Carl Valentin DPM III xi Series, DPM III xi107, DPM III xi53, DPM III xi128 Service Instructions Manual
DPM III XI
Service Instructions
Copyright by Carl Valentin GmbH / 79670250209
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 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
3
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
4
Service instructions
0209
10
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
5
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
6
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
7
2 Safety instructions
2.1 General safety instructions
⇒ Keep the area around the device clean during and after
maintenance.
⇒ Work in a safety-conscious 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
8
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
9
There are warning stickers on the direct print modules that draw your
attention to dangers. Therefore the warning stickers are not to be
removed as then you and others cannot be aware of dangers and may
be injured.
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
10
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
11
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
12
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
13
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
14
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
15
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
16
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
17
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
19
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
20
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
21
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
22
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
23
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
24
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.
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