parts from the ribbon mandrel. Before removing the stop disk [37B], loosen both set screws [37C]. [37] Removing the brake parts (A) from the unwinding mandrel. 8. Press the ribbon mandrel out of the bearing in the direction of the arrow [38].
  • Page 36 XLP 504 / XLP 506 Service manual Replacing the ribbon end sensor Checking the ribbon end sensor: See chapter Sensors on the CPU board on page 95. Tools • Torx screwdriver, size 10 • Side cutters Removing 1. Remove screw [40A], take off the sensor [40B].

  • Page 37: Ribbon Rewinding Mandrel -37

    XLP 504 / XLP 506 Service manual Ribbon rewinding mandrel Replacing Tools • Torx screwdriver, size 20 • Open-ended spanner, size 8 • Allen key 2.0 mm Removing 1. Removing the rear hood, see chapter Rear hood on page 23.
  • Page 38 XLP 504 / XLP 506 Service manual 6. Remove all parts from the ribbon mandrel. Before removing the brake package, loosen both set screws [45B]. [45] Parts of the braking clutch at the ribbon rewind mandrel. 7. Press the ribbon mandrel out of the bearing as shown [46].

  • Page 39: Setting The Braking Torque -39

    XLP 504 / XLP 506 Service manual Setting the braking torque The braking torques of the foil mandrels can be set by turning the red hexagon on each mandrel. Turn clock- wise to increase the torque. The traction exerted on the foil is in proportion to the winding/unwinding torque.

  • Page 40: Printing Unit -40

    Rear hood on page 23. [50] Print head pressure shaft (A) with pressure pads (B) and closing lever (C) at the XLP 504. [51] Print head pressure shaft (A) with pressure pads (B) and closing lever (C) at the XLP 506.
  • Page 41 (part no. A4631):  Intallation of washer DIN 988 5x10x1 (part no. A4631) [54E]: • XLP 504: Installation only at the outer pressure pad • XLP 506: Installation at all pressure pads 05/2018 | 03 Service Mechanics...

  • Page 42: Closing Lever Sensor -42

    XLP 504 / XLP 506 Service manual Closing lever sensor Testing the sensors: See chapter Sensor test page 94. Tools • Torx screwdriver, size 10 • Side cutters Removing 1. Remove screw [55B], take off the sensor [55A]. 2. Open cable clamps, cut cable ties. Remove cable from cable clamps.

  • Page 43: Material Transport -43

    XLP 504 / XLP 506 Service manual MATERIAL TRANSPORT Adjusting the friction of the material guide Tools • Torx screwdriver size 10 • Spring balance 10 N Measure the driving force 1. Push the material guide [57A] to approximately the centre of the guiding section.

  • Page 44: Replacing The Material Unwinder -44

    XLP 504 / XLP 506 Service manual Replacing the material unwinder Tools • Screwdriver, large • Torx screwdriver, size 20 Auxiliary materials • “Loctite Cleaner 7063” cleaning agent • “Loctite 243” glue Removing 1. Remove the guiding disk and adapter rings [59].

  • Page 45: Replacing The Feed Motor -45

    3. Remove the three screws [62B]. Remove the mo- tor. Installation Perform the installation in the reverse order to the re- [62] Motor and drive belt on XLP 504. moval. Note the following:  Tighten the belt: Press the motor downwards with the screws lightly tightened.

  • Page 46: Label Sensor -46

    XLP 504 / XLP 506 Service manual Label sensor Check label sensor: See chapter Sensor test page 94. Removing 1. Remove the rear hood. Rear hood on page 23. 2. Unplug the sensor cable from CPU board and re- move it from the cable holders.

  • Page 47: Xlp 504: Label Sensor For Very Short Labels -47

    XLP 504 / XLP 506 Service manual XLP 504: Label sensor for very short labels  Only applies to XLP 504 dispenser! [67] Label sensor for short labels. Very short labels are labels that are much shorter than the distance of 30 mm between the print head and punch sensor.
  • Page 48 XLP 504 / XLP 506 Service manual Installing [71] Installation area of sensor (circle). 1. Remove the rear hood. 2. Loosen the screw [68A]. [68] Loosen the screw (A). 3. Place the sensor as shown [69A]. Tighten the screw [69B].
  • Page 49 XLP 504 / XLP 506 Service manual [73] Installation of sensor cable (A). 5. Install the sensor cable as shown [73A]. 6. Connect the sensor cable to CN909 on the CPU board [74A].  Fasten the cable with terminals and cable ties so that it does not contact any moving parts.

  • Page 50: Internal Rewinder / Dispenser -50

    XLP 504 / XLP 506 Service manual INTERNAL REWINDER / DISPENSER Replacing the pinion Tools Hex socket screwdriver, 2 mm Removing 1. Remove the two set screws [75A] from the motor pinion. Remove the pinion. 2. Remove the two set screws [75B] from the plastic pinion.

  • Page 51: Replacing The Motor -51

    XLP 504 / XLP 506 Service manual Replacing the motor Tools Torx screwdriver, sizes 10 and 20 Removing 1. Remove both pinions, see Replacing the pinion on page 50. 2. Plug the motor cable onto the power stage board. 3. Remove the three screws [77A]. Remove the motor and bracket.

  • Page 52: Retrofitting The Internal Rewinder -52

    [80] (Main) components of the upgrade kits. A BLDC output stage board pensing and, additionally, a baffle plate [80E] (article B Rewinder no.: XLP 504: A5552, XLP 506: A101812). C Deflector shaft D Dispensing edge (only in the kit for dispensing) Tools E Baffleplate (only in the kit for rewinding) •...
  • Page 53 (2x Torx M4x16 [83B]). [83] Installing the deflector shaft (A) Installing the cable harness  Only XLP 504 “basic” (XLP 504 “peripheral” comes already equipped with the cable harness). 1. Remove the cover from the D-Sub installation opening.
  • Page 54 XLP 504 / XLP 506 Service manual Installing BLDC output stage board into XLP 50x “basic” 1. Screw the BLDC output stage board with heat sink to the right-hand position (2x Torx DG 40x10).  The solder side of the board is facing right.

  • Page 55: Installing The Dispensing Edge -55

    XLP 504 / XLP 506 Service manual Installing the dispensing edge If the XLP 50x is used as dispenser, a dispensing edge has to be installed in addition to the rewinder as follows: Tool Torx screwdriver size 10 Procedure: 1. Remove flange cover [89A], front bottom housing section [89B] and the tear-off edge [89C].

  • Page 56: Installing The Baffle Plate -56

    XLP 504 / XLP 506 Service manual Installing the baffle plate If the XLP 50x is used as dispenser, a dispensing edge has to be installed in addition to the rewinder as follows: Tool Torx screwdriver size 10 Procedure: 1. Remove the front bottom housing section [91B] and the tear-off edge [91A].

  • Page 57: Dispensing Edge Sensor -57

    XLP 504 / XLP 506 Service manual Dispensing edge sensor The sensor in use is pulsed and thus not sensitive to external light.  The sensor does not have to be adjusted.  It is not possible to use a longer dispensing edge.

  • Page 58: Parameter Settings -58

    XLP 504 / XLP 506 Service manual Parameter settings Switching the dispense function on/off Prerequisites:  Only for XLP 50x with internal rewinder and dis- pensing edge  Insert label material before activating the rewinder, otherwise an error message will appear! Switching on: Options >...
  • Page 59 XLP 504 / XLP 506 Service manual Parameters for authorised service technicians Options > Dispenser Options > Internal Rewinder men- us contain many special parameters for authorised ser- vice technicians that are only visible after starting the printer in production mode: •...

