Carl Valentin DYNACODE II Operating instructions

DYNACODE II
Service Instructions

Copyright by Carl Valentin GmbH / 7957225.0517
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:
CE
EU Low-Voltage Directive (2014/35/EU)
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

Dynacode II
Table of Contents
05.17
Service Instructions
3
Table of Contents
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
2.2Safety Handling when Working with Electricity ....................... 9
2.3 Environmentally-Friendly Disposal........................................ 10
3General Notes ...................................................................... 11
3.1 Continuous Mode .................................................................. 11
3.2 Intermittent Mode................................................................... 12
3.3 Change the Module Type...................................................... 13
4Electronics (Replacing Components) ............................... 15
4.1 Primary Fuses ....................................................................... 15
4.2 CPU PCB............................................................................... 16
4.3 Battery ................................................................................... 17
4.4 Input/Output Board................................................................ 17
4.5 Power Supply Unit................................................................. 19
5Cleaning ............................................................................... 21
5.1 Cleaning Instructions............................................................. 21
5.2 Transfer Ribbon Roller .......................................................... 22
5.3 Printhead ............................................................................... 22
6Printhead.............................................................................. 23
6.1 Replace the Printhead........................................................... 23
6.2 Angle Adjustment .................................................................. 24
7Ribbon Cassette (Replacing Components) ...................... 25
7.1 Track Roller ........................................................................... 25
7.2 Return Pulley......................................................................... 27
7.3 Ribbon Rewinder Roll/Unwinder Roll.................................... 28
8Printing Carriage (Replacing Components) ..................... 29
8.1 Printhead Fastener, Pressure Bail, Interlayer ....................... 30
8.2 Guiding Carriage ................................................................... 31
8.3 Motor Circuit Board................................................................ 32
9Print Mechanics (Replacing Components)....................... 33
9.1 Pneumatic Valve.................................................................... 33
9.2 Pressure Switch..................................................................... 34
9.3 Encoder ................................................................................. 35
9.4 Limit Switch ........................................................................... 36
9.5 Cassette Switch..................................................................... 37
9.6 LEDs...................................................................................... 38
10 Error Correction................................................................... 39
11 Inputs and Outputs.............................................................. 49
11.1 Control Inputs and Outputs (Standard) ................................. 49
11.2 Control Inputs and Outputs (Option) ..................................... 54
12 Wiring Plans......................................................................... 59
12.1 Control Unit............................................................................ 59
12.2 Print Mechanics Dynacode II 53............................................ 60
12.3 Print Mechanics Dynacode II 107.......................................... 61
12.4 Print Mechanics Dynacode II 128.......................................... 62

Table of Contents
Dynacode II
4
Service Instructions
05.17
13 Layout Diagrams ................................................................. 63
13.1 CPU....................................................................................... 63
13.2 Power Electronics.................................................................. 64
13.3 Dispenser I/O......................................................................... 65
13.4 Motor Plate............................................................................ 66
14 Connector Assignment of Control Unit ............................ 67
15 Index ..................................................................................... 69

Dynacode II
Notes on this Document
05.17
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 the electronics and the
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
Dynacode II
6
Service Instructions
05.17
1.3 Cross References
References to specific items in a figure are marked with letters. They
are identified with parentheses in the text, e.g. (A). If no figure number
is provided, letters 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. (A, 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, page 35).
References to other documents have the following form: See
'operating manual'.
Drawings
Cross references to
chapters and sections
References to other
documents

Dynacode II
Safety Instructions
05.17
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
Dynacode II
8
Service Instructions
05.17
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
110 V AC …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).
NOTICE!
With the open printing unit (due to construction) the requirements
of EN 60950-1/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.
Protective equipment
General safety
instructions

Safety Instructions
Dynacode II
05.17
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.
CAUTION!
Two-pole fuse.
Before opening the housing cover, disconnect the
printing system from the mains supply and wait for a
moment until the power supply unit has discharged.
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.
Qualifications of
personnel
General precautions to
be heeded when
beginning maintenance

Safety Instructions
Dynacode II
10
Service Instructions
05.17
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.
Do 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.
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.
The electronics board of the printing system is equipped with a
battery. This must only be discarded in battery collection containers or
by public waste management authorities.
Further information on the WEEE directive is available on our website
www.carl-valentin.de.
Additional precautions
to be heeded for
devices with exposed
energized parts
Tools
What to do in case an
accident occurs

Dynacode II
General Notes
05.17
Service Instructions
11
3 General Notes
3.1 Continuous Mode
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.
Figure 1
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.
Figure 2
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.
Material Speed
Print Principle
Material Guiding

