Carl Valentin DPM III XI User manual

DPM III XI

Service Instructions

Copyright by Carl Valentin GmbH / 79670250209

Information on the scope of delivery, appearance, performance,

dimensions and weight reflect our knowledge at the time of printing.

We reserve the rights to make modifications.

All rights, including those regarding the translation, are reserved.

No part of this document may be reproduced in any form (print,

photocopy or any other method) or edited, copied or distributed

electronically without written permission from Carl Valentin GmbH.

Due to the constant further development of our devices discrepancies

between manual and device can occur.

Please check www.carl-valentin.de for the latest update.

Trademarks

All named brands or trademarks are registered brands or registered

trademarks of their respective owners and may not be separately

labelled. It must not be concluded from the missing labelling that it is

not a registered brand or a registered trademark.

Carl Valentin direct print modules comply with the following safety

guidelines:

CE

EG Low-Voltage Directive (2006/95/EC)

EG Electromagnetic Compatibility Directive (89/336/EEC)

Carl Valentin GmbH

Postfach 3744

78026 Villingen-Schwenningen

Neckarstraße 78 – 86 u. 94

78056 Villingen-Schwenningen

Phone

Fax

+49 7720 9712-0

+49 7720 9712-9901

E-Mail

Internet

info@carl-valentin.de

www.carl-valentin.de

DPM IIIxi 
Table of Contents 
 

Service instructions 

 
Table of Contents 
 
Notes on this Document ....................................................... 5 
1  User Notes ............................................................................... 5 
2  Instructions .............................................................................. 5 
3  Cross References .................................................................... 6 
Safety Instructions ................................................................ 7 
1  General Safety Instructions ..................................................... 7 
2  Safety Handling when Working with Electricity ..................... 10 
Electronics ........................................................................... 11 
1  Replace the Primary Fuse ..................................................... 11 
2  Replace the Secondary Fuse ................................................ 12 
3  Replace the CPU PCB .......................................................... 13 
4  Replace the Printhead FPGA ................................................ 14 
5  Replace the Input/Output FPGA ............................................ 14 
6  Replace the Battery ............................................................... 14 
7  Replace the Power Supply Unit ............................................. 15 
8  Replace the Compact Flash Card Slot .................................. 16 
9  Replace the Input/Output Board ............................................ 17 
Retrofit with Options ........................................................... 19 
1  RS-485 and RS-422 .............................................................. 19 
2  Ethernet ................................................................................. 20 
Mechanics ............................................................................ 21 
1  Replace the Printhead ........................................................... 21 
2  Angle adjustment ................................................................... 23 
3  Replace the Tooth Belt (Linear Drive) ................................... 24 
4  Retrofit the Brake ................................................................... 25 
5  Replace the Zero Point Photocell .......................................... 26 
6  Replace the End Position Photocell ...................................... 27 
7  Adjust the Ribbon Drive ......................................................... 28 
8  Adjust the Ribbon Tension .................................................... 29 
9  Lubrication ............................................................................. 30 
Error Correction ................................................................... 31 
Control Inputs and Outputs ................................................ 41 
1  Version I ................................................................................ 41 
2  Version II ............................................................................... 45 
Wiring Plans ......................................................................... 51 
1  Electronics ............................................................................. 51 
2  Mechanics ............................................................................. 52 
Layout Diagrams ................................................................. 57 
1  CPU ....................................................................................... 57 
2  Power Supply Unit (Revision C) ............................................ 59 
3  Compact Flash Card Slot ...................................................... 61 
4  I/O Board 24V ........................................................................ 62 
5  Ethernet ................................................................................. 64 
6  Distributor Board .................................................................... 65 
7  Carriage Board ...................................................................... 67 
8  Motor Adapter ........................................................................ 69 
Connection Plan of Back Panel Plugs............................... 71 
1  Motors .................................................................................... 71 
2  Printhead Signals .................................................................. 71 
3  Sensors ................................................................................. 72 

Table of Contents

DPM IIIxi

4

Service instructions

0209

11 Connection Plan of Interfaces ............................................ 73

11.1 Centronics ............................................................................. 73

11.2 RS-232 .................................................................................. 73

11.3 RS-485 and RS-422 .............................................................. 74

11.4 Ethernet ................................................................................. 75

11.5 USB 1.0 ................................................................................. 75

12 Index ..................................................................................... 77

DPM IIIxi

Notes on this Document

0209

Service instructions

5

1 Notes on this Document

1.1 User Notes

This service manual is intended for qualified service and maintenance

staff.

