Carl Valentin DPM III XI User manual

Copyright by Carl Valentin GmbH / 7967005A.0418
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 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
[phone]
[phone]
E-Mail
Internet
[e-mail]
www.carl-valentin.de

DPM III xi series
Table of contents
04.18
Operating manual
3
Table of contents
Table of contents.............................................................................. 3
1Introduction............................................................................ 5
1.1 General Instructions ................................................................ 5
1.2 Intended Use........................................................................... 5
1.3 Safety Instructions................................................................... 6
2Machine Overview................................................................. 9
2.1 Print Mechanics....................................................................... 9
2.2 Connector Assignment of Control Unit.................................. 10
2.3 Connector Assignment of Control Unit IP Version ................ 11
2.4 Print Principle ........................................................................ 12
3Operating Conditions.......................................................... 13
4Technical Data ..................................................................... 17
4.1 Control Inputs and Outputs (Standard) ................................. 18
4.2 Control Inputs and Outputs (Option) ..................................... 23
5Installation and Initiation.................................................... 27
5.1 Installation of Print Mechanics at Machines.......................... 28
5.2 Connection of Pneumatic Power Supply............................... 29
5.3 Adjustment of Pressure Power.............................................. 30
5.4 Connecting the Direct Print Module....................................... 31
5.5 Before Initial Operation.......................................................... 31
5.6 Print Control........................................................................... 32
5.7 Initiation ................................................................................. 32
5.8 Loading Transfer Ribbon....................................................... 33
6Foil Keyboard....................................................................... 35
6.1 Keyboard Assignment (Standard) ......................................... 35
6.2 Keyboard Assignment (Text Entry/Customized/Memory Card)
36
7Function Menu..................................................................... 39
7.1 Menu Structure...................................................................... 39
7.2 Print Settings......................................................................... 41
7.3 Machine Parameters ............................................................. 42
7.4 Layout Settings...................................................................... 45
7.5 Ribbon Save.......................................................................... 46
7.6 Device Settings...................................................................... 47
7.7 I/O Parameters...................................................................... 49
7.8 Network (DPM IIIxi optional only).......................................... 50
7.9 Interface................................................................................. 51
7.10 Emulation............................................................................... 52
7.11 Date & Time........................................................................... 53
7.12 Service Functions.................................................................. 54
7.13 Main Menu............................................................................. 56
8Compact Flash Card............................................................ 57
9Maintenance and Cleaning................................................. 63
9.1 General Cleaning................................................................... 63
9.2 Cleaning the Transfer Ribbon Drawing Roller....................... 64
9.3 Cleaning the Printhead.......................................................... 64
9.4 Replacing the Printhead........................................................ 65
9.5 Transfer Ribbon Tension....................................................... 66
9.6 Angle Adjustment .................................................................. 67
9.7 Zero Point Adjustment........................................................... 68
9.8 Print Quality Optimisation...................................................... 69
9.9 Cycle Optimisation................................................................. 70

Table of contents
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Operating manual
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10 Signal Diagrams .................................................................. 71
10.1 Mode 1 (single item processing) ........................................... 71
10.2 Mode 2 (continuous mode).................................................... 72
10.3 Mode 4 (continuous mode).................................................... 73
10.4 Mode 8 (single item processing) ........................................... 74
11 Error Correction................................................................... 75
12 Additional Information........................................................ 85
12.1 Column Printing..................................................................... 85
12.2 Hotstart.................................................................................. 86
12.3 Password............................................................................... 88
13 Environmentally-Friendly Disposal ................................... 91
14 Index ..................................................................................... 93

DPM III xi series
Introduction
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Operating manual
5
1 Introduction
1.1 General 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
Datum
Information in the display
1.2 Intended Use
The direct print module is a state-of-the-art device which complies
with the recognized safety-related rules and regulations. Despite this,
a danger to life and limb of the user or third parties could arise and the
direct print module or other property could be damaged while
operating the device.
The direct print module may only be used while in proper working
order and for the intended purpose. Users must be safe, aware of
potential dangers and must comply with the operating instructions.
Faults, in particular those which affect safety, must be remedied
immediately.

Introduction
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Operating manual
04.18
The direct print module is solely intended to print suitable media which
have been approved by the manufacturer. Any other or additional use
is not intended. The manufacturer/supplier is not liable for damage
resulting from misuse. Any misuse is at your own risk.
Intended used includes heeding the operating manual, including the
maintenance recommendations/regulations specified by the
manufacturer.
NOTICE!
The complete documentation is included in the scope of
delivery on CD ROM and can also currently be found in the
internet.
1.3 Safety Instructions
The direct print module is designed for power supply systems of
230 V. 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 (see Technical Data).
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.
In case of cleaning and maintenance with an open cover, ensure that
clothing, hair, jewellery and similar personal items do not contact the
exposed rotating parts.
NOTICE!
With the open printing unit (due to construction) the requirements
of EN60950-1 regarding fire protection casing are not fulfilled.
These must be ensured by the installation into the end device.
The print unit can get hot during printing. Do not touch the printhead
during operation. Cool down the print unit before changing material,
removal or adjustment.
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.

