Carl Valentin DUOPRINT Service Instructions Manual
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Carl Valentin DUOPRINT Service Instructions Manual

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DUOPRINT
Service Instructions

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Summary of Contents for Carl Valentin DUOPRINT

  • Page 1 DUOPRINT 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 label printers comply with the following safety guidelines: EG Low-Voltage Directive (2006/95/EC) EG Electromagnetic Compatibility Directive (2004/108/EC)

  • Page 3: Table Of Contents

    DuoPrint Series Table of Contents Table of Contents   Table of Contents ................3     Notes on this Document ............5 User Notes ................5     Instructions ................5     Cross References ..............6      ...

  • Page 5: Notes On This Document

    DuoPrint 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 label printer. Information about operation of the direct print module can be taken from our operating manual.

  • Page 6: Cross References

    Notes on this Document DuoPrint 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

    DuoPrint 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 DuoPrint Series Protective equipment 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.

  • Page 9: Safety Handling When Working With Electricity

    DuoPrint 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 10: Environmentally-Friendly Disposal

    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.

  • Page 11: Cleaning

    DuoPrint Series Cleaning Cleaning DANGER! Risk of death by electric shock!  Disconnect the label printer from power supply before performing any maintenance work. NOTICE! When cleaning the label printer, personal protective equipment such as safety goggles and gloves are recommended.

  • Page 12: General Cleaning

    Cleaning DuoPrint Series 3.1 General Cleaning CAUTION! Abrasive cleaning agents can damage the label printer!  Do not use abrasives or solvents to clean the outer surface of the label printer.  Remove dust and paper fuzz in the printing area with a soft brush or vacuum cleaner.

  • Page 13: Cleaning The Printhead

    DuoPrint Series Cleaning 3.3 Cleaning the Printhead Printing can cause accumulation of dirt at printhead e.g. by colour particles of transfer ribbon, and therefore it is necessary to clean the printhead in regular periods depending on operating hours, environmental effects such as dust etc.

  • Page 14: Cleaning The Label Photocell

    Cleaning DuoPrint Series 3.4 Cleaning the Label Photocell CAUTION! Label photocell can be damaged!  Do not use sharp or hard objects or solvents to clean the label photocell. The label photocell can become dirtied with paper dust and this can adversely affect label detection.

  • Page 15: Replacing Components

    DuoPrint Series Replacing Components Replacing Components 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.

  • Page 16: Replacing The Printhead

    Replacing Components DuoPrint Series 4.2 Replacing the Printhead CAUTION! The printhead can be damaged by static electricity discharges and impacts!  Set up the device on a grounded, conductive surface.  Ground your body, e.g. by wearing a grounded wristband.
  • Page 17 DuoPrint Series Replacing Components Figure 6 1. Attach plug connections. Installing the printhead 2. Position printhead in printhead mounting bracket in such a way that the pins are secured in the corresponding holes in the head plate. 3. Lightly keep printhead mounting bracket on the printer roller with one finger and check for correct positioning of the printhead.

  • Page 18: Replacing The Printer Roller

    Replacing Components DuoPrint Series 4.3 Replacing the Printer Roller Figure 7 1. Remove left printer cover. Removing the Loosen 3 screws at the lower left printer edge and 3 screws at the print roller chassis upper edge. 2. Remove the protective conductor at the inside of the printer cover.

  • Page 19: Replacing The Label Photocell

    DuoPrint Series Replacing Components 4.4 Replacing the Label Photocell NOTICE! Soiling of the label photocell can also cause malfunctions. Before replacing the label photocell, check whether it is soiled and clean it if necessary (see chapter 3.4, page 14). Figure 8 1.

  • Page 20: Replacing Cpu Pcb

    Replacing Components DuoPrint Series 4.5 Replacing CPU PCB Figure 9 HINWEIS! Save the printer configuration onto CF card. 1. Unplug the printer from the electrical outlet. Removing the CPU PCB 2. Unplug all interface cables from the printer rear. 3. Remove the CF card from the slot.
  • Page 21 DuoPrint Series Replacing Components Installing the CPU PCB 1. Screw the angles with the CPU PCB. 2. Insert the CPU PCB into the printer and lock it carefully in the snap fits. 3. Fix the CPU PCB with the 4 bolts (A).

  • Page 22: Replacing The Power Supply

    Replacing Components DuoPrint Series 4.6 Replacing the Power Supply Figure 10 1. Unplug the printer from the electrical outlet. Removing the power supply 2. Remove the CPU PCB cover (see chapter 4.5, page 20). 3. Unplug all cable connections from power supply (C).

  • Page 23: Replacing The Battery

    DuoPrint Series Replacing Components 4.7 Replacing the Battery DANGER! Danger of explosion when exchanging the battery improper.  Pay attention to polarity. Figure 11 1. Lift up the fixing bracket by means of a non-metallic device (e.g. plastic ruler). 2. Remove the defective battery.

  • Page 25: Adjustments, Settings And Alignments

    DuoPrint Series Adjustments, settings and alignments Adjustments, settings and alignments 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.

  • Page 26: Adjusting The Printhead Position

    Adjustments, settings and alignments DuoPrint Series 5.2 Adjusting the Printhead Position Complete the following printhead settings to achieve the best possible print image:  Align the heating line with the highest point of the print roller. Density of the print image is the greatest at this point.
  • Page 27 DuoPrint Series Adjustments, settings and alignments After adjusting parallelism and no even strong pressure exists over Pressure balance the complete print width, by means of a plate (C, Figure 12) the right/left balance can be set as follows: 1. Loosen screw (D, Figure 12) about one quarter turn.

