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AP 4.4 – AP 5.4 – AP 5.6 – AP 7.t – 64-xx Gen. 3 – DPM Gen. 3 – ALX 92x Gen. 3 – PEM – PM 3000
Firmware
About Firmware ............................................. 2
Please note ............................................... 2
System Requirements ............................... 2
Current firmware versions ......................... 3
Loaded firmware version ........................... 4
Download source ...................................... 5
Updating firmware .........................................7
Notes about the update procedure ............7
Loading from a CompactFlash card ...........7
Loading via data interface ..........................9
Forced bootloader start ............................11
Error messages .......................................12
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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 tech-
nicians.
« Firmware should therefore only be updated by experienced operators or
service technicians.
« Update firmware only, if
• a newly provided function is badly needed
• the printer doesn´t work properly
« Never switch off the printer during a firmware update.

System Requirements
This description of firmware update is valid for the printer types:
• AP 4.4/5.4/5.6
• AP 7.t
• 64-xx Gen. 3
• ALX 92x Gen. 3
• DPM Gen. 3
• PEM
• PM 3000
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Current firmware versions

By means of the following table, the currently valid firmware version for each
printer can be detected. The „Comment“ column helps to find the right printer
type.

CAUTION! - There is a risk of the Flash memory on the CPU board being pro-
grammed faulty. If this a) happens, the board can only be repaired in the fac-
tory.
« Install at least firmware version 3.12, if the printer is a RoHS-conform
AP 4.4, AP 5.4 or AP 7.t.
a) Exact: If the forced bootloader start doesn´t work , see chapter Forced bootloader start  on page 11.

Oldest Current
Printer Feature
firmware firmware
Until appr. 08/2006
AP 4.4 CPU board: A4252 to index -03 1.02 2.34
2 MB ROM, 8 MB RAM
Since appr. 09/2006
AP 4.4 RoHS CPU board: A4252 from index -04 3.12 3.33-SR1
4 MB ROM, 16 MB RAM
Red housing
AP 5.4 Until appr. 08/2006 1.02 3.33-SR1
CPU board: A3927 up to index -03
Red housing
AP 5.4 RoHS Since appr. 09/2006 3.12 3.33-SR1
CPU board: A3927 from index -04
Gray housing
AP 5.4 MLK 7.33 7.33
CPU board: A100150 from index -00
AP 5.6 CPU board: A100150 from index -00 7.33 7.33
Until appr. 08/2006
AP 7.t 2.34 3.33-SR1
CPU board: A3927 up to index -03
Since appr. 09/2006
AP 7.t RoHS 3.12 3.33-SR1
CPU board: A3927 from index -04
64-xx Gen. 3 Since appr. 01/2007
ALX 92x G. 3 CPU board: A6621 up to index -04
5.03 5.33-SR1
DPM Gen. 3 Starting with serial number
PEM 0695980701
[Tab. 1] Overview firmware versions.
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Oldest Current
Printer Feature
firmware firmware
64-xx Gen. 3 Since appr. 11/2009
ALX 92x G. 3 CPU board: A6621 from index -05
6.33 6.33
DPM Gen. 3 Starting with serial number
PEM Gen. 3 0825660911
Since appr. 04/2007
CPU board: A6621
PM 3000 5.03 5.33-SR1
Starting with serial number
0705200704
[Tab. 1] Overview firmware versions.

Loaded firmware version

There are three ways to find out, which firmware version is actually loaded into
the printer:

Display after After switching on the printer, the installed firmware version is displayed for a
switching-on few seconds:
Example: AP 5.4, firmware version x.xx:
AP 5.4
Vx.xx

Parameter menu Showing the firmware version: call SERVICE DATA > MODULE FW VERS. >
System version
System version
Vx.xx

Status printout The first line of the info-printout „Printer status“ shows the version number of
the installed firmware [1].
« For printing call PRINT INFO > Printer status.

[1] Firmware version (A) on the „Printer status“ printout.

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Download source
Firmware download Both, current and older firmware files are provided on the Avery Dennison web
site for download.
Procedure:
1. Click on www.monarch.averydennison.com  to get onto the web site of
the Avery Dennison Printer Systems Division.
¯ Alternatively, enter the web address into a browser and click on
Products > Links > Downloads.
2. In section „Firmware“, select the appropriate printer type from the pull-
down list.
A window showing a list of the current firmware versions opens.
3. Click on the desired firmware version.
4. Follow the download instructions.

