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Carl Valentin Dynacode Series Service Instructions Manual

Thermal transfer direct printing systems
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DYNACODE
Service Instructions

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Summary of Contents for Carl Valentin Dynacode Series

  • Page 1 DYNACODE Service Instructions...
  • Page 2 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)

  • Page 3: Table Of Contents

    Dynacode series Table of contents Table of contents   Table of contents ................3     Notes on this document ............5 User notes ................5     Warnings ................. 5     Cross references ..............6      ...
  • Page 4 Table of contents Dynacode series     Connection plan of interfaces ..........65 11.1 Centronics ................65     11.2 RS-232 .................. 65     11.3 Ethernet ................. 66     11.4 USB 1.0 ................. 66        ...

  • Page 5: Notes On This Document

    Dynacode series Notes on this document Notes on this document 1.1 User notes This service manual is intended for qualified service and maintenance staff. This manual contains information about hardware and mechanical part of the direct print module. Information about operation of the direct print module can be taken from our operating manual.

  • Page 6: Cross References

    Notes on this document Dynacode series 1.3 Cross references References to specific items in a figure are marked with item Item numbers 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.

  • Page 7: Safety Instructions

    Dynacode series Safety instructions Safety instructions 2.1 General safety instructions  Workplace and Keep the area around the device clean during and after method of working maintenance.  Work in a safety-conscious manner.  Store dismantled device parts in a safe place while maintenance is being performed.
  • Page 8 Safety instructions Dynacode series If a possible danger to your eyes is present, wear protective goggles, Protective clothing especially in the following cases:  when knocking in or knocking out pins and similar parts with a hammer  when using spring hooks ...

  • Page 9: Safety Handling When Working With Electricity

    Dynacode series Safety instructions 2.2 Safety handling when working with electricity  Qualifications of The following work may only be performed by instructed and personnel trained electricians:  work on the electrical assemblies  work on the device while it is open and connected to the power supply.

  • Page 11: General Notes

    Dynacode series General notes General notes 3.1 Continuous mode Please note that the material has sufficient adhesion at the pressure Material speed 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.

  • Page 12: Intermittent Mode

    General notes Dynacode series 3.2 Intermittent mode Print principle 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.

  • Page 13: Change Module Type

    Dynacode series General notes 3.3 Change module type Press key to access the function menu. Press key as long as you arrive at the service functions menu. Press key to select the menu. Press key as long as you arrive at the 'Paper Counter' menu.

  • Page 15: Electronics

    Dynacode series Electronics Electronics DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged. 4.1 Replacing primary fuse...

  • Page 16: Replacing Cpu Pcb

    Electronics Dynacode series 4.2 Replacing CPU PCB Figure 5 1. If possible, save the configuration of module to a CompactFlash Removing the card. CPU PCB 2. Unplug the module from the electrical outlet. 3. Remove cover of control unit. 4. Detach all interface cables from the CPU PCB.

  • Page 17: Replacing Battery

    Dynacode series Electronics 4.3 Replacing battery DANGER! Danger of explosion when exchanging the battery improper.  Pay attention to polarity. 1. Lift up the fixing bracket by means of a non-metallic device (e.g. plastic ruler). 2. Remove the defective battery.

  • Page 18: Replacing Power Supply Unit

    Electronics Dynacode series 4.5 Replacing power supply unit 1. Remove cover of control unit. Figure 6 2. Unscrew retaining screws (A) of power supply unit (B) from electronics underside. At the same time hold power supply unit. Figure 7 3. Deposit power supply unit next to the control unit (see photo).

  • Page 19: Replacing Compact Flash Card Slot

    Dynacode series Electronics 4.6 Replacing Compact Flash card slot Figure 9 1. Remove cover of control unit. 2. Unplug connecting cable to CPU at slot (A). 3. Unscrew retaining screws (B) at fastener. 4. Remove defective slot. 5. Install a new slot in reverse order.