  • Page 28: Adjusting The Ribbon Rewinder/Unwinder

    Adjustments, settings and alignments DuoPrint Series 5.3 Adjusting the Ribbon Rewinder/Unwinder Figure 13 Due to the many different transfer ribbon variants regarding roller width, length and qualities it is necessary to provide the possibility to set transfer ribbon tension. The transfer ribbon tension is to set in such way that no wrinkles in the ribbon appear but it is transported in the same way as the labels.

  • Page 29: Adjusting The Head Photocell

    DuoPrint Series Adjustments, settings and alignments 5.4 Adjusting the Head Photocell The head photocell prevents printing from occurring when the printhead is open. Figure 14 1. Unplug the printer from the electrical outlet. 2. Remove left printer cover. Loosen 3 screws at the lower left printer edge and 3 screws at the chassis upper edge.

  • Page 30: Setting The Pressure Curve (Ribbon Save)

    Adjustments, settings and alignments DuoPrint Series 5.5 Setting the Pressure Curve (Ribbon Save) If the ribbon save function is activated and the printhead is not enough lifted up from the label material, then the pressure curve is to be adjusted anew. The pressure curve is onto the shaft of the ribbon save motor (A).
  • Page 31 DuoPrint Series Adjustments, settings and alignments The sketch (siehe Figure 16) shows from behind the shaft of ribbon save motor (A) with pressure curve (B) and disc (C). The bearing ring (D) with the attached sole plate (E) is underneath.

  • Page 32: Setting The Supporting Bar (Ribbon Save)

    Adjustments, settings and alignments DuoPrint Series 5.6 Setting the Supporting Bar (Ribbon Save) Figure 17 If the transfer ribbon save function is active and a paper jam occurs or if the print position onto the label is incorrect, this could be traced back to an inadequate adjustment of the supporting bar (A).

  • Page 33: Oil And Lubricate

    DuoPrint Series Adjustments, settings and alignments 5.7 Oil and Lubricate NOTICE! Make sure when oiling and greasing that no lubricants deposit on photocells, electronic components, circuit boards, printhead and rolls. A = Grease B = Low viscosity oil C = Oil...

  • Page 35: Refitting Options

    DuoPrint Series Refitting Options Refitting Options 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.

  • Page 37: Error Correction

    DuoPrint 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 38 Error correction DuoPrint 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 39 DuoPrint 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 40 Error correction DuoPrint 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 41 DuoPrint 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 42 Error correction DuoPrint 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 43 DuoPrint 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 44 Error correction DuoPrint 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 45 DuoPrint 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 47: Control Inputs And Outputs

    DuoPrintSeries Control inputs and outputs Control inputs and outputs By means of a maximum of 16 control inputs and outputs which, in the following, are also referred to as ports, different functions of the printer system can be triggered and operating states can be displayed. The ports are provided by means of a D-Sub bushing (26pin HD) at the rear panel of the printer system and are galvanically isolated from protective earth (PE) by means of an optocoupler semi-conductor...
  • Page 48 Control inputs and outputs DuoPrint Series Configuration of D-Sub socket Figure 22 Port 1 to Port 16 = Assignment for I/O Profile 'Std_Label' Identification Description / Function Port 1 Print start (Input) Port 2 No function Port 3 Counter Reset (Input)
  • Page 49 DuoPrint Series Control inputs and outputs Identification Description / Function + 5 VDC 5 Volt DC output for external use. Max. 1 A. This voltage is provided from direct print module and can be used e.g. as control voltage. Never apply any external voltage to this output.
  • Page 50 Control inputs and outputs DuoPrint Series Device connection to a machine with S7-300 SPS. Example 1 Figure 23 Device connection to a operating panel. Example 2 Figure 24 Service Instructions 01.13...
  • Page 51 DuoPrint Series Control inputs and outputs Device connection version if 'Option: 2. LED'. Example 3 Figure 25 When connecting a reed contact with a control input, the contact must Precautions have a switching capacity of min. 1 A in order to prevent the contact from sticking due to the inrush current.

  • Page 53: Wiring Plan

    DuoPrintSeries Wiring Plan Wiring Plan Figure 26 01.13 Service Instructions...
  • Page 54 Wiring Plan DuoPrint Series Figure 27 Service Instructions 01.13...

  • Page 55: Connection Plans

    DuoPrintSeries Connection Plans 10 Connection Plans 10.1 CPU Figure 28 Jumper plan JP1 (Debug) JP2 (Schreibschutz) closed closed Boot sector Programming closed open Delivery 01.13 Service Instructions...

  • Page 56: Power Electronics

    Connection Plans DuoPrint Series 10.2 Power Electronics Figure 29 Service Instructions 01.13...

  • Page 57: Index

    DuoPrintSeries Index 11 Index A  Adjustments, settings, alignments Head photocell ................29 Oil and lubricate ................33 Pressure curve (ribbon save) ........... 30, 31 Print mechanism ................25 Printhead position ..............26, 27 Ribbon rewinder ................28 Ribbon unwinder ................28 Supporting bar (ribbon save) ............
  • Page 58 Index DuoPrint Series J  Jumper plan CPU ................55 L  Label photocell Cleaning ..................14 Replacing ..................19 Lubricate and oil ................. 33 O  Oil and lubricate ................. 33 P  Power electronics, connection plan ............ 56 Power supply, replacing ..............22 Pressure curve (ribbon save), setting ..........
  • Page 60 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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