Firmware packages for New firmware comes as a ZIP file, which carries one of the following names,
printers according to its purpose (x.xx = firmware version):
File Description
• Contains the complete firmware for the printers: 64-xx/
ALX 92x/DPM (each Gen. 3) as well as PEM/PM 3000
64HP_Vx.xx.zip
• Does not comprise subsystem firmware, e. g. motor
output stage, operation panel, USI, AI
• Contains the complete firmware for the printers:
AP 4.4 RoHS/AP 5.4/AP 5.4 black/AP 5.6/AP 7.t
32_Vx.xx.zip
• Does not comprise firmware for the subsystem „output
stage board BLDC-motor“
[Tab. 2] Overview printer firmware packages.

The ZIP files contain the following files (example file: 64HP_Vx.xx.zip)
File Description
64HP_Vx.xx.s3b Firmware file
Start this batch file in the windows command line („DOS
SYSTEM.bat prompt“). The file contains the command
copy 64HP_Vx.xx.s3b lpt1 /b
Download wizard for update by data interface, see Loa-
download.exe
ding via data interface  on page 9
readme.txt File containing a short instruction for firmware updates
[Tab. 3] Files contained in the firmware package.
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Firmware packages for Besides the printer firmware, in some cases the firmware for subsystems has
subsystems also to be updated. This can e. g. be firmware for:
• USI interface
• Applicator interface (AI)
• Motor output stages
File Description
• Firmware for the USI interface
• Can be updated the same way as printer firmware, if
USI_Vx.zip the printer firmware version is at least 5.31.
• See topic section Service Electronics , chapter
„USI board“
• Firmware for the Applicator Interface (AI).
• Can be updated the same way as printer firmware, if
AI_Vx.xx.zip the printer firmware version is at least 5.31.
• ALX 92x: see topic section Applicator Interface ,
chapter „System requirements“.
• Firmware for BLDC motor output stage.
BLDCAP54Vx.zip • See topic section Service Electronics , chapter
„Output stage board BLDC motor“.
[Tab. 4] Overview firmware packages for subsystems.

The ZIP files contain the following files (example file: USI_Vx.xx.zip)
File Description
USI_Vx.xx.s3b Firmware file
Start this batch file in the windows command line („DOS
SYSTEM.bat prompt“). The file contains the command
copy USI_Vx.xx.s3b lpt1 /b
[Tab. 5] Files contained in the firmware packages for subsystems.

¯ Only update subsystem firmware after the update of the printer firmware!
Example:
After updating the firmware of an ALX 92x, it may happen, that the firmware of
the built-in applicator interface (AI) is too old. Then, the following message ap-
pears:
Status 5212
Vx.x für AI rec

(Vx.x for AI required)

« Update firmware for AI.
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Updating firmware

Notes about the update procedure

There are two methods of loading the firmware into the printer:
• From a memory card (recommended method); Advantages: fast, secure,
independent from the operatin system
See chapter Loading from a CompactFlash card  on page 7.
• Using a data interface (serial or parallel) by aid of the Download Wizard.
See chapter Loading via data interface  on page 9.

Loading from a CompactFlash card

In standalone mode 1. If not already done, create a folder „\FORMATS“ on the memory card.
2. Copy the firmware file (e. g. 32_Vx.xx.s3b) into folder „\FORMATS“.
3. Switch the printer off.
4. Insert the memory card into the card slot at the printer.
5. Switch the printer on. In Online mode, press the buttons Online+Esc to get
into standalone mode.
6. Select the file „32_Vx.xx.s3b“.
7. Confirm the yes/no query.
8. The firmware is now loaded automatically. The following is displayed:
Programmdownload
xxx: kilobytes loaded
Kbytes: xxx

This message appears if the data was transferred correctly:

Switch off
Remove card

During the first system start after loading the new firmware, the following mes-
sage appears:
Param. Recovered

Afterwards follows an automatic reset.

