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QCOLVCZ4M/Z6M SV Series Interface Cable Kit for Z4M and Z6M

The enclosed kit contains all of the parts necessary to connect a Model Z4M or Z6M (ZxM) printer to an external Hand Held Products SV type scanner/verifier. A mounting stand is also required for the SV unit. Hand Held Products offers two types of mounting stands or the application may require a custom stand. A mounting stand is supplied separately from this kit. Knowledge of the ZxM Printer Menu Operation and Hand Held Products ScanView software for SV Series setup is required for installing the verifier.

System Operation Overview This interface is designed so if the SV unit senses a bar code problem, the printer will stop with a “HEAD OPEN” error. In this condition, SV unit LEDs 1 and/or 2 will be ON (for print quality or no read errors respectively) and the printer will display a HEAD OPEN error. To continue printing, press and release the SV unit RESET button then press and release the printer PAUSE button. System Considerations and Limits Label Material and Label Sensor: This kit interfaces with the ZxM media sensor circuit. There are two media sensors in the ZxM – reflective and transmissive. Most applications use the movable, “default” reflective sensor. Applications involving pre-printed labels or other complex forms on the label surface may require the fixed position “alternate” transmissive sensor. This kit contains a sensor interface cable for both, but both sensor interface cables cannot be used simultaneously. This kit may not be suitable for applications where label material types requiring both sensor types are being alternately used. Label Calibration: This kit interfaces with the ZxM Head Open error logic to pause the printer if the verifier detects an error. This puts a constraint on the system that requires the printer’s HEAD CLOSE menu choice to be set to FEED. It also requires the verifier to be either disconnected or powered down whenever the printer is placed in label calibration mode. Label Length: The recommended label length is .75 in (1.9 cm) to 1.5 in (3.8 cm), depending on the sensor. System Power up: If the SV unit and printer are powered up together, such as from a common power strip, the printer must be set for NO MOTION on the MEDIA POWER UP menu. If the application requires printer motion upon power up, the

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SV unit must be powered up after the printer has completed its power up sequence. Batch vs. On Demand printing: There are special considerations for batch printing vs. on demand printing applications where the printer stops after each label is printed. They are addressed in steps 38 through 40 in the kit installation procedure. Kit List

Qty Description

1 36-inch long verifier interface cable with 15-pin connector on one end and 5-pin connector on the other. Cable includes a verifier power supply.

6 PCBA/Printer interface cables marked 1, 2, 3, 4, 5, and 6 6 Plastic tie wraps. 1 External power supply with power cord. 2 Flat clip clamps. 1 4 inches long by 2 inches wide Velcro with adhesive backing. 2 2 inches long by 1 inches wide Velcro with adhesive backing. 1 Interface PCB assembly (PCBA). 1 Installation instructions.

Caution: Before beginning installation procedure, AC power to the printer must be turned off. It is recommended the power cable be disconnected from the printer.

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Kit Installation Procedure

1. Turn off the power to the printer. 2. Remove the printer left side cover to expose the kit mounting area by removing two screws accessible from the media side of the printer when the media cover is opened. See Figure 1.

Figure 1

Remove two screws to remove side panel

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Figure 2

3. Install two (2) flat clip cable clamps under the top cover in the approximate locations as shown in Figure 2.

Flat Cable Clamps

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4. Remove backing from 4 inch Velcro strip and apply to center of solder side of the Hand Held Products interface PCBA. See Figure 3. 5. Remove backing from both 2 inch Velcro strips and apply to the inside top of the printer enclosure as shown in Figure 3.

Figure 3

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6. Attach the PCBA with J5 and J6 towards the center of the printer as shown in Figure 4. Make sure J5 and J6 are in locations shown because adjustments described later are easier to access and the view of the sync led are best in this orientation. 7. This completes installation of the PCBA assembly. Proceed to the remarks that precede the steps describing connection of interface cables.

Figure 4

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The next set of steps describes installation of the verifier interface cable. This cable incorporates a DB15 connector on one end and a 5-pin header on the other. It is routed between the interface PCB and the verifier through an area behind the front panel of the ZxM. 8. Loosen the front panel of the ZxM by loosening the screw on the inside of the front panel. See Figure 5.

Figure 5

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9. Connect the 5-pin header of the verifier interface cable to J3 of the interface PCBA. See Figure 7. 10. Route the cable behind the front panel as shown in Figure 6. Make sure there to allow enough cable length outside the printer to connect to the SV unit.

Figure 6

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11. Re-install the ZxM front panel. See Figure 7. 12. The cable is now ready to connect to the SV unit after. That step will be included in the SV Unit Setup Procedure.

