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Carl Valentin DPM IV, Service Instructions Manual

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DPM IV 

Mechanics (Replace Components) 

 

05.19 

Service Instructions 

27 

 

5 

Mechanics (Replace Components) 

5.1  Printhead 

 

CAUTION! 

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

 

Set up the direct print module on a grounded, 
conductive surface. 

 

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

 

Do not touch the contacts on the plug connections. 

 

Do not touch the printing line with hard objects or your 
hands. 

 

A

B

A

C

C

 

Figure 13

 

 

1.  Open dust cover or remove it by unscrewing four screws at the 

hinges. 

2.  Remove the transfer ribbon. 

3.  Push the print carriage into an appropriate service position. 

4.  Remove the printhead cable (C). 

5.  Remove the screws (A) and the printhead (B). 

 

 

Removing the 
printhead 

Summary of Contents for DPM IV

Page 1: ......

Page 2: ...cies 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 print modules comply with ...

Page 3: ...ace Components 27 5 1 Printhead 27 5 2 Transfer Ribbon Tension Adjustment 29 5 3 Angle Adjustment 30 5 4 Printhead Bracket 31 5 5 Linear Bearing for Printhead Bracket 32 5 6 Short Stroke Cylinder 33 5 7 Transfer Ribbon Roller 34 5 8 Toothed Belt Motor 35 5 9 Linear Toothed Belt 36 5 10 Print Carriage 38 5 11 Print Carriage PCB and Connecting Cable in the Energy Chain40 5 12 Valve 42 5 13 Zero Sens...

Page 4: ...Table of Contents DPM IV 4 Service Instructions 05 19 10 Layout Diagrams 87 10 1 CPU 87 10 2 Power Supply Unit 88 11 Pin Assignment of Control Unit 89 12 Index 91 ...

Page 5: ...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 clo...

Page 6: ... always refer to the graphic directly above the text If a reference is made to another graphic the figure number is specified e g A 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 page 35 References to other documents have the following form See operating manual Drawings Cross references t...

Page 7: ...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...

Page 8: ...dule 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 Maintenance and servicing work can only be carried out by trained personnel Operating personnel must be trained by the operator on the basis of the operating manual Depending on use ensure that clothing...

Page 9: ... only be performed by instructed and trained electricians work on the electrical assemblies work on the device while it is open and connected to the power supply Locate the emergency stop or power switch so that it can be actuated in case of an emergency Unplug the device from the electrical outlet before performing the following work removing or installing power supply units working in the immedi...

Page 10: ...ged to take back and dispose of old equipment that was manufactured after 13 August 2005 As a principle this old equipment may not be delivered to communal collecting points It may only be organised used and disposed of by the manufacturer Valentin products accordingly labelled can therefore be returned to Carl Valentin GmbH This way you can be sure your old equipment will be disposed of correctly...

Page 11: ...ve it by unscrewing the four screws at the hinges 3 Insert the feather key C into the corresponding slot B at the shaft 4 Insert the hub D onto the shaft and fix it with the shaft protection E 5 Remove the transport safety rubber from the brake F 6 Push the brake F over the hub and fasten it with the integrated screws at the brake support so that the cable outlet of the connecting line is at the f...

Page 12: ...ropriate threaded holes are designated at the bottom of the print mechanics D The suitable screws B are included with delivery of this option 2 The suitable distance between the printhead and the counter pressure plate is already preset 3 On the bottom face of the carrier of counter pressure plate A are threaded holes M4 C which can be used for mounting the unit onto a plate or similar ...

Page 13: ...Instructions 13 3 3 Protective cover for the control unit IP65 NOTICE By mounting the optional protective cover the protection class IP 65 according to DIN EN 60529 is achieved for the control unit of DPM IV A B C D E F G H I J K L M N Figure 3 ...

Page 14: ...e cover G to the control unit A with the four screws I and the sealing rings H 9 Remove the upper part of the cable entry strip K after removing the both screws J 10 Remove the cable grommets M that fit to the respective connection cables from the cable entry strip K and enclose the cables two to three centimeters in front of the protective cover G 11 Place the cable entry strip K in front of the ...

Page 15: ...table cable grommets in different sizes are available ex works The size diameter is indicated on the respective grommet D F K O Figure 4 For loading of print data the integrated USB interface O is accessible from the outside NOTICE The protection class IP 65 is only achieved if the cap of the interface is firmly closed i e no USB stick or data cable is inserted Do not bend the connection cable D F...

