Carl Valentin COMPA II Service Manual
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Carl Valentin COMPA II Service Manual

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COMPA II
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Summary of Contents for Carl Valentin COMPA II

  • Page 1 COMPA II Service Instructions...
  • Page 2 It must not be concluded from the missing labelling that it is not a registered brand or a registered trademark. Carl Valentin label printers comply with the following safety guidelines: EG Low-Voltage Directive (2006/95/EC) EG Electromagnetic Compatibility Directive (2004/108/EC)

  • Page 3: Table Of Contents

    Compa II series Table of contents Table of contents   Table of contents ................3     Notes on this document ............5 User notes ................5     Warnings ................. 5     Cross references ..............6    ...

  • Page 5: Notes On This Document

    Compa II series Notes on this document Notes on this document 1.1 User notes This service manual is intended for qualified service and maintenance staff. This manual contains information about hardware and mechanical part of the label printers 103/8 T, 104/8, 106/12, 106/24, 108/12 T, 162/12 and 162/12 T.

  • Page 6: Cross References

    Notes on this document Compa II series 1.3 Cross references References to specific items in a figure are marked with item Item numbers 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.

  • Page 7: Safety Instructions

    Compa II series Safety instructions Safety instructions 2.1 General safety instructions  Workplace and Keep the area around the device clean during and after method of working maintenance.  Work in a safety-conscious manner.  Store dismantled device parts in a safe place while maintenance is being performed.
  • Page 8 Safety instructions Compa II series If a possible danger to your eyes is present, wear protective goggles, Protective clothing especially in the following cases:  when knocking in or knocking out pins and similar parts with a hammer  when using spring hooks ...

  • Page 9: Safety Handling When Working With Electricity

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

  • Page 10: Printer Rear (Ports)

    Compa II series Printer Rear (Ports) Printer Rear (Ports) 6.1 - LED orange 6.1 - Lighting = Connection active 6.1 - Flashing = Data transfer 6.1 - Off = No connection 6.2 - LED green 6.2 - Lighting = Speed 100 MBit 6.2 -...

  • Page 11: Cleaning

    Compa II series Cleaning Cleaning 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. Cleaning schedule...

  • Page 12: General Cleaning

    Cleaning Compa II series 4.1 General cleaning CAUTION! Abrasive cleaning agents can damage the label printer!  Do not use abrasives or solvents to clean the outer surface of the label printer.  Remove dust and paper fuzz in the printing area with a soft brush or vacuum cleaner.

  • Page 13: Cleaning The Label Photocell

    Compa II series Cleaning 4.4 Cleaning the label photocell Compa II 103 T, 104, CAUTION! 106 and 108 T Label photocell can be damaged!  Do not use sharp or hard objects or solvents to clean the label photocell. The label photocell can become dirtied with paper dust and this can adversely affect label detection.
  • Page 14 Cleaning Compa II series Compa II 162 + 162 T Figure 3 1. Turn lever (1) counter clockwise to lift up the printhead. 2. Remove labels and transfer ribbon from the label printer. 3. Remove hexagonal wrench (7) from its retainer and remove the rear cover of printer.

  • Page 15: Replacing Components

    Compa II series Replacing components Replacing components DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.
  • Page 16 Replacing components Compa II series CAUTION! The printhead can be damaged by static electricity discharges and impacts!  Set up printer on a grounded, conductive surface.  Ground your body, e.g. by wearing a grounded wristband.  Do not touch contacts on the plug connections (2, 3).

  • Page 17: Adjusting The Print Position

    Compa II series Replacing components 5.3 Adjusting the Print Position Press key to access the function menu. Press key as long as you arrive the Service Functions menu. Press key to select the menu. Press key as long as you arrive the menu item Zero point adjustment.

  • Page 18: Replacing The Print Roller And Rewind Assist Roller

    Replacing components Compa II series 5.4 Replacing the print roller and rewind assist roller Figure 6 1. Turn lever (1) counter clockwise to lift up the printhead. Removing the side plate 2. Lift the pinch roller (5) off the rewind assist roller.

  • Page 19: Replacing The Slipping Clutches

    Compa II series Replacing components 5.5 Replacing the slipping clutches The rewinder for the transfer ribbon and the internal rewinder are coupled to slipping clutches in the main drive. The supply hub of the transfer ribbon is braked with a slipping clutch during printing.
  • Page 20 Replacing components Compa II series 1 = Snap ring Installing the slipping 2 = Slipping clutch clutch on the rewinder 3 = Coupling disks 4 = Winder axis 5 = Collar of belt wheel Figure 9 1. Slide coupling (2) onto the winder axis (4).

  • Page 21: Replacing The Label Photocell

    7. Pull out the label photocell (1) via the tab (4) toward the cover side. Compa II 162 + 162 T: That way the distance plate (3) is pushed out of label photocell guide. 1. Insert the label photocell (1) into the guide from the cover side and Installing the label slide it onto the tab (5) toward the rear cover until it stops.

