Carl Valentin Dynacode II IP User manual

Type
User manual
DYNACODE II IP
Ingress Protection Version
Service Instructions
Copyright by Carl Valentin GmbH / 7957325.1119
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 EU
directives:
• EU Low-Voltage Directive (2014/35/EU)
• EU Electromagnetic Compatibility Directive (2014/30/EU)
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 II IP
Table of Contents
11.19
3
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 ....................... 9
2.3 Environmentally-Friendly Disposal ........................................ 10
3 General Notes ...................................................................... 11
3.1 Continuous Mode .................................................................. 11
3.2 Intermittent Mode ................................................................... 12
3.3 Change the Module Type ...................................................... 13
4 Electronics (Replace Components) ................................... 15
4.1 Primary Fuses ....................................................................... 15
4.2 CPU PCB ............................................................................... 16
4.3 Battery ................................................................................... 18
4.4 Input/Output Board ................................................................ 19
4.5 Power Supply Unit ................................................................. 21
4.6 HMI Components ................................................................... 22
5 Cleaning ............................................................................... 25
5.1 General Information ............................................................... 25
5.2 Clean the Transfer Ribbon Roller .......................................... 26
5.3 Clean the Printhead ............................................................... 26
6 Printhead .............................................................................. 27
6.1 Replace the Printhead ........................................................... 27
6.2 Angle Adjustment (Intermittent Mode) ................................... 29
7 Ribbon Cassette (Replacing Components) ...................... 31
7.1 Track Roller ........................................................................... 31
7.2 Return Pulley ......................................................................... 33
7.3 Ribbon Rewinder Roll/Unwinder Roll .................................... 34
8 Printing Carriage (Replacing Components) ..................... 35
8.1 Printhead Fastener, Pressure Bail, Interlayer ....................... 36
8.2 Guiding Carriage ................................................................... 37
8.3 Motor Circuit Board................................................................ 38
9 Print Mechanics (Replacing Components) ....................... 39
9.1 Pneumatic Valve .................................................................... 39
9.2 Pressure Switch ..................................................................... 40
9.3 Encoder ................................................................................. 41
9.4 Limit Switch ........................................................................... 42
9.5 Cassette Switch ..................................................................... 43
9.6 LEDs ...................................................................................... 44
10 Error Correction ................................................................... 45
11 Control Inputs and Outputs ................................................ 55
12 Wiring Plans ......................................................................... 65
12.1 Control Unit ............................................................................ 65
12.2 Print Mechanics Dynacode II IP53 ........................................ 66
12.3 Print Mechanics Dynacode II IP107 ...................................... 67
12.4 Print Mechanics Dynacode II IP128 ...................................... 68
13 Layout Diagrams ................................................................. 69
13.1 CPU ....................................................................................... 69
13.2 Power Supply Unit ................................................................. 70
13.3 Motor Plate ............................................................................ 71
14 Connector Assignment of Control Unit ............................ 73
15 Index ..................................................................................... 75
Table of Contents
Dynacode II IP
4
Service Instructions
11.19
Dynacode II IP
Notes on this Document
11.19
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
Dynacode II IP
6
Service Instructions
11.19
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 II IP
Safety Instructions
11.19
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 an electric drill
• 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 II IP
8
Service Instructions
11.19
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
110 V AC … 230 V AC. Connect the direct print module only to
electrical outlets with a ground contact.
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 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.
Protective equipment
General safety
instructions
Safety Instructions
Dynacode II IP
11.19
Service Instructions
9
Unauthorized interference with electronic modules or their software
can cause malfunctions.
Other unauthorized work or modifications to the direct print module
can endanger operational safety.
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.
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.
Qualifications of
personnel
General precautions to
be heeded when
beginning maintenance
Additional precautions
to be heeded for
devices with exposed
energized parts
Safety Instructions
Dynacode II IP
10
Service Instructions
11.19
 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.
2.3 Environmentally-Friendly Disposal
Manufacturers of B2B equipment are obliged to take back and
