Carl Valentin DUOPRINT Operating instructions

DUOPRINT
Service Instructions

Copyright by Carl Valentin GmbH / 7981025.0113
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 label printers comply with the following safety guidelines:
CE EG Low-Voltage Directive (2006/95/EC)
EG Electromagnetic Compatibility Directive (2004/108/EC)
Carl Valentin GmbH
Postfach 3744
78026 Villingen-Schwenningen
Neckarstraße 78 – 86 u. 94
78056 Villingen-Schwenningen
Phone
Fax
[phone]
[phone]
E-Mail
Internet
[email protected]
www.carl-valentin.de

DuoPrint Series Table of Contents
01.13 Service Instructions 3
Table of Contents
Table of Contents............................................................................. 3
1Notes on this Document....................................................... 5
1.1User Notes............................................................................... 5
1.2Instructions .............................................................................. 5
1.3Cross References.................................................................... 6
2Safety Instructions................................................................ 7
2.1General Safety Instructions ..................................................... 7
2.2Safety Handling when Working with Electricity ....................... 9
2.3Environmentally-Friendly Disposal ........................................ 10
2.4Connector Pin Assignment (Printer Rear)............................. 10
3Cleaning ............................................................................... 11
3.1General Cleaning................................................................... 12
3.2Cleaning the Printer Roller .................................................... 12
3.3Cleaning the Printhead.......................................................... 13
3.4Cleaning the Label Photocell................................................. 14
4Replacing Components ...................................................... 15
4.1Tool list .................................................................................. 15
4.2Replacing the Printhead ........................................................ 16
4.3Replacing the Printer Roller .................................................. 18
4.4Replacing the Label Photocell............................................... 19
4.5Replacing CPU PCB.............................................................. 20
4.6Replacing the Power Supply ................................................. 22
4.7Replacing the Battery ............................................................ 23
5Adjustments, settings and alignments ............................. 25
5.1Adjusting the print mechanism .............................................. 25
5.2Adjusting the Printhead Position ........................................... 26
5.3Adjusting the Ribbon Rewinder/Unwinder............................. 28
5.4Adjusting the Head Photocell ................................................ 29
5.5Setting the Pressure Curve (Ribbon Save) ........................... 30
5.6Setting the Supporting Bar (Ribbon Save) ............................ 32
5.7Oil and Lubricate ................................................................... 33
6Refitting Options ................................................................. 35
6.1Refitting the Input/Output Plate ............................................. 35
7Error correction................................................................... 37
8Control inputs and outputs ................................................ 47
9Wiring Plan........................................................................... 53
10Connection Plans................................................................ 55
10.1CPU ....................................................................................... 55
10.2Power Electronics.................................................................. 56
11Index ..................................................................................... 57

DuoPrint Series Notes on this Document
01.13 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 label printer.
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.
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

Notes on this Document DuoPrint Series
6 Service Instructions 01.13
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

DuoPrint Series Safety Instructions
01.13 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 an electric drill
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 DuoPrint Series
8 Service Instructions 01.13
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 label printer is designed for power supply systems of
110-230 V. Connect the label printer only to electrical outlets with a
ground contact.
Couple the label printer to devices using extra low voltage only.
Before making or undoing connections, switch off all devices involved
(computer, printer, accessories etc.).
Operate the label printer in a dry environment only and do not get it
wet (sprayed water, mist etc.).
Do not operate the label printer in explosive atmosphere and not in
proximity of high voltage power lines.
Operate the label printer 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.
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 label printer 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 label printers 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.
DANGER!
Danger to life and limb from power supply!
Do not open the casing.
Protective equipment
General safety
instructions

DuoPrint Series Safety Instructions
01.13 Service Instructions 9
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

Safety Instructions DuoPrint Series
10 Service Instructions 01.13
2.3 Environmentally-Friendly Disposal
Manufacturers of B2B equipment are obliged to take back and
dispose of old equipment that was manufactured after 13 August
2005. As a principle, this old equipment may not be delivered to
communal collecting points. 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.
Carl Valentin GmbH thereby fulfils all obligations regarding timely
disposal of old equipment and facilitates the smooth reselling of these
products. Please understand that we can only take back equipment
that is sent free of carriage charges.
Further information on the WEEE directive is available on our website
www.carl-valentin.de.
2.4 Connector Pin Assignment (Printer Rear)
Figure 1
A Power supply
B External Output/Input (Option)
C Compact Flash card slot
D USB interface
E Serial interface RS-232
Pin 2 = TXD, Pin 3 = RXD, Pin 5 = GND,
Pin 7 = CTS, Pin 8 = RTS
F Ethernet 10/100 interface
1 = LED orange
Lighting = Connection active
Flashing = Data transfer
Off = No connection
2 = LED green
Lighting: Speed 100 MBit
Off: Speed 10 MBit
G USB host for USB keyboard and
USB memory stick
H Centronics

DuoPrint Series Cleaning
01.13 Service Instructions 11
3 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.
Maintenance task Frequency
General cleaning
(see chapter 3.1, page 12).
As necessary.
Cleaning printer roller
(see chapter 3.2, page 12).
Each time the label roll is
changed or when the printout and
label transport are adversely
affected.
Cleaning printhead
(see chapter 3.3, page 13).
Each time the transfer ribbon is
changed or when the printout is
adversely affected.
Cleaning label photocell
(see chapter 3.4, page 14).
When exchanging the label roll.
NOTICE!
The handling instructions for the use of Isopropanol (IPA) must
be observed. In the case of skin or eye contact, immediately
wash off the fluid thoroughly with running water. If the irritation
persists, consult a doctor. Ensure good ventilation.
WARNING!
Risk of fire by easily inflammable label soluble!
When using label soluble, dust must be completely
removed from the label printer and cleaned.
Cleaning schedule

Cleaning DuoPrint Series
12 Service Instructions 01.13
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.
Clean outer surfaces with an all-purpose cleaner.
3.2 Cleaning the Printer Roller
A soiled print roll can lead to reduced print quality and can affect
transport of material.
Figure 2
1. Open printer cover.
2. Turn red lever (D) counter clockwise to lift up the printhead (A).
3. Remove labels and transfer ribbon form the label printer.
4. Remove deposits with roller cleaner and a soft cloth.
5. Turn the roller (B + C) manually step by step to clean the
complete roller (only possible when printer is switched off, as
otherwise the step motor is full of power and the roller is kept in its
position).