  • Page 60: Replacing Electronic Components -60

    XLP 504 / XLP 506 Service manual REPLACING ELECTRONIC COMPONENTS Important information CAUTION! - Protect the electronic compo- nents against damage from electrostatic discharge.  Wear protective ESD gear.  Place the device on an earthed pad before opening it.

  • Page 61: Cpu Board -61

    XLP 504 / XLP 506 Service manual CPU board [96] CPU board in XLP 504 “peripheral”. Tools Torx screwdriver, sizes 10 and 20 Removing 1. Unplug all cables from the board. 2. Remove the two screws [96A] from the rear side of the printer.

  • Page 62: Output Stage Of Stepper Motor -62

    1. Unplug all cables from the board [97B]. 2. Remove the two screws [97A] from the heat sink. Remove the board. [97] Output stage board of the stepper motor (B) in a XLP 504 Installation “peripheral dispenser“. Perform the installation in the reverse order to the re- moval.

  • Page 63: Output Stage Of Bldc Motor -63

    2. Remove the two screws [98B] from the bracket. Re- move the board. Installation Perform the installation in the reverse order to the re- [98] Output stage board of the BLDC motor (B) in XLP 504 “peri- pheral dispenser“. moval. Note the following: ...

  • Page 64: I/O Board -64

    XLP 504 / XLP 506 Service manual I/O board The I/O board is available optionally. Tools Torx screwdriver, size 10 Removing 1. Remove the CPU board See chapter CPU board on page 61. 2. Unplug all cables from the board.

  • Page 65: Power Supply -65

    4. If present: Remove the pinion from the internal re- winder. Replacing the pinion on page 50. [101] XLP 504 with CPU board removed. Removing the cable 1. Unplug the cable [101A] from the motor power stage board(s). 2. Remove the cable [101B] from the fastenings [101C].
  • Page 66 XLP 504 / XLP 506 Service manual 3. Remove the cable holders [102A].. 4. Unplug the cable [102B] from the print head and feed it through the opening in the printer wall. Removing the power supply 1. Remove the screws [103A] from the rear side of the printer.

  • Page 67: Service Electronics

    XLP 504 / XLP 506 Service manual Service Electronics HANDLING BOARDS ESD protection CAUTION! - The boards can be destroyed by static discharge!  Before opening the printer, place it on a grounded surface.  Earth your body using an ESD bracelet or other suitable means, before touching a board.

  • Page 68: Cpu Board -68

    XLP 504 / XLP 506 Service manual CPU BOARD Connections [105] CPU board connections (A100150). 05/2018 | 04 Service Electronics...
  • Page 69 XLP 504 / XLP 506 Service manual Code of components on the board: • CNxxxx = Connector • Dxxxx = LED • JPxxx = Jumper List of components on the board: A CN1201: Power supply B CN601: Feed motor C CN1202: D-Sub harness, marking „POWER“...

  • Page 70: Interfaces -70

    XLP 504 / XLP 506 Service manual Interfaces Overview interfaces [106] External interfaces at XLP 50x. A Foot switch connector B USB host connector C USB device connector D Serial interface (RS 232) E Ethernet interface F Signal interface (on optional I/O board)
  • Page 71 XLP 504 / XLP 506 Service manual USB device connector Signal n. c. Data- Data+ Suitable cable for PC connection: USB cable A/B (article number: A5799) Serial interface (RS 232) Signal (CD) (DTR) (DSR) (RI) Pin 9 supplies 5 V/170 mA, if JP701 is set.

  • Page 72: Sensor Connections -72

    XLP 504 / XLP 506 Service manual Sensor connections Schematic diagram for connectors CN905 to CN909 on the CPU board: Belegung Anode Kathode Kollektor Emitter Lithium Battery WARNING! Danger of explosion if battery is incorrectly replaced.  Replace only with the same or equivalent type recommended by the manufacturer.
  • Page 73 XLP 504 / XLP 506 Service manual  When handling batteries, wear finger covers or gloves made of rubber, cotton, etc. to protect the battery from dirt. 3. Take used battery out of the socket; insert the new battery. ...

  • Page 74: Output Stage Board M4A For Stepper Motor -74

    XLP 504 / XLP 506 Service manual OUTPUT STAGE BOARD M4A FOR STEPPER MOTOR Connections, settings [109] Connections at the output stage board (A2742) A Connection for D-Sub-harness, sensor of the peripheral device (cable marking „SENSOR 1“ (J4) K (GND) E (GND) [110] Connection diagram sensor.

  • Page 75: Xlp 504: Output Stage Board M5A For Stepper Motor -75

    XLP 504 / XLP 506 Service manual XLP 504: OUTPUT STAGE BOARD M5A FOR STEPPER MOTOR Application notes • Die Endstufe M5A wird als Endstufe für die Motoren der Optionen LTSA und TCS eingesetzt, die nur für den XLP 504 vorgesehen sind •...

