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Dynacode

Carl Valentin Dynacode User manual

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DYNACODE
Service Instructions
Copyright by Carl Valentin GmbH / 7957005.1112
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 Machinery Directive (98/37/EC)
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
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Table of Contents
1 Notes on this Document ....................................................... 5
1.1 User Notes ............................................................................... 5
1.2 Instructions .............................................................................. 5
1.3 Cross References .................................................................... 6
2 Safety Instructions ................................................................ 7
2.1 General Safety Instructions ..................................................... 7
2.2 Safety Handling When Working With Electricity .................... 10
3 General Notes ...................................................................... 11
3.1 Continuous Mode .................................................................. 11
3.2 Intermittent Mode ................................................................... 12
3.3 Change the Module Type ...................................................... 13
4 Electronics ........................................................................... 15
4.1 Replace the Primary Fuse ..................................................... 15
4.2 Replace the CPU PCB .......................................................... 16
4.3 Replace the Battery ............................................................... 17
4.4 Replace the Input/Output Board ............................................ 17
4.5 Replace the Power Supply Unit ............................................. 18
4.6 Replace the Compact Flash Card Slot .................................. 19
5 Mechanics ............................................................................ 21
5.1 Replace the Printhead ........................................................... 21
5.2 Replace the Printhead Cable ................................................ 23
5.3 Angle Adjustment (Intermittent Mode) ................................... 23
5.4 Replace Parts at the Cassette ............................................... 24
5.5 Replace Parts at the Printing Carriage .................................. 26
5.6 Replace the Motor Circuit Board ........................................... 28
5.7 Replace Parts at the Print Mechanics ................................... 29
5.8 Replace the Encoder ............................................................. 30
5.9 Replace the Dual Reflective Encoder.................................... 31
5.10 Replace the Limit Switch, Cover Switch and LED ................. 31
6 Error Correction ................................................................... 33
7 Control Inputs and Outputs ................................................ 43
7.1 Version I ................................................................................ 43
7.2 Version II ............................................................................... 47
8 Wiring Plans ......................................................................... 53
8.1 Electronics ............................................................................. 53
8.2 Mechanics ............................................................................. 54
9 Layout Diagrams ................................................................. 57
9.1 CPU ....................................................................................... 57
9.2 Power Supply Unit ................................................................. 58
9.3 Compact Flash Card Slot ...................................................... 59
9.4 I/O Board 24V ........................................................................ 60
9.5 Motor Circuit Board................................................................ 61
10 Connection Plan of Back Panel Plugs............................... 63
10.1 Voltage .................................................................................. 63
10.2 Printhead Signals .................................................................. 63
10.3 Touch Panel .......................................................................... 64
10.4 Encoder (Continuous Mode) ................................................. 64
Table of Contents
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11 Connection Plan of Interfaces ............................................ 65
11.1 Centronics ............................................................................. 65
11.2 RS-232 .................................................................................. 65
11.3 Ethernet ................................................................................. 66
11.4 USB 1.0 ................................................................................. 66
12 Index ..................................................................................... 67
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Notes on this Document
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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
instructionsl, 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
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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 letters. They
are identified with parentheses in the text, e.g. (A). If no figure number
is provided, letters 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. (A, 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, page 35).
References to other documents have the following form: See
'operating manual'.
Drawings
Cross references to
chapters and sections
References to other
documents
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Safety Instructions
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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
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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 from
110 V AC … 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
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Safety Instructions
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Service instructions
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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
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Service instructions
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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
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General Notes
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3 General Notes
3.1 Continuous Mode
Please note that the material has sufficient adhesion at the pressure
transducer roll or encoder roll to permit the exact speed by the
encoder.
It is only possible to print when respecting the operating conditions,
i.e. the speed has to be observed.
Figure 1
After starting a print order the printhead moves against the print
medium. The feed of material is registered by the encoder and then
evaluated. The printhead is in start position as long as the printing
onto the moving material is finished and then it moves back to its
home position.
NOTICE!
In case the encoder is connected to the counter-pressure roll or
the encoder roll you have to observe that the material has
sufficient adhesion at the pressure roll or encoder roll to
guarantee an exact speed by the encoder.
Figure 2
Material speed
Print principle
Material guiding
General Notes
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Service instructions
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3.2 Intermittent Mode
Figure 3
After starting a print order the printhead moves against the print
medium. Afterwards the printing carriage moves corresponding to the
set or transferred layout length linear over the material which is to be
printed. After the print procedure the printhead again lifts up and the
printing carriage moves again to the starting position.
NOTICE!
The direct print module is delivered with a default print length of
65 mm. In order to use the maximum print length, the print
position value must be changed to 93 (Function Menu: Machine
Parameters).
A: Print position/start position value = 93 mm
B: Print position/start position value = 83
C: Max. position print end
D: Stand-by position
Print principle
Print position
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3.3 Change the Module Type
Press the key to access the function menu.
Press the key until the menu Service Functions is displayed.
Press the key to select the menu.
Press the key until the menu item Paper Counter is displayed.
Press the key to access the menu Password.
Enter the service password '2904'.
Press the key to confirm the entry.
Press the key and to select the module type.
Press the key to confirm the entry.
The changed module type is indicated in the display.
Press the key to move to the next menu item.
Indication if a standard motor (ID166) or a stronger motor (ID267) is
installed.
Press the key to move to the next menu item.
Press the key and to select if a left or a right print module is
mounted.
General Notes
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Service instructions
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Electronics
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4 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.
4.1 Replace the Primary Fuse
Figure 4
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 (microfuse two T4A 250 V).
Electronics
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Service instructions
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4.2 Replace the CPU PCB
Figure 5
1. If possible, save the configuration of module to a CompactFlash
card.
2. Unplug the module from the electrical outlet.
3. Remove the cover of control unit.
4. Detach all interface cables from the CPU PCB.
5. Remove the fixing screws at the Centronics interface.
6. Remove the screws (A) from I/O board (B).
7. Remove the I/O board.
8. Remove the hexagon bolt and all retaining screws at the CPU
PCB.
9. Carefully remove the CPU PCB.
1. Place the CPU PCB onto the retainers.
2. Secure the PCB and I/O board with screws (A).
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
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4.3 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.
4.4 Replace the Input/Output Board
The installation and removal of I/O plate is described in chapter 4.2 on
page 16.
In the Service Functions menu the inputs/outputs can be controlled.
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
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Service instructions
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4.5 Replace the Power Supply Unit
Figure 6
1. Remove the cover of control unit.
Figure 7
2. Unscrew the retaining screws (A) of the
power supply unit (B) from electronics
underside.
At the same time hold the power supply
unit.
Figure 8
3. Deposit the power supply unit next to
the control unit (see photo).
4. Remove the transparent cover above
the clamps (C).
5. Loosen the clamps (C) and remove all
wires.
6. Insert again the power supply unit in
reverse order. At the same time see the
correct cable assignment at the
clamps!
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4.6 Replace the Compact Flash Card Slot
Figure 9
1. Remove the cover of control unit.
2. Unplug the connecting cable to CPU at the slot (A).
3. Unscrew the retaining screws (B) at fastener.
4. Remove the defective slot.
5. Install a new slot in reverse order.
NOTICE!
For damages at the transparent cover, the slot must be
dismantled with fastener. For that purpose, remove 4 retaining
screws (C) at rear panel.
Electronics
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