This manual contains information about the electronics and the

mechanical part of the direct print module.

Information about operation of the direct print module can be taken

from our operating manual.

If a problem arises that cannot be solved with help of this service

instructions, then please contact your responsible dealer.

1.2 Instructions

Basic information and warning references with the corresponding

signal words for the danger level are as follows specified in this

manual:

DANGER identifies an extraordinarily great and immediate

danger which could lead to serious injury or even death.

WARNING identifies a possible danger would could lead

to serious bodily injury or even death if sufficient

precautions are not taken.

WARNING of cutting injuries.

Pay attention that cutting injuries caused by blades, cutting

devices or sharp-edged parts are avoided.

WARNING of hand injuries.

Pay attention that hand injuries caused by closing

mechanical parts of a machine/equipment are avoided.

WARNING of hot surfaces.

Pay attention so as not to come into contact with hot

surfaces.

CAUTION indicates a potentially dangerous situation

which could lead to moderate or light bodily injury or

damage to property.

NOTICE gives you tips. They make a working sequence

easier or draw attention to important working processes.

Gives you tips on protecting the environment.



Handling instruction



Optional accessories, special fittings

Date

Information in the display

Notes on this Document

DPM IIIxi

6

Service instructions

0209

DANGER!

Risk of death via electric shock!

 Before opening the housing cover, disconnect the

printing system from the mains supply and wait for

a moment until the power supply unit has

discharged.

CAUTION!

Two-pole fuse.

 Before opening the housing cover, disconnect the

printing system from the mains supply and wait for a

moment until the power supply unit has discharged.

1.3 Cross References

References to specific items in a figure are marked with item

numbers. They are identified with parentheses in the text, e.g. (9). If

no figure number is provided, item numbers in the text always refer to

the graphic directly above the text. If a reference is made to another

graphic, the figure number is specified, e.g. (2, in figure 5).

For a cross reference to chapters and sections, the chapter number

and page number are specified, e.g. a reference to this section: see

chapter 1.3.2, on page 35).

References to other documents have the following form: See

'operating manual'.

Item numbers

Cross references to

chapters and sections

References to other

documents

DPM IIIxi

Safety Instructions

0209

Service instructions

7

2 Safety Instructions

2.1 General Safety Instructions

 Keep the area around the device clean during and after

maintenance.

 Work in a safety-conscious manner.

 Store dismantled device parts in a safe place while maintenance

is being performed.

CAUTION!

The drawing in of items of clothing by moving parts can

lead to injuries.

 If possible, do not wear clothing which could be

caught by moving device parts.

 Button or roll up shirt or jacket sleeves.

 Tie or pin up long hair.

 Tuck the ends of scarves, ties and shawls into your

clothing or secure them with non-conductive clips.

DANGER!

Risk of death from increased flow of current via metals

parts which come into contact with the device.

 Do not wear clothing with metal parts.

 Do not wear jewellery.

 Do not wear glasses with a metal frame.

If a possible danger to your eyes is present, wear protective goggles,

especially in the following cases:

• when knocking in or knocking out pins and similar parts with a

hammer

• when using spring hooks

• when loosening or inserting springs, snap rings and gripping rings

• when soldering

• when using solvents, cleaning agents or other chemicals

Workplace and

method of working

Clothing

Protective clothing

Safety Instructions

DPM IIIxi

8

Service instructions

0209

WARNING!

Risk of injury in case of missing or faulty protective

equipment.

 After performing maintenance work, attach all safety

equipment (covers, safety precautions, ground cables

etc.).

 Replace faulty parts and those which have become

unusable.

The direct print module is designed for power supply systems of

230 V AC. Connect the direct print module only to electrical outlets

with a ground contact.

NOTICE!

When changing the mains voltage the fuse value is to adapt

accordingly.

Couple the direct print module to devices using extra low voltage only.

Before making or undoing connections, switch off all devices involved

(computer, printer, accessories etc.).

Operate the direct print module in a dry environment only and do not

get it wet (sprayed water, mist etc.).

Do not operate the direct print module in explosive atmosphere and

not in proximity of high voltage power lines.