General Notes
Dynacode II
12
Service Instructions
05.17
3.2 Intermittent Mode
Lift
Print surface
Feed
Packaging material
Printhead
Figure 3
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.
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.
Figure 4
A: Print pos. / Start pos. value = 93
B: Print pos. / Start pos. value = 83
C: Max. position print end
D: Stand-by position
Print Principle
Print position

General Notes
Dynacode II
05.17
Service Instructions
13
3.3 Change the Module Type
Tap on the Functions button.
On the left side of the display, select Maintenance/ System Settings.
Select Printer Info, tap on the desired Printer Type and confirm your
selection.
In order to change the printer type, the service password must be
entered.
Password: 2904
After entering the service password, the device is restarted.
Maintenance - System
settings

General Notes
Dynacode II
14
Service Instructions
05.17

Dynacode II
Electronics (Replacing Components)
05.17
Service Instructions
15
4 Electronics (Replacing Components)
DANGER!
Risk of death via electric shock!
Before opening the housing cover, disconnect the
printing system from the mains supply and wait for a
moment until the power supply unit has discharged.
4.1 Primary Fuses
A
AA
B
B
Figure 5
1. Unplug the control unit from the electrical outlet.
2. Unscrew all screws (A) and remove the housing.
3. Pull the fuse-holder (B) from the housing.
4. Replace the fuses (2x T4A 250 V).
5. Push the fuse-holer (B) into the housing until it engages.
6. Close the housing of the printing sytsem.

Electronics (Replacing Components)
Dynacode II
16
Service Instructions
05.17
4.2 CPU PCB
A
B
A
B
B
C
D
Figure 6
NOTICE!
Save the configuration of direct print module onto a CF card.
1. Unplug the control unit from the electrical outlet.
2. Remove the cover of control unit.
3. Unplug all connections from the CPU PCB (C).
4. Remove the fixing screws (A).
5. Remove all screws (B) from the CPU PCB.
6. Remove the CPU BCP (C) carefully.
1. Install the CPU PCB (C) with the interface connections into the
connection plate.
2. Fix the CPU PCB with screws (B).
3. Tighten the screws (A).
4. Insert all plug connections on the PCB.
5. Restore all interface connections.
6. Connect again the power cable.
7. Verify the firmware version and update it, if necessary.
8. Load the configuration of the direct print module from CF card.
Otherwise set the configuration with help from the function menu.
Remove the
CPU PCB
Install the
CPU PCB

Dynacode II
Electronics (Replacing Components)
05.17
Service Instructions
17
4.3 Battery
DANGER!
Danger of explosion due to improper replacement of the
battery!
Use non-conductive tools.
Pay attention to polarity.
1. Lift up the fixing bracket by means of a non-metallic device (e.g.
plastic ruler).
2. Remove the battery.
3. Instert a new battery (CR 2032) into the support (D, Figure 6).
NOTICE!
Pay attention to polarity.
4.4 Input/Output Board
NOTICE!
The inputs/outputs can be tested in the Service Functions.
If an input is activated then the position corresponding to this
input changes to 1.
To activate an output, move the cursor to the corresponding
position and press the keys and to set value 1.
To deactivate the output, set the corresponding position again
to 0.
Inputs and outputs marked with 'x' are not occupied (example
at the left side). The example refers to the I/O Profile
'standard_direct' (see function menu I/O Parameters).

Electronics (Replacing Components)
Dynacode II
18
Service Instructions
05.17
A AB
Figure 7
1. Unplug the control unit from the electrical outlet
2. Remove the cover of control unit.
3. Remove the CPU PCB (see chapter 4.2, page 16).
4. Remove all connections from the I/O interface (B).
5. Remove the screws (A).
6. Remove the I/O board.
1. Install the new I/O board.
2. Tighten the screws (A).
3. Insert again all connections.
4. Install the CPU PCB.
5. Close the housing of control unit.
6. Connect again the power cable.
Remove the
I/O board
Install the
I/O board

Dynacode II
Electronics (Replacing Components)
05.17
Service Instructions
19
4.5 Power Supply Unit
BC
Figure 8
D
D
D
DA A
A A
Figure 9
1. Unplug the control unit from the electrical outlet.
2. Remove the CPU PCB (see chapter 4.2, page 16).
3. Remove the insulating plate (C).
4. Remove the plug connectors (D) from the power unit (B).
5. Loosen the screws (A) of the power supply unit (B).
At the same time hold the power supply unit.
1. Place the new power unit in the control unit and fix it with the
screws (A).
2. Connect the plug connectors (D) to the power unit (B).
3. Fix the insulating plate (C).
4. Install the CPU PCP.
5. Close the housing of control unit.
6. Connect again the power cable.
Remove the power
supply unit
Install the power
supply unit

Electronics (Replacing Components)
Dynacode II
20
Service Instructions
05.17