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Carl Valentin DPM III xi Series Service Instructions Manual

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DPM III XI
Service Instructions
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  • Page 1 DPM III XI Service Instructions...
  • Page 2 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: EG Low-Voltage Directive (2006/95/EC)

  • Page 3: Table Of Contents

    DPM III xi series Table of contents Table of contents Table of contents ................3 Notes on this document ............5 User notes ................5 Instructions ................5 Cross references ..............6 Safety instructions ..............7 General safety instructions ............7 Safety handling when working with electricity .......
  • Page 4 Table of contents DPM III xi series Connection plan of back panel plugs........ 69 10.1 Motors ..................69 10.2 Printhead signals ..............69 10.3 Sensors ................. 70 Connection plan of interfaces ..........71 11.1 Centronics ................71 11.2 RS-232 .................. 71 11.3...

  • Page 5: Notes On This Document

    DPM III xi series Notes on this document 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.

  • Page 6: Cross References

    Notes on this document DPM III xi series 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.

  • Page 7: Safety Instructions

    DPM III xi series Safety instructions Safety instructions 2.1 General safety instructions ⇒ Workplace and Keep the area around the device clean during and after method of working maintenance. ⇒ Work in a safety-conscious manner. ⇒ Store dismantled device parts in a safe place while maintenance is being performed.
  • Page 8 Safety instructions DPM III xi series Protective equipment 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.
  • Page 9 DPM III xi series Safety instructions 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.

  • Page 10: Safety Handling When Working With Electricity

    Safety instructions DPM III xi series 2.2 Safety handling when working with electricity ⇒ Qualifications of The following work may only be performed by instructed and personnel trained electricians: • work on the electrical assemblies • work on the device while it is open and connected to the power supply.

  • Page 11: Electronics

    DPM III xi series Electronics 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.

  • Page 12: Replacing Secondary Fuse

    Electronics DPM III xi series 3.2 Replacing secondary fuse Figure 2 1. Unplug the machine and then open its cover. Now the power supply unit is visible. 2. Remove the fuse (A) which is placed on it. F1: microfuse 10A/T = protection of all power unit voltages...

  • Page 13: Replacing Cpu Pcb

    DPM III xi series Electronics 3.3 Replacing CPU PCB Figure 3 1. If possible, save the configuration of module on a Compact Flash Removing the CPU PCB card. 2. Unplug the print mechanics from the electrical outlet. 3. Remove cover of control unit.

  • Page 14: Replacing Printhead Fpga

    Electronics DPM III xi series 3.4 Replacing printhead FPGA 1. Remove the FPGA from the PLCC support base with suitable displacement pincer. 2. Press the new FPGA into the support base and pay attention to position of polarity. 3.5 Replacing input/output FPGA 1.

  • Page 15: Replacing Power Supply Unit

    DPM III xi series Electronics 3.7 Replacing power supply unit Figure 4 1. Unplug all connections. 2. Unscrew the screws at the rectifier Z1. 3. Remove screws at the bottom of electronics. 4. Remove the defective power supply unit. 5. Deposit the new power supply unit in the electronics.

  • Page 16: Replacing Compact Flash Card Slot

    Electronics DPM III xi series 3.8 Replacing Compact Flash card slot Figure 5 1. Remove cover of control unit. 2. Unplug connecting cable to the power supply unit at slot. 3. Unscrew retaining screws at the side panel. 4. Remove the defective slot.

  • Page 17: Replacing Input/Output Board

    DPM III xi series Electronics 3.9 Replacing input/output board Figure 6 1. Unplug connection cables of I/O board to the rear panel. 2. Separate defective board from CPU. 3. Insert new board. 4. Insert again the connecting cable according to wiring plan (see chapter 8.1 on page 49).

  • Page 19: Refitting Options

    DPM III xi series Refitting options Refitting options 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.