  • Page 76: Jumper Settings -76

    XLP 504 / XLP 506 Service manual Jumper settings JP101 JP100/5-6 JP100/3-4 JP100/1-2 [114] Position of the jumpers JP100 and JP101 on the M5A output stage board (orange = jumper is set). Pin assignments [115] Connections on the M5A output stage board.
  • Page 77 XLP 504 / XLP 506 Service manual Posno. Description Pinout Connection for D-Sub-harness, sensor of the peripheral device (cable marking „SENSOR 1“) (J4) K (GND) E (GND) Connection for D-Sub-harness, motor of the peripheral device (cable marking „MOTOR“ (J3) Connection CPU board (J2)
  • Page 78 XLP 504 / XLP 506 Service manual OUTPUT STAGE BOARD FOR BLDC MOTOR Notes • BLDC = brushless direct current • Application: XLP 50x with internal rewinder Firmware version • Printer firmware: at least 3.34 • Firmware output stage driver: at least 6...
  • Page 79 XLP 504 / XLP 506 Service manual K (GND) E (GND) [117] Connection diagram sensor. B Jumper J101/102/103 J103 J102 J101 [118] Jumpers J101 and J102 connected. C Connection rewinder motor (CN102) D Connection CPU board (CN103) E Connection power supply (CN104)
  • Page 80 XLP 504 / XLP 506 Service manual I/O-BOARD Connections, settings [119] Connections at the I/O-board (A3926). A Signal interface (D-Sub15; CN201) B Connection CPU board (CN102) C RS 232/422/485 (D-Sub9; CN101) Application The I/O board may be used for 3 different applications: •...
  • Page 81 XLP 504 / XLP 506 Service manual Setting the Interface Parameters With an I/O board mounted, the following additional menus appear in the printer menu: • Interface > Serial Port 3 contains all parameters required to configure the serial interface.
  • Page 82 XLP 504 / XLP 506 Service manual Signal Description Condition(s) for activating PAUSE\ A high-low change switches the printer START_PRINT\ is high to the pause mode. Another high-low Input change switches the printer back into online mode If the parameter Options >...
  • Page 83 XLP 504 / XLP 506 Service manual Circuit diagrams for signal inputs D C /D C 5V..24V Eingang Masse [121] I/O board: Input circuitry and possible connections to external electronics. The input signals are supplied by an internal, galvanically decoupled 5 V source.
  • Page 84 XLP 504 / XLP 506 Service manual Circuit diagrams for signal outputs DC/DC 5 - 24 V Sicherung +24V +24V Ausgang Sicherung Masse 5 - 24 V +24V +24V Ausgang Masse [122] I/O board: Output driver and possible connections to external electronics.
  • Page 85 XLP 504 / XLP 506 Service manual Fuses: The fuses used on the I/O board are polymeric positive temperature coefficient resistors. If they trip, they don´t blow and after cooling down, they work again. They don´t need to be replaced.
  • Page 86 XLP 504 / XLP 506 Service manual Serial interfaces Pin assignment RS 232 [124] Pinout RS 232  CAUTION! - Pin assignment „viewed at from PC“! (printer = DCE) Signal (Host) Signal direction from I/O-board Short with DTR and DSR...
  • Page 87 XLP 504 / XLP 506 Service manual RS 422/485 termination: At the last printer at the RS 422/485 line, connect the following pins (inside of the cable connector): • Pins 3 and 4 (Tx-) • Pins 6 and 7 (Tx+)
  • Page 88 XLP 504 / XLP 506 Service manual Circuit diagram RS485 interface RS 485 2 wire +- R pkkrC 1/ ΩC C 4/ Ω pkkrC 1/ ΩC C 4/ Ω pkkrC 120Ω Printer 1 T x D Pmd Pam 110Ω Printer n ap.
  • Page 89 XLP 504 / XLP 506 Service manual OPERATION PANEL Connections [128] Operation panel board (N100468). A Connection CPU board 05/2018 | 04 Service Electronics...
  • Page 90 XLP 504: POWER SWITCH FOR 600 DPI PRINT HEAD Notes • Article number: N100479 • Required firmware version for XLP 504 600 dpi: at least 7.71 Connections / LEDs [129] Power switch board for 600 dpi print head. A Connection to CPU board (CN1001, cable N100472)
  • Page 91 XLP 504 / XLP 506 Service manual POWER SUPPLY Connections [130] Power supply (A3958). A Connections for output stage boards +45V +45V [131] Pin assignment connections for output stage boards. B Connection for CPU board Power Fail +45V Temp. Sense +45V [132] Pin assignment connection CPU board.
  • Page 92 XLP 504 / XLP 506 Service manual Specifications Power • Maximum continuous average output power: 196 W • Peak power: 276 W  Peak must not last longer than 30 ms  Limitation of peaks per minute: max. 3 Voltage range...
  • Page 93 Connecting non-original devices to this interface can damage the printer. In the worst case the printer can start to burn.  Only connect original Novexx Solutions peripheral devices to this interface. [134] D-Sub15 connection for peripheral devices at an XLP 504 „peripheral“. Signal Emitter 2 (GND) Collector 2 (sensor input signal)
  • Page 94 XLP 504 / XLP 506 Service manual SENSOR TEST General notes  Activating the sensor test: call parameter Tools > Test > Sensor test. By means of the sensor test, you can check the function of each sensor: [135] Display after calling „Sensor test“.
  • Page 95 XLP 504 / XLP 506 Service manual Sensors on the CPU board Sensor Sensor # Connector # Typical value Condition name 0.01 Punch CN 905 8-20 No material in light barrier 30-90 Only backing paper in light barrier 140-255 Label material in light barrier 0.02...
  • Page 96 XLP 504 / XLP 506 Service manual Sensors on the stepper motor output stage board Sensor Typical Sensor # Conn. # Periph. Condition name value Dispensing 4.01 Peri. 1 edge sen- Dispensing edge light barrier open Dispensing edge light barrier covered Cutter <=10...
  • Page 97 XLP 504 / XLP 506 Service manual Sensor Typical Sensor # Connector # Condition name value APSF signal frequency < 76 Hz 15.07 F (Hz) CN804 76-254 Frequency in Hz Frequency more than 254 Hz APSF signal frequency < 100 Hz 15.08...
  • Page 98 XLP 504 / XLP 506 Service manual Settings SENSOR SETTINGS Setting sensors The following cases require the sensor or all sensors to be set newly: • A sensor was replaced • The CPU board was replaced • A punch sensor fork with additional reflex sensor was mounted...
  • Page 99 By doing so, the print head sensor is set. Reflex sensor  Setting only for XLP 504 with optional reflex mark label sensor! 1. Call the sensor setting dialog. 2. Use the arrow keys to toggle to sensor „00.04 Reflex“.
  • Page 100 By doing so, the reflex sensor is set. XLP 504: Punch sensor for short labels  Setting only for XLP 504 dispenser with optional punch sensor for short labels! For further information about this punch sensor, see chapter XLP 504: Label sensor for very short labels ...
  • Page 101 XLP 504 / XLP 506 Service manual Setting the material end sensor This printer type is equipped with a single light sensor which is designed to detect both, punches and material end. The sensor must be able to detect three different states: •...
  • Page 102 XLP 504 / XLP 506 Service manual ADJUSTING THE IMPRINT POSITION Printing on especially long labels may require under certain circumstances, that the imprint position has to be adjusted. Do this in the following way: Prerequisites • Print > Material > Punch offset = „0 mm“.
  • Page 103 XLP 504 / XLP 506 Service manual 6. Measure the distance between the black squares and the label front edge. Put the value into Tools > Adjustment > Punch y calibr.. Repeat steps 5 and 6, until the black squares exactly flush the label front edge.
  • Page 104 XLP 504 / XLP 506 Service manual Parameter Menu OVERVIEW  Click on a link in the table to get to the parameter description. Print Options Print contrast  Feed speed  Selection └ (Break diameter ) X - Printadjust ...
  • Page 105 XLP 504 / XLP 506 Service manual System Printer Language Print interface Tear-off edge Language  Print Interpret.  Print interface  └ Dispenseposition  Access authoriz.  EasyPlug Setting Network Factory settings  ├ Character filter  ├ IP Addressassign ...
  • Page 106 XLP 504 / XLP 506 Service manual Info Drives Model ID  └ Memory Data ├ Drive C  Status Printouts ├ RAM memory size  └ Drive D  ├ Demo label  ├ Flash mem size  ├...
  • Page 107 XLP 504 / XLP 506 Service manual ALPHABETICAL PARAMETER LIST #VW/I Interface Delete Job Foil end warning -145 -110 -141 Access authoriz. Delete Spooler Foil length -136 -111 -114 Appl. waitpos. Delimiter Char Foil mode -123 -149 -111 Application mode...