Page 16: ......

Page 17: ...y fuses are not accessible from the outside A B A A A C C A B A A A C C Figure 5 Figure 6 1 Unplug the control unit from the electrical outlet 2 Unscrew the four screws A 3 Vertically remove the front plate B Disconnect disturbing connection cables from the connectors 4 Pull the fuse holder C from the housing 1 Replace the fuses two T4A 250 V 2 Push the fuse holder C into the housing until it enga...

Page 18: ...osition again to 0 Inputs and outputs marked with x are not occupied B C A A Figure 7 1 Unplug the control unit from electrical outlet 2 Unscrew the four screws on the rear and remove the front plate see chapter 4 1 page 17 3 Unscrew the retaining screws A at the SUB D socket 4 Remove the I O plate B and disconnect the plug in connector C 1 Connect the new I O board B with the appropriate cable C ...

Page 19: ... 3 Disconnect all plug in connectors D from the distributor board C 4 Unscrew the retaining screws B at the SUB D socket 5 Unscrew the screw A 6 Remove the distributor board C 1 Place the new distributor board C 2 Fasten the retaining screws B and the screw A 3 Connect all plug in connectors D with the new distributor board C 4 Reinstall the front plate 5 Connect the power supply cable Removing th...

Page 20: ... the electrical outlet 2 Unscrew the four screws on the rear and remove the front plate see chapter 4 1 page 17 3 Remove the distributor plate see chapter 4 3 page 19 4 Remove the I O board see chapter 4 2 page 18 5 Disconnect all plug in connectors from the CPU PCB D 6 Unscrew the screw A 7 Remove the six hexagonal bolts B 8 Carefully remove the CPU PCB D Removing the CPU PCB ...

Page 21: ...y 3 Fasten again the PCB D with the screws A and the hexagonal bolts B 4 Connect all plug in connectors to the PCB 5 Reinstall the I O board see chapter 4 2 page 18 6 Reinstall the distributor plate see chapter 4 3 page 19 7 Reinstall the front plate 8 Restore all interface connections 9 Connect the power supply cable 10 Check the firmware version and update it if necessary 11 Load the configurati...

Page 22: ...rews on the rear and remove the front plate see chapter 4 1 page 17 3 Remove the distributor plate see chapter 4 3 page 19 4 Lift up the fixing bracket by means of a non metallic device e g plastic ruler 5 Remove the battery 1 Install a new battery CR 2032 in the bracket A NOTICE Please pay attention to the correct polarity 2 Reinstall the distributor plate see chapter 4 3 page 19 3 Reinstall the ...

Page 23: ...ectors B from the power supply unit C 4 Unscrew the retaining screws A9 of the power supply unit Hold the power supply unit while unscrewing the retaining screws 5 Remove the power supply unit 1 Place the new power supply unit in the control unit housing and tighten it with the retaining screws A 2 Connect the plug in connectors B with the power supply unit C 3 Reinstall the front plate 4 Connect ...

Page 24: ... the plug in connector of the CPU HMI L 4 Carefully remove the connection line H of touch panel from the plug in connector of CPU HMI L 5 After removing the connection cable to CPU and removing the four screws M remove the CPU HMI L 6 Remove the six screws J 7 Lift the top display bar K and the bottom display bar I 8 Remove the graphic module A and the seal F from the depression 9 The touch panel ...

Page 25: ...ust not project into the field of view of the touch panel 3 Apply the top display bar K and the bottom display bar I on the edge of the graphic module A 4 Tighten the six screws J 5 Insert the new CPU HMI L tighten the four screws M and plug again the connection cable to the CPU 6 Plug the FFC cable E into the plug in connector of the CPU HMI L 7 Plug all connecting cables into the plug in connect...

Page 26: ...Electronics Replace Components DPM IV 26 Service Instructions 05 19 ...

Page 27: ...urface Ground your body e g by wearing a grounded wristband Do not touch the contacts on the plug connections Do not touch the printing line with hard objects or your hands A B A C C Figure 13 1 Open dust cover or remove it by unscrewing four screws at the hinges 2 Remove the transfer ribbon 3 Push the print carriage into an appropriate service position 4 Remove the printhead cable C 5 Remove the ...