Operate the direct print module only in an environment protected

against abrasive dust, swarf and other similar impurity.

Maintenance and servicing work can only be carried out by trained

personnel.

Operating personnel must be trained by the operator on the basis of

the operating manual.

Depending on use, ensure that clothing, hair, jewellery and similar

personal items do not contact the exposed rotating parts and/or the

moving parts (e.g. print carriage).

NOTICE!

With the open printing unit (due to construction) the requirements

of EN 60950-1/EN 62368-1 regarding fire protection casing are

not fulfilled. These must be ensured by the installation into the end

device.

The print unit and parts of it (e.g. motor, printhead) can get hot during

printing. Do not touch the printhead during operation. Cool down the

print unit before changing material, removal or adjustment.

Never use highly inflammable consumables.

Carry out only the actions described in these operating instructions.

Any work beyond this may only be performed by the manufacturer or

upon agreement with the manufacturer.

Unauthorized interference with electronic modules or their software

can cause malfunctions.

Protective equipment

General safety

instructions

DPM IIIxi

Safety Instructions

0209

Service instructions

9

Other unauthorized work or modifications to the direct print module

can endanger operational safety.

Always have service work done in a qualified workshop, where the

personnel have the technical knowledge and tools required to do the

necessary work.

There are warning stickers on the direct print modules that draw your

attention to dangers. Therefore the warning stickers are not to be

removed as then you and others cannot be aware of dangers and may

be injured.

The direct printing unit must be integrated with the Emergency Stop

circuit when it is incorporated into the overall machine.

All isolating safety equipment must be installed before starting-up the

machine.

DANGER!

Danger to life and limb from power supply!

 Do not open the casing.

CAUTION!

Two-pole fuse.

 Before opening the housing cover, disconnect the

printing system from the mains supply and wait for a

moment until the power supply unit has discharged.

Safety Instructions

DPM IIIxi

10

Service instructions

0209

2.2 Safety Handling when Working with Electricity

 The following work may only be performed by instructed and

trained electricians:

• work on the electrical assemblies

• work on the device while it is open and connected to the

power supply.

 Locate the emergency-stop or power switch so that it can be

actuated in case of an emergency.

 Unplug the device from the electrical outlet before performing

the following work:

• removing or installing power supply units

• working in the immediate vicinity of exposed power supply

parts

• mechanical inspection of power supply parts

• modifying the device circuits.

 Ensure that the device is de-energized.

 Check the workplace for possible sources of danger, e.g. moist

floors, defective extension cables, faulty protective conduction

connections.

 Give another person the task of remaining near the workplace.

This person must be familiar with the location and operation of

the emergency-stop and power switches and switch off the

power if danger arises.

 Use only one hand while working on electrical circuits when a

device is switched on. Hold the other hand behind your back or

put it in your jacket pocket.

This prevents the electricity from flowing through your body.

 Do not use worn or damaged tools.

 Use only tools and testing equipment that is suitable for the

respective task.

 Proceed in a very cautions and calm manner.

 Avoid endangering yourself.

 Switch the power off.

 Request medical help (emergency physician).

 Call for first aid if necessary.

Qualifications of

personnel

General precautions to

be heeded when

beginning maintenance

Additional precautions

to be heeded for

devices with exposed

energized parts

Tools

What to do in case an

accident occurs

DPM IIIxi

Electronics

0209

Service instructions

11

3 Electronics

DANGER!

Risk of death via electric shock!

 Before opening the housing cover, disconnect the

printing system from the mains supply and wait for

a moment until the power supply unit has

discharged.

3.1 Replace the Primary Fuse

Figure 1

The primary fuse is in line filter block that can be accessed from

outside.

1. Unplug the machine and then open its cover.

2. Remove the fuse-holder which is behind.

3. Replace the fuse (value = 3,15A/T).

Electronics

DPM IIIxi

12

Service instructions

0209

3.2 Replace the Secondary Fuse

Figure 2

1. Unplug the machine and then open its cover.

Now the power supply unit is visible.

2. Remove the fuse (A) which is placed on it.

F1: microfuse 10A/T = protection of all power unit voltages

DPM IIIxi

Electronics

0209

Service instructions

13

3.3 Replace the CPU PCB

Figure 3

1. If possible, save the configuration of module on a Compact Flash

card.

