Carl Valentin DPM III xi Series, DPM III xi107, DPM III xi53, DPM III xi128 Service Instructions Manual

DPM III XI

Service Instructions

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:

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

+49 7720 9712-0 +49 7720 9712-9901

E-Mail Internet

info@carl-valentin.de www.carl-valentin.de

DPM III xi series

Table of contents

0209

Service instructions

Table of contents

Table of contents .............................................................................. 3

1 Notes on this document ....................................................... 5

1.1 User notes ............................................................................... 5

1.2 Instructions .............................................................................. 5

1.3 Cross references ..................................................................... 6

2 Safety instructions ................................................................ 7

2.1 General safety instructions ...................................................... 7

2.2 Safety handling when working w ith elec tricity ....................... 10

3 Electronics ........................................................................... 11

3.1 Replacing primary fuse .......................................................... 11

3.2 Replacing secondary fuse ..................................................... 12

3.3 Replacing CPU PCB.............................................................. 13

3.4 Replacing printhead FPGA .................................................... 14

3.5 Replacing input/output FPGA ................................................ 14

3.6 Replacing battery................................................................... 14

3.7 Replacing power supply unit ................................................. 15

3.8 Replacing Compact Flash card slot ....................................... 16

3.9 Replacing input/output board ................................................ 17

4 Refitting options .................................................................. 19

4.1 RS-485 and RS-422 .............................................................. 19

4.2 Ethernet ................................................................................. 20

5 Mechanics ............................................................................ 21

5.1 Replacing printhead............................................................... 21

5.2 Angle adjustment ................................................................... 23

5.3 Replacing tooth belt (linear drive) .......................................... 24

5.4 Refitting brake ....................................................................... 25

5.5 Replacing zero point photocell .............................................. 26

5.6 Replacing end position photocell ........................................... 27

5.7 Adjusting ribbon drive ............................................................ 28

5.8 Adjusting ribbon tension ........................................................ 29

5.9 Lubrication ............................................................................. 30

6 Error correction ................................................................... 31

7 Control inputs and outputs ................................................ 41

7.1 Version I ................................................................................ 41

7.2 Version II ............................................................................... 45

8 Wiring plans ......................................................................... 49

8.1 Electronics ............................................................................. 49

8.2 Mechanics ............................................................................. 50

9 Layout diagrams .................................................................. 55

9.1 CPU ....................................................................................... 55

9.2 Power supply unit (revision C) ............................................... 57

9.3 Compact Flash card slot ........................................................ 59

9.4 I/O board 24V ........................................................................ 60

9.5 Ethernet ................................................................................. 62

9.6 Distributor board .................................................................... 63

9.7 Carriage board ....................................................................... 65

9.8 Motor adapter ........................................................................ 67

Table of contents

DPM III xi series

Service instructions

0209

Connection plan of back panel plugs................................ 69

10.1 Motors .................................................................................... 69

10.2 Printhead signals ................................................................... 69

10.3 Sensors ................................................................................. 70

11 Connection plan of interfaces ............................................ 71

11.1 Centronics ............................................................................. 71

11.2 RS-232 .................................................................................. 71

11.3 RS-485 and RS-422 .............................................................. 72

11.4 Ethernet ................................................................................. 73

11.5 USB 1.0 ................................................................................. 73

12 Index ..................................................................................... 75

DPM III xi series

Notes on this document

0209

Service instructions

1 Notes on this docume nt

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 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

DPM III xi series

Service instructions

0209

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.

CAUTION!

Two-pole fuse.

⇒ 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.

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

DPM III xi series

Safety instructions

0209

Service instructions

2 Safety instructions

2.1 General safety instructions

⇒ Keep the area around the device clean during and after

maintenance.

⇒ Work in a safety-conscious m anner . ⇒ 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 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

DPM III xi series

Service instructions

0209

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 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. 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 en d dev ice. 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.

Protective equipment

General safety instructions

DPM III xi series

Safety instructions

0209

Service 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.

The direct printing unit must be integrated with the Em er genc y Stop circuit when it is incorporated into the overal l m achine.

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.

CAUTION!

Two-pole fuse.

⇒ 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.

Safety instructions

DPM III xi series

Service instructions

0209

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 em er genc y-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 devic e 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

DPM III xi series

Electronics

0209

Service instructions

3 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.

3.1 Replacing primary fuse

Figure 1

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 (value = 3,15A/T).

Electronics

DPM III xi series

Service instructions

0209

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

DPM III xi series

Electronics

0209

Service instructions

3.3 Replacing CPU PCB

Figure 3

1. If possible, save the configuration of module on a Compact Flash

card.

2. Unplug the print mechanics from the electrical outlet.

3. Remove cover of control unit.

4. Detach all connections from the CPU PCB.

5. Remove fixing screws at the Centronics interface.

6. Remove all retaining screws at CPU PCB.

7. Carefully remove CPU PCB.

1. Place CPU PCB onto the retainers.

2. Secure the PCB board with screws.

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

Electronics

DPM III xi series

Service instructions

0209

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. Separate I/O board from CPU board.