  • Page 21: Mechanics

    Dynacode series Mechanics Mechanics DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged. Printing can cause accumulation of dirt at printhead e.g. by colour...
  • Page 22 Mechanics Dynacode series Figure 10  Remove ribbon cassette. Removing the printhead  Move printhead unit in an appropriate service position.  Press printhead support (B) slightly downwards until an Allen key (2.5) can be inserted in the screws (D).

  • Page 23: Replacing Printhead Cable

    Dynacode series Mechanics 5.2 Replacing printhead cable After replacing the printhead cable 'signal', fold the cable as illustrated. Figure 11 5.3 Angle adjustment (intermittent mode) The installation angle of the printhead is default 26° to the print surface. However, manufacturing tolerances of printhead and mechanics can require another angle.

  • Page 24: Replacing Parties At Cassette

    Mechanics Dynacode series 5.4 Replacing parties at cassette View of cassette Figure 13 The track roller can also be removed without previous Replacing track roller loosening of roll. For this purpose use a screw driver with max. diameter of 5 mm and remove the screw.
  • Page 25 Dynacode series Mechanics Replacing return pulley 1. At cassette outside, remove a vertical strut by loosening 3 socket head screws at the inside. 2. Unscrew the socket head screw (A) of the corresponding roll. 3. Now you can remove bushing (B), centring bearing (D) and return pulley (C).

  • Page 26: Replacing Parties At Printing Carriage

    Mechanics Dynacode series 5.5 Replacing parties at printing carriage Views of printing carriage Figure 17 Figure 18 Figure 19 ® Use screw locking adhesive Loctite 243™ to secure screws (B+F) against unintentional unscrewing. Service instructions 0808...
  • Page 27 Dynacode series Mechanics Replacing printhead fastener, pressure bail and interlayer 1. Remove cassette. 2. By means of a tweezers, push both tension springs (C) from spring pillar (B). 3. Unplug printhead cable (E) from printhead (A). 4. Remove socket head screws (G).

  • Page 28: Replacing Motor Circuit Board

    Mechanics Dynacode series 5.6 Replacing motor circuit board Figure 22 1. Remove rear-mounted mechanics cover after loosening the collateral screws. 2. Unplug all wires at motor circuit board and remove the connecting cables between control unit and print mechanics. 3. Lever the retaining screws (B).

  • Page 29: Replacing Parties At Print Mechanics

    Dynacode series Mechanics 5.7 Replacing parties at print mechanics Replacing pneumatic DANGER! valve and pressure Risk of injury via a short-circuit. control device Because of technical reasons, the adjusting screw of pressure control device unit is on a tension potential of 5V.

  • Page 30: Replacing Encoder

    Mechanics Dynacode series 5.8 Replacing encoder 1. Remove rear-mounted mechanics cover after loosening the collateral screw. 2. Unplug the connecting cables between print mechanics and control unit at the mechanics. 3. Remove the hexagon bolts at the plugs (see chapter 5.6 on page 28).

  • Page 31: Dual Reflective Encoder

    Dynacode series Mechanics 5.9 Dual reflective encoder 1. Remove rear-mounted mechanics cover after loosening the collateral screw. 2. Remove connecting line (A) for dual reflective encoder (C). 3. Unscrew screw (B). 4. Remove the dual reflective encoder (C) carefully from the nut.