  • Page 108 XLP 504 / XLP 506 Service manual Matend adjust Punch y calibr. Start print mode -160 -161 -119 Matend tolerance Punchlevel Start rew. curr. -160 -113 -133 Materiallength Punchmode Start source -112 -112 -131 Materialtype Ram disk size Status output...
  • Page 109 XLP 504 / XLP 506 Service manual PARAMETER REFERENCE Print contrast Setting range Default setting Step width Easy Plug [1...105] % #!H, #PC2045 CAUTION! The parameter Print contrast affects directly the life durance of the print head. It counts: „The higher the setting of Print contrast is, the lower is the life durance of the print head“.
  • Page 110 XLP 504 / XLP 506 Service manual X - Printadjust Setting range Default setting Step width Easy Plug [-15...15] mm 0.0 mm 0.1 mm #PC1020 The zero point of the mask is moved in relation to the edge of the label on the X- axis, i. e. lengt- hways to the material.
  • Page 111 XLP 504 / XLP 506 Service manual Delete Spooler Setting range Default setting Step width Easy Plug #!CA Pressing key 4 deletes all print jobs queued in the spooler. Foil mode Einstellungen Default setting Step width Easy Plug Thermo transfer...
  • Page 112 XLP 504 / XLP 506 Service manual Materialtype Settings Default setting Step width Easy Plug Endless, Punched Punched #PC1005, #IM Definition of the used label material. A distinction is made between endless material and gapped material (hole gaps, self-adhesive material with register gaps). The detected gap position corre- sponds to the start of the label.
  • Page 113 • Reflex (upper): n. a. • Short label opt.: Activates the optional short label sensor  Appears only in XLP 504 printers which are equipped with the short label sensor.  In XLP 50x with activated dispenser, the short label sensor is automatically activated.
  • Page 114 XLP 504 / XLP 506 Service manual Mat. end detect. (Material end detection) Settings Default setting Step width Easy Plug Off, Transparent Transparent The material end detection can be deactivated for processing labels with gaps longer than 15 mm, or if using material with a high fluctuation in light transparency (Status message „5002 material end“...
  • Page 115 XLP 504 / XLP 506 Service manual Tradit. Imaging Setting range Default setting Step width Easy Plug No, Yes  Only in service mode Up to firmware version x.31, the barcode height was calculated with the formula:   x ...
  • Page 116 XLP 504 / XLP 506 Service manual Rotated barcodes Setting range Default setting Step width Easy Plug Normal, Optimized Optimized #PC1013, #YB Improves readability of rotated (90° and 270°) bar codes. • Normal: „Normal“ printing without special processing of rotated bar codes.
  • Page 117 XLP 504 / XLP 506 Service manual Feed speed Setting range Default setting Step width Easy Plug [2.0...6.0] Inch/s 4.0 Inch/s 1 Inch/s #PC1004, #PR   (Options > Selection > Periph. device Parameter is only visible with deactivated dispense function ...
  • Page 118 XLP 504 / XLP 506 Service manual • Tear-off edge: Sets the printer firmware to the tear-off edge option. The punch is fed forward to the tear-off edge. 05/2018 | 09 Parameter Menu...
  • Page 119 XLP 504 / XLP 506 Service manual • Dispenser: Activates the dispensing option (requires internal rewind option + dispensing edge). • Intern. rewinder: Activates the internal rewind option (requires internal rewind option + deflecti- on plate). • LTSA: Activates both, the applicator and the dispenser options.
  • Page 120 XLP 504 / XLP 506 Service manual • Off: Signals at the FEED input are ignored. • On: Feeding of one label on the falling signal edge. The display shows „I/O board feed“ during feeding. Requirements are: – Offline mode or „stopped mode“ or „I/O pause mode“.
  • Page 121 XLP 504 / XLP 506 Service manual Error polarity Settings Default setting Step width Easy Plug Level high activ, Level Level low active #PC3208 low active  Only with an I/O board mounted. Switches the polarity of the ERROR signal •...
  • Page 122 XLP 504 / XLP 506 Service manual • Mode0 inactive: No print end signal. • Mode1 low level: Low, if the print module is just printing a label, otherwise high. The output is also deactivated (= low) as long as labels are fed with “Feed Button” or “Feed Signal”.
  • Page 123 XLP 504 / XLP 506 Service manual Defines, if the application process starts with applying („After start sig.“) or with printing („After print“). Requirements: Printjob transferred, printer is switched „Online“ (display „Home“). • After start sig.: The start signal triggers the application of an already printed and dispensed la- bel.
  • Page 124 XLP 504 / XLP 506 Service manual Cut mode Settings Default setting Step width Easy Plug Real 1:1 mode, Batch mode, Normal 1:1 Real 1:1 mode #PC1014 mode  (Options > Selection > Periph. device Only with mounted and activated cutter = „Cutter“).
  • Page 125 XLP 504 / XLP 506 Service manual 1. Printing Novexx Novexx 2. Stop printing + Novexx Novexx Novexx 3. Continue printing [142]Printing process in Batch mode (schematic). • Normal 1:1 mode: In N1:1 mode, cutting takes place during printing. The zero-line of the printing is shifted 18 mm in y-direction.
  • Page 126 XLP 504 / XLP 506 Service manual Cut width Setting range Default setting Step width Easy Plug [0...MAX_CUT_WIDTH] MAX_CUT_WIDTH #PC1016, #CW  (Options > Selection > Periph. device Only with mounted and activated cutter = „Cutter“). The values for MAX_CUT_WIDTH depend on printer type and print head:...
  • Page 127 XLP 504 / XLP 506 Service manual • at head: The material rest position in idle times is at the print head • at cutter: The material rest position in idle times is at the cutter to avoid material being wrapped...
  • Page 128 XLP 504 / XLP 506 Service manual Normal 1:1 mode • The printer cannot print on the whole label surface. A stripe at the label beginning stays unprin- ted. The width of the unprintable stripe is calculated as follows: Distance print line to dispensing edge (25 mm) + Dispense position See also: Parameter Options >...
  • Page 129 XLP 504 / XLP 506 Service manual Real 1:1 mode • The printer can print the whole label surface. • After dispensing a label, the beginning of the next label is drawn back under the print head. • The output volume is lower than in Batch Mode or Normal 1:1 Mode.
  • Page 130 XLP 504 / XLP 506 Service manual • tightened xxx: Setup of the tightened dancer arm (xxx = actual sensor value). The setting follows in both cases this scheme: 1. Bring the dancer arm to its loose position. 2. Press key 3.
  • Page 131 XLP 504 / XLP 506 Service manual There are two ways of setting back the counter: • Set the parameter Display mode (see above) to "Job rest quant." , then back to "Dispense coun- ter" and confirm by pressing the o. k. key.
  • Page 132 XLP 504 / XLP 506 Service manual • If a further start signal arrives, before the current label is completely printed. • Only with I/O board: If a reprint is requested, before the first label after powering on is printed.
  • Page 133 XLP 504 / XLP 506 Service manual This parameter influences the rewinder current with 25 mm rewinder diameter (min. rewinder dia- meter). Problem Solution The label web runs too loose around the dispensing edge during prin- ter operation. Increase the setting The label roll is wound up too loose.
  • Page 134 XLP 504 / XLP 506 Service manual Start cur. len. (Start current length) Setting range Default setting Step width Easy Plug [10...40] mm 30 mm 1 mm #PC2507  Only visible in service mode  Only if Options > Selection > Periph. device = „Dispenser“...
  • Page 135 XLP 504 / XLP 506 Service manual  Only if Options > Selection > Periph. device = „Dispenser“ oder „Intern. rewinder“ Sets the brake current. See also parameter Pullback current  on page 134. Break diameter Setting range Default setting...
  • Page 136 XLP 504 / XLP 506 Service manual Access authoriz. (Access authorization) Settings Default setting Step width Easy Plug Off, Power-up code, Operator, #PC2053 Supervisor, Operator auto Limits the access either to all printer functions (Power-up code) or only to the parameter menu (user or supervisor mode).