Now the I/O FPGA is visible.

2. Remove the FPGA from the PLCC support base with suitable

displacement pincer.

3. Press the new FPGA into the support base and pay attention to

position of polarity.

3.6 Replacing battery

DANGER!

Danger of explosion when exchang ing the batt ery 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 battery.

3. Insert a new battery (CR 2032) into the support and pay attention

to position of polarity.

DPM III xi series

Electronics

0209

Service instructions

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 suppl y unit.

5. Deposit the new power supply unit in the electronics.

Pay attention that no lines are clamped under the heat sink of power supply unit.

6. Insert all connections in the appropriate plug-in positions.

7. Screw again the power supply unit.

Electronics

DPM III xi series

Service instructions

0209

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.

5. The installation of the new slot is to be effected in reverse order.

DPM III xi series

Electronics

0209

Service instructions

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).

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.

DPM III xi series

Refitting options

0209

Service instructions

4 Refitting opti ons

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 RS-485 and RS-422

Figure 7

1. Replace the installed input/output port by an input/output port

which is equipped with RS-485 or RS-422 ex tens ion.

2. Replace the line to INPUT2 by the line with 9-pin DSUB socket.

3. Insert the new line into position ST5 on the input/output plate.

4. OUTPUT1, INPUT1 and OUTPUT2 have to be installed according

to the wiring plan (see chapter 8.1 on page 49).

Refitting options

DPM III xi series

Service instructions

0209

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.

5. Fix the plate with the corresponding screws.

6. Fix the plate with the already removed screw at the distance bolt.

DPM III xi series

Mechanics

0209

Service instructions

5 Mechanics

DANGER!

Risk of death via electric shock!

⇒ Before op en ing the ho using cover, dis con nec t the

device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.

Printing can cause accumulation of dirt at printhead e.g. by colour particles of transfer ribbon, and therefore it is necessary to clean the printhead in regular periods depending on operating hours, environmental effects such as dust etc.

CAUTION!

Printhead can be damaged!

⇒ Do not use sharp or hard objects to clean the

printhead.

⇒ Do not touch protective glass layer of the printhead.

• Remove transfer ribbon material.

• Clean printhead surface with special cleaning pen or a cotton

swab dipped in pure alcohol.

• Allow printhead to dry for 2-3 minutes before commissioning the

device.

5.1 Replacing printhead

CAUTION!

The printhead can be damaged by static electricity discharges and impacts!

⇒ Set up direct print module on a grounded, conductive

surface.

⇒ Ground your body, e.g. by wearing a grounded

wristband.

⇒ Do not touch contacts on the plug connections. ⇒ Do not touch printing line with hard objects or your

hands.

Cleaning the printhead

Mechanics

DPM III xi series

Service instructions

0209

Figure 9

1. Remove transfer ribbon material.

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

1. Insert connection assembly to the new printhead.

2. Hold printhead holder with a finger slightly on the pressure roll and

check the correct position of printhead.

3. Screw in screw (1) and tighten it with an Allen key.

4. Insert again transfer r ibb on material.

5. Start a test print to check printhead position.

6. Enter the resistance value of the new printh ead in the ser vice

functions (dot resistance). The value is indicated on the type plate of printhead.

Removing the printhead

Installing the printhead

DPM III xi series

Mechanics

0209

Service instructions

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.

⇒ Change factory settings only in exceptional cases.

• Loosen slightly two Allen head screws (2).

• Move setscrews (1) to adjust the angle between printhead and

printhead support. Tighten = decrease angle Loosen = increase angle

• Beide Gewindestifte sind immer gleich weit zu verdrehen.

• Tighten again the Allen head screws (2).

• Start a print order with approx. 3 layouts to check the correct

unwrinkled ribbon run.

NOTICE!

The slots serve for position control. Pay attention to a parallel adjustment.

Mechanics

DPM III xi series

Service instructions

0209

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.

3. Remove 2 screws and take away the cable energy chain from the

printer carriage.

4. Remove 1 screw and 2 brass pillars and take away the distributor

board from the carriage. It is unnecessary to unplug the connectors.

5. Loosen socket screws (1) and take away the belt support.

6. Loosen 2 socket screws and open the washer lock.

7. Remove the belt (2).

8. Remove the fixing of belt clamp (3) and loosen the belt clamp by

loosen 2 x M5 socket screws.

9. Load the new belt in the belt tightener around the carrying wheel

and the main driving pinion. Fix it with the washer lock at the carriage.

10. Mount the washer lock and the belt support.

11. Clamp the belt with 2 x M5 socket screws and fix the belt tightener

with 2 x M5 nuts.

NOTICE!

Belt clamping:

In central position of printing carriage max. 10 mm compliance of the belt of finger pressure.

12. The installation of all components is to be effected in reverse

order.