  • Page 20: Ethernet

    Refitting options DPM III xi series 4.2 Ethernet Figure 8 1. Remove the cover of control unit. 2. Remove the screws between power unit connection (ST13) and bus plug (ST1). 3. Screw the distance bolt M3x15 in this position. 4. Insert Ethernet plate in the break-down and insert the plate into ST1.

  • Page 21: Mechanics

    DPM III xi series Mechanics Mechanics 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.
  • Page 22 Mechanics DPM III xi series Figure 9 1. Remove transfer ribbon material. Removing the printhead 2. Move printhead unit in an appropriate service position. 3. Remove screws (1) and afterwards the printhead. 4. Remove rear-mounted connection assembly from printhead Installing the 1.

  • Page 23: Angle Adjustment

    DPM III xi series Mechanics 5.2 Angle adjustment Figure 10 The installation angle of the printhead is default 26° to the print surface. However, manufacturing tolerances of printhead and mechanics can require another angle. CAUTION! Damage of printhead by unequal use! Higher wastage of ribbon by faster ripping.

  • Page 24: Replacing Tooth Belt (Linear Drive)

    Mechanics DPM III xi series 5.3 Replacing tooth belt (linear drive) Figure 11 1. Remove 4 screws from the upper case and then remove the cover. 2. Remove 6 screws form the cover at the back and then remove the cover.

  • Page 25: Refitting Brake

    DPM III xi series Mechanics 5.4 Refitting brake 1. Remove 4 screws and remove the upper cover. 2. Place the brake next to the main transmission motor. 3. Tighten the brake loosely with 2 x M4x12 socket screws. 4. Hang the driving belt of brake in the main transmission motor and brake.

  • Page 26: Replacing Zero Point Photocell

    Mechanics DPM III xi series 5.5 Replacing zero point photocell Figure 12 1. Remove 4 screws and then the upper cover. 2. Loosen 6 screws and remove the cover at the back. 3. Remove the photocell plug ST6 onto the distributor board of the printing carriage.

  • Page 27: Replacing End Position Photocell

    DPM III xi series Mechanics 5.6 Replacing end position photocell Figure 13 1. Unscrew the 4 screws and remove the upper cover. 2. Remove the photocell plug ST5 onto the distributor board. 3. Unscrew 2 socket screws and remove the end position photocell.

  • Page 28: Adjusting Ribbon Drive

    Mechanics DPM III xi series 5.7 Adjusting ribbon drive Figure 14 The use of another ribbon width or length can require the change of ribbon tension. NOTICE! Generally: As few ribbon tension as possible, as much as necessary! Set the ribbon tension that no wrinkles appear in the transfer ribbon and the ribbon is transported correctly.

  • Page 29: Adjusting Ribbon Tension

    DPM III xi series Mechanics 5.8 Adjusting ribbon tension Figure 15 For a regular print quality it is necessary that the transfer ribbon is to tighten even over its width. With the nuts (1) it is possible to regulate a different transfer ribbon tension by a sideways overturn of the printhead.

  • Page 30: Lubrication

    Mechanics DPM III xi series 5.9 Lubrication Figure 16 1. Clean the linear guiding (1) and the guiding shaft (2) with a cleaning cloth (possibly soaked with spirits). 2. Lubricate the sections with thin oil. 3. Lubricate the guiding bearing (3) of the transfer ribbon tension roll with thin oil.

