Carl Valentin Dynacode II IP53 User manual

DYNACODE II IP
Ingress Protection Version
OperatingManual

Copyright by Carl Valentin GmbH / 7957305.0321
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 EU
directives:
•Low-Voltage Directive (2014/35/EU)
•Electromagnetic Compatibility Directive (2014/30/EU)
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

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Table of Contents
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Table of Contents
1Introduction.................................................................... 7
1.1 General Instructions.......................................................7
1.2 Intended Use.................................................................7
1.3 Safety Instructions .........................................................8
1.4 Decommissioning and Dismantling.................................9
2Machine Overview........................................................ 11
2.1 Connection Side of Print Mechanics.............................11
2.2 Connector Assignment of Control Unit..........................12
3Continuous Mode......................................................... 13
3.1 Material Speed.............................................................13
3.2 Print Principle ..............................................................13
3.3 Material Guiding...........................................................14
4Intermittent Mode......................................................... 15
4.1 Print Principle ..............................................................15
4.2 Print Position ...............................................................15
5Operating Conditions................................................... 17
6Technical Data.............................................................. 21
6.1 Control Inputs and Control Outputs..............................23
6.2 Registered Functions/Profiles for Inputs/Outputs..........27
7Installation and Initial Operation................................. 33
7.1 Install the Print Mechanics at Machines........................34
7.2 Required Space for Cable Outgoing.............................35
7.3 Connect the Pneumatic Power Supply .........................36
7.4 Install the protective cover for control unit IP65 ............37
7.5 Adjust the Pressure Power...........................................40
7.6 Connect the Direct Print Module...................................41
7.7 Before Initial Operation................................................41
7.8 Print Control.................................................................42
7.9 Initial Operation............................................................42
8Load Transfer Ribbon Cassette .................................. 43
8.1 Transfer Ribbon with Coating Outside..........................43
8.2 Transfer Ribbon with Coating Inside.............................44
8.3 Increase the Clamping Force for Ribbon Roll ...............45
9Water and Dust Protection Unit .................................. 47
9.1 Transfer Ribbon Cassette / Cleaning Cassette.............47
9.2 Use the Cleaning Cassette...........................................48
10 Function Menu ............................................................. 49
10.1 Menu Structure (Continuous Mode)..............................49
10.2 Menu Structure (Intermittent Mode)..............................54
10.3 Print Settings...............................................................59
10.4 Machine Parameters (Continuous Mode).....................60
10.5 Machine Parameters (Intermittent Mode)......................62
10.6 Layout Settings............................................................64

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10.6.1 Extended Layout Settings................................64
10.6.2 General Parameters........................................64
10.7 Device Settings............................................................65
10.7.1 Print Job .........................................................65
10.7.2 Print Control....................................................67
10.7.3 User Environment ...........................................67
10.7.4 General Parameters........................................67
10.8 I/O Parameters ............................................................68
10.8.1 I/O Port Parameter 1-8....................................68
10.8.2 I/O Port Parameter 9-16..................................68
10.8.3 General Parameters........................................68
10.9 Ribbon Saving / Foil Saving.........................................70
10.10 Ribbon Saving STANDARD (Continuous Mode)...........71
10.10.1 Required Parameters......................................71
10.10.2 Print Performance Information.........................73
10.10.3 Expert Parameters..........................................73
10.10.4 General Parameters........................................75
10.11 Ribbon Saving SHIFT (Continuous Mode)....................75
10.11.1 Required Parameters......................................75
10.11.2 Ribbon Saving SHIFT Parameters...................77
10.11.3 Expert Parameters..........................................79
10.11.4 General Parameters........................................80
10.12 Ribbon Saving SAVESTRT (Continuous Mode)............81
10.12.1 Required Parameters......................................81
10.12.2 Expert Parameters..........................................82
10.12.3 General Parameters........................................84
10.13 Ribbon Saving STANDARD (Intermittent Mode............85
10.13.1 Required Parameters......................................85
10.13.2 Expert Parameters..........................................86
10.13.3 General Parameters........................................86
10.14 Ribbon Saving SHIFT (Intermittent Mode)....................87
10.14.1 Required Parameters......................................87
10.14.2 Ribbon Saving SHIFT Parameters...................88
10.14.3 Expert Parameters..........................................91
10.14.4 General Parameters........................................91
10.15 Network.......................................................................92
10.16 Interface......................................................................93
10.16.1 COM1.............................................................93
10.16.2 General Parameters........................................93
10.17 Emulation ....................................................................94
10.18 Date/Time....................................................................95
10.18.1 Daylight Saving Time (DST)............................95
10.18.2 Start Daylight Saving Time..............................95
10.18.3 End Daylight Saving Time...............................95
10.18.4 General Parameters........................................95
10.19 Service Functions........................................................96
10.19.1 Sensor Status.................................................96
10.19.2 Device Status..................................................97