  • Page 137 XLP 504 / XLP 506 Service manual • Custom defaults: If custom parameter settings were stored before (see parameter System > Cu- stom defaults), those are restored.  „Custom defaults“ only appears, if custom settings have already been stored. • Factory defaults: The parameters are set to factory defaults. After switching on, the query ap- pears , if the setup wizard is supposed to be started (Run Setup Wizard?).
  • Page 138 XLP 504 / XLP 506 Service manual  The value set here remains when the factory settings are carried out. Realtime Clock Settings Default setting Step width Easy Plug dd.mm.yyyy hh:mm Setting the realtime clock (date and time). Those data can be processes using the Easy Plug #YC, #YS or #DM commands.
  • Page 139 XLP 504 / XLP 506 Service manual Overview of the set memory areas: see parameter Memory Status  on page 163. Font downl. area Setting range Default setting Step width Easy Plug [128...MAX ] KByte 256 KByte 128 KByte #PC2047 Maximum size, depends on the memory equipment and usage of the printer If speedo-fonts are supposed to be used, they have first to be copied to a reserved RAM disk area.
  • Page 140 XLP 504 / XLP 506 Service manual Miss. label tol. (Missing label tolerance) Setting range Default setting Step width Easy Plug [0...50] #PC2029 The maximum search path for gaps which cannot be found can be varied. In cases of difficult gap detection (i.
  • Page 141 XLP 504 / XLP 506 Service manual Foil end warning Setting range Default setting Step width Easy Plug [5.0...300.0] mm 25.0 mm 0.1 mm #PC2083 Setting of a limit length for the remaining ribbon. If the remaining ribbon length falls below the set value, appears a…...
  • Page 142 XLP 504 / XLP 506 Service manual Error reprint Settings Default setting Step width Easy Plug On, Off #PC2022 If an error occurs while a label is printed, the last printed label is reprinted. For label layouts conta- ining variable data (for example, count fields), disable the reprint function.
  • Page 143 XLP 504 / XLP 506 Service manual • Compact left: Setting for 50 mm material width. The parameter values are printed on the left side of the parameter names: Value: Parameter name Print Interpret. Settings Default setting Step width Easy Plug...
  • Page 144 XLP 504 / XLP 506 Service manual Character filter Settings Default setting Step width Easy Plug Chars >= 20Hex, All characters Chars >= 20Hex #PC2014 • Chars >= 20Hex: Filter function is activated. Characters smaller than 20H are filtered out of the data flow.
  • Page 145 XLP 504 / XLP 506 Service manual EasyPlug errors Setting range Default setting Step width Easy Plug Tolerant handl., Strict handling Tolerant handl. Handling of errors caused by faulty Easy Plug commands. • Tolerant handl.: The label is printed, after the Easy Plug/Bitimage error was acknowledged.
  • Page 146 XLP 504 / XLP 506 Service manual • Easyplug: Interface that is defined in INTERFACE PARA >EASYPLUGINTERPR > Print interface as input interface for print data • Serial Com1: Serial interface Com 1.  Only available for selection, if the interface is not occupied by another function.
  • Page 147 XLP 504 / XLP 506 Service manual Darkness Setting range Default setting Step width Easy Plug [0...30] Print contrast for ZPL printjobs. This setting is modified by printjobs which contain print contrast in- formation. The print contrast set by Print > Print contrast...
  • Page 148 XLP 504 / XLP 506 Service manual Image Save Path Settings Default setting Step width Easy Plug Drive C:, Internal RAM Internal RAM Selects the memory to be used by the ^IS and ^IL commands.  Interpreter Version: 1.10 or higher.
  • Page 149 XLP 504 / XLP 506 Service manual Delimiter Char Setting Default setting Step width Easy Plug 0x2C = „Comma“ Used as a parameter place marker in ZPL format instructions. Command ^PR Settings Default setting Step width Easy Plug Disable, Enable Enable •...
  • Page 150 XLP 504 / XLP 506 Service manual • DHCP: IP address is assigned automatically. The assigned IP address is displayed for a mo- ment on the printer display, while the printer is starting.  A change of this parameter setting forces a printer restart.
  • Page 151 XLP 504 / XLP 506 Service manual DHCP host name Setting range Default setting Step width Easy Plug #PC1513 Host name of the printer. Default setting: „Device name“ + the last 3 figures of the MAC adress WEB server Settings...
  • Page 152 XLP 504 / XLP 506 Service manual • On: Switches the web server on. • Off: Switches the web server off. WEB display refr (Web server display refresh) Setting range Default setting Step width Easy Plug [0...20] s #PC1510 ...
  • Page 153 XLP 504 / XLP 506 Service manual FTP server Settings Default setting Step width Easy Plug On, Off #PC1507 The File Transfer Protocol (FTP) server (RFC959) allows access to the internal RAM disk of the printer and, if available, to the memory card. The FTP server is capable of multisession mode, without evaluating the user name when logging in.
  • Page 154 XLP 504 / XLP 506 Service manual Sync. interval Setting range Default setting Step width Easy Plug [0...9999] s 3600 s  Parameter only appears in service mode.  Only appears if Print interface > Network > Services > Time client = „On“.
  • Page 155 XLP 504 / XLP 506 Service manual • Always zero: Check bit is always 0 (zero). Sending and receiving without parity check. Stop bits Settings Default setting Step width Easy Plug [1..2] #PC1204 #PC1355 Print interface > Serial Port 1 > Baud rate Print interface >...
  • Page 156 XLP 504 / XLP 506 Service manual Frame error Settings Default setting Step width Easy Plug #PC1207 Display, Ignore Display #PC1358 Print interface > Serial Port 1 > Baud rate Print interface > Serial Port 3 > Baud rate (only with I/O board) •...
  • Page 157 XLP 504 / XLP 506 Service manual Gen.Support Data (Generate support data) Generates the folder „SupportData“ on the selected memory medium and stores the following dia- gnosis files therein: • Setup.for (for details see Tools > Diagnostic > Store Parameters) Tools >...
  • Page 158 XLP 504 / XLP 506 Service manual EasyPlug Monitor Settings Default setting Step width Easy Plug Off, Serial Com1 #PC5113  Parameter only appears in service mode. The parameter activates the logging of received Easy Plug data. Data is transmitted to the serial interface (Com1).
  • Page 159 XLP 504 / XLP 506 Service manual Service done Settings Default setting Step width Easy Plug No, Yes  Parameter only appears in service mode. Increases the counter level of the "Service operations" counter on the "Service Status" printout by See parameter Service Status ...
  • Page 160 XLP 504 / XLP 506 Service manual Sets all counters on the info printout „Service Status“ to zero. See also parameter Service Status  on page 169. Sensor Adjust  Parameter only appears in service mode. For detailed instructions sensor adjustment, please refer to chapter Sensor settings ...
  • Page 161 XLP 504 / XLP 506 Service manual Punch y calibr. Setting range Default setting Step width Easy Plug [-3.0...3.0] mm 0.0 mm 0.1 mm #PC5104  Parameter only appears in service mode. Compensating the variation of distance between punch sensor and thermal bar of the print head.
  • Page 162 XLP 504 / XLP 506 Service manual Printer Status A protocol can be printed to get an overview of customer-specific parameter settings [148]. A material width of 100 mm is necessary to print the reports. The status print-out is approx. 200 mm long.
  • Page 163 XLP 504 / XLP 506 Service manual Memory Status Prints an overview over: • Internal Memory Configuration [149A] • Files that are stored on the internal memory (RAM disc) [149B] • Files that are stored on an external memory medium [149C] (if any) ...
  • Page 164 XLP 504 / XLP 506 Service manual Font Status Print samples of all installed characters, bar codes and line samples (several pages): • Page „Font / Line Library“ shows a list of the internal fonts [150] and line styles [151].
