Carl Valentin Dynacode II Series User manual

Copyright by Carl Valentin GmbH / 7957205.0816
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 Machinery Directive (2006/42/EG)
EG Low-Voltage Directive (2006/95/EG)
EG Electromagnetic Compatibility Directive (2004/108/EG)
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

Dynacode II Series
Table of Contents
08.16
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 Connection Side of Print Mechanics ....................................... 9
2.2 Connector Assignment of Control Unit.................................. 10
3Continuous Mode................................................................ 11
3.1 Material Speed ...................................................................... 11
3.2 Print Principle ........................................................................ 11
3.3 Material Guiding .................................................................... 12
4Intermittent Mode ................................................................ 13
4.1 Print Principle ........................................................................ 13
4.2 Print Position ......................................................................... 13
5Operating Conditions.......................................................... 15
6Technical Data ..................................................................... 19
6.1 Control Inputs and Outputs (Standard) ................................. 21
6.2 Control Inputs and Outputs (Option) ..................................... 26
6.3 Registered functions/profiles for inputs/outputs .................... 30
6.4 Pin Assignment of Encoder Socket ...................................... 32
7Installation and Initial Operation........................................ 33
7.1 Installation of Print Mechanics at Machines.......................... 34
7.2 Required Space for Cable Outgoing ..................................... 35
7.3 Connection of Pneumatic Power Supply............................... 36
7.4 Adjustment of Pressure Power.............................................. 37
7.5 Connecting the Direct Print Module....................................... 38
7.6 Before Initial Operation.......................................................... 38
7.7 Print Control........................................................................... 39
7.8 Initial Operation ..................................................................... 39
8Loading the Transfer Ribbon Cassette ............................. 41
8.1 Transfer Ribbon With Coating Outside.................................. 41
8.2 Transfer Ribbon With Coating Inside .................................... 42
8.3 Increasing the Clamping Force for Ribbon Roll .................... 43
9Function Menu..................................................................... 45
9.1 Menu Structure (Continuous Mode) ...................................... 45
9.2 Menu Structure (Intermittent Mode) ...................................... 48
9.3 Print Settings......................................................................... 51
9.4 Machine Parameters (Continuous Mode).............................. 52
9.5 Machine Parameters (Intermittent Mode).............................. 54
9.6 Layout.................................................................................... 56
9.7 Ribbon Save (Continuous Mode) .......................................... 57
9.8 Ribbon Save (Intermittent Mode) .......................................... 58
9.9 Device Settings...................................................................... 58
9.10 I/O Parameters...................................................................... 60
9.11 Network ................................................................................. 60
9.12 Remote Console.................................................................... 61
9.13 Interface................................................................................. 61
9.14 Emulation............................................................................... 62
9.15 Date & Time........................................................................... 63
9.16 Service Functions.................................................................. 64
9.17 Main Menu............................................................................. 66

Table of Contents
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Operating Manual
08.16
10 Touch-Screen Display......................................................... 67
10.1 Touch-Screen Display Structure ........................................... 67
10.2 Different Menus..................................................................... 68
10.3 Favorites List......................................................................... 69
10.4 Parameter Input..................................................................... 71
10.5 Navigation Zones................................................................... 73
10.6 Maintenance Zone................................................................. 74
10.7 Memory Menu........................................................................ 78
10.8 Information Zone ................................................................... 80
10.9 Change to Foil Keyboard....................................................... 80
11 Maintenance and Cleaning................................................. 81
11.1 General Cleaning................................................................... 81
11.2 Cleaning the Transfer Ribbon Roller..................................... 82
11.3 Cleaning the Printhead.......................................................... 82
11.4 Replacing the Printhead........................................................ 83
11.5 Angle Adjustment (Intermittent Mode)................................... 85
11.6 Print Quality Optimisation...................................................... 86
11.7 Cycle Optimisation (Intermittent Mode)................................. 87
12 Signal Diagrams .................................................................. 89
12.1 Continuous Mode .................................................................. 89
12.2 Intermittent Mode................................................................... 93
13 Error Correction................................................................... 95
14 Additional Information...................................................... 105
14.1 Hotstart................................................................................ 105
14.2 Password Protection............................................................ 107
15 Ribbon Save / Foil Saving ................................................ 109
15.1 Explication ........................................................................... 109
15.2 Standard Ribbon Save (Continuous Mode) ........................ 110
15.3 Shift Ribbon Save (Continuous Mode)................................ 112
15.4 SaveStrt Ribbon Save (Continuous Mode) ......................... 115
15.5 Standard Ribbon Save (Intermittent Mode)......................... 115
15.6 Shift Optimierung (intermittierender Modus) ....................... 116
16 Environmentally-Friendly Disposal ................................. 117
17 Index ................................................................................... 119

Dynacode II Series
Introduction
08.16
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.
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.
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.

