Carl Valentin Dynacode Series Operating instructions

DYNACODE
Service Instructions

Copyright by Carl Valentin GmbH / 7957005.1112
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 (98/37/EC)
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
[email protected]
www.carl-valentin.de

Dynacode series Table of contents
0808 Service instructions 3
Table of contents
Table of contents.............................................................................. 3
1Notes on this document ....................................................... 5
1.1User notes ............................................................................... 5
1.2Warnings ................................................................................. 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
3General notes....................................................................... 11
3.1Continuous mode .................................................................. 11
3.2Intermittent mode................................................................... 12
3.3Change module type ............................................................. 13
4Electronics ........................................................................... 15
4.1Replacing primary fuse.......................................................... 15
4.2Replacing CPU PCB.............................................................. 16
4.3Replacing battery................................................................... 17
4.4Replacing input/output board ................................................ 17
4.5Replacing power supply unit ................................................. 18
4.6Replacing Compact Flash card slot....................................... 19
5Mechanics ............................................................................ 21
5.1Replacing printhead .............................................................. 21
5.2Replacing printhead cable..................................................... 23
5.3Angle adjustment (intermittent mode) ................................... 23
5.4Replacing parties at cassette ................................................ 24
5.5Replacing parties at printing carriage.................................... 26
5.6Replacing motor circuit board................................................ 28
5.7Replacing parties at print mechanics .................................... 29
5.8Replacing encoder................................................................. 30
5.9Dual reflective encoder.......................................................... 31
5.10Replacing limit switch, cover switch and LED ....................... 31
6Error correction................................................................... 33
7Control inputs and outputs ................................................ 43
7.1Version I ................................................................................ 43
7.2Version II ............................................................................... 47
8Wiring plans......................................................................... 53
8.1Electronics ............................................................................. 53
8.2Mechanics ............................................................................. 54
9Layout diagrams.................................................................. 57
9.1CPU ....................................................................................... 57
9.2Power supply unit .................................................................. 58
9.3Compact Flash card slot........................................................ 59
9.4I/O board 24V ........................................................................ 60
9.5Motor circuit board................................................................. 61
10Connection plan of back panel plugs................................ 63
10.1Tension.................................................................................. 63
10.2Printhead signals................................................................... 63
10.3Touch Panel .......................................................................... 64
10.4Encoder (continuous mode) .................................................. 64

Table of contents Dynacode series
4 Service instructions 0808
11Connection plan of interfaces............................................ 65
11.1Centronics ............................................................................. 65
11.2RS-232 .................................................................................. 65
11.3Ethernet ................................................................................. 66
11.4USB 1.0 ................................................................................. 66
12Index ..................................................................................... 67

Dynacode series Notes on this document
0808 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
instructionsl, then please contact your responsible dealer.
1.2 Warnings
Warnings are presented with three signal words for the different levels
of danger.
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.
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.

Notes on this document Dynacode series
6 Service instructions 0808
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

Dynacode series Safety instructions
0808 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.
Workplace and
method of working
Clothing

Safety instructions Dynacode series
8 Service instructions 0808
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
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.
Protective clothing
Protective equipment

Dynacode series Safety instructions
0808 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

Dynacode series General notes
0808 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.
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.
Figure 2
Material speed
Print principle
Material guiding

General notes Dynacode series
12 Service instructions 0808
3.2 Intermittent mode
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.
The direct print module is delivered with a default print length of
65 mm. In order to use the maximum print length, the print position
value must be changed to 93 (Function Menu: Machine
Parameters).
A: Print position/start position value = 93 mm
B: Print position/start position value = 83
C: Max. position print end
D: Stand-by position
Print principle
Print position

Dynacode series General notes
0808 Service instructions 13
3.3 Change module type
Press key to access the function menu.
Press key as long as you arrive at the service functions menu.
Press key to select the menu.
Press key as long as you arrive at the 'Paper Counter' menu.
Press key to access the 'Password' menu.
Enter the service password '2904'.
Press key to confirm the entry.
Press key and to select the module type.
Press key to confirm the entry.
The changed module type is indicated in the display.
Press key to arrive at the next display.
Indication if a standard motor (ID166) or a stronger motor (ID267) is
installed.
Press key to arrive at the next display.
Press key and to select if a left or a right print module is
mounted.

Dynacode series Electronics
0808 Service instructions 15
4 Electronics
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 Replacing primary fuse
Figure 4
The primary fuse is in line filter block that can be accessed from
outside.
1. Unplug the machine and then open its cover.
2. Remove the fuse-holder which is behind.
3. Replace the fuse (microfuse 2,0 AT).

Electronics Dynacode series
16 Service instructions 0808
4.2 Replacing CPU PCB
Figure 5
1. If possible, save the configuration of module to a CompactFlash
card.
2. Unplug the module from the electrical outlet.
3. Remove cover of control unit.
4. Detach all interface cables from the CPU PCB.
5. Remove fixing screws at the Centronics interface.
6. Remove screws (A) from I/I board (B).
7. Remove I/O board.
8. Remove hexagon bolt and all retaining screws at CPU PCB.
9. Carefully remove CPU PCB.
1. Place CPU PCB onto the retainers.
2. Secure the PCB and I/O board with screws (A).
3. Insert all plug connections on the PCB.
4. Restore all interface connections.
5. Connect the power cable.
6. Update the firmware if necessary.
7. If possible, load the configuration from memory card. Otherwise,
set the configuration by the function menu.
Removing the
CPU PCB
Installing the
CPU PCB

Dynacode series Electronics
0808 Service instructions 17
4.3 Replacing battery
DANGER!
Danger of explosion when exchanging the battery
improper.
Pay attention to polarity.
1. Lift up the fixing bracket by means of a non-metallic device (e.g.
plastic ruler).
2. Remove the defective battery.
3. Insert a new battery into the support and pay attention to position
of polarity.
4.4 Replacing input/output board
The installation and removal of I/O plate is described in chapter 4.2 on
page 16.
It is possible to test the inputs/outputs in the Service Functions menu.
In case an input is activated then the position which corresponds to
this input changes to 1.
An output can be activated by positioning the cursor at the
corresponding position and then using the keys and to set the
value to 1.
If the value is set to 0, the output is deactivated.

Electronics Dynacode series
18 Service instructions 0808
4.5 Replacing power supply unit
Figure 6
1. Remove cover of control unit.
Figure 7
2. Unscrew retaining screws (A) of power
supply unit (B) from electronics
underside.
At the same time hold power supply
unit.
Figure 8
3. Deposit power supply unit next to the
control unit (see photo).
4. Remove transparent cover above the
clamps (C).
5. Loosen clamps (C) and remove all
wires.
6. Insert again the power supply unit in
reverse order. At the same time see the
correct cable assignment at the
clamps!

Dynacode series Electronics
0808 Service instructions 19
4.6 Replacing Compact Flash card slot
Figure 9
1. Remove cover of control unit.
2. Unplug connecting cable to CPU at slot (A).
3. Unscrew retaining screws (B) at fastener.
4. Remove defective slot.
5. Install a new slot in reverse order.
For damages at the transparent cover, the slot must be
dismantled with fastener. For that purpose, remove 4
retaining screws (C) at rear panel.