Carl Valentin DYNACODE User manual

DYNACODE
Operating Manual

Copyright by Carl Valentin GmbH / 7957005.1015
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
10.15 Operating manual 3
Table of contents
Table of contents.............................................................................. 3
1Important notes ..................................................................... 5
1.1Intended use............................................................................ 5
1.2Environmentally-friendly disposal............................................ 6
1.3Figures..................................................................................... 6
1.4Continuous mode .................................................................... 8
1.5Intermittent mode..................................................................... 9
2Safety notes ......................................................................... 11
2.1Warnings ............................................................................... 12
2.2Operating conditions.............................................................. 13
3Technical data...................................................................... 17
3.1Control inputs and outputs (standard) ................................... 18
3.2Control inputs and outputs (option) ....................................... 23
3.3Plug & Play ............................................................................ 27
3.4Pin assignment of encoder socket ....................................... 28
4Installation and Initiation.................................................... 29
4.1Installation of print mechanics at machines .......................... 30
4.2Connection of pneumatic power supply ................................ 32
4.3Adjustment of pressure power............................................... 33
4.4Connecting the direct print module........................................ 34
4.5Before initial operation........................................................... 34
4.6Print control ........................................................................... 35
4.7Initiation ................................................................................. 35
5Loading ribbon cassette..................................................... 37
5.1Ribbon coating outside.......................................................... 37
5.2Ribbon coating inside ............................................................ 38
5.3Increasing the clamping force for ribbon roll ......................... 39
6Foil keyboard....................................................................... 41
6.1Keyboard assignment (standard) .......................................... 41
6.2Keyboard assignment (text entry/customized) ...................... 42
7Function menu..................................................................... 45
7.1Menu structure (continuous mode)........................................ 45
7.2Menu structure (intermittent mode) ....................................... 47
7.3Print settings.......................................................................... 49
7.4Machine parameters (continuous mode)............................... 50
7.5Machine parameters (intermittent mode) .............................. 52
7.6Layout settings ...................................................................... 54
7.7Ribbon save (continuous mode)............................................ 55
7.8Ribbon save (intermittent mode) ........................................... 56
7.9Device settings ...................................................................... 57
7.10I/O parameters....................................................................... 59
7.11Network ................................................................................. 60
7.12Remote console..................................................................... 60
7.13Interface................................................................................. 61
7.14Emulation............................................................................... 62
7.15Date & time............................................................................ 63
7.16Service functions ................................................................... 64
7.17Main menu............................................................................. 67
7.18Display during printing........................................................... 69
8Compact Flash card............................................................ 71

Table of contents Dynacode series
4 Operating manual 10.15
9Maintenance and cleaning.................................................. 75
9.1Cleaning the printhead .......................................................... 75
9.2Replacing the printhead ........................................................ 75
9.3Angle adjustment* ................................................................. 77
9.4Print quality optimisation ....................................................... 78
9.5Cycle optimisation* ................................................................ 79
10Signal diagrams................................................................... 81
10.1Continuous mode .................................................................. 81
10.2Intermittent mode................................................................... 85
11Error correction................................................................... 87
12Additional information........................................................ 97
12.1Column printing ..................................................................... 97
12.2Password............................................................................... 98
12.3Hotstart ................................................................................ 100
13Ribbon save....................................................................... 101
13.1Explication ........................................................................... 101
13.2Standard ribbon save (continuous mode) ........................... 102
13.3Shift ribbon save (continuous mode)................................... 105
13.4SaveStrt ribbon save (continuous mode) ............................ 108
13.5Standard ribbon save (intermittent mode)........................... 109
13.6Shift ribbon save (intermittent mode) .................................. 110
14Index ................................................................................... 111

Dynacode series Important notes
10.15 Operating manual 5
1 Important notes
The Dynacode is equipped with 8 vector, 6 bitmap and 6 proportional
fonts. It is possible to print inverse, in italic format or 90 degrees
turned fonts.
The handling of our durable print module is easy and comfortable. The
settings are made with the keys of the foil keyboard. At each time the
two-line display shows the current status.
An enormously high print quality is obtained by most modern
printhead technology.
By a new-developed electronics a maximum print speed of up to 800
mm/s (continuous mode) and 600 mm/s (intermittent mode) can be
achieved. Time-saving update of the print module software is possible
via the interface. The print module can be adapted by the large
selection of options to each function.
As default, the print module is equipped with a parallel, serial, USB
and Ethernet interface. The device automatically recognizes by which
interface it is controlled.
Time-saving update is possible by interface.
Thanks to the large number of options the print module can be
adapted to each task.
1.1 Intended use
The continuous and intermittent operating Dynacode is a direct print
module with high resolution for installation in horizontal and vertical
packaging machines. Not only the easy to change ribbon cassette is
convincing but also different print widths, left and right versions and
because of the separate control unit it is possible to integrate the
Dynacode almost in 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 creation
software.
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.
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 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.
Intended used includes heeding the operating manual, including the
maintenance recommendations/regulations specified by the
manufacturer.