Introduction
Dynacode II Series
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Operating Manual
08.16
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 110-
230 V. 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.
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.
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.

Dynacode II Series
Introduction
08.16
Operating Manual
7
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.

Dynacode II Series
Machine Overview
08.16
Operating Manual
9
2 Machine Overview
The continuous and intermittent operating direct print module with
high resolution is designed for installation in horizontal and vertical
packaging machines. Convincing is the availability of left and right
versions. Thanks to the separate control unit it is possible to integrate
the direct print module almost in each packaging process without any
problems.
Flexible labelling of packaging foil is effected either by means of
Windows printer driver included in delivery or by our proven design
software Labelstar Office.
With 8 vector fonts, 6 bitmap fonts and 6 proportional fonts the direct
print module has a large selection at different font types. It can be
printed inverse, in italic format or 90 degrees turned fonts.
The handling of our durable direct print modules is easy and
comfortable. The device settings can be made by the integrated,
intuitive touch-screen display.
By a new-developed electronics a maximum print speed up to 800
mm/s (continuous mode) and max. 600 mm/s (intermittent mode) can
be achieved.
Time-saving printer update is possible by interface.
As default, the direct print module is equipped with a parallel, serial,
USB and Ethernet interface. Additionally, the direct print module is
equipped with an USB Host that permits the connection of an external
USB keyboard and/or an USB memory stick. The direct print module
automatically recognizes by which interface it is controlled.
Thanks to the large number of options the direct print module can be
adapted to each task.
2.1 Connection Side of Print Mechanics
1 =
Pneumatic connection
2 =
Connecting cable SPI
(printhead + sensors)
3 =
Connecting cable Power
Figure 1

Machine Overview
Dynacode II Series
10
Operating Manual
08.16
2.2 Connector Assignment of Control Unit
N
A B C D E F G
M L K J HI
Figure 2
A =
Switch
B =
Serial interface RS-232
C =
USB Host interface (USB-B)
D =
Connecting cable Power
E =
Ethernet interface
F =
USB interface (USB-A)
G =
CF card slot
H =
Connection encoder
I =
Connecting cable SPI (printhead + sensor)
J =
Standard
Option
SUB-D female connector 15pin
External socket I/O-24
see chapter 6.1
SUB-D male connector 9pin
External input 5-8
see chapter 6.1
K =
Externer Ausgang 5-8 (Output II)
L =
Externer Eingang 1-4 (Input I)
M =
Externer Ausgang 1-4 (Output I)
N =
Power line

Dynacode II Series
Continuous Mode
08.16
Operating Manual
11
3 Continuous Mode
3.1 Material Speed
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.
3.2 Print Principle
Figure 3
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.

Continuous Mode
Dynacode II Series
12
Operating Manual
08.16
3.3 Material Guiding
Figure 4
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.

Dynacode II Series
Intermittent Mode
08.16
Operating Manual
13
4 Intermittent Mode
4.1 Print Principle
Figure 5
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.
4.2 Print 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 (see chapter 9.5 Machine
Parameters (Intermittent Mode), page 54).
Figure 6
A: Print pos. / Start pos. value = 93
C: Max. position print end
B: Print pos. / Start pos. value = 83
D: Stand-by position

Dynacode II Series
Operating Conditions
08.16
Operating Manual
15
5 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 5 (Operating Conditions),
chapter 8 (Loading the Transfer Ribbon Cassette) and chapter 11
(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.
Conditions for
installation place

Operating Conditions
Dynacode II Series
16
Operating Manual
08.16
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.
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 61000-6-3: 01-2007
Interference voltage to wires according to EN 55022: 05-2008
Interference field power according to EN 55022: 05-2008
System perturbation according to EN 61000-3-2: 09-2005
Flicker according to EN 61000-3-3: 05-2002
Installation of
power supply
Technical data of
power supply
Anti-interference
measures
Stray radiation and
immunity from
disturbance

Dynacode II Series
Operating Conditions
08.16
Operating Manual
17
Immunity according to EN 61000-6-2: 03-2006
Stray radiation against discharge of static electricity according to
61000-4-2: 03-2009
Electromagnetic fields according to EN 61000-4-3: 05-2006,
ENV 50204: 03-1995
Fast transient burst according to EN 61000-4-4: 07-2005
Störfestigkeit gegen Stoßspannungen (Surge) gemäß EN 61000-
4-5: 11-2006
High-frequency tension according to EN 61000-4-6: 03-2009
Voltage interruption and voltage drop according to EN 61000-4-
11: 02-2005
EN 60950-1: 2006 - Safety of pachaging machines
EN 60204-1: 2006 - Safety of machinery - Electrical equipment of
machines - Part 1
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
Stray radiation and
immunity from
disturbance
Machine safety
Connecting lines to
external machines
Installation of
data lines

