Carl Valentin DPM III xi Series Operating instructions

DPM III XI
Service Instructions

Copyright by Carl Valentin GmbH / 79670250209
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
0209
Service instructions
3
Table of contents
Table of contents.............................................................................. 3
1Notes on this document ....................................................... 5
1.1 User notes ............................................................................... 5
1.2 Instructions .............................................................................. 5
1.3 Cross references..................................................................... 6
2Safety instructions................................................................ 7
2.1 General safety instructions...................................................... 7
2.2 Safety handling when working with electricity....................... 10
3Electronics ........................................................................... 11
3.1 Replacing primary fuse.......................................................... 11
3.2 Replacing secondary fuse..................................................... 12
3.3 Replacing CPU PCB.............................................................. 13
3.4 Replacing printhead FPGA.................................................... 14
3.5 Replacing input/output FPGA................................................ 14
3.6 Replacing battery................................................................... 14
3.7 Replacing power supply unit ................................................. 15
3.8 Replacing Compact Flash card slot....................................... 16
3.9 Replacing input/output board ................................................ 17
4Refitting options.................................................................. 19
4.1 RS-485 and RS-422.............................................................. 19
4.2 Ethernet................................................................................. 20
5Mechanics ............................................................................ 21
5.1 Replacing printhead............................................................... 21
5.2 Angle adjustment................................................................... 23
5.3 Replacing tooth belt (linear drive).......................................... 24
5.4 Refitting brake ....................................................................... 25
5.5 Replacing zero point photocell .............................................. 26
5.6 Replacing end position photocell........................................... 27
5.7 Adjusting ribbon drive............................................................ 28
5.8 Adjusting ribbon tension........................................................ 29
5.9 Lubrication............................................................................. 30
6Error correction ................................................................... 31
7Control inputs and outputs ................................................ 41
7.1 Version I ................................................................................ 41
7.2 Version II ............................................................................... 45
8Wiring plans......................................................................... 49
8.1 Electronics............................................................................. 49
8.2 Mechanics ............................................................................. 50
9Layout diagrams.................................................................. 55
9.1 CPU....................................................................................... 55
9.2 Power supply unit (revision C)............................................... 57
9.3 Compact Flash card slot........................................................ 59
9.4 I/O board 24V ........................................................................ 60
9.5 Ethernet................................................................................. 62
9.6 Distributor board.................................................................... 63
9.7 Carriage board....................................................................... 65
9.8 Motor adapter ........................................................................ 67

Table of contents
DPM III xi series
4
Service instructions
0209
10 Connection plan of back panel plugs................................ 69
10.1 Motors.................................................................................... 69
10.2 Printhead signals................................................................... 69
10.3 Sensors ................................................................................. 70
11 Connection plan of interfaces............................................ 71
11.1 Centronics ............................................................................. 71
11.2 RS-232 .................................................................................. 71
11.3 RS-485 and RS-422.............................................................. 72
11.4 Ethernet................................................................................. 73
11.5 USB 1.0 ................................................................................. 73
12 Index ..................................................................................... 75

DPM III xi series
Notes on this document
0209
Service instructions
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 hardware and 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
DPM III xi series
6
Service instructions
0209
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.
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.
1.3 Cross references
References to specific items in a figure are marked with item
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. If a reference is made to another
graphic, the figure number is specified, e.g. (2, 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, on page 35).
References to other documents have the following form: See
'operating manual'.
Item numbers
Cross references to
chapters and sections
References to other
documents

DPM III xi series
Safety instructions
0209
Service instructions
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 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
DPM III xi series
8
Service instructions
0209
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
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.
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.
Protective equipment
General safety
instructions

DPM III xi series
Safety instructions
0209
Service instructions
9
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.

Safety instructions
DPM III xi series
10
Service instructions
0209
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.
⇒To 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.
Qualifications of
personnel
General precautions to
be heeded when
beginning maintenance
Additional precautions
to be heeded for
devices with exposed
energized parts
Tools
What to do in case an
accident occurs