Important notes Dynacode series
6 Operating manual 10.15
1.2 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.
1.3 Figures
Figure 1
1 = Pneumatic connection
2 = Connecting cable SPI (printhead + sensors)
3 = Connecting cable power
Connection side of
print mechanics

Important notes Dynacode series
10.15 Operating manual 7
Figure 2
1 = External output 1-4 (Output I)
2 = Touch panel connection
3 = Encoder connection
4 = Connecting cable SPI (printhead + sensor)
5 = Placeholder for second serial interface (option)
6 = Connecting cable 'power'
7 = Compact Flash card slot
8 = External output 5-8 (Output II)
9 = Standard Option
SUB-D plug 9-pin
External input 5-8
see chapter 3.1
SUB-D plug 15-pin
External bushing I/O-24
see chapter 3.1
10 = Extrnal input 1-4 (Input I)
11 = RS 232 interface
12 = Centronics interface
13 = Ethernet interface
14 = USB interface
15 = Power supply with switch
Connector assignment
of control unit

Important notes Dynacode series
8 Operating manual 10.15
1.4 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 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.
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 4
Material speed
Print principle
Material guiding

Important notes Dynacode series
10.15 Operating manual 9
1.5 Intermittent mode
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.
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 (see chapter 7.5. Machine
parameters (intermittent mode), page 52.
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 Safety notes
10.15 Operating manual 11
2 Safety notes
The direct print module is designed for power supply systems from
110 V to 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 (see 'Technical data').
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.
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.

Safety notes Dynacode series
12 Operating manual 10.15
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.
2.1 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.

Dynacode series Safety notes
10.15 Operating manual 13
2.2 Operating conditions
Before initial operation and during operation these operating
conditions have to be observed to guarantee save and interference-
free service of our devices.
Therefore please carefully read these operating conditions.
Shipment and storage of our devices are only allowed in original
packing.
Installation and initial operation of direct print module is only allowed if
operating conditions were fulfilled.
Commissioning is prohibited until it can be established that, where
relevant, the machine into which the partly completed machinery is to
be incorporated complies with the provisions of Machinery Directive
2006/42/EC.
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 module is only allowed by especially trained
persons.
Perform trainings regularly.
Content of the training are chapter 2.2 (Operating conditions),
chapter 5 (Loading ribbon cassette) and chapter 9 (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.
CPU of direct print module is equipped with a lithium battery (type CR
2032) for which the battery regulation is to apply. This regulation plans
that unloaded batteries have to be given to used battery collecting
containers of trade and public carries. In case that batteries were not
completely discharged you have to make arrangements for short-
circuits. At a shutdown of direct print module the battery has to be
disposed in either case separately from direct print module.
DANGER!
Danger of life by explosion!
Use nonconducting tools.
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.
Instructions for
lithium battery
Conditions for
installation place

Safety notes Dynacode series
14 Operating manual 10.15
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.
Power line voltage and power line frequency: See type plate
Allow. tolerance of power line voltage: +6% … −10% of nominal value
Allow. 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. You can 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.
Emitted interference according to EN 61000-6-4: 08-2002
Interference voltage to wires according to EN 55022: 09-2003
Interference field power according to EN 55022: 09-2003
System perturbation according to EN 61000-3-2: 09-2005
Flicker according to EN 61000-3-3: 05-2002
Immunity to interference according to EN 61000-6-2: 03-2006
Stray radiation against discharge of static electricity according to
EN 61000-4-2: 12-2001
Electromagnetic fields according to EN 61000-4-3: 11-2003
Fast transient burst according to EN 61000-4-4: 07-2005
Surge according to EN 61000-4-5: 12-2001
High-frequency tension according to EN 61000-4-6: 12-2001
Voltage interruption and voltage drop according to EN 61000-4-
11: 02-2005
This is a machine of type A. This machine can cause interferences
in residential areas; in this case it can be required from operator to
accomplish appropriate measures and be responsible for it.
Installation of
power supply
Technical data of
power supply
Anti-Interference
measures:
Stray radiation and
immunity from
disturbance

Dynacode series Safety notes
10.15 Operating manual 15
EN 415-2 - Safety of pachaging machines
EN 60204-1:2006 - Safety of machinery - Electrical equipment of
machines - Part 1
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 60950.
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.
Allowable lines
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)
Maximum line length: interface V 24 (RS-232C) - 3 m at max. 19200 bds
Centronics - 3 m
USB - 3 m
Ethernet - 100 m
To avoid inadmissible heating, free air convection has to be ensured.
Protection according IP: 20
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
Machine safety
Connecting lines to
external machines
Installation of
data lines
Air convection
Limit values

Safety notes Dynacode series
16 Operating manual 10.15
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.
Guarantee