DPM III xi series

Mechanics

0209

Service instructions

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.

5. Tighten the fixing screws of brake.

6. Insert the connecting line of brake in ST2 onto the distributor

board.

7. Mount again the upper cover.

Mechanics

DPM III xi series

Service instructions

0209

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.

4. Loosen 2 socket screws and remove zero point photocell.

5. The installation of the new photocell is to be effected in reverse

order.

NOTICE!

The photocell must be moved in the long holes completely to the outside (see direction of arrow).

DPM III xi series

Mechanics

0209

Service instructions

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 distri but or boar d.

3. Unscrew 2 socket screws and remove the end position photocell.

4. The installation of the new photocell is to be effected in reverse

order.

Mechanics

DPM III xi series

Service instructions

0209

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.

1. Tighten the socket screws (1) to increase the transfer ribbon

tension.

2. Loosen the socket screws (1) to reduce the transfer ribbon

tension.

3. Start a print order with approx. 3 layouts to check the correct

unwrinkled ribbon run.

DPM III xi series

Mechanics

0209

Service instructions

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.

CAUTION!

Folding at transfer ribbon!

⇒ Change factory settings only in exceptional cases.

1. By loosen a nut the printhead moves down at the corresponding

side. The transfer ribbon tension is increased.

2. By tightening a nut the printhead moves up at the corresponding

side. The transfer ribbon tension is reduced.

NOTICE!

A strong regulation has result to the pressure power of printhead.

3. Start a print order with approx. 3 layouts to check the correct

unwrinkled ribbon run.

Mechanics

DPM III xi series

Service instructions

0209

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.

4. Lubricate the guiding shaft (4) of the printhead bracket with thin oil

at the adjusting screws.

DPM III xi series

Error correction

0209

Service instructions

6 Error correction

Error message

Cause

Remedy

Line too high

Line rises up completely or

partly over the upper edge of label.

Move line down (increase Y

value). Check rotation and font.

Line too low

Line rises up completely or

partly over the bottom edge of label.

Move line up (reduce Y value).

Check rotation and font.

Character set

One res. several characters of

the text is res. are not available in the selected font.

Change text.

Change font.

Unknown code type

Selected code is not available.

Check code type.

Unvalid position

Selected position is not

available.

Check position.

CV font

Selected font is not available.

Check font.

Vector font

Selected font is not available.

Check font.

Measuring label

While measuring no label was

found. Set label length is too large.

Check label length and if labels

are inserted correctly. Restart measuring anew.

No label found

No label available.

Soiled label photocell. Labels not inserted correctly.

Insert new label roll.

Check if labels are inserted correctly.

Clean the label photocell.

No ribbon

During the print order the

ribbon roll becomes empty. Defect at the transfer ribbon

photocell.

Change transfer ribbon.

Check transfer ribbon photocell (service functions).

COM FRAMING

Stop bit error.

Check stop bits.

Check baud rate. Check cable (printer and PC).

COM PARITY

Parity error.

Check parity.

Check baud rate. Check cable (printer and PC).

COM OVERRUN

Loss of data at serial interface

(RS-232).

Check baud rate.

Check cable (printer and PC).

Error correction

DPM III xi series

Service instructions

0209

Error message

Cause

Remedy

Field numer

Received line number is invalid

at RS-232/parallel interf ac e.

Check sent data.

Check connection PC - printer.

Length mask

Invalid length of received mask

statement.

Check sent data.

Check connection PC - printer.

Unknown mask

Transferred mask statement is

invalid.

Check sent data.

Check connection PC - printer.

Missing ETB

No end of data found.

Check sent data.

Check connection PC - printer.

Invalid character

One res. several characters of

the text is res. are not available in the selected font.

Change text.

Change font.

Invalid statement

Unknown transferred data

record.

Check sent data.

Check connection PC - printer.

Invalid check digit

For check digit control the

entered res. received check digit is wrong.

Calculate check digit anew.

Check code data.

Invalid SC number

Selected SC factor is invalid for

EAN res. UPC.

Check SC factor.

Invalid number of

digits

Entered digits for EAN res.

UPC are invalid < 12; > 13.

Check number of digits.

Check digit

calculation

Selected check digit calculation

is not available in the bar code.

Check calculation of check

digit. Check bar code type.

Invalid extension

Selected zoom factor is not

available.

Check zoom factor.

Offset sign

Entered sign is not available.

Check offset value.

Offset value

Entered offset value is invalid.

Check offset value.

Printhead

temperature

Printhead temperature is too

high. Defective printhead sensing

device.

Reduce contrast.

Change printhead.

Cutter error

With cut an error occurred.

Paper jam.

Check label run.

Check cutter run.

Invalid parameter

Entered data do not correspond

to the characters allowed from the application identifier.

Check code data.

DPM III xi series

Error correction

0209

Service instructions

Error message

Cause

Remedy

Application

Identifier

Selected application identif ier is

not available in GS1-128.