To load firmware for subsystems, use the appropriate *.s3b file, see chapter
Firmware packages for subsystems  on page 6.
Further information about standalone mode can be found in the user manual,
topic section Advanced applications , chapter „Standalone mode“.
Detailed information on using memory cards can be found in the Plug-in Card
Manual .
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Starting the update 1. Copy the file „32_Vx.xx.s3b“ into the root directory on a memory card..
automatically
2. Rename „32_Vx.xx.s3b“ to „AUTOSTRT.for“.
3. Switch the printer off.
4. Insert the memory card into the card slot at the printer.
5. Switch the printer on. The firmware is now loaded automatically.
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Loading via data interface

General notes The firmware update via data interface is done by means of the utility program
„Download Wizard“, which must be installed on the PC in advance.

System requirements PC
• Operating System: Windows 95/98/ME/NT/2000/XP/Vista.
• The PC must be equipped with a serial or parallel interface.
Printer types
All types listed in the header line of this document.
Installation file
• „SetupFirmwareDownload.exe“, see Documentation-CD, folder „\Utilities“
• „Download.exe“ is contained in the printer firmware packages
Installation 1. Start the setup program („SetupFirmwareDownload.exe“).
A window opens [2].

[2] Click „yes“.

2. Click „yes“.
A file selection window opens [3].

[3] Select an installation folder.

3. Select an installation folder and click „Continue“.

The download wizard will now be installed.
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Starting the program The setup program places an icon on the Windows desktop [4].

[4] Click on this icon to start the program.

1. Click on the icon to start the program.

The program window opens [5].
2. Click on „Choose Dir“ [5A].
A file selection window appears.
3. Open the folder which contains the firmware files and click on the file „Sys-
tem.bat“. The so marked file appears in the left half of the program window
[5B].

[5] Program window of „FirmwareDownload“ - here you can select the appropriate batch file and start
the download process.

4. Open the list „Communication Device“ to select the interface which should
be used for the download.
¯ The appropriate interface must be selected at the printer (parameter
INTERF. PARAM.> EASYPLUGINTERPR > Interface)!
¯ If a serial interface is supposed to be used, open the menu „File>
Settings> COMx“ to set the transmission parameters. Those have to match
the parameters set in the printer menu.
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5. Click on the batch file („System.bat“) in the left part of the program window
[5].
The command lines contained in the batch file now appear in the right part.
6. Click „Start“ to start the download process.
The printer display shows:
Programmdownload
xxx: bytes loaded
Kbytes: xxx

The following is now displayed:

7. If the download was successful, the printer now switches to offline mode:
OFFLINE 0 JOBS

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.
• Display text at AP 4.4/AP 5.4 rot/AP 7.t (Vx.x = Bootloader version, e. g.
V3.1)
Boot Loader Vx.x
115KB,8N1/Centro.

• Display text at
AP 5.4 black/AP 5.6/PEM/PM 3000 and 64-xx/ALX 92x/
DPM (each Gen. 3) (Vx.x = Bootloader version, e. g. V3.1; yyyyy = internal
CPU board name)
Boot Loader Vx.xx
115KB,8N1/Centro.
Avery Dennison
yyyyy

This condition may be caused, for example, by switching off the printer while
the firmware is being downloaded or due to a similar fault.

Procedure 1. Switch the printer off.

2. Connect printer and PC using the Centronics interface.
Alternatively connect via serial interface (115000 Baud).
3. Switch the printer on while press and hold down the Cut+Prog keys. The
bootloader prompt appears (see display text above).
4. Load the file „32_Vx.xx.s3b“ as described in chapter Loading via data in-
terface  on page 9
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Error messages
Typical error message Firmware damaged or not available, see chapter Forced bootloader start  on
page 11.
Boot Loader Vx.x
115KB,8N1/Centro.

Printer breaks down It may happen, that the printer hangs up directly after switching it on, during
during startup initializing. In such a case it is adviseable to skip the initialization. After doing
so, the printer switches to online mode, where parameter settings can be
changed or firmware can be reloaded:
1. Switch the device off.
2. Switch the device on while holding the buttons Cut 1), Feed and Prog
pressed, until the following is displayed:
PrintStatus: 6007
Print ctrl stop

3. Press the Online-button.

The device switches now into offline mode. From there, parameter settings
can be changed or firmware can be loaded.

1) DPM, PEM, ALX 92x: Instead of „Cut“ press the Apply-button.