DPM III xi series
Introduction
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Operating manual
7
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
device from the mains supply and wait approx. 2 - 3
minutes until the power supply unit has discharged.

DPM III xi series
Machine Overview
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Operating manual
9
2 Machine Overview
The direct print module is equipped with 8 vector, 6 bitmap and 6
proportional fonts. It is possible to print inverse, in italic format or 90
degrees turned fonts.
The handling of our durable print module is easy and comfortable. The
settings are made with the keys of the foil keyboard. At each time the
two-line display shows the current status.
An enormously high print quality is obtained by most modern
printhead technology.
Time-saving update of the design software is possible by interface.
As default, the print module is equipped with a parallel, serial and
USB interface. Additionally the IP version is by default equipped with
Ethernet interface. The device automatically recognizes by which
interface it is controlled.
Thanks to the large number of options the print module can be
adapted to each task.
2.1 Print Mechanics
Figure 1
1 =
Zero point adjustment
2 =
Printing carriage
3 =
End position control
4 =
Ribbon rewinding unit
5 =
Printhead
6 =
Ribbon unwinding unit

Machine Overview
DPM III xi series
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Operating manual
04.18
2.2 Connector Assignment of Control Unit
Figure 2
1 =
External output 1-4 (Output I)
2 =
External input 1-4 (Input I)
3 =
External output 5-8 (Output II)
4 =
Standard
Option
SUB-D plug 15-pin
External bushing I/O-24
see chapter 4.1
SUB-D plug 9-pin
External input 5-8
see chapter 4.1
5 =
Centronics interface
6 =
RS-232 interface
7 =
Ethernet interface (option)
8 =
Connecting cable power
9 =
Connecting cable motor
10 =
Connecting cable signal
11 =
Connecting cable sensors
12 =
Power supply
13 =
PS/2 keyboard connection
14 =
USB interface

DPM III xi series
Machine Overview
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Operating manual
11
2.3 Connector Assignment of Control Unit IP Version
Figure 3
1 =
External output 1-4 (Output I)
2 =
External input 1-4 (Input I)
3 =
External output 5-8 (Output II)
4 =
External bushing I/O-24
5 =
RS-232 interface
6 =
Ethernet interface
7 =
Centronics interface
8 =
USB interface
9 =
Connecting cable sensors
10 =
Connecting cable power
11 =
Connecting cable signal
12 =
Connecting cable motor
13 =
Power switch
14 =
Electric supply

Machine Overview
DPM III xi series
12
Operating manual
04.18
2.4 Print Principle
Figure 4
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.

DPM III xi series
Operating Conditions
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Operating manual
13
3 Operating Conditions
Before initial operation and during operation these operating
conditions have to be observed to guarantee save and interference-
free service of our direct print modules.
Therefore please carefully read these operating conditions.
Shipment and storage of our direct print modules are only allowed in
original packing.
Installation and initial operation of direct print modules is only allowed
if operating conditions were fulfilled.
Commissioning is prohibited until it can be established that, where
relevant, the machine into which the partly completed machinery is to
be incorporated complies with the provisions of Machinery Directive
2006/42/EC.
Initial operation, programming, operation, cleaning and service of our
direct print modules are only recommended after careful study of our
manuals.
Operation of direct print modules is only allowed by especially trained
persons.
NOTICE!
Perform trainings regularly. Content of the training are chapter
Operating Conditions, Loading Transfer Ribbon and chapter
Maintenance and Cleaning.
These indications are also valid for someone else's equipment
supplied by us.
Only use original spare and exchange parts.
Please contact the manufacturer with respect to spare/wear parts.
The installation place of direct print module should be even, free of
vibration and currents of air are to be avoided.
The direct print modules have to be installed to ensure optimal
operation and servicing.
The installation of the power supply to connect our direct print
modules has to be effected according to the international rules and
regulations, especially the recommendations of one of the three
following commissions:
International Electronic Commission (IEC)
European Committee for Electro technical Standardisation
(CENELEC)
Verband Deutscher Elektrotechniker (VDE)
Our direct print modules are constructed according to VDE and have
to be connected to a grounded conductor. The power supply has to be
equipped with a grounded conductor to eliminate internal interfering
voltage.
Conditions for
installation place
Installation of
power supply