Check code data.

HIBC definition

F Missing HIBC system sign.

Missing primary code.

Check definition of HIBC code.

System clock

Real Time Clock function is

selected but the battery is empty.

Defective RTC.

Change battery.

Change RTC component.

No CF interface

Interrupted connection CPU -

CF card. Defective CF card interface.

Check connection CPU - CF

card interface. Check CF card interface.

No print memory

No print CF found.

Check CF assembly on CPU.

Printhead open

At start of a print order the

printhead is open.

Close the printhead and start

print order anew.

BCD invalid format

BCD error

Invalid format for the calculation of Euro variable.

Check entered format.

BCD overflow

BCD error

Invalid format for the calculation of Euro variable.

Check entered format.

BCD division

BCD error

Invalid format for the calculation of Euro variable.

Check entered format.

FLASH ERROR

Flash component error.

Run a software update.

Change CPU.

Length command

Invalid length of the received

command statement.

Check data sent.

Check connection PC - printer.

No drive

CF card not found / not

correctly inserted.

Insert CF card correctly.

Drive error

Impossible to read CF card

(faulty).

Check CF card, if necessary

change it.

Not formatted

CF Card not formatted.

Format CF card.

Delete current

directory

Attempt to delete the actual

directory.

Change directory.

Path too long

Too long indication of path.

Indicate a shorter path.

Error correction

DPM III xi series

Service instructions

0209

Error message

Cause

Remedy

Drive write-

protected

Memory card is write-protected.

Deactivate write protection.

Directory not file

Attempt to indicate a directory

as file name.

Correct your entry.

File already open

Attempt to change a file during

an access is active.

Select another file.

No file/directory

File does not exist on CF card.

Check file name.

Invalid file name

File name contains invalid

characters.

Correct entry of name, remove

special characters.

Internal file error

Internal file system error.

Please contact your distributor.

Root full

The max. number (64) of main

directory entries is reached.

Delete at least one main

directory entry and create subdirectories.

Drive full

Maximum CF capacity is

reached.

Use new CF Card, delete no

longer required files.

File/directory

exists

The selected file/directory

already exists.

Check name, select a different

name.

File too large

During copying procedure not

enough memory space onto target drive available.

Use a larger target card.

No update file

Errors in update file of

firmware.

Start update file anew.

Invalid graphic file

The selected file does not

contain graphic data.

Check file name.

Directory not empty

Attempt to delete a not empty

directory.

Delete all files and sub-

directories in the desired directory.

No interface

No CF card drive found.

Check connection of CF card

drive. Please contact your distributor

No CF card

No CF card is inserted.

Insert CF card in the slot.

Webserver error

Error at start of web server.

Please contact your distributor.

Wrong FPGA

The direct print module is

equipped with the wrong FPGA.

Please contact your distributor.

End position

The label length is too long.

The number of labels per cycle is too much.

Check label length res. the

number of labels per cycle.

DPM III xi series

Error correction

0209

Service instructions

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

missing.

Check input signal.

Row too long

Wrong definition of column

width res. number of columns.

Reduce the column width res.

correct the number of columns.

Scanner

The connected bar code

scanner signals a device error.

Check the connection

scanner/printer. Check scanner (dirty).

Scanner NoRead

Bad print quality.

Printhead completely soiled or defective.

Print speed too high.

Increase contrast.

Clean printhead or exchange (if necessary).

Reduce print speed.

Scanner data

Scanned data does not

correspond to the data which is to print.

Exchange printhead.

Invalid page

As page number either 0 or a

number > 9 is selected.

Select a number between 1

and 9.

Page selection

A page which is not available is

selected.

Check the defined pages.

Page not defined

The page is not defined.

Check the print definition.

Format user guiding

Wrong format for customised

entry.

Check the format string.

Format date/time

Wrong format for date/time.

Check the format string.

Hotstart CF

No CF card found.

If option hotstart was activated,

a CF card must be inserted. Switch off the printer before

inserting the memory card.

Flip/Rotate

Selection of print of several

columns and also mirror/rotate.

It is only possible to select one

of both functions.

System file

Loading of temporary hotstart

files.

Not possible.

Shift variable

Faulty definition of shift times

(overlapping times).

Check definition of shift times.

GS1 Databar

General GS1 Databar error.

Check definition and parameter

of GS1 Databar code.

IGP error

Protocol error IGP.

Check sent data.

Error correction

DPM III xi series

Service instructions

0209

Error message

Cause

Remedy

Time generation

Printing creation was still active

at print start.

Reduce print speed.

Use printers' output signal for synchronisation.

Use bitmap fonts to reduce generating time.

Transport protection

Both DPM position sensors

(start/end) are active.

Displace zero point sensor

Check sensors in service functions menu

No font data

Font and web data is missing.

Run a software update.

No layout ID

Label ID definition is missing.

Define label ID onto the label.

Layout ID

Scanned data does not

correspond to defined ID.