  • Page 31: Error Correction

    DPM III xi series Error correction Error correction Error message Cause Remedy Line too high Line rises up completely or Move line down (increase Y partly over the upper edge of value). label. Check rotation and font. Line too low Line rises up completely or Move line up (reduce Y value).
  • Page 32 Error correction DPM III xi series Error message Cause Remedy Field numer Received line number is invalid Check sent data. at RS-232/parallel interface. Check connection PC - printer. Length mask Invalid length of received mask Check sent data. statement. Check connection PC - printer.
  • Page 33 DPM III xi series Error correction Error message Cause Remedy Application Selected application identifier is Check code data. Identifier not available in GS1-128. HIBC definition F Missing HIBC system sign. Check definition of HIBC code. Missing primary code. System clock Real Time Clock function is Change battery.
  • Page 34 Error correction DPM III xi series Error message Cause Remedy Drive write- Memory card is write-protected. Deactivate write protection. protected Directory not file Attempt to indicate a directory Correct your entry. as file name. File already open Attempt to change a file during Select another file.
  • Page 35 DPM III xi series Error correction Error message Cause Remedy Zero point Defective photocell. Change photocell. Compressed air Pressure air is not connected. Check pressure air. External releaser External print release signal is Check input signal. missing. Row too long Wrong definition of column Reduce the column width res.
  • Page 36 Error correction DPM III xi series Error message Cause Remedy Time generation Printing creation was still active Reduce print speed. at print start. Use printers' output signal for synchronisation. Use bitmap fonts to reduce generating time. Transport protection Both DPM position sensors Displace zero point sensor (start/end) are active.
  • Page 37 DPM III xi series Error correction Error message Cause Remedy Scanner layout Scanner data does not Check adjustment of scanner. difference correspond to bar code data. Check scanner settings / connection. COM break Serial interface error. Check settings for serial data transmission as well as cable (printer-PC).
  • Page 38 Error correction DPM III xi series Error message Cause Remedy Housing open When starting the print order Close the housing cover and the housing cover is not closed. start the print order anew. EAN.UCC code Transferred EAN.UCC code is Verify bar code data (see invalid.
  • Page 39 DPM III xi series Error correction Error message Cause Remedy Print asynchronous The label photocell does not Check label size and gap size. work in the order as it is expected according to print data. The settings of the photocell Check label photocell settings.
  • Page 40 Error correction DPM III xi series Error message Cause Remedy Script user error Error in LUA script user input. Correct the input value. No reprint available No label data for reprinting Send new label data to the available. printer. Printhead short Electrical short at the printhead.

  • Page 41: Control Inputs And Outputs

    DPM III xi series Control inputs and outputs Control inputs and outputs 7.1 Version I Plug connection - back side of control unit Figure 17 A = External output 1-4 (Output I) B = External input 1-4 (Input I) C = External output 5-8 (Output II)
  • Page 42 Control inputs and outputs DPM III xi series Example Connection of a lamp to a 24V relay by Out 1: Figure 19 Output II PIN (bushing) Output II Figure 17, C Out 5: Print-Ready signal It is indicated if the print module is ready to process a start impulse.
  • Page 43 DPM III xi series Control inputs and outputs Control inputs By means of the control inputs it is possible to control printing. The control inputs at Input I are electroplated separated and have to be provided with an external tension source. The signal level is active "HIGH".
  • Page 44 Control inputs and outputs DPM III xi series Input II PIN (pin) Input II Figure 17, D In 5: Not used In 6: Not used Figure 23 In 7: Not used In 8: Not used Service instructions 0209...

  • Page 45: Version Ii

    DPM III xi series Control inputs and outputs 7.2 Version II Plug connection - back side of control unit Figure 24 A = External output 1-4 (Output I) B = External input 1-4 (Input I) C = External output 5-8 (Output II)
  • Page 46 Control inputs and outputs DPM III xi series Example Connection of a lamp to a 24V relay by Out 1: Figure 26 Output II PIN (bushing) Output II Figure 24, C Out 5: Print-Ready signal It is indicated if the print module is ready to process a start impulse.
  • Page 47 DPM III xi series Control inputs and outputs Control inputs 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".
  • Page 48 Control inputs and outputs DPM III xi series External bushing I/O-24 This input is executed as 15-pole and provides user- Figure 24, D sided 24V/100mA. In case of using this bushing, exists no galvanic separation. Function 1, 6 5, 10...