Page 28: ... in the printhead support 3 Tighten again the screws A 4 Connect the printhead cable C 5 Insert the transfer ribbon 6 Enter the resistance value of the new printhead in the Service Functions heater resistance The value is indicated on the type plate of printhead 7 Start a test print to check the printhead position Installing the printhead ...

Page 29: ...s overturn of the printhead CAUTION Folding at transfer ribbon Only change the factory settings 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 ...

Page 30: ...d by unequal use Higher wastage of ribbon by faster ripping Only change the factory settings in exceptional cases 1 Loosen slightly two Allen head screws A 2 Move the threaded screws C to adjust the angle between printhead and printhead support Tighten decrease angle Loosen increase angle 3 Both threaded screws C must be adjusted with the very same number of turns 4 Tighten again the Allen head sc...

Page 31: ... If necessary remove the counter pressure plate 4 Remove the printhead see chapter 5 1 page 27 5 Remove the two nuts A 6 Remove the discs and springs inside Be sure to observe the proper sequence and position 7 Pull out the printhead bracket B from the linear guidings and remove it downwards NOTICE If necessary the printhead unit can be further dismantled For replacing the linear bearing and the s...

Page 32: ...he transfer ribbon 6 Close the dust cover or fasten it with four screws at the hinges 5 5 Linear Bearing for Printhead Bracket B B A A A Figure 17 1 Remove the printhead bracket see chapter 5 4 page 31 2 Remove the four screws A and the linear bearing B 1 Install the new linear bearing and screw in the four screws A 2 Reinstall the printhead bracket see chapter 5 4 page 31 NOTICE First screw the s...

Page 33: ...ube D 4 Unscrew the push in fittings C from the short stroke cylinders B 1 Tighten the push in fittings C to the new short stroke cylinders B 2 Press the pneumatic tube into the push in fittings and place the short stroke cylinder 3 Tighten the screws A 4 Reinstall the printhead bracket see chapter 5 4 page 31 NOTICE Before the mounting of push in fittings C examine the pneumatic tubes D for damag...

Page 34: ...ll the transfer ribbon roller D outwards through the holes in the plate Hold the gear E while this procedure 1 Install a new transfer ribbon roller D and insert it in the gear E 2 Reinstall the bearing C and the lock washer B 3 Tighten the both pins F of the gear E One pin F must meet the milled surface of the roller axle NOTICE Take care that the roller has no axial backslash otherwise wrinkling ...

Page 35: ...Tip slightly the brake bracket B until the toothed belt G can be removed upwards If necessary loosen further the screws D or remove them completely 1 Place the new toothed belt G over the belt wheel F to push it over the second belt wheel 2 Place the counter bearing A and tighten it with the screws I 3 Reinstall the locking ring H 4 Pull the brake bracket B forward and tighten the screws D at the ...

Page 36: ... cover G 2 Push the print carriage into an appropriate service position 3 Remove the two lock nuts A and the below washer 4 Unscrew the two screws B by a few turns The belt tensioner C moves to the inside and loosens the toothed belt I 5 Unscrew the screws J and remove the clamping piece E 6 Pull the toothed belt I out of the toothed belt wheel D H Removing the linear toothed belt ...

Page 37: ...lamping part E according to the smaller figure 4 Tighten the two screws B by a few turns NOTICE Ensure a parallel position of the belt tensioner C to the side panel The belt must run centrically on the toothed belt wheel D H When drifting on one side loosen or fasten one of the screws B slightly CAUTION By closing the screws B the belt tension is produced Stronger wear and premature termination of...

Page 38: ...d remove the top cover F 3 Push the print carriage into an appropriate service position 4 Remove the transfer ribbon 5 Unscrew the two lock nuts A and remove the washer below 6 Loosen the two screws B by a few turns The belt tensioner C moves to the inside and loosens the toothed belt H 7 Unscrew the screws I and remove the clamping piece D 8 Unscrew the screws N Q K N M O P L R Figure 23 Removing...

Page 39: ...t carriage Hold the print carriage M while this procedure NOTICE Carefully insert the guiding shafts into the linear bearing in order to avoid damages to the sealing 3 Guide the top guiding shaft K with the flange L through the hole in the side panel P Place the slider R for the zero control and push the guiding shaft K through the linear guidings of print carriage Hold the print carriage M while ...