Wrong label loaded from CF

card.

RFID no label

RFID unit cannot recognise a

label.

Displace RFID unit or use an

offset.

RFID verify

Error while checking

programmed data.

Faulty RFID label.

Check RFID definitions

RFID timeout

Error at programming the RFID

label.

Label positioning.

Faulty label.

RFID data

Faulty or incomplete definition

of RFID data.

Check RFID data definitions.

RFID tag type

Definition of label data does not

correspond with the used label.

Check storage partitioning of

used label type

RFID lock

Error at programming the RFID

label (locked fields).

Check RFID data definitions.

Label was already programmed.

RFID programming

Error at programming the RFID

label.

Check RFID definitions.

Scanner timeout

The scanner could not read the

bar code within the set timeout time.

Defective printhead.

Wrinkles in transfer ribbon. Scanner wrong positioned. Timeout time too short.

Check printhead.

Check transfer ribbon. Position scanner correctly,

corresponding to the set feeding.

Select longer timeout time.

DPM III xi series

Error correction

0209

Service instructions

Error message

Cause

Remedy

Scanner layout

difference

Scanner data does not

correspond to bar code data.

Check adjustment of scanner.

Check scanner settings / connection.

COM break

Serial interface error.

Check settings for serial data

transmission as well as cable (printer-PC).

COM general

Serial interface error.

Check settings for serial data

transmission as well as cable (printer-PC).

No software

printhead FPGA

No printhead-FPGA data

available.

Please contact your

responsible distributor.

Load software

printhead FPGA

Error when programming

printhead-FPGA.

Please contact your

responsible distributor.

100

Upper position

Sensor signal up is missing

(option APL 100).

Check input signals /

compressed-air supply.

101

Lower position

Sensor signal down is missing

(option APL 100).

Check input signals /

compressed-air supply.

102

Vacuum plate empty

Sensor does not recognise a

label at vacuum plate (option APL 100).

Check input signals /

compressed-air supply.

103

Start signal

Print order is active but device

not ready to process it.

Check start signal.

104

No print data

Print data outside the defined

label. Selection of wrong module type

(design software).

Check selected module type.

Check selection of left/right version.

105

Printhead

No original printhead is used.

Check the used printhead.

Contact your distributor.

106

Invalid Tag type

Wrong Tag type.

Tad data do not match the Tag type in the printer.

Adapt data or use the correct

Tag type.

107

RFID invalid

RFID module is not activated.

No RFID data can be processed.

Activate RFID module or

remove RFID data from label data.

108

GS1-128 invalid

Transferred GS1-128 bar code

is invalid.

Verify bar code data (see GS1-

128 bar code specification).

109

EPC parameter

Error at EPC calculation.

Verify data (see EPC

specification).

Error correction

DPM III xi series

Service instructions

0209

Error message

Cause

Remedy

110

Housing open

When starting the print order

the housing cover is not closed.

Close the housing cover and

start the print order anew.

111

EAN.UCC code

Transferred EAN.UCC code is

invalid.

Verify bar code data (see

corresponding specification).

112

Print carriage

Printing carriage does not

move.

Check gear belt (possibly

broken).

113

Applicator error

Error while using applicator.

Check applicator.

114

Left position

Left final position switch is not

in correct position.

Check LEFT final position

switch for correct function and position.

Check function of pneumatics for cross traverse.

115

Right position

Right final position switch is not

in correct position.

Check RIGHT final position

switch for correct function and position.

Check function of pneumatics for cross traverse.

116

Print position

The print position is not correct.

Check TOP and RIGHT final

position switch for correct function and position.

Check pneumatics for function

117

XML parameter

The parameters in the XML file

are not correct.

Please contact your

responsible distributor.

118

Invalid variable

Transferred variable is invalid

with customized entry.

Select correct variable without

customized entry and transfer it.

119

No ribbon

During the print order the

ribbon roll becomes empty. Defect at the transfer ribbon

photocell.

Change transfer ribbon.

Check transfer ribbon photocell (service functions).

120

Wrong directory

Invalid target directory when

copying.

Target directory must not be

within the source directory. Check target directory.

121

No label found

No label found at the rear

printhead (DuoPrint). Soiled label photocell. Labels not inserted correctly.

Insert new label roll.

Clean the label photocell. Check if labels are inserted

correctly.

122

IP occupied

The IP address was already

assigned.

Assign a new IP address.

DPM III xi series

Error correction

0209

Service instructions

Error message

Cause

Remedy

123

Print asynchronous

The label photocell does not

work in the order as it is expected according to print data.

Check label size and gap size. The settings of the photocell

are not correct.

Check label photocell settings.

Settings of label size and gap

size are not correct.

Check correct loading of label

material.

No label found at the rear

printhead.

Insert new label roll. Soiled label photocell.

Clean the label photocell.

Labels not inserted correctly.

Check if labels are inserted

correctly.

124

Speed too slow.