Operating Conditions
Dynacode II Series
18
Operating Manual
08.16
To avoid inadmissible heating, free air convection has to be ensured.
Protection according IP: 20
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)
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.
Air convection
Limit values
Guarantee

Dynacode II Series
Technical Data
08.16
Operating Manual
19
6 Technical Data
Dynacode II 53
Dynacode II 107
Dynacode II 128
Print width
53.3 mm
106.6 mm
128 mm
Resolution
300 dpi
300 dpi
300 dpi
Print speed
Continuous mode
50 … 800 mm/s
50 … 600 mm/s
50 … 450 mm/s
Intermittent mode
50 … 600 mm/s
50 … 600 mm/s
50 … 600 mm/s
Back speed
intermittend mode only: max. 600 mm/s
Print length
Continuous mode
6000 mm
3000 mm
3000 mm
Intermittent mode
75 mm
75 mm
75 mm
Frame passage width
customized
customized
customized
Printhead
Corner Type
Corner Type
Corner Type
Acoustic emission (measuring distance 1 m)
Average sound power level
60 dB(A)
65 dB(A)
68 dB(A)
Transfer ribbon
Ink
outside / inside (option)
Max. roll diameter
98 mm
82 mm
75 mm
Core diameter
25.4 mm / 1"
25.4 mm / 1"
25.4 mm / 1"
Max. length
900 m
600 m
450 m
Max. width
55 mm
110 mm
130 mm
Dimensions in mm (width x height x depth)
Print mechanics
w/o mounting frame
204 x 182 x 235
204 x 182 x 290
204 x 182 x 310
with mounting frame
depends on passage width
Control unit
251 x 96 x 207 - connecting cable set to mechanics 2.5 m
Weight
Print mechanics
9.5 kg
11 kg
11.7 kg
Electronics (incl. cable)
5.5 kg
5.5 kg
5.5 kg
Elektronik
Processor
High Speed 32 Bit
RAM
16 MB
Slot
Compact Flash card type I
Battery cache
for Real-Time clock (storage of data with shut-down)
Warning signal
acoustic signal when error
Interfaces
Serial
RS-232C (up to 115.200 Baud)
USB
2.0 High Speed Slave
Ethernet
10/100 Base T, LPD, RawIP-Printing, DHCP, HTTP, FTP
2 x USB Master
connection for external USB keyboard and memory stick
Connection values
Pneumatic connection
min. 6 bar dry and free of oil
Nominal voltage
110 … 230 V / 50 … 60 Hz
Nominal current
230 V / 1.5 A −110 V / 3 A
Fuse values
2x T4A 250 V
Operation data
Temperature
5 … 40 °C
Humidity
max. 80% (non-condensing)

Technical Data
Dynacode II Series
20
Operating Manual
08.16
Dynacode II 53
Dynacode II 107
Dynacode II 128
Operation panel
Touchscreen Display
800 x 480 pixel with background lighting
screen size 7"
Operating functions
Home, function menu, maintenance, memory card, print start, test print,
feed, about menu
Settings
date, time, shift times
11 language settings (others on demand)
print and device parameters, interfaces, password protection
Monitoring
Stop printing if
end of ribbon / end of layout / printhead open
Status report
extensive status print with information about settings
e.g. print length counter, runtime counter,
photocell interface and network parameters
printout of all internal fonts and all supported bar codes
Fonts
Font types
6 Bitmap fonts, 8 Vector fonts/TrueType fonts, 6 proportional fonts
other fonts on demand
Character sets
Windows 1250 up to1257, DOS 437, 850, 852, 857
all West and East European Latin, Cyrillic, Greek
and Arabic (option) characters are supported
other character sets on demand
Bitmap fonts
size in width and height 0,8 … 5,6
zoom 2 … 9, orientation 0°, 90°, 180°, 270°
Vektor fonts/
TrueType fonts
size in width and height 1 … 99 mm
variable zoom
orientation 0°, 90°, 180°, 270°
Font attributes
depending on character font - bold, Italic, inverse, vertical
Font width
variable
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 7 Code, PZN 8 Code,
UPC-A, UPC-E
2D bar codes
Aztec Code, 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
all bar codes are variable in height, module width and ratio.
orientation 0°, 90 °, 180°, 270°.
Optionally with check digit and human readable line.
Software
Configuration
ConfigTool
Process control
NiceLabel
Design software
Labelstar Office Lite, Labelstar Office
Windows printer driver
Windows 7®32/64 Bit, Windows 8®32/64 Bit
Windows 8.1®32/64 Bit, Windows 10®32/64 Bit,
Windows Server 2008®(R2) 64 Bit
Windows Server 2012®64 Bit, Windows Server 2012®(R2) 64 Bit
Technical details are subject to change.