Figure 7

5-pin header of verifier interface cable

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The next set of steps describes installation of the PCBA interface cables. The cables interface with the printer Head Open logic and appropriate media sensor signal. The cable set includes six cables marked 1 through 6. One end of each cable incorporates a white colored connector to connect to the ZxM motherboard or cable to the motherboard. The other end incorporates a brown colored header that interfaces to the PCBA. Four of the cables will be connected and two will remain spare. The spares will be determined by which media sensor is being used in the application. NOTE: The type of media sensor being used for the application must be known at this time for proper operation. 13. Disconnect the 5-pin header on the ZxM motherboard labeled P4. See Figure 8 for reference.

Figure 8

Example: Disconnected cable from ZxM motherboard

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14. Connect the 5 pin female connector of Cable 3 to the 5-pin connector on the ZxM motherboard. See Figure 9 for reference. 15. Connect the 4-position header on the other end of Cable 3 to J5 on the Hand Held Products interface PCB. See Figure 11.

Figure 9

Example: Cable harness connected to ZxM motherboard

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16. Connect the 5 pin male connector of Cable 4 to the printer cable that was connected to the ZxM motherboard. See Figure 10 for reference. 17. Connect the 4-position header on the other end of Cable 4 to J6 on the Hand Held Products interface PCB. See Figure 11.

Figure 10 At this point, the head open interface cable has been installed. The next set of steps describes how to install the appropriate media sensor interface cables. 18. If the movable “normal” reflective sensor is being used in this application, disconnect the 3-pin header on the ZxM motherboard labeled P6. See Figure 8 for reference. If the “alternate” transmissive media sensor is to be used in this application, go to step 23. 19. Connect the 3 pin female connector of Cable 6 to the 3-pin connector P6 on the ZxM motherboard. See Figure 9 for reference. 20. Connect the 4-position header on the other end of Cable 6 to J1 on the Hand Held Products interface PCB. See Figure 11. 21. Connect the 3 pin male connector of Cable 5 to the printer cable that was connected to the ZxM motherboard P6. See Figure 10 for reference. 22. Connect the 4-position header on the other end of Cable 5 to J2 on the Hand Held Products interface PCBA. See Figure 11.

Example: Cable harness connected to cable that was connected to ZxM motherboard

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23. The reflective sensor interface is now installed. Proceed to the remarks just above step 28. 24. If the fixed position “alternate” transmissive sensor is being used in this application, disconnect, disconnect the 4-pin header on the ZxM motherboard labeled P5. See Figure 8 for reference. 25. Connect the 4 pin female connector of Cable 2 to the 4-pin connector P5 on the ZxM motherboard. See Figure 9 for reference. 26. Connect the 4-position header on the other end of Cable 2 to the Hand Held Products interface PCBA J1. See Figure 11. 27. Connect the 4 pin male connector of Cable 1 to the printer cable that was connected to the ZxM motherboard P5. See Figure 10 for reference. 28. Connect the 4-position header on the other end of Cable 1 to J2 on the Hand Held Products interface PCBA. See Figure 11. The transmissive sensor interface is now installed. The next set of steps will ensure the correct media sensor is being used and the interface PCB is adjusted properly to the sensor. Knowledge of printer menus and available label material used in the application are required. 29. Install labels being used in the application into the printer. 30. Apply power to the printer. 31. If the printer and SV unit will be powered up together, go to the ZxM MEDIA POWER UP menu and set to “NO MOTION.” If printer motion is required on power up, the SV unit must be powered up after the printer completes its power up sequence. 32. Go to the ZxM HEAD CLOSE menu selection. Set it to “FEED.” 33. Go to the ZxM SENSOR SELECT menu and set to “REFLECTIVE” if the sensor interface cable is connected to P6 on the ZxM motherboard. Set to “TRANSMISSIVE” if the interface cable is connected to P5 on the ZxM motherboard. 34. Calibrate the printer to the installed labels. 35. Set all the new printer settings PERMANENT 36. Notice the led labeled D4 on the Hand Held Products interface PCBA. See Figure 11. In these steps it may be more convenient to remove the PCBA from the Velcro mount and hold it by hand. 37. Run some labels through the printer – either by form feed, printing labels or moving manually and verify the led illuminates briefly one time each time a label gap goes through the printer label sensor. 38. If the led does not turn on once per label, adjust the gain potentiometer on the PCBA (near connector J3) until it does. See figure 11.