  • Page 22: Replacing The Cpu Pcb

    Replacing components Compa II series 5.7 Replacing the CPU PCB Figure 12 1. If possible, save the printer configuration to a CompactFlash card. Removing the CPU PCB 2. Unplug the printer from the electrical outlet. 3. Detach all interface cables from the back of the printer.

  • Page 23: Replacing The Power Supply Unit

    Compa II series Replacing components 5.8 Replacing the power supply unit Figure 13 1. Unplug the printer from the electrical outlet. Removing the power supply unit 2. Remove the CPU PCB (see chapter 5.7, on page 22). 3. Remove the two screws (6) of the cover plate (5).

  • Page 24: Replacing The Wlan Module

    Replacing components Compa II series 5.9 Replacing the WLAN module Figure 14 1. Unplug the printer from the electrical outlet. Removing the WLAN module 2. Screw off the left printer cover. 3. Remove the CPU PCB (see chapter 5.7, on page 22).

  • Page 25: Replacing The Printhead Fpga

    Compa II series Replacing components 5.10 Replacing the printhead FPGA 1. Remove defective FPGA (2) from PLCC support base with a suitable displacement pincer. 2. Pay attention to polarity and press the new FPGA into the support base. 5.11 Replacing the battery...

  • Page 26: Replacing The Safety Fuse

    Replacing components Compa II series 5.12 Replacing the safety fuse F1: Microfuse 10A/T = Protection of complete power supply voltages Figure 16 1. Remove left printer cover. Unscrew two screws at the upper left printer edge. 2. Remove CPU PCB (see chapter 5.7, on page 22).

  • Page 27: Adjustments, Settings And Alignments

    Compa II series Adjustments, settings and alignments Adjustments, settings and alignments DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.

  • Page 28: Measuring The Winding Torques At Ribbon Rewinder/Unwinder

    Adjustments, settings and alignments Compa II series 6.2 Measuring the winding torques at ribbon rewinder/unwinder Measurement of the winding torque at the transfer ribbon take up and supply hub occurs by determining the pulling forces on a test collar attached to the winder.

  • Page 29: Measuring The Torques At The Internal Rewinder

    Compa II series Adjustments, settings and alignments 6.3 Measuring the torques at the internal rewinder Measurement of the winding torque at the internal rewinder occurs by determining the pulling forces with a cord wrapped around the rewinder. Measurement occurs without a test collar.

  • Page 30: Setting The Winding Torque

    Adjustments, settings and alignments Compa II series 6.4 Setting the winding torque The winding torque of a winder can be changed at the knurled ring of the respective slipping clutch. The numbers on the knurled ring stand for the value of the winding torque: ...

  • Page 31: Adjusting The Print Mechanism

    Compa II series Adjustments, settings and alignments 6.5 Adjusting the print mechanism Major adjustment of the printing mechanism beyond format-based settings is only required if the printhead assembly has been removed or parts in this area have been replaced. Excluded from this is the replacement of the printhead, after which readjustment is generally not required.
  • Page 32 Adjustments, settings and alignments Compa II series Preparing the label printer for adjustment Figure 20 1. Load labels and transfer ribbon which extend across the entire printing width. 2. Move the transfer ribbon deflection to the central position (3) with the screw (2).

  • Page 33: Adjusting The Position Of Printhead

    3. If the printhead is not aligned properly, use the screws (2) to align the lines on the printhead with the tips of the grooves and/or with Compa II 162 + 162 T to align the lines on the printhead mounting bracket with the front edge of the slides (5).

  • Page 34: Adjusting The Head Contact Pressure

    Adjustments, settings and alignments Compa II series 4. Start a test print (see 'operating manual'). 5. If the horizontal lines in the test grid are not parallel with the label edges, adjust the parallelism with the screws (2). 6. Set the best possible image quality by maintaining parallelism via turning the screws (2a) and (2b) in an alternating fashion.

  • Page 35: Adjusting The Transfer Ribbon Feed Path

    8. If bowing is not necessary, turn the screw (2) clockwise until the screw is just barely clamping. Figure 23 only for Compa II 104/8, 106/12, 106/24, 162/12 11.15 Service instructions...

  • Page 36: Adjusting The Belt Tension At Main Drive Motor

    Adjustments, settings and alignments Compa II series 6.9 Adjusting the belt tension at main drive motor CAUTION! The toothed belt could be damaged if adjustment is carried out improperly. Improper adjustment or insufficient tension of the toothed belt could cause it to rub against the label photocell during printing, which would damage the belt.

  • Page 37: Adjusting The Head Switch

    Compa II series Adjustments, settings and alignments 6.10 Adjusting the head switch The head switch prevents printing from occurring when the printhead is open. Figure 25 1. Unplug the printer from the electrical outlet. 2. Remove the rear cover. 3. Lock printhead.

  • Page 39: Refitting Options

    Compa II series Refitting options Refitting options DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.

  • Page 40: Internal Rewinder

    Refitting options Compa II series 7.2 Internal rewinder Figure 27 1. Remove label material. 2. Remove left printer cover. Unscrew two screws at the upper left printer edge. 3. Remove black protective cap in order to use the opening for the internal rewinding unit.