  • Page 165 XLP 504 / XLP 506 Service manual Internal Line Styles: Use the line style number (fist column [151]) with one of the Easy Plug commands #YL or #YR  to print lines in the matching style. Easy Plug commands: Refer to the Easy Plug Manual, topic section “Command description“.
  • Page 166 XLP 504 / XLP 506 Service manual Internal bar codes: The pages titled „Barcode Library“ show print samples of the internal bar codes [152], [153]. [152]Print sample „Font Status“, section „Barcode Library“. • Onedimensional bar codes are printed with the Easy Plug command #YB, see manual Easy Plug, topic section „Command description“.
  • Page 167 XLP 504 / XLP 506 Service manual [153]Print sample „Font Status“, section „Barcode Library“: Listing of RSS-Codes and 2-dim. bar codes. 05/2018 | 09 Parameter Menu...
  • Page 168 XLP 504 / XLP 506 Service manual Flashdata Status Prints a list of all fonts stored in the flash memory. This can be e. g. customized fonts or diagnostic data. For detailed information about diagnosis data refer to chapter Reading out diagnostic data ...
  • Page 169 XLP 504 / XLP 506 Service manual Service Status Print the Service status report to read about operation time, no. of services, no. of exchanged parts and other matters of service interest (one page). Tools > Service > Serv. data...
  • Page 170 XLP 504 / XLP 506 Service manual Reference label Prints a label with some examples of barcodes, fonts, logos. The table at the bottom end of the label contains the settings or print contrast and print speed, with which the label was printed. The empty fields can be filled with the applied print head pressure and the applied ribbon and label material (for purpose of comparison).
  • Page 171 XLP 504 / XLP 506 Service manual Textile Care Sym Prints the content of the internal care symbol fonts: [157]Content of the internal care symbol fonts 200 and 202. Head run length No setting option - Only display Easy Plug #!PG30018 Shows the total "covered distance"...
  • Page 172 XLP 504 / XLP 506 Service manual Cuts on knife No setting option - Only display Easy Plug #!PG30020  Only with mounted and activated cutter. Shows the number of cuts done by one knife. The counter is reset with each calling of the parameter Tools >...
  • Page 173 XLP 504 / XLP 506 Service manual Tot. mat. length No setting option - Only display Easy Plug #!PG30021 Shows the total "covered distance" of the feed roller. Other than the counter Roll run length, this coun- ter is not reset after a roller exchange.
  • Page 174 No setting option - Only display Easy Plug #!PG30057  „XLP 504 peripheral with internal rewinder“ only. Shows the applied PIC version on the internal rewinder motor output stage board. RAM memory size No setting option - Only display Easy Plug #!PG30007 Shows the available RAM memory size.
  • Page 175 XLP 504 / XLP 506 Service manual Flash mem size No setting option - Only display Easy Plug #!PG30008 Shows the available Flash memory size. The abbreviation which is displayed behind the memory size indicates the manufacturer of the applied Flash-RAM.
  • Page 176 XLP 504 / XLP 506 Service manual Custom defaults No setting option - Only display Easy Plug #!PG30013 There are customer specific parameter settings available that can be used for factory reset purpo- System > Factory settings. se. See parameter...
  • Page 177 XLP 504 / XLP 506 Service manual PCB part number No setting option - Only display Easy Plug #!PG30042 Shows the part number of the board without components. Board part numb. No setting option - Only display Easy Plug #!PG30043 Shows the part number of the board with components.
  • Page 178 XLP 504 / XLP 506 Service manual Foil diameter No setting option - Only display Easy Plug #!PG30026 Shows the calculated foil diameter: A measurement routine calculates the actual ribbon roll diame- ter with an exactness of 7.5%. The parameter System >...
  • Page 179 XLP 504 / XLP 506 Service manual Malfunctions STATUS REPORTS General information about status reports Display of status reports During operation, tests are continually carried out to determine whether a malfunction has oc- curred. If a malfunction is detected, the corresponding status report appears on the display.
  • Page 180 XLP 504 / XLP 506 Service manual Locking error messages are messages that are caused by serious errors. This state can be can- celled by a restart (press the keys 1+2+3) or by switching the printer off. General software errors Errors in the firmware can never be completely ruled out.
  • Page 181 XLP 504 / XLP 506 Service manual Reference of status reports 1000 No new command General software error, read chapter General software errors  on page 180. 1001 Parameter table General software error, read chapter General software errors  on page 180.
  • Page 182 XLP 504 / XLP 506 Service manual 1013 Comm. flag inc. General software error, read chapter General software errors  on page 180. 1014 Uninit integer General software error, read chapter General software errors  on page 180. 1015 Uninit float General software error, read chapter General software errors ...
  • Page 183 XLP 504 / XLP 506 Service manual 1029 Param. incorr. Incorrect parameter in the Easy Plug command. Check Easy Plug sequence.   Please read the notes in chapter Easy Plug errors  on page 180. 1030 Command incorr. Error during the command interpretation.
  • Page 184 XLP 504 / XLP 506 Service manual 1091 Wrong var field An error occured while interpreting the text string of a variable data field. The error could e.g. be caused by a #YT or a #YB command (Easy Plug). Self-acknowledging error.
  • Page 185 XLP 504 / XLP 506 Service manual  Check the Easy Plug command on admissible values and correct them if necessary.  Please read the notes in chapter Easy Plug errors  on page 180. 1115 > than Boundary A sent Easy Plug command contains a value which exceeds the admissible range at the top limit.
  • Page 186 XLP 504 / XLP 506 Service manual 1130 Float overflow Number of figures is too high for a floating comma variable. Reduce the number of figures.  1131 Logo cache full A logo or several logos was/were sent which is/are too huge for the logo buffer.
  • Page 187 XLP 504 / XLP 506 Service manual  Check value for Y position for signs.  Please read the notes in chapter Easy Plug errors  on page 180. 1174 Max width: right Maximum label width, right, reached. Elements such as character, line or logo do not fit into the physical print format (self-acknowledging) Result: Only elements which completely fit into the print format are printed.
  • Page 188 XLP 504 / XLP 506 Service manual  Please read the notes in chapter Unspecific errors  on page 180. 1242 New FE in job Faulty memory assignment for print jobs.  Please read the notes in chapter Unspecific errors ...
  • Page 189 XLP 504 / XLP 506 Service manual 1277 Wrong #!S.. Faulty Easy Plug code. Faulty use of the immediate command "#!S..". The specified parameter val- ue exceeds the admissible value range (P, R).  Specify an admissible parameter value. ...
  • Page 190 XLP 504 / XLP 506 Service manual  Please read the notes in chapter Easy Plug errors  on page 180. 1321 Bar Code Object Faulty Easy Plug code regarding the declaration of a bar code.  Please read the notes in chapter Easy Plug errors ...
  • Page 191 XLP 504 / XLP 506 Service manual 1333 Logo not there Selected logo does not exist. Check file name / existence of the logo.  1334 #YV Data incorr. Illegal entries for a #YV field (variables data field).  Acknowledge by pressing key 4.
  • Page 192 XLP 504 / XLP 506 Service manual Refer to chapter „Technical specifications“ for the maximum label width. Reduce the label width set by the #IM-command in the concerned print job, until the label width  matches the maximum print width.
  • Page 193 XLP 504 / XLP 506 Service manual 1502 ZPL comand tab. Error level1 General software error, read chapter General software errors  on page 180. 1503 Filename Too Long Error level1 Filename is too long.  Rename the file with a shorter name.