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Figure 11

At this point, the interface is installed and ready to operate for batch printing. If on-demand printing operation is used in the application, one more adjustment is required to ensure a No read condition is detected at the time the label is printed, rather than the possibly when the next label is printed. If batch printing will be used, proceed to step 41. 39. To adjust for on-demand printing, the timer potentiometer on the interface PCBA must be adjusted. It is located near J5. See Figure 11. 40. Feed the longest label to be used in the application through the printer at the same print speed that will be used. 41. Adjust the timer potentiometer so that the led labeled D4 goes off a short period of time after the label stops. (It does not matter when it turns on.) This will ensure the end of the sync period will occur after the label has gone through the verifier laser beam. 42. Turn off printer power. 43. Re-mount the interface PCBA to the top inside surface of the printer. 44. Tie and route the interface cables neatly so they do not interfere with any moving parts. See Figure 12.

LED D4

Gain Potentiomer

Timer Potentiomer

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Figure 12 45. Re-install the printer side panel. At this point, the interface cable is installed. To complete the system installation, proceed to the SV Unit Setup Procedure.

Interface cables neatly tied

Interface cables not interfering with moving parts

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SV Unit Setup Procedure 1. Install the SV mounting stand. (If it is a Hand Held Products “Sky Hook” it

will be mounted on the left side panel.) 2. Mount the SV unit on the stand at the approximate distance stated on the

label mounted on the side of the SV unit. This is preliminary for power up. Accurate adjustment will be performed a few steps later in this procedure.

3. Connect the verifier interface cable to the SV I/O connector. 4. Connect a communication cable between the SV Comm connector and a

PC running ScanView software. 5. Connect the included power supply to the verifier interface cable and plug

in the power supply to turn on the SV unit. 6. The laser beam is now visible. For best results the beam must be placed in

a location where the bar codes are stable when moving through the beam. For “picket fence” (horizontal) oriented bar codes, the recommended

beam location is on the printer tear bar or at the back of the tear bar on the platen. Make the beam angle as vertical as possible by placing the beam so it just misses the printer top cover before it hits the tear bar or platen.

7. Place a sample bar code in the center of the intended laser beam path. For best results, this sample should match the type of bar code(s) and material that is to be analyzed in the final application. Knowing the X dimension (narrow element width of the bar code(s)) is required for best focus and accurate analyses. Note: SV Calibration symbols have a 10 mil X dimension unless otherwise indicated.

8. Take a Scan Profile with ScanView. 9. Ensure the bar code(s) is in the center of the scan path. 10. Ensure the scan profile contains no distortion from light reflecting from

objects in or near the light path. One major aspect in a good profile is the low reflectance points (the bars) in the symbol are uniform all the way across the code. Optimum signal amplitude should be adjusted so the bar code element reflectances are between the 90% and 10% marks shown in yellow on the screen. Scanner angle has the most effect on the signal amplitude.

11. Continue adjusting the SV unit’s placement until a good scan profile is obtained. The scan angle may have to be altered slightly or a light shield may have to be installed in extreme cases to achieve a good reflectance profile. If adjustment of scan angle does not produce the correct signal amplitude or placement, adjust scanner gain and offset per the Adjusting Scanner Gain and Offset Section in the SV User’s Guide.

12. Place ScanView in Session Mode. 13. Click on the Report an Analysis Speed button. 14. Ensure that “X mils” in the lower panel of the Bar Code Analysis Screen

matches the X dimension of the symbol within +/- .1 mil.

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15. Adjust distance of the SV unit from the bar code until the X dimension matches the desired value. (If X is analyzed as too large, move the scanner farther away; if “X mils” is too small, move the scanner closer.)

16. Repeat steps 11 through 15 until no further mounting adjustments are required.

17. Remove the symbol from the laser beam path. 18. Set the proper SV output mode for this kit – Mode 1 (Command ~LV01). See

the Mode 1 description below. Other modes are also compatible with this kit - contact Hand Held Products Technical Support for Details.

19. Set the proper SV initialization (Command ~PR0210). 20. Set the verifier sync mode to edge (Command ~LX1), polarity rising edge

(Command ~LP1). 21. Set the verifier for the appropriate number of codes per sync interval for

the application via the ~LN## Command. (Example ~LN01 counts for 1 bar code minimum per label.)

22. Program the verifier’s fail parameters as desired. 23. Connect AC power cord to the printer. 24. The verifier and printer are now ready to operate. Figure 13a – Good Reflectance Profile

Figure 13b – Bad Reflectance Profile

Example of a “good” scan reflectance profile: a. Consistent amplitude. b. Amplitude within

yellow lines. c. Amplitude at least 6

lines high.

Bar code signal amplitude out of range: above yellow line and also off the graph.

Bar code low reflectance points not in straight, consistent values.