The print speed is too slow.

Increase the speed of

customers' machine.

125

DMA send buffer

Communication problem HMI.

Restart the printer.

126

UID conflict

Configuration RFID

programming faulty.

Run RFID initialising.

127

Module not found

RFID module not available.

Check the RFID module

connection. Please contact your

responsible distributor.

128

No release signal

No print release by higher-level

control (customer machine).

Activate release signal at the

higher-level control.

129

Wrong firmware

Firmware does not match the

used printer type.

Use firmware that fits to the

printer type. Please contact your

responsible distributor.

130

Language missing

Language file for the set printer

language is not available.

Please contact your

responsible distributor.

131

Wrong material

Label material does not fit to

printing data.

User label material with

suitable label and/or gap

length.

132

Invalid mark-up tag

Invalid mark-up formatting

characters in text.

Correct the formatting

characters in the text.

133

Script not found

LUA script file not found.

Check the file name.

134

Script failure

LUA script is incorrect.

Check the script.

Error correction

DPM III xi series

Service instructions

0209

Error message

Cause

Remedy

135

Script user error

Error in LUA script user input.

Correct the input value.

136

No reprint available

No label data for reprinting

available.

Send new label data to the

printer.

137

Printhead short

circuit

Electrical short at the printhead.

Check the used printhead.

Please contact your distributor.

138

Too little ribbon

Transfer ribbon ends.

Change transfer ribbon.

DPM III xi series

Control inputs and outputs

0209

Service instructions

7 Control inputs and outputs

7.1 Version I

Figure 17

A = External output 1-4 (Output I) B = External input 1-4 (Input I) C = External output 5-8 (Output II) D = External input 5-8 (Input II)

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 17, A

Figure 18

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

Control inputs and outputs

DPM III xi series

Service instructions

0209

Connection of a lamp to a 24V relay by Out 1:

Figure 19

Output II

Figure 17, C

Figure 20

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

DPM III xi series

Control inputs and outputs

0209

Service instructions

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".

Input I

Figure 17, B

Figure 21

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 22

Control inputs

Example

Control inputs and outputs

DPM III xi series

Service instructions

0209

Input II

Figure 17, D

Figure 23

PIN (pin) Input II

In 5: Not used

In 6: Not used

In 7: Not used

In 8: Not used

DPM III xi series

Control inputs and outputs

0209

Service instructions

7.2 Version II

Figure 24

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 24, A

Figure 25

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

Control inputs and outputs

DPM III xi series

Service instructions

0209

Connection of a lamp to a 24V relay by Out 1:

Figure 26

Output II

Figure 24, C

Figure 27

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

DPM III xi series

Control inputs and outputs

0209

Service instructions

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 24, B

Figure 28

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 29

Control inputs

Example

Control inputs and outputs

DPM III xi series

Service instructions

0209

External bushing I/O-24

Figure 24, D

This input is executed as 15-pole and provides user-

sided 24V/100mA. In case of using this bushing, exists no galvanic separation.

Figure 30

Function

1, 6

Gnd

5, 10

24 V / 100 mA

Print start (NPN initiator)

Print start (PNP initiator)

Print start by

potential-free contact

Signal lamp

24 V / 100 mA (error)

Example 1

Example 2

Example 3

DPM III xi series

Wiring plans

0209

Service instructions

8 Wiring plans

8.1 Electronics

Figure 31

Wiring plans

DPM III xi series

Service instructions

0209

8.2 Mechanics

Figure 32

DPM III xi53 right version

DPM III xi series

Wiring plans

0209

Service instructions

Figure 33

DPM III xi53 left version

Wiring plans

DPM III xi series

Service instructions

0209

Figure 34

DPM III xi107 + xi128 right version

DPM III xi series

Wiring plans

0209

Service instructions

Figure 35

DPM III xi107 + xi128 left version

DPM III xi series

Layout diagrams

0209

Service instructions

9 Layout diagra m s

9.1 CPU

Figure 36

Layout diagrams

DPM III xi series

Service instructions

0209

JP1

JP2

JP3

JP4

JP5

JP6

JP7

BOOT

1-2

open

closed

1-2

closed

open

2 charging circuits

2-3

open

1-2

closed

JP8

JP9

JP10

JP11

JP12

JP13

JP14

BOOT

1-2

1-2 - 1-2

1-2

open

2 charging circuits

2-3

1-2

2-3

closed

1-2

Bausteine ICs:

U1; U2

FLASH memory

32 Bit RISC CPU

U5; U6

DRAM

RESET component

U10

RTC (Real Time Clock)

U11

Input/Output FPGA

U13

RS-232 component

U14

USB (Universal Serial Bus) component

U20

Printhead FPGA

U28

Serial EEPROM

ST1

Bus plug

ST5

Combined sensor signals

ST9

Zero position photocell

ST10

End position photocell

ST11

Cover switch

ST12

Compressed-air control

ST13

Connection to power unit

ST15

Transfer ribbon control

ST16, 17, 19

I/O, RS-485, RS-422 (Option)