Dynacode series Technical data
10.15 Operating manual 17
3 Technical data
Dynacode 53 Dynacode 107 Dynacode 128
Print width 53,3 mm 106,6 mm 128 mm
Frame passage width customized
Print length
Continuous mode
Intermittent mode
6000 mm
75 mm
3000 mm
75 mm
3000 mm
75 mm
Resolution 300 dpi
Print speed
Continuous mode
Intermittent mode
50 … 800 mm/s
50 … 600 mm/s
50 … 600 mm/s
50 … 600 mm/s
50 … 450 mm/s
50 … 600 mm/s
Back speed only intermittent mode: max. 600 mm/s
Printhead Corner Type
Acoustic emission
Average sound pressure level
Measuring dist. 1 m
60 dB(A)
Measuring dist. 1 m
65 dB(A)
Measuring dist. 1 m
68 dB(A)
Built-in fonts 8 vector fonts
6 bitmap fonts, 6 proportional fonts
font height: min. 1 mm - max. 99 mm
1D bar codes CODABAR, Code 128, Code 2/5 interleaved, Code 39, Code 39 ext.,
Code 93, EAN 13, EAN 8, EAN ADD ON, GS1-128, Identcode, ITF 14,
Leitcode, Pharmacode, PZN 7 Code, PZN 8 Code, UPC-A, UPC-E
2D bar codes Aztec Code, CODABLOCK F, DataMatrix, GS1 DataMatrix,
MAXICODE, PDF 417, QR Code
Composite bar codes GS1 DataBar Expanded, GS1 DataBar Limited, GS1 DataBar
Omnidirectional, GS1 DataBar Stacked, GS1 DataBar Stacked
Omnidirectional, GS1 DataBar Truncated
Interface serial: RS-232C (up to 115200 baud) - parallel: Centronics
USB: 1.1 - Ethernet: 10/100 Base-T
Transfer ribbon
Core diameter
Max. length
Max. width
Coating outside
25,4 mm / 1"
900 m (Ø 98 mm)
55 mm
inside (option)
25,4 mm / 1"
600 m (Ø 82 mm)
110 mm
inside (option)
25,4 mm / 1"
450 m (Ø 75 mm)
130 mm
inside (option)
Dimensions in mm (width x height x depth)
Print mechanics
without mounting frame 204 x 180 x 234 204 x 180 x 290 204 x 180 x 312
with mounting frame depends on passage width
Control unit 240 x 125 x 332 - connecting cable to mechanics 2,5 m
Weight
Print mechanics
Electronics (incl. cable)
9,5 kg
5,5 kg
11 kg
5,5 kg
11,7 kg
5,5 kg
Connection values
Pneumatic connection
Nominal voltage
Nominal current
Fuse values
min. 6 bar dry and free of oil
110 … 230 V / 50 … 60 Hz
230 V / 1,5 A −110 V / 3 A
230 V / 2 AT −110 V / 4 AT
Operating conditions
Temperature
Relative humidity
5 … 40 °C
max. 80% (non-condensing)
Technical modifications are subject to change.

Technical data Dynacode series
18 Operating manual 10.15
3.1 Control inputs and outputs (standard)
Figure 6
A = External output 1-4 (Output I)
B = External input 1-4 (Input I)
C = External output 5-8 (Output II)
D = External bushing 15pin (I/O-24)
By means of the signal outputs different operating states of the print
module can be queried.
The signal outputs are provided by two 9-pin SUB-D-bushings
(OUTPUT I and OUTPUT II) on the back side of the control unit.
They consist of optocoupler semiconductor sections, which are
connected through and/or blocked according to different operating
states.
The maximum allowable current in a semiconductor section is
lmax = 30 mA.
Output I
Figure 6, A
Figure 7
PIN (bushing) Output I
Out 1: Error message
Each error status such as ribbon
error is displayed.
Out 2: Print order
The print module was activated by a
print order.
Out 3: Generation
The print module is filled with current
layout data.
Out 4: Layout print
The content of print memory is
transferred on the printable medium
by means of the printhead.
Plug connection - back
side of control unit
Control outputs

Dynacode series Technical data
10.15 Operating manual 19
Connection of a lamp to a 24V relay by Out 1:
Figure 8
Output II
Figure 6, C
Figure 9
PIN (bushing) Output II
Out 5: Print-Ready signal
It is indicated if the print module is
ready to process a start impulse. In
contrary to the print order signal, the
generating time is taken into
consideration.
Out 6: Printhead up
The printhead has reached the upper
rest position (e.g. return to zero
point).
Out 7: Return to start
After termination of print procedure
the flexible part of the print module is
moved back to the start position.
After the start position was reached a
new start can be released.
Out 8: Prior warning of transfer
ribbon end
Example

Technical data Dynacode series
20 Operating manual 10.15
By means of the control inputs it is possible to control printing. The
control inputs at Input I are galvanic separated and have to be
provided with an external tension source. The signal level is active
"HIGH".
Input I
Figure 6, B
Figure 10
PIN (pin) Input I
In 1: Print start
In 2: Not used
In 3: Reset external counter
In 4: Not used
Connection of a switch with 24V voltage supply by In 1:
Figure 11
Control inputs
Example