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Mode 1 Specification A. I/O operation

1. System will operate in Edge Sync or Envelope sync mode (~LX#) 2. Sync polarity programmable (~LP#) 3. Port 1 will go active OFF (no current) on an error condition. 4. Port 2 will go active ON (sink current) on an error condition. 5. Pushing the reset button or power re-cycle will place Ports 1 and 2 in their inactive states and reset

the # codes per sync counter. 6. Error conditions available are:

a. Partial Read (Programmable, ~LQ#, ~Lp#) b. % decode (Programmable, ~LD##) c. Bad Quiet Zone (~PB816xxx100) d. ANSI Defects grade (Programmable, ~PB806xxx000) e. ANSI Decodability grade (Programmable, ~PB802xxx100) f. Symbol Contrast grade (Programmable, ~PB804xxx100) g. No Read (if sync is received) h. Number of codes per sync programmable (~LN##) i. Mandatory symbol modulo check digits

B. LED Operation

1. LED1 will turn on if Outputs 1 and 2 go active due to ANSI, contrast, or quiet zone failure 2. LED2 will turn on if Outputs 1 and 2 go active due to a partial or no read condition

Note; Both LEDs can be on in cases where multiple bar codes are analyzed in a sync period. C. Calibration Procedure

Two procedures are available to calibrate the unit. Procedure 1: a) Remove all bar codes from the laser beam path. b) Place the supplied calibration symbol in the laser beam in the same position (distance and angle) as the

labels to be verified will be scanned. c) Press and hold the RESET button on the SV100 until the Calibration LED begins to flash. d) Release the RESET button immediately after the Calibration LED begins flashing. e) If calibration is successful, the laser beam will go off and the Calibration LED will go off. Remove the

calibration symbol from the beam path, then Press and release the RESET button to turn the beam on. The SV100 is now ready to operate.

f) If calibration is unsuccessful, the Calibration LED will be either on steadily or flashing. In this case, repeat the calibration procedure.

Procedure 2: a) Place the supplied calibration symbol in the laser beam in the same position (distance and angle) as the

labels to be verified will be scanned. b) Send “~SC” into the SV100 serial port. This will cause the Calibration LED to flash. c) If calibration is successful, the laser beam will go off and the Calibration LED will go off. Remove the

calibration symbol from the beam path, then Press and release the RESET button to turn the beam on. The SV100 is now ready to operate.

d) If calibration is unsuccessful, the Calibration LED will be either on steadily or flashing. In this case, repeat the calibration procedure.

SV Commands Important to this System This system is operating in a “mode” rather than fully programmable logic. The port activation parameters are programmable via the ~PB8 rather than ~PB1, ~PB2, etc. for each individual port. Other commands, such as

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mode commands are also available. The commands most useful for this system application are described below. Please see the SV100 Operator’s Guide for additional command description details. ~LV01 This command sets this mode of operation.

~Lp0 This command turns off all partial decode logic at the decoder level.

~Lp1 This command turns on partial decode logic at the decoder level.

~LQ1 This command allows partial decodes to activate the output ports

~LQ0 This command disables partial decodes to activate output ports.

NOTE: In SV firmware versions x238 and lower, ~LQ commands are not implemented and the command ~HQ1 must be used to disable partial decodes from activating ports. In this case the standard data transmission format is modified and ScanView will not display data characters correctly.

~LDxx This command sets the % decode threshold for a passing condition. Partial decodes must be enabled at the decoder level and port level for this command to be used to activate ports. xx = failure threshold. Example ~LD75: if 74 % or less of scans on a code were not fully decoded, this sets a failure for this parameter.

~PB816xxx100 This command sets the minimum percent of scans on a code, which calculate good quiet zones to determine an acceptable quiet zone analysis. The field xxx is the minimum passing threshold. Example: if xxx = 030, a minimum of 30% of all fully decoded scans on a code must calculate a good quiet zone, or a failure condition is set for this parameter.

~PB806xxx000 This command sets the threshold for the ANSI Defects calculation on a code to set a failure condition. The field xxx is the passing threshold for the calculation. For example: if xxx = 025, a Defects analysis of 26% or higher will cause a failure condition for this parameter.

~PB802xxx100 This command sets the threshold for the ANSI Decodability calculation on a code to set a failure condition. The field xxx is the passing threshold for the calculation. For example: if xxx = 037, a Decodability analysis of 36% or lower will cause a failure condition for this parameter.

~PB804xxx100 This command sets the threshold for the ANSI Symbol Contrast calculation on a code to set a failure condition. The field xxx is the passing threshold for the calculation. For example: if xxx = 020, a Symbol Contrast analysis of 19% or lower will cause a failure condition for this parameter.

~LN## This command sets the minimum number of codes to be read during a sync period. ## = the number of codes. For example: ~LN02 causes a No Read condition to be set if less than 2 bar codes are fully decoded during a sync interval.

~Hx This command stores all parameters into non-volatile memory. This command should be the last command sent after parameters are programmed via the above commands.