Operating Conditions
DPM III xi series
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Operating manual
04.18
Power line voltage and power line frequency: See type plate
Allowable tolerance of power line voltage:
+6% …−10% of nominal value
Allowable tolerance of power line frequency:
+2% …−2% of nominal value
Allowable distortion factor of power line voltage: <=5%
In case your net is infected (e.g. by using thyristor controlled
machines) anti-interference measures have to be taken. It is possible
to use one of the following possibilities:
Provide separate power supply to our direct print modules.
In case of problems please connect capacity-decoupled isolation
transformer or similar interference suppressor in front of our direct
print modules.
Emitted interference according to EN 55022
Interference voltage to wires according to EN 55022:2011-04
Interference field power according to EN 55022:2011-04
System perturbation according to EN 61000-3-2:2010-03
Flicker according to EN 61000-3-3:2014-03
Immunity according to EN 61000-6-2:2011-06
Stray radiation against discharge of static electricity according to
EN 61000-4-2:2009-12
Electromagnetic fields according to EN 61000-4-3:2011-04
Fast transient burst according to EN 61000-4-4:2013-04
Surge according to EN 61000-4-5:2007-06
High-frequency tension according to EN 61000-4-6:2009-12
Voltage interruption and voltage drop according to EN 61000-4-
11:2005-02
NOTICE!
This is a machine of type A. This machine can cause
interferences in residential areas; in this case it can be
required from operator to accomplish appropriate measures
and be responsible for it.
EN 60950-1: 2006 - Safety of pachaging machines
EN 60204-1: 2006 - Safety of machinery - Electrical equipment of
machines - Part 1
Technical data of
power supply
Anti-interference
measures
Stray radiation and
immunity from
disturbance
Machine safety

DPM III xi series
Operating Conditions
04.18
Operating manual
15
All connecting lines have to be guided in shielded lines. Shielding has
to be connected on both sides to the corner shell.
It is not allowed to guide lines parallel to power lines. If a parallel
guiding cannot be avoided a distance of at least 0.5 m has to be
observed.
Temperature of lines between: −15 …+80 °C.
It is only allowed to connect devices which fulfil the request 'Safety
Extra Low Voltage' (SELV). These are generally devices which are
checked corresponding to EN 60950.
The data cables must be completely protected and provide with metal
or metallised connector housings. Shielded cables and connectors are
necessary, in order to avoid radiant emittance and receipt of electrical
disturbances.
Allowable lines
Shielded line:
4 x 2 x 0,14 mm² ( 4 x 2 x AWG 26)
6 x 2 x 0,14 mm² ( 6 x 2 x AWG 26)
12 x 2 x 0,14 mm² (12 x 2 x AWG 26)
Sending and receiving lines have to be twisted in pairs.
Maximum cable length:
interface V 24 (RS-232C) - 3 m (with shielding)
USB - 3 m
Ethernet - 100 m
To avoid inadmissible heating, free air convection has to be ensured.
DPM IIIxi: Protection according IP 20
DPM III xi IP: Protection according IP 65
Ambient temperature °C (operation): Min. +5 Max. +40
Ambient temperature °C (transport, storage): Min. −25 Max. +60
Relative air humidity % (operation): Max. 80
Relative air humidity % (transport, storage): Max. 80
(bedewing of direct print modules not allowed)
Connecting lines to
external machines
Installation of
data lines
Air convection
Limit values

Operating Conditions
DPM III xi series
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Operating manual
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We do not take any responsibility for damage caused by:
Ignoring our operating conditions and operating manual.
Incorrect electric installation of environment.
Building alterations of our direct print modules.
Incorrect programming and operation.
Not performed data protection.
Using of not original spare parts and accessories.
Natural wear and tear.
When (re)installing or programming our direct print modules please
control the new settings by test running and test printing. Herewith you
avoid faulty results, reports and evaluation.
Only specially trained staff is allowed to operate the direct print
modules.
Control the correct handling of our products and repeat training.
We do not guarantee that all features described in this manual exist in
all models. Caused by our efforts to continue further development and
improvement, technical data might change without notice.
By further developments or regulations of the country illustrations and
examples shown in the manual can be different from the delivered
model.
Please pay attention to the information about admissible print media
and the notes to the direct print module maintenance, in order to avoid
damages or premature wear.
We endeavoured to write this manual in an understandable form to
give and you as much as possible information. If you have any queries
or if you discover errors, please inform us to give us the possibility to
correct and improve our manual.
Guarantee