dispose of old equipment that was manufactured after 13 August
2005. As a principle, this old equipment may not be delivered to
communal collecting points. It may only be organised, used and
disposed of by the manufacturer. Valentin products accordingly
labelled can therefore be returned to Carl Valentin GmbH.
This way, you can be sure your old equipment will be disposed of
correctly.
Carl Valentin GmbH thereby fulfils all obligations regarding timely
disposal of old equipment and facilitates the smooth reselling of these
products. Please understand that we can only take back equipment
that is sent free of carriage charges.
The electronics board of the printing system is equipped with a
battery. This must only be discarded in battery collection containers or
by public waste management authorities.
Further information on the WEEE directive is available on our website
www.carl-valentin.de.
Tools
What to do in case an
accident occurs
Dynacode II IP
General Notes
11.19
11
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.
Figure 2
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.
Material Speed
Print Principle
Material Guiding
General Notes
Dynacode II IP
12
Service Instructions
11.19
3.2 Intermittent Mode
Lift
Print surface
Feed
Packaging material
Printhead
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 of 75 mm,
the print position value must be changed to 93.
Figure 4
A: Print pos. / Start pos. value = 93
B: Print pos. / Start pos. value = 83
C: Max. position print end
D: Stand-by position
Print Principle
Print position
General Notes
Dynacode II IP
11.19
Service Instructions
13
3.3 Change the Module Type
Tap on the Functions button.
On the left side of the display, select Maintenance/ System Settings.
Select Printer Info, tap on the desired Printer Type and confirm your
selection.
In order to change the printer type, the service password must be
entered.
Password: 2904
After entering the service password, the device is restarted.
Maintenance - System
settings
General Notes
Dynacode II IP
14
Service Instructions
11.19
Dynacode II IP
Electronics (Replace Components)
11.19
15
4 Electronics (Replace Components)
DANGER!
Risk of death via electric shock!
 Before opening the housing cover, disconnect the device
from the mains supply and wait for a moment until the
power supply unit has discharged.
4.1 Primary Fuses
NOTICE!
The primary fuses are not accessible from the outside.
A
B
A
A
A
C
C
Figure 5
1. Unplug the control unit from the electrical outlet.
2. Unscrew the four screws (A).
3. Vertically remove the front plate (B). Disconnect disturbing
connection cables from the connectors.
4. Pull the fuse-holder (C) from the housing.
1. Replace the fuses (two T4A 250 V).
2. Push the fuse-holder (C) into the housing until it engages.
3. Reinstall the front plate (B). Plug the connection cables in.
Removing the
primary fuses
Installing the
primary fuses
Electronics (Replace Components)
Dynacode II IP
16
Service Instructions
11.19
4.2 CPU PCB
A A
B B B
C
D
Figure 6
NOTICE!
Save the configuration onto a CF card.
1. Unplug the control unit from the electrical outlet.
2. Unscrew the four screws on the rear and remove the front plate
(see chapter 4.1, page 15).
3. Disconnect all plug-in connectors from the CPU PCB (C).
4. Unscrew the screws (A + B).
5. Carefully remove the CPU PCB (C).
Removing the
CPU PCB
Dynacode II IP
Electronics (Replace Components)
11.19
Service Instructions
17
1. If not available, move the cover of the CF card slot (D) from the
old CPU to the new CPU.
2. Insert the CPU PCB (C) with the interface sockets into the
connection plate and turn the hexagonal bolts of the serial
interface if necessary.
3. Fasten again the PCB (C) with the screws (A + B).
4. Connect all plug-in connectors to the PCB.
5. Reinstall the front plate.
6. Restore all interface connections.
7. Connect the power supply cable.
8. Check the firmware version and update it, if necessary.
9. Load the configuration from the CF card. Otherwise set the
configuration with the function menu.
Installing the
CPU PCB
Electronics (Replace Components)
Dynacode II IP
18
Service Instructions
11.19
4.3 Battery
DANGER!
Danger of explosion due to improper replacement of the
battery!
 Use non-conductive tools.
 Pay attention to polarity.
A
Figure 7
1. Unplug the control unit from the electrical outlet.
2. Unscrew the four screws on the rear and remove the front plate
(see chapter 4.1, page 15).
3. Lift up the fixing bracket by means of a non-metallic device (e.g.
plastic ruler).
4. Remove the battery
1. Install a new battery (CR 2032) in the bracket (A).
NOTICE!
Please pay attention to the correct polarity.
2. Reinstall the front plate.
3. Connect the power supply cable.
Removing the battery
Installing the battery
Dynacode II IP
Electronics (Replace Components)
11.19
Service Instructions
19
4.4 Input/Output Board
NOTICE!
The inputs/outputs can be tested in the Service Functions.
In case of an active input, the position corresponding to this input
changes to 1.
To activate an output, move the cursor to the corresponding position
and set value 1. To deactivate the output, set the corresponding
position again to 0.
Inputs and outputs marked with 'x' are not occupied.
D D
CBA B
Figure 8
1. Unplug the control unit from electrical outlet.
2. Unscrew the four screws on the rear and remove the front plate
(see chapter 4.1, page 15).
3. Remove the CPU PCB (see chapter 4.1, page 15).
4. Unscrew the retaining screws (D) at the SUB-D socket.
5. Remove the screws (B).
6. Remove the I/O plate (A) and disconnect the plug-in connector
(C).
Removing the
input/output board
Electronics (Replace Components)
Dynacode II IP
20
Service Instructions
11.19
1. Connect the new I/O board (A) with the appropriate cable (C) and
place it.
2. Fasten the retaining screws (D).
3. Tighten the screws (B).
4. Reinstall the CPU PCB (see chapter 4.1, page 15).
5. Reinstall the front plate.
6. Connect the power supply cable.
Installing the
input/output board
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Carl Valentin Dynacode II IP User manual

Type
User manual

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