Page 40: ...nt unit cover at the rear to work from the back of the device 2 Unscrew the three screws B and lift the print carriage A 3 Remove all connectors from the print carriage PCB and replace the PCB if necessary NOTICE Open the energy chain on the inside For this procedure carefully clip on the opening crossbars C and open them 4 Open the complete energy chain on the inside Remove and replace the connec...

Page 41: ...B 2 Close the energy chain For this procedure close the opening crossbars C Figure 24 3 Insert all connectors on the new print carriage PCB 4 Place the print carriage PCB A Figure 24 and tighten it with the three screws B Figure 24 5 Reinstall the print carriage see chapter 5 10 page 38 Installing the print carriage PCB and the connecting cable in the energy chain ...

Page 42: ...2 Remove the print carriage PCB see chapter 5 11 page 40 3 Remove the printhead see chapter 5 1 page 27 4 Remove the screws F 5 Disconnect the pneumatic tube E 6 Remove the hexagonal bolts G 7 Remove the screw B 8 Pull the complete bracket for valve D with the components backwards until the valve C can be removed and replaced NOTICE Alternative to the steps 2 to 8 remove the drive motor A for the ...

Page 43: ...ure 25 with components 2 Tighten the screw B Figure 25 3 Connect the pneumatic tube E Figure 25 4 Tighten the screws F Figure 25 5 Tighten the hexagonal bolts G Figure 25 6 Reinstall the printhead see chapter 5 1 ppage 27 7 Reinstall the print carriage PCB see chapter 5 11 page 40 8 Reinstall the print carriage see chapter 5 10 page 38 Installing the valve ...

Page 44: ...ld the print carriage G pull off and remove the upper guiding shaft E including the flange F from the hole in the side panel I Meanwhile remove the slider K for the zero control 6 Remove the screw A together with the zero sensor 7 Remove the screw D together with the end position sensor 8 Remove the respective plug in connector of the connecting cable from the carriage board see chapter 5 11 page ...

Page 45: ...l I Figure 27 Place the slider K Figure 27 for the zero control and push it through the linear guidings of the print carriage hold the print carriage G Figure 27 while this procedure NOTICE Carefully insert the guiding shafts into the linear guiding in order to avoid damage to the sealing 6 Tighten the screw J Figure 27 7 Tighten the screws H Figure 27 NOTICE Move the print carriage over the compl...

Page 46: ...hree lock washers I from the shaft J In each case one lock washer is before the belt wheel H and one lock washer behind the belt wheel H 10 Pull the transfer ribbon shaft J outwards the bearing seat Hold the belt wheel H while this procedure If necessary reduce the belt tension by loosening the motor adjusting screws 1 Hold the belt wheel H and insert the transfer ribbon shaft J into the bearing 2...

Page 47: ...ell is possible NOTICE Given the many available types of transfer ribbon varying in roller width roller length and quality it must be possible to adjust the transfer ribbon tension The transfer ribbon tension must be set such that no wrinkles or creases can form in the ribbon but that it runs as slip free as the film material Running the ribbon at too high tension may avoid wrinkles but can also l...

Page 48: ...ove it by unscrewing four screws at the hinges 4 Remove the transfer ribbon 5 Push the print carriage into an appropriate service position 6 Remove the connector A on the back from the encoder C 7 Unscrew the two screws D 8 Remove the encoder C with the bracket B from behind from the print carriage 9 Clip out the encoder C of the bracket B NOTICE The space is very cramped If necessary carefully us...

Page 49: ... a way that the smaller NOT the greater fork of encoder C Figure 29 immerse in the roller E Figure 29 of the transfer ribbon unwinder 3 Tighten the two screws D Figure 29 4 Insert the connector A Figure 29 on the rear into the encoder C Figure 29 5 Insert the transfer ribbon 6 Close the dust cover or fasten it with the four screws at the hinges 7 Fasten the rear cover with six countersunk screws 8...

Page 50: ...G B L C I H J K Figure 30 1 Unscrew the six countersunk screws and remove the top cover 2 Open dust cover or remove it by unscrewing four screws at the hinges 3 Remove the transfer ribbon 4 Push the print carriage into an appropriate service position M N O P Figure 31 Removing the top linear bearing ...