2. Unplug the print mechanics from the electrical outlet.

3. Remove the cover of control unit.

4. Detach all connections from the CPU PCB.

5. Remove the fixing screws at the Centronics interface.

6. Remove all retaining screws at CPU PCB.

7. Carefully remove the CPU PCB.

1. Place the CPU PCB onto the retainers.

2. Secure the PCB board with screws.

3. Insert all plug connections on the PCB.

4. Restore all interface connections.

5. Connect the power cable.

6. Update the firmware if necessary.

7. If possible, load the configuration from memory card. Otherwise,

set the configuration by the function menu.

Remove the

CPU PCB

Install the

CPU PCB

Electronics

DPM IIIxi

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Service instructions

0209

3.4 Replace the Printhead FPGA

1. Remove the FPGA from the PLCC support base with a suitable

displacement pincer.

2. Press the new FPGA into the support base and pay attention to

the position of polarity.

3.5 Replace the Input/Output FPGA

1. Separate the I/O board from the CPU board.

Now the I/O FPGA is visible.

2. Remove the FPGA from the PLCC support base with a suitable

displacement pincer.

3. Press the new FPGA into the support base and pay attention to

the position of polarity.

3.6 Replace the Battery

DANGER!

Danger of explosion due to improper replacement of the

battery!

 Use non-conductive tools.

 Pay attention to polarity.

1. Lift up the fixing bracket by means of a non-metallic device (e.g.

plastic ruler).

2. Remove the battery.

3. Insert a new battery (CR 2032) into the support and pay attention

to position of polarity.

DPM IIIxi

Electronics

0209

Service instructions

15

3.7 Replace the Power Supply Unit

Figure 4

1. Unplug all connections.

2. Unscrew the screws at the rectifier Z1.

3. Remove the screws at the bottom of electronics.

4. Remove the defective power supply unit.

5. Deposit the new power supply unit in the electronics.

Pay attention that no lines are clamped under the heat sink of

power supply unit.

6. Insert all connections in the appropriate plug-in positions.

7. Screw again the power supply unit.

Electronics

DPM IIIxi

16

Service instructions

0209

3.8 Replace the Compact Flash Card Slot

Figure 5

1. Remove the cover of control unit.

2. Unplug the connecting cable to the power supply unit at slot.

3. Unscrew the retaining screws at the side panel.

4. Remove the defective slot.

5. The installation of the new slot is to be effected in reverse order.

DPM IIIxi

Electronics

0209

Service instructions

17

3.9 Replace the Input/Output Board

Figure 6

1. Unplug the connection cables of the I/O board to the rear panel.

2. Separate the defective board from the CPU.

3. Insert the new board.

4. Insert again the connecting cable according to the wiring plan (see

chapter 8.1 on page 51).

In the Service Functions menu the inputs/outputs can be tested.

In case an input is activated then the position which corresponds to

this input changes to 1.

An output can be activated by positioning the cursor at the

corresponding position and then using the keys and to set the

value to 1.

If the value is set to 0, the output is deactivated.

Electronics

DPM IIIxi

18

Service instructions

0209

DPM IIIxi

Retrofit with Options

0209

Service instructions

19

4 Retrofit with Options

DANGER!

Risk of death via electric shock!

 Before opening the housing cover, disconnect the

printing system from the mains supply and wait for a

moment until the power supply unit has discharged.

4.1 RS-485 and RS-422

Figure 7

1. Replace the installed input/output port by an input/output port

which is equipped with RS-485 or RS-422 extension.

2. Replace the line to INPUT2 by the line with 9-pin DSUB socket.

3. Insert the new line into position ST5 on the input/output plate.

4. OUTPUT1, INPUT1 and OUTPUT2 have to be installed according

to the wiring plan (see chapter 8.1 on page 51).

Retrofit with Options

DPM IIIxi

20

Service instructions

0209

4.2 Ethernet

Figure 8

1. Remove the cover of control unit.

2. Remove the screws between the power unit connection (ST13)

and the bus plug (ST1).

3. Screw the distance bolt M3x15 in this position.

4. Insert the Ethernet plate in the break-down and insert the plate

into ST1.

5. Fix the plate with the corresponding screws.

6. Fix the plate with the already removed screw at the distance bolt.

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Carl Valentin DPM III XI User manual

Carl Valentin DPM III XI User manual

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