  • Page 33: Error Correction

    Dynacode series Error correction Error correction Error message Cause Remedy Line rises up completely or Move line down (increase Y Line too high partly over the upper edge of value). label. Check rotation and font. Line rises up completely or Move line up (reduce X value).
  • Page 34 Error correction Dynacode series Error message Cause Remedy Received line number is invalid Check sent data. Field numer at RS-232 and Centronics. Check connection PC - printer. Invalid length of received mask Check sent data. Length mask statement. Check connection PC - printer.
  • Page 35 Dynacode series Error correction Error message Cause Remedy Selected application identifier is Check code data. Application not available in GS1-128. Identifier F Missing HIBC system sign. Check definition of HIBC code. HIBC definition Missing primary code. Real Time Clock function is Change battery.
  • Page 36 Error correction Dynacode series Error message Cause Remedy Memory card is write-protected. Deactivate write protection. Drive write- protected Attempt to indicate a directory Correct your entry. Directory not file as file name. Attempt to change a file during Select another file.
  • Page 37 Dynacode series Error correction Error message Cause Remedy Defective photocell. Change photocell. Zero point Pressure air is not connected. Check pressure air. Compressed air External print release signal is Check input signal. External releaser missing. Wrong definition of column Reduce the column width res.
  • Page 38 Error correction Dynacode series Error message Cause Remedy Printing creation was still active Reduce print speed. Time generation at print start. Use printers' output signal for synchronisation. Use bitmap fonts to reduce generating time. Both DPM position sensors Displace zero point sensor Transport protection (start/end) are active.
  • Page 39 Dynacode series Error correction Error message Cause Remedy Scanner data does not Check adjustment of scanner. Scanner layout correspond to bar code data. difference Check scanner settings / connection. Serial interface error. Check settings for serial data COM break transmission as well as cable (printer-PC).
  • Page 40 Error correction Dynacode series Error message Cause Remedy When starting the print order Close the housing cover and Housing open the housing cover is not closed. start the print order anew. Transferred EAN.UCC code is Verify bar code data (see EAN.UCC code...
  • Page 41 Dynacode series Error correction Error message Cause Remedy The label photocell do not work Check label size and gap size. Print asynchronous in the order as it is expected according to print data. The settings of the photocell Check label photocell settings.

  • Page 43: Control Inputs And Outputs

    Dynacode series Control inputs and outputs Control inputs and outputs 7.1 Version I Plug connection - back side of control unit Figure 29 A = External output 1-4 (Output I) B = External input 1-4 (Input I) C = External output 5-8 (Output II)
  • Page 44 Control inputs and outputs Dynacode series Connection of a lamp to a 24V relay by Out 1: Example Figure 31 Output II PIN (bushing) Output II Figure 29, C Out 5: Print-Ready signal It is indicated if the print module is ready to process a start impulse.
  • Page 45 Dynacode series Control inputs and outputs By means of the control inputs it is possible to control printing. The Control inputs control inputs at Input I are electroplated separated and have to be provided with an external tension source. The signal level is active "HIGH".
  • Page 46 Control inputs and outputs Dynacode series Input II PIN (pin) Input II Figure 29, D In 5: Not used In 6: Not used Figure 35 In 7: Not used In 8: Not used Service instructions 0808...

  • Page 47: Version Ii

    Dynacode series Control inputs and outputs 7.2 Version II Plug connection - back side of control unit Figure 36 A = External output 1-4 (Output I) B = External input 1-4 (Input I) C = External output 5-8 (Output II)
  • Page 48 Control inputs and outputs Dynacode series Connection of a lamp to a 24V relay by Out 1: Example Figure 38 Output II PIN (bushing) Output II Figure 36, C Out 5: Print-Ready signal It is indicated if the print module is ready to process a start impulse.
  • Page 49 Dynacode series Control inputs and outputs By means of the control inputs it is possible to control printing. The Control inputs control inputs at Input I are galvanic separated and have to be provided with an external tension source. The signal level is active "HIGH".
  • Page 50 Control inputs and outputs Dynacode series This input is executed as 15-pole and provides user- External bushing I/O-24 Figure 36, D sided 24V/100mA. In case of using this bushing, exists no galvanic separation. Function 1, 6 5, 10 24 V / 100 mA...
  • Page 51 Dynacode series Control inputs and outputs Example 3 0808 Service instructions...

  • Page 53: Wiring Plans

    Dynacode series Wiring plans Wiring plans 8.1 Electronics Figure 43 0808 Service instructions...

  • Page 54: Mechanics

    Wiring plans Dynacode series 8.2 Mechanics Dynacode 53 Figure 44 Service instructions 0808...
  • Page 55 Dynacode series Wiring plans Dynacode 107 Figure 45 0808 Service instructions...
  • Page 56 Wiring plans Dynacode series Dynacode 128 Figure 46 Service instructions 0808...