  • Page 49: Wiring Plans

    DPM III xi series Wiring plans Wiring plans 8.1 Electronics Figure 31 0209 Service instructions...

  • Page 50: Mechanics

    Wiring plans DPM III xi series 8.2 Mechanics DPM III xi53 right version Figure 32 Service instructions 0209...
  • Page 51 DPM III xi series Wiring plans DPM III xi53 left version Figure 33 0209 Service instructions...
  • Page 52 Wiring plans DPM III xi series DPM III xi107 + xi128 right version Figure 34 Service instructions 0209...
  • Page 53 DPM III xi series Wiring plans DPM III xi107 + xi128 left version Figure 35 0209 Service instructions...

  • Page 55: Layout Diagrams

    DPM III xi series Layout diagrams Layout diagrams 9.1 CPU Figure 36 0209 Service instructions...
  • Page 56 Layout diagrams DPM III xi series Jumper plan BOOT open closed closed open open 2 charging open open closed closed closed circuits JP10 JP11 JP12 JP13 JP14 BOOT open open 2 charging closed circuits Bausteine ICs: Component overview U1; U2...

  • Page 57: Power Supply Unit (Revision C)

    DPM III xi series Layout diagrams 9.2 Power supply unit (revision C) Figure 37 0209 Service instructions...
  • Page 58 Layout diagrams DPM III xi series Component overview Motor driver ribbon motor Motor driver feed motor Control component printhead heater voltage Voltage control 5V Voltage control 24V Bridge-connected rectifier Secondary fuse 10A/T P canal MOS-FET 100V/50A printhead voltage Plug-in positions...

  • Page 59: Compact Flash Card Slot

    DPM III xi series Layout diagrams 9.3 Compact Flash card slot Figure 38 The following Compact Flash cards can be used: • 512 MB • 1 GB • 2 GB 0209 Service instructions...

  • Page 60: I/O Board 24V

    Layout diagrams DPM III xi series 9.4 I/O board 24V I/O board with external sensor Figure 39 Jumper plan Only valid for complete equipped I/O plate Function Jumper position JP6 RS-422 full duplex RS-485 half duplex Service instructions 0209...
  • Page 61 DPM III xi series Layout diagrams Component overview EPLD Component Optocoupler outputs 1-4 (Output1) Optocoupler outputs 5-8 (Output2) Optocoupler inputs 1-4 (Input1) Optocoupler inputs 5-8 (Input2) Driver inputs Driver RS-422 / RS-485 Optocoupler DTR/DIR Optocoupler TXD1 Optocoupler RXD1 Voltage transformer 5V ±5V...

  • Page 62: Ethernet

    Layout diagrams DPM III xi series 9.5 Ethernet Figure 40 Service instructions 0209...

  • Page 63: Distributor Board

    DPM III xi series Layout diagrams 9.6 Distributor board Right version Figure 41 Plug-in positions Feed motor Heater voltage for KCE 53/12 ST10 End point photocell ST14 Cover switch ST12 Compressed-air control ST19 Brake ST21 Option encoder ST22 Motor signals from electronics...
  • Page 64 Layout diagrams DPM III xi series Left version Figure 42 Plug-in positions Feed motor Heater voltage for KCE 53/12 ST10 Final point photocell ST14 Cover switch ST12 Compressed-air control ST19 Brake ST21 Option encoder ST22 Motor signals from electronics ST23...

  • Page 65: Carriage Board

    DPM III xi series Layout diagrams 9.7 Carriage board Right version Figure 43 Plug-in positions KCE 53/12 KCE 107/12 Transfer ribbon motor Valve Connection distributor plate Transfer ribbon control Zero point photocell 0209 Service instructions...
  • Page 66 Layout diagrams DPM III xi series Left version Figure 44 Plug-in positions KCE 53/12 KCE 107/12 Transfer ribbon motor Valve Connection distributor plate Transfer ribbon control Zero point photocell Service instructions 0209...