DuoPrint Series Cleaning
01.13 Service Instructions 13
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.
CAUTION!
Printhead can be damaged!
Do not use sharp or hard objects to clean the
printhead.
Do not touch protective glass layer of the printhead.
Figure 3
1. Open printer cover.
2. Turn red lever (D, in Figure 2) anticlockwise to lift up the
printhead.
3. Remove labels and transfer ribbon from the label printer.
4. Clean printhead surface with special cleaning pen or a cotton
swab dipped in pure alcohol.
5. Allow printhead to dry for 2-3 minutes before commissioning the
printer.

Cleaning DuoPrint Series
14 Service Instructions 01.13
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.
Figure 4
1. Open printer cover.
2. Turn red lever anticlockwise to lift up the printhead.
3. Remove labels and transfer ribbon from the label printer.
4. Blow out the photocell (A) with pressure gas spray.
Observe strictly the instructions on the spray can!
5. Clean the label photocell (A) additionally with a cleaning card (B)
before soaked in pure alcohol. Move the cleaning card from one
side to the other (see illustration).
6. Reload the labels and transfer ribbon.

DuoPrint Series Replacing Components
01.13 Service Instructions 15
4 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.
4.1 Tool list
Some service work requires the following tools:
Philips-head screwdriver, size 1
Hexagonal wrench 1.5 mm
Hexagonal wrench 2.5 mm
Spring scale 10 N
Spring scale 25 N

Replacing Components DuoPrint Series
16 Service Instructions 01.13
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.
Do not touch contacts on the plug connections.
Do not touch the printhead with hard objects or your
hands.
Figure 5
1. Open the printer cover.
2. Remove labels and transfer ribbon from the label printer.
3. When printhead is closed, loosen the fixing screws (G).
4. Remove the label guiding between the printheads.
5. Turn red lever (E) anticlockwise to lift up the printhead.
6. If the printhead (5) is not disengaged on the pressure roller (J),
continue loosen the fixing screws (G).
7. Remove the printhead carefully to the front until you can reach the
plug connections.
8. Remove plug connections and then remove printhead.
Removing the
printhead

DuoPrint Series Replacing Components
01.13 Service Instructions 17
Figure 6
1. Attach plug connections.
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.
4. Screw in fixing screws (G) and tighten it.
5. Install again the label guiding.
6. Reload labels and transfer ribbon.
7. Check resistance value on the type plate of printhead and if
necessary change the value in the menu Service functions/Heater
resistance.
Installing the printhead

Replacing Components DuoPrint Series
18 Service Instructions 01.13
4.3 Replacing the Printer Roller
Figure 7
1. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
2. Remove the protective conductor at the inside of the printer cover.
3. Loosen screws (A) and remove tear off edge (if mounted) before
the pressure roller.
4. Turn red lever (E) counter clockwise to lift up the printhead.
5. Loosen pins (F) from belt pulley (G) on the print roller (D).
6. Remove protective disc (C) and ball bearing (B).
7. Pull print roller (D) through the drillings outwards.
Hold the belt pulley (G).
1. Insert the new print roller (D) through the drillings and the belt
pulley (G).
2. Mount the ball bearing (B) and the protective disc (C).
3. When reassembling the belt pulley (G), a pin must meet the milled
surface of roller axe.
4. Tighten pins (F) strongly.
The roller has to be installed precisely.
5. Connect the protective conductor to the inside of cover.
6. Mount again the printer cover.
Removing the
print roller
Installing the
print roller

DuoPrint Series Replacing Components
01.13 Service Instructions 19
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. Remove media from the printer.
2. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
3. Remove the protective conductor at the inside of the printer cover.
4. Turn knurled knob (A) counter clockwise, until the photocell (C)
can be removed from the adjusting axis (B).
5. Unplug the cable from the plug on the rear end of the label
photocell (C).
1. Connect the cable to the label photocell (C).
2. Place photocell (C) on the adjusting axis (B) and turn knurled
knob (A) in clockwise direction until the photocell arrives at the
desired position.
3. Connect the protective conductor to the inside of printer cover.
4. Install the left printer cover.
5. Adjust the label photocell.
NOTICE!
When reinstalling the photocell take care that the photocell runs
centrically in the plate aperture. One-sided tilting can entail a
worse signal level or label accumulation.
Removing label
photocell
Installing the label
photocell

Replacing Components DuoPrint Series
20 Service Instructions 01.13
4.5 Replacing CPU PCB
Figure 9
HINWEIS!
Save the printer configuration onto CF card.
1. Unplug the printer from the electrical outlet.
2. Unplug all interface cables from the printer rear.
3. Remove the CF card from the slot.
4. Unscrew the left printer cover.
5. Unscrew the cover at the CPU PCB (B).
6. Unplug all connections from the CPU PCB.
7. Remove the 4 bolts (A) of the CPU PCB.
8. Remove the CPU PCB carefully from the snap fits.
9. Unscrew the both angles of CPU PCB.
Removing the
CPU PCB