Page 51: ...top guiding shaft A Figure 31 with the flange B Figure 31 through the holes in the side panel G Figure 31 Place the slider L Figure 31 for the zero control and push it through the linear guiding M Figure 31 of print carriage Hold the print carriage K Figure 31 while this procedure NOTICE Carefully insert the guiding shaft into the linear bearing to avoid damage to the seals 4 Tighten the screws H ...

Page 52: ...L C I H J K Figure 32 1 Unscrew the three countersunk screws and the two cylinder screws J 2 Open dust cover or remove it by unscrewing four screws at the hinges 3 Remove the transfer ribbon 4 Push the print carriage into an appropriate service position M N O P Figure 33 Removing the bottom linear bearing ...

Page 53: ...n the screw R 4 Tighten the screw S 5 Tighten the screws O Figure 33 6 Guide the guiding shaft below F Figure 32 with the flange D Figure 32 through the holes in the side panel G Figure 32 Push the guiding shaft through the linear bearing N Figure 32 Hold the print carriage K Figure 32 while this procedure NOTICE Carefully insert the guiding shaft into the linear bearing to avoid damage to the sea...

Page 54: ...move the bottom cover 3 Open dust cover or remove it by unscrewing four screws at the hinges 4 Push the print carriage into an appropriate service position 5 Unscrew the four screws A and remove the cover plate B 6 Unscrew the four screws I and remove the cover F 7 Unscrew the two screws H 8 Remove the cable tie on the bottom side of the connection plate E 9 Remove the cover sensor G and pull from...

Page 55: ...e 3 Tighten the cover F with the four screws I 4 Tighten the cover plate B with the four screws A 5 Close dust cover or fasten it with four screws at the hinges 6 Fasten bottom cover with three countersunk screws and two cylinder screws D 7 Fasten top cover with six countersunk screws C NOTICE Finally check the switching of the cover switch It is a Reed switch i e the magnet at the dust cover rele...

Page 56: ...sunk screws I and remove the rear cover H 3 Open dust cover or remove it by unscrewing four screws at the hinges 4 Push the print carriage into an appropriate service position 5 Unscrew the four screws A and remove the cover plate B 6 Remove all connectors from the motor PCB F 7 Unscrew the two hexagonal bolts E 8 Unscrew the four screws G and carefully remove the motor PCB F Removing the motor PC...

Page 57: ... Tighten the two hexagonal bolts E 3 Insert all connectors into the motor PCB F 4 Place the cover plate B and tighten it with the four screws A 5 Close dust cover or fasten it with four screws at the hinges 6 Fasten rear cover H with six countersunk screws I 7 Fasten top cover C with six countersunk screws D Installing the motor PCB ...

Page 58: ...e position 4 Unscrew the four screws A and remove the cover plate B 5 Unplug the plug in connector C of pressure sensor H from the motor board D 6 Remove the pneumatic tube F from the push in fitting G For easier operation open some elements of the energy chain see the notice in chapter 5 11 page 40 7 Unscrew the two screws J 8 Completely remove the connector block I with the pressure sensor H 9 U...

Page 59: ...with the pressure sensor H 3 Tighten the two screws J 4 Press the pneumatic tube F onto the push in fitting G 5 Plug the plug in connector C of the pressure sensor H onto the motor board D 6 Tighten the cover plate B with the four screws A 7 Close the dust cover or fasten it with the four screws at the hinges 8 Fasten the top cover with the six countersunk screws Installing the pressure sensor ...

Page 60: ...Mechanics Replace Components DPM IV 60 Service Instructions 05 19 ...

Page 61: ...ded 6 1 General Information NOTICE The handling instructions for the use of Isopropanol IPA must be observed In the case of skin or eye contact immediately wash off the fluid thoroughly with running water If the irritation persists consult a doctor Ensure good ventilation CAUTION Abrasive cleaning agents can damage the printing system Do not use abrasives or solvents to clean the outer surface of ...

Page 62: ...roller can lead to reduced print quality and can affect transport of material B A Figure 38 1 Open dust cover or remove it by unscrewing four screws at the hinges 2 Remove the transfer ribbon 3 Remove deposits with roller cleaner and a soft cloth 4 If the roller A appears damaged replace it ...

Page 63: ... 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 B A Figure 39 1 Open the dust cover or remove it by unscrewing the four screws at the hinges 2 Remove the transfer ribbon 3 Clean printhead surface B with special cleaning pen or a cotton swab dipped in pure alcohol 4 Before using t...