ST20

Memory Card

ST21

Foil keyboard

ST22

Printhead KCE107/12 and KCE 53/12

ST24

LCD display

Jumper plan

Component overview

Plug-in positions

DPM III xi series

Layout diagrams

0209

Service instructions

9.2 Power supply unit (revision C)

Figure 37

Layout diagrams

DPM III xi series

Service instructions

0209

Motor driver ribbon motor

U13

Motor driver feed motor

U16

Control component printhead heater voltage

U17

Voltage control 5V

U18

Voltage control 24V

Bridge-connected rectifier

Secondary fuse 10A/T

P canal MOS-FET 100V/50A printhead voltage

ST3

Motor plug ribbon motor

ST5

Motor plug feed motor

ST6

Heater voltage printhead

ST7

Toroidal transformer

ST9

Connection CPU

ST10

Fan

ST11

24V/Brake/Valve

Voltage for CPU (VCC)

24V

Heater voltage printhead (VDK)

40V

Input voltage (VIN)

GND

Mass

Component overview

Plug-in positions

Measuring points

DPM III xi series

Layout diagrams

0209

Service instructions

9.3 Compact Flash card slot

Figure 38

The following Compact Flash cards can be used:

• 512 MB

• 1 GB

• 2 GB

Layout diagrams

DPM III xi series

Service instructions

0209

9.4 I/O board 24V

Figure 39

Only valid for complete equipped I/O plate

Function

Jumper position JP6

RS-422 full duplex

2-1

RS-485 half duplex

2-3

I/O board with external sensor

Jumper plan

DPM III xi series

Layout diagrams

0209

Service instructions

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

U10

Optocoupler RXD1

U11

Voltage transformer 5V ±5V

U20, 21

Interface components RS-422 / RS-485

ST1

Outputs 1-4 (Output1)

ST2

Outputs 5-8 (Output2)

ST3

Inputs 1-4 (Input 1)

ST4

Inputs 5-8 (Input2)

ST5

RS-485 / RS-422

ST 16, 17, 19

Connection CPU

Component overview

Plug-in positions

Layout diagrams

DPM III xi series

Service instructions

0209

9.5 Ethernet

Figure 40

DPM III xi series

Layout diagrams

0209

Service instructions

9.6 Distributor board

Figure 41

ST5

Feed motor

ST6

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

ST23

Printhead signals from electronics

ST24

Sensor signals from electronics

ST27

Connection carriage plate

ST28

Motor signals from electronics

ST29

Printhead signals from electronics

Right version

Plug-in positions

Layout diagrams

DPM III xi series

Service instructions

0209

Figure 42

ST5

Feed motor

ST6

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

Printhead signals from electronics

ST24

Sensor signals from electronics

ST27

Connection carriage plate

ST28

Motor signals from electronics

ST29

Printhead signals from electronics

Left version

Plug-in positions

DPM III xi series

Layout diagrams

0209

Service instructions

9.7 Carriage board

Figure 43

ST1

KCE 53/12

ST2

KCE 107/12

ST3

Transfer ribbon motor

ST4

Valve

ST5

Connection distributor plate

ST6

Transfer ribbon control

ST7

Zero point photocell

Right version

Plug-in positions

Layout diagrams

DPM III xi series

Service instructions

0209

Figure 44

ST1

KCE 53/12

ST2

KCE 107/12

ST3

Transfer ribbon motor

ST4

Valve

ST5

Connection distributor plate

ST6

Transfer ribbon control

ST7

Zero point photocell

Left version

Plug-in positions

DPM III xi series

Layout diagrams

0209

Service instructions

9.8 Motor adapter

Figure 45

ST1

Connection distributor plate

ST2

Brake

ST4

Feed motor

ST5

Final point photocell

Right version

Plug-in positions

Layout diagrams

DPM III xi series

Service instructions

0209

Figure 46

ST1

Connection distributor plate

ST2

Brake

ST4

Feed motor

ST5

Final point photocell

Left version

Plug-in positions

DPM III xi series

Connection plan of back panel plugs

0209

Service instructions

10 Connec t ion plan of back panel plugs

10.1 Motors

Figure 47

Signal

1-2; 14-15

FEED motor

24V 6 Control signal VALVE

Control signal BRAKE

7-8; 19-20

RIBBON motor

10.2 Printhead signals

Figure 48

Signal

1, 14

2, 10, 15, 16, 17, 18

GND

DATAIN

CLOCK

/LATCH

B.E.O.