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10.19.3 Ribbon Service................................................98
10.19.4 Brake Service..................................................99
10.19.5 I/O Status........................................................99
10.19.6 Encoder Service............................................100
10.19.7 General Parameters......................................101
10.20 Password...................................................................101
10.20.1 Operation......................................................102
10.20.2 Network ........................................................102
10.21 Maintenance..............................................................103
10.21.1 Test Function................................................103
10.21.2 Print Preview.................................................103
10.21.3 LCD..............................................................104
10.21.4 System Settings............................................104
10.22 Main Menu.................................................................104
11 Touch-Screen Display................................................ 105
11.1 Touch-Sscreen Display Structure...............................105
11.2 Different Menus .........................................................106
11.3 User-Defined Info Field..............................................107
11.4 Favorites List.............................................................109
11.5 Parameter Input.........................................................111
11.6 Navigation Zones.......................................................113
11.7 Maintenance Zone.....................................................114
11.8 Process Data.............................................................119
11.9 Memory Menu............................................................121
11.10 Information Zone........................................................123
11.11 Change to Foil Keyboard ...........................................123
12 Maintenance and Cleaning........................................ 125
12.1 General Cleaning.......................................................125
12.2 Clean the Transfer Ribbon Roller...............................126
12.3 Clean the Printhead...................................................126
12.4 Replace the Printhead................................................127
12.5 Angle Adjustment (Intermittent Mode) ........................129
12.6 Print Quality Optimisation...........................................130
12.7 Cycle Optimisation (Intermittent Mode).......................131
13 Signal Diagrams......................................................... 133
13.1 Continuous Mode.......................................................133
13.2 Intermittent Mode.......................................................137
14 Error Correction......................................................... 139
15 Additional Information............................................... 149
15.1 Hotstart......................................................................149
15.2 Cycles for the continuous mode.................................151
15.3 Cycles for the intermittent mode.................................157
16 Environmentally-Friendly Disposal........................... 161
17 Index ........................................................................... 163

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Dynacode II IP
Introduction
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Operating Manual
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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
Date
Information in the display
1.2 Intended Use
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.

Introduction
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Intended used includes heeding the operating manual, including the
maintenance recommendations/regulations specified by the
manufacturer.
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 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.
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 AC. 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.
Maintenance and servicing work can only be carried out by trained
personnel.
Operating personnel must be trained by the operator on the basis of
the operating manual.
Depending on use, ensure that clothing, hair, jewellery and similar
personal items do not contact the exposed rotating parts and/or the
moving parts (e.g. print carriage).

Dynacode II IP
Introduction
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Operating Manual
9
NOTICE!
With the open printing unit (due to construction) the requirements
of EN 62368-1 regarding fire protection casing are not fulfilled.
These must be ensured by the installation into the end device.
The print unit and parts of it (e.g. motor, printhead) can get hot during
printing. Do not touch the printhead during operation. Cool down the
print unit before changing material, removal or adjustment.
Never use highly inflammable consumables.
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.
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.
1.4 Decommissioning and Dismantling
NOTICE!
The decommissioning of printing system can only be carried out
by trained staff.
CAUTION!
Danger of injury by imprudent handling when lifting or placing
the printing system.
Do not underestimate the weight of the printing system
(9 … 12 kg).
Protect the printing system against uncontrolled
movement.

Introduction
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Dynacode II IP
Machine Overview
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Operating Manual
11
2 Machine Overview
The continuous and intermittent operating direct print module is a
direct print module with high resolution for installation in horizontal and
vertical packaging machines. Not only the easy to change ribbon
cassette and/or cleaning cassette is convincing but also different print
widths, left and right versions and because of the separate control unit
the direct print module can be integrated in almost 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 eight vector fonts, six bitmap fonts and six 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.
The advanced technology achieves a high print quality.
Time-saving firmware update is possible by interface. As default, the
direct print module is equipped with a 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
Figure 1
A = Pneumatic connection
B = Connecting cable SPI
B = (printhead + sensors)
C = Connecting cable Power

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2.2 Connector Assignment of Control Unit
A B C
DEFGHIJKLM
21
NO
Figure 2
A =
Function keys
B =
Touch Panel
C =
Status LED
D =
Encoder connection
E =
Slot for memory card
F =
Connecting cable SPI
G =
External inputs/outputs
H =
USB port
I =
Ethernet port
J =
USB host for USB keyboard and USB stick
K =
Connecting cable Power
L =
Serial interface RS-232
M =
Power supply
N =
Grounding bolt
O =
Switch
1 - LED green
1 - Lighting = Speed 100 MBit
1 - Off = Speed 10 MBit
2 - LED orange
2 - Lighting = Connection active
2 –Flashing = Data transfer
2 - Off = No connection

Dynacode II IP
Continuous Mode
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Operating Manual
13
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
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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.

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Intermittent Mode
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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 10.5 Machine
Parameters (Intermittent Mode), page 62).
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

Intermittent Mode
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Dynacode II IP
Operating Conditions
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17
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.
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 (Load Transfer Ribbon Cassette) and chapter 12
(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
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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. Please 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.
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 62368-1.
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.
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
Technical data of
power supply
Anti-interference
measures
Connecting lines to
external machines
Installation of
data lines
Allowable lines

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Operating Conditions
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To avoid inadmissible heating, free air convection has to be ensured.
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)
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

Operating Conditions
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