Page 64: ...Cleaning DPM IV 64 Service Instructions 05 19 ...

Page 65: ...ilable Check font 8 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 9 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 10 No ribbon During the print order the ribb...

Page 66: ...git anew Check code data 21 Invalid SC number Selected SC factor is invalid for EAN res UPC Check SC factor 22 Invalid number of digits Entered digits for EAN res UPC are invalid 12 13 Check number of digits 23 Check digit calculation Selected check digit calculation is not available in the bar code Check calculation of check digit Check bar code type 24 Invalid extension Selected zoom factor is n...

Page 67: ... printhead and start print order anew 36 BCD invalid format BCD error Invalid format for the calculation of Euro variable Check entered format 37 BCD overflow BCD error Invalid format for the calculation of Euro variable Check entered format 38 BCD division BCD error Invalid format for the calculation of Euro variable Check entered format 39 FLASH ERROR Flash component error Run a software update ...

Page 68: ...r required files 54 File directory exists The selected file directory already exists Check name select a different name 55 File too large During copying procedure not enough memory space onto target drive available Use a larger target card 56 No update file Errors in update file of firmware Start update file anew 57 Invalid graphic file The selected file does not contain graphic data Check file na...

Page 69: ...ich is to print Replace printhead 71 Invalid page As page number either 0 or a number 9 is selected Select a number between 1 and 9 72 Page selection A page which is not available is selected Check the defined pages 73 Page not defined The page is not defined Check the print definition 74 Format user guiding Wrong format for customised entry Check the format string 75 Format date time Wrong format...

Page 70: ...l Displace RFID unit or use an offset 88 RFID verify Error while checking programmed data Faulty RFID label Check RFID definitions 89 RFID timeout Error at programming the RFID label Label positioning Faulty label 90 RFID data Faulty or incomplete definition of RFID data Check RFID data definitions 91 RFID tag type Definition of label data does not correspond with the used label Check storage part...

Page 71: ...r signal down is missing Check input signals compressed air supply 102 Vacuum plate empty Option applicator Sensor does not recognize a label at vacuum plate 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...

Page 72: ...correct function and position Check function of pneumatics for cross traverse 116 Print position Option applicator 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 var...

Page 73: ...munication 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 Firmw...

Page 74: ... 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 139 Hardware error A hardware component could not be found Please contact your responsible distribu...

Page 75: ...played The ports are provided by means of a D Sub bushing 26pin HD at the rear panel of the printer system and are galvanically isolated from protective earth PE by means of an optocoupler semi conductor route Each port can be configured as input and as output This function however is predefined in the printer software and cannot be changed by the user The following parameters can be changed and s...

Page 76: ...ith the terminal of the control voltage and the control inputs are switched to active By means of the option 2nd LED COM VDC for Inputs can optionally be connected with the terminal of the control voltage Then the control inputs are switched to active VDC for Outputs 20 Common supply connection of all control outputs VDC for Outputs must be connected with the terminal of the control voltage Never ...

Page 77: ...dule and can be used e g as control voltage Never apply any external voltage to this output Port 1 to Port 16 Assignment for I O Profile Std_Direct Port Pin Description Function 11 Input 10 Print start 12 Input 11 No function 13 Input 11 Counter reset 14 Input 12 No function 15 Input 12 Error reset 16 Input 13 No function 17 Input 13 No function 18 Input 14 No function 19 Output 15 Error 10 Output...

Page 78: ...le to load Bit 5 Input 19 Output 15 Error 10 Output 16 No function 11 Output 16 No function 12 Output 17 No function 13 Output 17 Ready 14 Output 18 No function 15 Output 18 Return printing carriage 16 Output 19 Transfer ribbon prior warning The files must be saved onto the CF card in the user directory The files must start with 1 or 2 digits 1_Etikett prn 02_Etikett prn The files can be saved wit...

Page 79: ...12 Output 17 Printing 13 Output 17 Ready 14 Output 18 No function 15 Output 18 Return 16 Output 19 Transfer ribbon prior warning Port 1 to Port 16 Assignment for I O Profile Old_Direct0 Port Pin Description Function 11 Input 10 Print start 12 Input 11 Error reset 13 Input 11 Counter reset 14 Input 12 No function 15 Input 12 No function 16 Input 13 No function 17 Input 13 No function 18 Input 14 No...