  • Page 194 XLP 504 / XLP 506 Service manual 1511 Bar Parm Error Error level1 Parameters to a barcode command is wrong or does not conform with specs.  Modify the bar code command. 1512 Code128 Mode Err Error level1 Code128 barcode command specifying mode type other than 'AUTO'.
  • Page 195 XLP 504 / XLP 506 Service manual 1520 Unsupported Cmd Error level1 Non critical commands that is not supported by this printer.  Check and modify the commands in the printjob. 1521 Unsupported: x Error level2 Critical commands that is not supported by this printer.
  • Page 196 XLP 504 / XLP 506 Service manual 1530 Inc free str mem Error level2 Not enough free store memory. System > Memory > Free store size  Increase the value set in (at least 2048 Kbytes). 1531 Inc RAM disc Error level2 Not enough RAM disc.
  • Page 197 XLP 504 / XLP 506 Service manual 2004 Exp. quotemark The number of quotemarks in the expression is not a multiple of two. Check the quotemarks in the expression and correct their number.  2005 Exp. comma pos. Unexpected comma in the expression.
  • Page 198 XLP 504 / XLP 506 Service manual 3002/3005/3008/3015/3017 Com x Frame Receive error at the RS232 interface COMx (x = [1…5]). Acknowledge by pressing key 4.   Check parameter setting at printer and host. 3010 Spooler Overflow Fault which is caused by a faulty handshake at an interface. The consequence is an overflowing data buffer at the printer, because the host doesn´t stop to send data to the printer.
  • Page 199 XLP 504 / XLP 506 Service manual One of the following status messages may follow second: Status Missing output stage for the following device: 5005 Knife-fault Cutter motor 5006 Head-fault Print head liftmotor 5008 Ribbon end Ribbon motor [Tab. 36] Those status messages indicate, that the device is not connected to the I2C bus.
  • Page 200 Close the cover or print head lever respectively. 5004 Rewinder mat. tear Label material at the backing paper rewinder is torn off. (XLP 504 with rewinder) The backing paper sleeve was too large during material initialization; the backing paper web could not be tightened. ...
  • Page 201 XLP 504 / XLP 506 Service manual 5025 I2C Polling xx Polling error during communication via the I2C bus with the device xx (see tab. 38). Switch printer off and then back on again after 30 sec. If the error message continues to appear, ...
  • Page 202 XLP 504 / XLP 506 Service manual 5064 Rewinder full Happens with dispenser version printers: Shows up, when the diameter of the rewinded backing paper roll has become too large.  Clear the rewinding mandrel.  Press key 4 to acknowledge.
  • Page 203 (because it´s backward compatible). 5300 BLDC EEPROM err. General EEPROM read/write error on the BLDC driver board (XLP 504 with internal rewinder).  Switch printer off and than on again after 30 seconds. If the status message continues to appear, change the BLDC board.
  • Page 204 XLP 504 / XLP 506 Service manual  If there are already some printjobs in the printer queue: wait until those are processed. 6000 Param. incorrect Novram check sum error. System >Hardware Setup > Head resistance)  Check the setting of the print head resistance (parameter , before you press key 4 –...
  • Page 205 XLP 504 / XLP 506 Service manual 6010 Printengine soft General software error, read chapter General software errors  on page 180. 6030 Param. checksum Wrong parameter checksum.  None. The message is merely informativ. 6031 New Parameters By loading a new firmware version, some new parameters have been added to the parameter menu.
  • Page 206 XLP 504 / XLP 506 Service manual  Acknowledge by pressing key 4.  Check, if a memory card is inserted. If the memory card was inserted after switching on the printer: switch the printer off and on again. ...
  • Page 207 XLP 504 / XLP 506 Service manual 8106 Fonttype wrong General software error, read chapter General software errors  on page 180. 8107 Character set General software error, read chapter General software errors  on page 180. 8108 Symbol set General software error, read chapter General software errors ...
  • Page 208 XLP 504 / XLP 506 Service manual 8302 Barcode checksum Error during calculation of the bar code check sum. Check transmitted data.   If the error continues to occur please contact the manufacturer. Send the transmitted Easy Plug data.
  • Page 209 XLP 504 / XLP 506 Service manual 8401 PDF417 Lines Bar code PDF417: illegal number of lines. Alter number of lines.  8402 PDF417 Columns Bar code PDF417: illegal number of columns.  Alter number of columns. 8403 PDF417 Style Bar code PDF417: incorrect style.
  • Page 210 XLP 504 / XLP 506 Service manual 8760 EAN128 field len The number of data after a data identifier does not correspond to the definition for this data identi- fier.  Change the number of data. 8761 EAN128 Data type The data type (alphanumeric, numeric) after a data identifier does not correspond to the definition for this data identifier.
  • Page 211 XLP 504 / XLP 506 Service manual  Transform the graphics file into another file format or use another graphic in a supported format. Check, if the spelling of the file extention is correct. 8851 Graphic open The graphics file declared in the Easy Plug #YG command cannot be found on the compactflash card.
  • Page 212 XLP 504 / XLP 506 Service manual 8900 Codablock columns Bar code Codablock: illegal number of columns. Correct number of columns.  8901 Codablock rows Bar code Codablock: illegal number of rows.  Correct number of rows. 8902 Codablock softw.
  • Page 213 XLP 504 / XLP 506 Service manual In this case, the network will not be initialised. To enable work with the network, a valid MAC ad- dress must be programmed on the board. This can only be done by an authorized service techni- cian or by the manufacturer.
  • Page 214 XLP 504 / XLP 506 Service manual  Replace the print head 9014 Motor voltage Faulty 45 V motor supply voltage. A possible cause is a short circuit, that is the print head is defec- tive. • Print head was connected to the wrong connector on the CPU board.
  • Page 215 XLP 504 / XLP 506 Service manual • Displayed information about the error source • Label layout, logfiles, etc. as described in chapter Unspecific errors  on page 180 9024 Not possible ! Detecting the material length (a function, which is normally used with MLI) is not possible, because a printjob is currently processed.
  • Page 216 XLP 504 / XLP 506 Service manual • invalid record type  Switch printer off and on again. Check the download data. 9101 Invalid Header Occurs during a download. The sent files have a format error in the header. ...
  • Page 217 XLP 504 / XLP 506 Service manual The status message is cancelled automatically. The download continues. 9113 RFID Update Fail. Occurs during a firmware update of a RFID module, if the update failed.  Switch printer off and on again.
  • Page 218 XLP 504 / XLP 506 Service manual • System > Memory > Font downl. area System > Memory > Free store size • 05/2018 | 04 Malfunctions...
  • Page 219 XLP 504 / XLP 506 Service manual FAULT LOCATION Notes about fault location Status reports should be printed to check the mechanical and electronic function capabilities – pro- vided that no obvious no defectives are evident. Data transmission Problem Possible cause...
  • Page 220 XLP 504 / XLP 506 Service manual Problem Possible cause Solution Print position shifted in Gap position not recognised Correct photoelectric switch zero line using or against print consistently due to gap parameter Print > Material > Punch offset direction contour [Tab.
  • Page 221 XLP 504 / XLP 506 Service manual Problem Possible cause Solution Printing directly on roller Use sufficient wide material/foil High running performance Replace roller Check print contrast setting (press Prog. button in Deformation Power setting too high for print Print > Print...
  • Page 222 XLP 504 / XLP 506 Service manual Problem Possible cause Solution Check setting print contrast (press Prog. button in Print > Print contrast) and if Print head setting too low on-line mode or parameter nec. correct. Ribbon inserted incorrectly Check and if necessary correct...