DPM III xi series
Technical Data
04.18
Operating manual
17
4 Technical Data
DPM III xi53
DPM III xi107
DPM III xi128
Print width
53,3 mm
106,6 mm
128 mm
Print length
60 mm, 140 mm, 240 mm, 340 mm, 447 mm, 570 mm, 630 mm
Resolution
300 dpi
Print speed
50…450 mm/s*
50…450 mm/s*
50…400 mm/s*
Back speed
50…500 mm/s*
50…500 mm/s*
50…400 mm/s*
Printhead
Corner Type
Built-in fonts
vector fonts: 8
bitmap fonts: 6
proportional fonts: 6
font height: min. 1 mm - max. 99 mm
Bar codes
1D bar codes
CODABAR, Code 128, Code 2/5 interleaved, Code 39, Code 39 extended,
Code 93, EAN 13, EAN 8, EAN ADD ON, GS1-128, Identcode, ITF 14,
Leitcode, Pharmacode, PZN Code, UPC-A, UPC-E
2D bar codes
CODABLOCK F, DataMatrix, GS1 DataMatrix, MAXICODE,
PDF 417, QR Code
Composite bar codes
GS1 DataBar Expanded, GS1 DataBar Limited, GS1 DataBar Omnidirectional,
GS1 DataBar Stacked, GS1 DataBar Stacked Omnidirectional, GS1 DataBar
Truncated
Interface
Serial: RS-232C (up to 19200 Baud); Parallel: Centronics; USB: 1.1
Ethernet: 10/100 Base-T**
Transfer ribbon
Core diameter
Length max.
Width max.
Colour
25,4 mm / 1"
450 m (Ø 85 mm)
55 mm
outside/inside
25,4 mm / 1"
450 m (Ø 85 mm)
110 mm
outside/inside
25,4 mm / 1"
450 m (Ø 85 mm)
130 mm
outside/inside
Module memory
Memory card
max. 4 MB
Compact Flash Card: 1 GB, 2 GB
Dimensions in mm (width x height x depth)
Print mechanics
(print length + 230) x
170 x 260
(print length + 230) x
170 x 3150
(print length + 230) x
x 170 x 335
Control unit
285 x 130 x 350 - connecting cable to mechanics 2,5 m
Weight
Print mechanics
Electronics (incl. cable)
(depending on print width)
e.g. xi53 x 60 mm = 7,3 kg / xi128 x 630 mm = 23 kg
10,5 kg
Connection values
Pneumatic connection
Air consumption typical*
* hub 1,5 mm
150 cycle/minute
6 bar operating pressure
Nominal voltage
Nominal current
Safety values
min. 6 bar dry and free of oil
DPM IIIxi 53: 150 ml/min –DPM IIIxi 107+128: 300 ml/min
standard: 230 V / 50-60 Hz
option: 115 V / 50-60 Hz
230 V / 1,5 A −115 V / 3 A
230 V / 3,15 AT −115 V / 6,3 A
Operation data
Ingress Protection Rating
Temperature
Relative humidity
IP 65 (IP version only)
5-40 °C
max. 80% (non-condensing)
Technical modifications are subject to change.
*depending on installation position
** for DPM IIIxi optional only

Technical Data
DPM III xi series
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Operating manual
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4.1 Control Inputs and Outputs (Standard)
Figure 5
A = External output 1-4 (Output I)
B = External input 1-4 (Input I)
C = External output 5-8 (Output II)
D = External bushing 15pin (I/O-24)
By means of the signal outputs different operating states of the print
module can be queried.
The signal outputs are provided by two 9-pin SUB-D-bushings
(OUTPUT I and OUTPUT II) on the back side of the control unit.
They consist of optocoupler semiconductor sections, which are
connected through and/or blocked according to different operating
states.
The maximum allowable current in a semiconductor section is
lmax = 30 mA.
Output I
Figure 5, A
Figure 6
PIN (bushing)
Output I
Out 1: Error message
Each error status such as ribbon
error is displayed.
Out 2: Print order
The print module was activated by a
print order.
Out 3: Generation
The print module is filled with current
layout data.
Out 4: Layout print
The content of print memory is
transferred on the printable medium
by means of the printhead.
Plug connection - back
side of control unit
Control outputs

DPM III xi series
Technical Data
04.18
Operating manual
19
Connection of a lamp to a 24V relay by Out 1:
Figure 7
Output II
Figure 5, C
Figure 8
PIN (bushing)
Output II
Out 5: Print-Ready signal
It is indicated if the print module is
ready to process a start impulse. In
contrary to the print order signal, the
generating time is taken into
consideration.
Out 6: Printhead up
The printhead has reached the upper
rest position (e.g. return to zero
point).
Out 7: Return to start
After termination of print procedure
the flexible part of the print module is
moved back to the start position.
After the start position was reached a
new start can be released.
Out 8: Prior warning of transfer
ribbon end
Example

Technical Data
DPM III xi series
20
Operating manual
04.18
By means of the control inputs it is possible to control printing. The
control inputs at Input I are galvanic separated and have to be
provided with an external tension source. The signal level is active
"HIGH".
Input I
Figure 5, B
Figure 9
PIN (pin)
Input I
In 1: Print start
In 2: Not used
In 3: Reset external counter
In 4: Not used
Connection of a switch with 24V voltage supply by In 1:
Figure 10
Control inputs
Example