Page 80: ...nce 47Ω 100nF 10 kΩ Output Tension 5 VDC 24 VDC Impedance 47Ω 100nF 10 kΩ 47Ω Current max High 15 mA Low 15 mA Port 16 Input Tension 5 VDC 24 VDC Impedance 100nF 10 kΩ Output Tension 5 VDC 24 VDC Impedance 100nF 10 kΩ Current max High 500 mA Darlington BCP56 16 Low 500 mA Darlington BCP56 16 Optocoupler Output TCMT4106 CTR 100 300 Vishay or TLP281 4 GB CTR 100 600 Toshiba Input TCMT4106 CTR 100 30...

Page 81: ...DPM IV Control Inputs and Outputs 05 19 Service Instructions 81 Device connection to a machine with S7 300 SPS Figure 42 Device connection to a operating panel Figure 43 Example 1 Example 2 ...

Page 82: ...nter s internal voltages 5 VDC EXT or 24 VDC EXT is used an external fuse e g 0 5 AF should be additionally installed to protect the printer electronics In the event of an inductive load an antiparallel connected diode for instance must be used to discharge the induction energy In order to minimize the influence of leakage currents at control outputs a resistor must depending on what is connected ...

Page 83: ...DPM IV Wiring Plans 05 19 Service Instructions 83 9 Wiring Plans 9 1 Control Unit Figure 45 ...

Page 84: ...Wiring Plans DPM IV 84 Service Instructions 05 19 9 2 Print Mechanics Left Version Figure 46 ...

Page 85: ...DPM IV Wiring Plans 05 19 Service Instructions 85 9 3 Print Mechanics Right Version Figure 47 ...

Page 86: ...Wiring Plans DPM IV 86 Service Instructions 05 19 ...

Page 87: ...out Diagrams 05 19 Service Instructions 87 10 Layout Diagrams 10 1 CPU Figure 48 JP1 JP2 INIT programming closed closed Boot software programming closed open Delivery closed open Jumper plan JP1 JP2 BAT 1 CR2032 ...

Page 88: ...Layout Diagrams DPM IV 88 Service Instructions 05 19 10 2 Power Supply Unit P1 P4 P6 P5 Figure 49 P1 100 240 VAC input P4 48V output P5 Protective conductor connection P6 Fan ...

Page 89: ... for CF card E Connecting cable connection print mechanics control unit F USB port G Ethernet interface H USB host for USB keyboard and USB stick I External inputs outputs J Serial interface RS 232 K Mains connection L Grounding bolt M Power switch 1 LED green 1 Lighting Speed 100 MBit 1 Off Speed 10 MBit 2 LED orange 2 Lighting Connection active 2 Flashing Data transfer 2 Off No connection ...

Page 90: ...Pin Assignment of Control Unit DPM IV 90 Service Instructions 05 19 ...

Page 91: ...plate Valentin retrofit 12 cover sensor replacing 54 55 CPU jumper plan 87 layout diagrams 87 CPU PCB replacing 20 21 D distributor board control unit replacing 19 document notes 5 E electricity safety handling 9 10 electronics replace components battery 22 CPU PCB 20 21 distributor board control unit 19 HMI components 24 25 input output board 18 power supply unit 23 primary fuses 17 encoder repla...

Page 92: ...n sensor replacing 44 45 linear bearing bottom replacing 52 53 linear bearing printhead bracket replacing 32 linear bearing top removing 50 linear bearing top replacing 51 linear toothed belt replacing 36 37 motor PCB replacing 56 57 pressure sensor replacing 58 59 print carriage PCB replacing 40 41 print carriage replacing 38 39 printhead bracket replacing 31 32 printhead replacing 27 28 rewinder...

Page 93: ... 84 wiring plan right version 85 printhead angle adjustment 30 cleaning 63 replacing 27 28 transfer ribbon tension 29 printhead bracket replacing 31 32 protective cover for control unit IP65 retrofit 13 14 15 R rewinder unwinder replacing 46 47 S safety handling when working with electricity 9 10 safety instructions 8 9 clothing 7 protective clothing 7 protective equipment 8 workplace 7 short stro...

Page 94: ...Index DPM IV 94 Service Instructions 05 19 V valve replacing 42 43 W wiring plans control unit 83 print mechanics left version 84 print mechanics right version 85 Z zero sensor replacing 44 45 ...

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