  • Page 223 XLP 504 / XLP 506 Service manual READING OUT DIAGNOSTIC 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 communication can be captured and analysed (comparable to the black box in an airplane).
  • Page 224 XLP 504 / XLP 506 Service manual Reading out via serial interface Prerequisites Terminal program, e. g. „Hyperterminal“ (is delivered with Windows operating systems). Procedure 1. Connect the printing device to a PC, using the serial interface. Set the transfer parameters to 115 kB, n, 8, 1 (default setting).
  • Page 225 Generating further record files:  Close Hyperterminal and start new. [163] Read out data.  Send the generated files with a descriptioin of the circumstances in which the error occured per email to the technical support at NOVEXX Solutions. 05/2018 | 00 Malfunctions...
  • Page 226 The diagnostic data is stored in folder \SupportData under the file name: Diagnose XLP 504 300 Dpi A100149091300004.log with: – XLP 504 300 Dpi: Printer type and print head resolution – A100149091300004: Serial number of the CPU board; equals the string in Info >...
  • Page 227 XLP 504 / XLP 506 Service manual Firmware NOTES ABOUT FIRMWARE Please note CAUTION! Executing or applying the update procedure incorrectly can set the device into a critical condition, which can only be rectified by trained technicians.  Firmware should therefore only be updated by experienced operators or service technicians.
  • Page 228 XLP 504 / XLP 506 Service manual UPDATING FIRMWARE Notes about the update procedure There are two methods of loading the firmware into the printer: • From an external memory medium (recommended method); Advantages: fast, secure, inde- pendent of the operating system of the host computer See chapter Update from a memory medium ...
  • Page 229 XLP 504 / XLP 506 Service manual Update via data interface Prerequisites: • The data interfaces of host computer and printer must be connected with a suitable data cable • The data interface must be set accordingly in the printer's parameter menu •...
  • Page 230 XLP 504 / XLP 506 Service manual [164] Entering a share name under Windows 7. Forced bootloader start Application notes If the message below shows up on the printer display immediately after the printer has been switched on, no valid or no firmware is available. In this case the firmware must be reloaded using the bootloader.
  • Page 231 XLP 504 / XLP 506 Service manual Appendix SETUP FILE FOR XLP 504 #!A1 #G Machine Setup for XLP 504 300 Dpi Version: V7.75 #G Serial number A100149091300004 #G MAC Address 00.0A.44.07.17.E5 #G Creation date 14.05.2018 13:10 #G----------------------------------------------------------------------------- #G Print...
  • Page 232 XLP 504 / XLP 506 Service manual #G----------------------------------------------------------------------------- #G Options ► I/O Board #G----------------------------------------------------------------------------- #PC3203/0 Start print mode : Pulse falling #PC3204/0 Reprint signal : Off #PC3205/0 Feed input : Off #PC3206/0 Pause input : Off #PC3207/0 Error output : Printer error...
  • Page 233 XLP 504 / XLP 506 Service manual #G----------------------------------------------------------------------------- #G Options ► TCS #G----------------------------------------------------------------------------- #PC3301/0 Changelabel Mode : Easyplug select #PC3303/10 Changelab Length : + 10 mm #PC3302/1 Changelab Print : With print #PC3304/0 Label Eject Mode : No #G----------------------------------------------------------------------------- #G Options ► LTSA...
  • Page 234 XLP 504 / XLP 506 Service manual #G----------------------------------------------------------------------------- #G Printer Language ► ZPL Setting #G----------------------------------------------------------------------------- #PC4002/15 Darkness : 15 #PC4006/0 Label Top : 0 Dots #PC4007/3 Left Position : 3 Dots #PC4010/0 Error Indication : OFF #PC4011/0 Error Checking : YES...
  • Page 235 XLP 504 / XLP 506 Service manual #PC1306/0 Data synch. : RTS/CTS #PC1307/0 Serial port mode : RS232 #PC1308/1 Frame error : Display #G----------------------------------------------------------------------------- #G Interface ► Serial Port 3 #G----------------------------------------------------------------------------- #PC1351/2 Baud rate : 9600 Baud #PC1353/8 No. of data bits : 8...
  • Page 236 XLP 504 / XLP 506 Service manual #G----------------------------------------------------------------------------- #G Info ► Status Printouts #G----------------------------------------------------------------------------- #G----------------------------------------------------------------------------- #G Info ► Statistics #G----------------------------------------------------------------------------- #G readonly ID=30018 Head run length : 1714 m #G readonly ID=30019 Roll run length : 1770 m #G readonly ID=30014 Serv.
  • Page 237 XLP 504 / XLP 506 Service manual #G----------------------------------------------------------------------------- #G Debug #G----------------------------------------------------------------------------- #PC5127/0 Debug interface : Off #PC5128/-1872945986 Debug IP address : 144.093.028.190 #PC5124/0 Debug mask #PC5404/0 Fields : Off #PC5400/0 Label generation : Off #PC5401/0 Print handling : Off #PC5402/0...
  • Page 238 XLP 504 / XLP 506 Service manual WIRING DIAGRAMS See next pages. 05/2018 | 06 Appendix...
  • Page 239 Closing lever sensor Reflex unten / Reflective bottom Netzteil Power supply A3958 A3958 E/A-Platine I/O board A3926 Druckkopf A4031 (8-Dot), A4431 (12-Dot) Printhead Optionales Bauteil oder Kabel Optional element or cable [165] Wiring of XLP 504 basic. 05/2018 | 06 Appendix...
  • Page 240 600 dpi Druckkopf / 600 dpi print head power switch board A5639 E/A-Platine I/O board A3926 Druckkopf A4031 (8-Dot), A4431 (12-Dot) Printhead Optionales Bauteil oder Kabel Optional element or cable [166] Wiring of XLP 504 basic 600 dpi. 05/2018 | 06 Appendix...
  • Page 241 XLP 504 / XLP 506 Service manual XLP 50x basic dispenser A3958 Vorschub- motor A3970 Drive motor A1005 POWER CPU-Platine A3958 A4202 CPU board A100150 A3971 A100433 Bedienfeld Operating panel N100468 A100529 Durchlicht / Transmissive A100529 Folienende-LS Ribbon end sensor A100529 Schließhebel-LS...
  • Page 242 Output stage for periph. device SENSOR 1 MOTOR Sub-D-Kabelbaum D-Sub cable harness A3958 A100341 E/A-Platine I/O board A3926 Druckkopf A4031 (8-Dot), A4431 (12-Dot) Printhead Optionales Bauteil oder Kabel Optional element or cable [168] Wiring of XLP 504 peripheral. 05/2018 | 06 Appendix...
  • Page 243 600 dpi print head power switch board Sub-D-Kabelbaum D-Sub cable harness A100341 A5639 E/A-Platine I/O board A3926 Druckkopf A4031 (8-Dot), A4431 (12-Dot) Printhead Optionales Bauteil oder Kabel Optional element or cable [169] Wiring of XLP 504 peripheral 600 dpi. 05/2018 | 06 Appendix...
  • Page 244 XLP 504 / XLP 506 Service manual XLP 50x peripheral dispenser A4958 I orspm uK- c otor A4917 DriBe c otor A0775 z OX ES W z R-z g . tine A2373 A4958 W z R Ko. rd A077057 A4910...
  • Page 245 XLP 504 / XLP 506 Service manual INSTALLING A GENERIC PRINTER UNDER WINDOWS 7 A firmware update via data line requires a „Generic printer“ to be installed on the host computer running under Windows 7. Follow this installation instruction: 1. Click START > DEVICES AND PRINTERS > ADD PRINTER.
  • Page 246 XLP 504 / XLP 506 Service manual 5. Under „Device Type“ choose STANDARD and GENERIC NETWORK CARD [173]. Click NEXT. [173] Entering information about the device type. 6. Enter GENERIC as manufacturer and GENERIC/TEXT ONLY as printer [174]. Click NEXT.
  • Page 247 XLP 504 / XLP 506 Service manual 7. Enter a printer name [175]. Click NEXT. [175] Enter a name for the printer. 8. Enter a share name [176]. Click NEXT.  The Share name must match MS-DOS conventions (max. 8 characters length, no special characters or spaces) [176] Defining a share name.
  • Page 248 Novexx Solutions GmbH Ohmstraße 3 85386 Eching Germany  +49-8165-925-0 www.novexx.com...

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