/STR2

/CONT2

/CONT4

/STR1

/CONT1

/CONT3

/CONT5

THERM

Connection plan of back panel plugs

DPM III xi series

Service instructions

0209

10.3 Sensors

Figure 49

Signal

2,8

GND

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)

1, 9

HEADCLOSE, PULLUP (Cover switch)

DPM III xi series

Connection plan of interfaces

0209

Service instructions

11 Connec t ion plan of interfaces

11.1 Centronics

Figure 50

Signal

STROBE

2-9

DATA1-8

ACK

BUSY

PERROR

SELECT

AUTOFD

15-16

GND

VCC1284 (4,7V)

19-30

GND

INIT

FAULT

33-35

XXX

SELECTIN

11.2 RS-232

Figure 51

Signal

XXX

RXD

TXD

4-5

GND

6-9

XXX

Connection plan of interfaces

DPM III xi series

Service instructions

0209

11.3 RS-485 and RS-422

Figure 52

PIN at

D-SUB

socket

Function RS-422

(full duplex)

Function RS-485

(half duplex)

n/c n/c 2

n/c n/c 3

n/c n/c 4 TxD−

n/c 5 TxD+

n/c 6

n/c

TxD (RTxD)−

n/c

TxD (RxD)+

8 RxD−

n/c 9 RxD+

n/c

DPM III xi series

Connection plan of interfaces

0209

Service instructions

11.4 Ethernet

Figure 53

PIN RJ45socket

Description

1 TX+

2 TX−

3 RX+

n/c 5

n/c 6 RX−

n/c 8

n/c

11.5 USB 1.0

3 4

Figure 54

Signal

n/c 2 D− 3 D+ 4 GND

DPM III xi series

Index

0209

Service instructions

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 ............................................................................... 65

Plug-in positions ............................................................................. 65

Centronics, connection plan (interfaces) ............................................ 71

Compact Flash card

Replacing slot ................................................................................. 16

Slot, layout diagram ........................................................................ 59

Component overview

CPU ................................................................................................ 56

I/O board 24V ................................................................................. 61

Power suppl y unit ........................................................................... 58

Connection plan, back panel plugs

Motors ............................................................................................. 69

Printhead signals ............................................................................ 69

Sensors ........................................................................................... 70

Connection plan, interfaces

Centronics ....................................................................................... 71

Ethernet .......................................................................................... 73

RS-232 ............................................................................................ 71

RS-422 ............................................................................................ 72

RS-485 ............................................................................................ 72

USB 1.0........................................................................................... 73

CPU

Component overview ...................................................................... 56

Jumper plan .................................................................................... 56

Layout diagram ............................................................................... 55

Plug-in positions ............................................................................. 56

Replacing ........................................................................................ 13

Distributor board, left version

Layout diagram ............................................................................... 64

Plug-in positions ............................................................................. 64

Distributor board, right version

Layout diagram ............................................................................... 63

Plug-in positions ............................................................................. 63

Electricity, safety handling .................................................................. 10

Index

DPM III xi series

Service instructions

0209

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 suppl y unit, replacing ........................................................... 15

Primary fuse, replacing ................................................................... 11

Printhead FPGA, replacing ............................................................. 14

Secondary fuse, replacing .............................................................. 12

Electronics, wiring plan ....................................................................... 49

Error messages/corrections ............................................................... 40

Error messages/Error corrections 31, 32, 33, 34, 35, 36, 37, 38, 39, 40 Ethernet

Layout diagram ............................................................................... 62

Refit options .................................................................................... 20

Ethernet, connection plan (interfaces) ............................................... 73

Final position photocell, replacing ...................................................... 27

I/O board 24V

Component overview ...................................................................... 61

Jumper plan .................................................................................... 60

Layout diagram ............................................................................... 60

Plug-in positions ............................................................................. 61

I/O board, replacing ............................................................................ 17

I/O FPGA, replacing ........................................................................... 14

Inputs/outputs ........................................... 41, 42, 43, 44, 45, 46, 47, 48

Jumper plan

CPU ................................................................................................ 56

I/O board 24V ................................................................................. 60

Layout diagrams

Carriage board, left version ............................................................ 66

Carriage board, right version .......................................................... 65

Compact Flash card slot ................................................................. 59

CPU ................................................................................................ 55

Distributor board, left version .......................................................... 64

Distributor board, right version ....................................................... 63

Ethernet .......................................................................................... 62

I/O board 24V ................................................................................. 60

Motor adapter, left version .............................................................. 68

Motor adapter, right version ............................................................ 67

Power suppl y unit ........................................................................... 57

Lubrication .......................................................................................... 30

Measuring points, power supply unit .................................................. 58

Mechanics

Brake, refitting ................................................................................. 25

Final position photocell, replacing .................................................. 27

Lubrication ...................................................................................... 30

DPM III xi series

Index

0209

Service instructions

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 ............................................................................. 68

Motor adapter, right version

Layout diagram ............................................................................... 67

Plug-in positions ............................................................................. 67

Motors, connection plan (back panel plugs)....................................... 69

Notes

Document ......................................................................................... 5

User .................................................................................................. 5

Warnings ........................................................................................... 5

Options, refit

Ethernet .......................................................................................... 20

RS-485/RS-422 .............................................................................. 19