Carl Valentin Dynacode User manual

Brand: Carl Valentin

Model: Dynacode

Type: User manual

DYNACODE

Service Instructions

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:

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

Dynacode 
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 
General Notes ...................................................................... 11 
1  Continuous Mode .................................................................. 11 
2  Intermittent Mode ................................................................... 12 
3  Change the Module Type ...................................................... 13 
Electronics ........................................................................... 15 
1  Replace the Primary Fuse ..................................................... 15 
2  Replace the CPU PCB .......................................................... 16 
3  Replace the Battery ............................................................... 17 
4  Replace the Input/Output Board ............................................ 17 
5  Replace the Power Supply Unit ............................................. 18 
6  Replace the Compact Flash Card Slot .................................. 19 
Mechanics ............................................................................ 21 
1  Replace the Printhead ........................................................... 21 
2  Replace the Printhead Cable ................................................ 23 
3  Angle Adjustment (Intermittent Mode) ................................... 23 
4  Replace Parts at the Cassette ............................................... 24 
5  Replace Parts at the Printing Carriage .................................. 26 
6  Replace the Motor Circuit Board ........................................... 28 
7  Replace Parts at the Print Mechanics ................................... 29 
8  Replace the Encoder ............................................................. 30 
9  Replace the Dual Reflective Encoder.................................... 31 
10  Replace the Limit Switch, Cover Switch and LED ................. 31 
Error Correction ................................................................... 33 
Control Inputs and Outputs ................................................ 43 
1  Version I ................................................................................ 43 
2  Version II ............................................................................... 47 
Wiring Plans ......................................................................... 53 
1  Electronics ............................................................................. 53 
2  Mechanics ............................................................................. 54 
Layout Diagrams ................................................................. 57 
1  CPU ....................................................................................... 57 
2  Power Supply Unit ................................................................. 58 
3  Compact Flash Card Slot ...................................................... 59 
4  I/O Board 24V ........................................................................ 60 
5  Motor Circuit Board................................................................ 61 
Connection Plan of Back Panel Plugs............................... 63 
1  Voltage .................................................................................. 63 
2  Printhead Signals .................................................................. 63 
3  Touch Panel .......................................................................... 64 
4  Encoder (Continuous Mode) ................................................. 64 

Table of Contents

Dynacode

Service instructions

0808

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

Dynacode

Notes on this Document

0808

Service instructions

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

Dynacode

Service instructions

0808

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

Dynacode

Safety Instructions

0808

Service instructions

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

Dynacode

Service instructions

0808

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

Dynacode

Safety Instructions

0808

Service instructions

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

Dynacode

Service instructions

0808

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

Dynacode

General Notes

0808

Service instructions

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

Dynacode

Service instructions

0808

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

Dynacode

General Notes

0808

Service instructions

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

Dynacode

Service instructions

0808

Dynacode

Electronics

0808

Service instructions

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

Dynacode

Service instructions

0808

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

Dynacode

Electronics

0808

Service instructions

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

Dynacode

Service instructions

0808

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!

Dynacode

Electronics

0808

Service instructions

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

Dynacode

Service instructions

0808

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Carl Valentin Dynacode User manual

Carl Valentin Dynacode User manual

Carl Valentin Dynacode User manual

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