  • Page 57: Layout Diagrams

    Dynacode series Layout diagrams Layout diagrams 9.1 CPU Figure 47 closed Jumper plan open closed 0808 Service instructions...

  • Page 58: Power Supply Unit

    Layout diagrams Dynacode series 9.2 Power supply unit Figure 48 48V output protective conductor connection  88~264VAC input Service instructions 0808...

  • Page 59: Compact Flash Card Slot

    Dynacode series Layout diagrams 9.3 Compact Flash card slot Figure 49 The following CompactFlash cards can be used:  512 MB  1 GB  2 GB 0808 Service instructions...

  • Page 60: I/O Board 24V

    Layout diagrams Dynacode series 9.4 I/O board 24V I/O board with external sensor Figure 50 In the function menu the verification of I/Os can be done in menu service functions. The signal levels input low are indicated as '-' and signal levels input high as .

  • Page 61: Motor Circuit Board

    Dynacode series Layout diagrams 9.5 Motor circuit board Top side Figure 51 Bottom side Figure 52 LEDs for tension Tension Tension power supply for CPU control printhead tension motor tension 0808 Service instructions...

  • Page 63: Connection Plan Of Back Panel Plugs

    Dynacode series Connection plan of back panel plugs 10 Connection plan of back panel plugs 10.1 Tension Figure 53 Signal 1-7, 14-19 8-13, 21-25 10.2 Printhead signals Figure 54 Signal Signal Printhead 7 M 1/2 INT Printhead 8 Reset 3...

  • Page 64: Touch Panel

    Connection plan of back panel plugs Dynacode series 10.3 Touch Panel Power supply for touch panel: 12-pole DIN bushing Illustration: connector - soldering side Figure 55 Signal A, B, C, D, E, L F, G, H, J, K, M 10.4 Encoder (continuous mode)

  • Page 65: Connection Plan Of Interfaces

    Dynacode series Connection plan of interfaces 11 Connection plan of interfaces 11.1 Centronics Figure 58 Signal STROBE DATA1-8 BUSY PERROR SELECT AUTOFD 15-16 VCC1284 (4,7V) 19-30 INIT FAULT 33-35 SELECTIN 11.2 RS-232 Figure 59 Signal 0808 Service instructions...

  • Page 66: Ethernet

    Connection plan of interfaces Dynacode series 11.3 Ethernet Figure 60 PIN RJ45- Bezeichnung Buchse TX− RX− 11.4 USB 1.0 Figure 61 Signal D− Service instructions 0808...

  • Page 67: Index

    Dynacode series Index 12 Index A  Angle adjustment, intermittent mode ..........23 B  Battery, replacing ................17 C  Centronics, connection plan (interfaces) ..........65 Change, module type ................. 13 Compact Flash card slot Layout diagram ................59 Replacing ..................19 Connection plan, back panel plugs Encoder ..................
  • Page 68 Index Dynacode series I  I/O board Layout diagram ................60 Replacing ..................17 Inputs/outputs ........... 43, 44, 45, 46, 47, 48, 49, 50 Interlayer (printing carriage), replacing ..........27 Intermittent mode, print position ............12 Intermittent mode, print principle ............12 J ...
  • Page 69 Dynacode series Index P  Pneumatic valve, replacing ..............29 Power supply unit Layout diagram ................58 Replacing ..................18 Pressure bail (printing carriage), replacing ........27 Pressure control device, replacing ............. 29 Primary fuse, replacing ............... 15 Printhead Cable, replacing ................23 Fastener (printing carriage), replacing ..........
  • Page 70 Index Dynacode series U  USB 1.0, connection plan (interfaces) ..........66 W  Warnings ....................5 Wiring plans Electronics ..................53 Mechanics (Dynacode 107) ............55 Mechanics (Dynacode 128) ............56 Mechanics (Dynacode 53) .............. 54 Service instructions 0808...
  • Page 71 Carl Valentin GmbH Neckarstraße 78 – 86 u. 94 . 78056 Villingen-Schwenningen Phone +49 (0)7720 9712-0 . Fax +49 (0)7720 9712-9901 info@carl-valentin.de . www.carl-valentin.de...

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