  • Page 67: Motor Adapter

    DPM III xi series Layout diagrams 9.8 Motor adapter Right version Figure 45 Plug-in positions Connection distributor plate Brake Feed motor Final point photocell 0209 Service instructions...
  • Page 68 Layout diagrams DPM III xi series Left version Figure 46 Plug-in positions Connection distributor plate Brake Feed motor Final point photocell Service instructions 0209...

  • Page 69: Connection Plan Of Back Panel Plugs

    DPM III xi series Connection plan of back panel plugs 10 Connection plan of back panel plugs 10.1 Motors Figure 47 Signal 1-2; 14-15 FEED motor Control signal VALVE Control signal BRAKE 7-8; 19-20 RIBBON motor 10.2 Printhead signals Figure 48...

  • Page 70: Sensors

    Connection plan of back panel plugs DPM III xi series 10.3 Sensors Figure 49 Signal 3, 11 RIBBONCTRL, PULLUP (transfer ribbon photocell) 4, 12 HEADDOWN, GND (Compressed-air control) 5, 13 FEEDCTRL, PULLUP (Zero point photocell) 6, 14 TCREND, PULLUP (Final point photocell)

  • Page 71: Connection Plan Of Interfaces

    DPM III xi series Connection plan of interfaces 11 Connection plan of interfaces 11.1 Centronics Figure 50 Signal STROBE DATA1-8 BUSY PERROR SELECT AUTOFD 15-16 VCC1284 (4,7V) 19-30 INIT FAULT 33-35 SELECTIN 11.2 RS-232 Figure 51 Signal 0209 Service instructions...

  • Page 72: Rs-485 And Rs-422

    Connection plan of interfaces DPM III xi series 11.3 RS-485 and RS-422 Figure 52 PIN at Function RS-422 Function RS-485 D-SUB (full duplex) (half duplex) socket TxD− TxD+ TxD (RTxD)− TxD (RxD)+ RxD− RxD+ Service instructions 0209...

  • Page 73: Ethernet

    DPM III xi series Connection plan of interfaces 11.4 Ethernet Figure 53 PIN RJ45- Description socket TX− RX− 11.5 USB 1.0 Figure 54 Signal D− 0209 Service instructions...

  • Page 75: Index

    DPM III xi series Index 12 Index Adjusting Ribbon drive ..................28 Ribbon tension ................29 Angle adjustment ................23 Battery, replacing ................14 Brake, refitting ..................25 Carriage board, left version Layout diagram ................66 Plug-in positions ................66 Carriage board, right version Layout diagram ................
  • Page 76 Index DPM III xi series Electronics Battery, replacing ................14 Compact Flash card slot, replacing ..........16 CPU PCB replacing ................ 13 I/O board, replacing ................ 17 I/O FPGA, replacing ................ 14 Power supply unit, replacing ............15 Primary fuse, replacing ..............11 Printhead FPGA, replacing .............
  • Page 77 DPM III xi series Index Printhead, replacing ..............21, 22 Ribbon drive, adjusting ..............28 Ribbon tension, adjusting ............... 29 Tooth belt (linear drive), replacing ..........24 Zero point photocell, replacing ............26 Motor adapter, left version Layout diagram ................68 Plug-in positions ................
  • Page 78 Index DPM III xi series Primary fuse ..................11 Printhead .................. 21, 22 Printhead FPGA ................14 Secondary fuse ................12 Tooth belt (linear drive) ..............24 Zero point photocell ................ 26 Ribbon Adjusting drive ................28 Adjusting tension ................29 RS-232, connection plan (interfaces) ..........
  • Page 80 Carl Valentin GmbH Neckarstraße 78 – 86 u. 94 . 78056 Villingen-Schwenningen Phone +49 7720 9712-0 . Fax +49 7720 9712-9901 [email protected] . www.carl-valentin.de...

This manual is also suitable for:

Dpm iii xi107Dpm iii xi53Dpm iii xi128

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