  • Page 41: Cutter

    Compa II series Refitting options 7.3 Cutter CAUTION! Risk of injury, particularly during maintenance, the cutter blades are sharp!  Switch off the before attaching the cutter!  The cutter may only be used when it is mounted on the printer! ...

  • Page 43: Error Correction

    Compa II series Error correction Error correction Error message Cause Remedy Line rises up completely or Move line down (increase Y Line too high partly over the upper edge of value). label. Check rotation and font. Line rises up completely or Move line up (reduce X value).
  • Page 44 Error correction Compa II series Error message Cause Remedy Received line number is invalid Check sent data. Field numer at RS-232 and Centronics. Check connection PC - printer. Invalid length of received mask Check sent data. Length mask statement. Check connection PC - printer.
  • Page 45 Compa II series Error correction Error message Cause Remedy Selected application identifier is Check code data. Application not available in GS1-128. Identifier F Missing HIBC system sign. Check definition of HIBC code. HIBC definition Missing primary code. Real Time Clock function is Change battery.
  • Page 46 Error correction Compa II series Error message Cause Remedy Memory card is write-protected. Deactivate write protection. Drive write- protected Attempt to indicate a directory Correct your entry. Directory not file as file name. Attempt to change a file during Select another file.
  • Page 47 Compa II series Error correction Error message Cause Remedy Defective photocell. Change photocell. Zero point Pressure air is not connected. Check pressure air. Compressed air External print release signal is Check input signal. External releaser missing. Wrong definition of column Reduce the column width res.
  • Page 48 Error correction Compa II series Error message Cause Remedy Printing creation was still active Reduce print speed. Time generation at print start. Use printers' output signal for synchronisation. Use bitmap fonts to reduce generating time. Both DPM position sensors Displace zero point sensor Transport protection (start/end) are active.
  • Page 49 Compa II series Error correction Error message Cause Remedy Scanner data does not Check adjustment of scanner. Scanner layout correspond to bar code data. difference Check scanner settings / connection. Serial interface error. Check settings for serial data COM break transmission as well as cable (printer-PC).
  • Page 50 Error correction Compa II series Error message Cause Remedy When starting the print order Close the housing cover and Housing open the housing cover is not closed. start the print order anew. Transferred EAN.UCC code is Verify bar code data (see EAN.UCC code...
  • Page 51 Compa II series Error correction Error message Cause Remedy The label photocell do not work Check label size and gap size. Print asynchronous in the order as it is expected according to print data. The settings of the photocell Check label photocell settings.

  • Page 53: Control Inputs And Outputs

    Compa II series Control inputs and outputs Control inputs and outputs By means of a maximum of 16 control inputs and outputs which, in the following, are also referred to as ports, different functions of the printer system can be triggered and operating states can be displayed.
  • Page 54 Control inputs and outputs Compa II series Configuration of D-Sub socket Figure 29 Port 1 to Port 16 = Assignment for I/O Profile 'Std_Label' Identification Description / Function Port 1 Print start and cut (Input) Port 2 Reprint last printed label (Input)
  • Page 55 Compa II series Control inputs and outputs Identification Description / Function + 5 VDC 5 Volt DC output for external use. Max. 1 A. This voltage is provided from direct print module and can be used e.g. as control voltage. Never apply any external voltage to this output.
  • Page 56 Control inputs and outputs Compa II series Device connection to a machine with S7-300 SPS. Example 1 Figure 30 Device connection to a operating panel. Example 2 Figure 31 Service instructions 11.15...
  • Page 57 Compa II series Control inputs and outputs Device connection version if 'Option: 2. LED'. Example 3 Figure 32 When connecting a reed contact with a control input, the contact must Precautions have a switching capacity of min. 1 A in order to prevent the contact from sticking due to the inrush current.

  • Page 59: Wiring Plan

    Compa II series Wiring plan 10 Wiring plan Figure 33 11.15 Service instructions...

  • Page 60: Cpu Component Placement Specification

    Wiring plan Compa II series 10.1 CPU component placement specification Figure 34 JP1 (Debug) JP2 (Write-protection) Jumper plan Boot sector closed closed Programming Delivery closed open Service instructions 11.15...

  • Page 61: Environmentally-Friendly Disposal

    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 63: Index

    Compa II series Index 12 Index A  Adjustments, settings, alignments Belt tension (main drive motor) ............36 Head contact pressure ..............34 Head switch ..................37 Print mechanism ............... 31, 32 Printhead position ................33 Transfer ribbon feed path ............... 35 Winding torques ............
  • Page 64 Index Compa II series H  Head contact pressure, adjusting ............34 Head switch, adjusting ............... 37 I  I/O plate, refit ..................39 Inputs/outputs ................53, 55 J  Jumper plan CPU ....................60 L  Label photocell Cleaning ..................13, 14 Replacing ..................21 N ...
  • Page 65 Compa II series Index T  Tool list ....................15 Transfer ribbon feed path, adjusting ..........35 W  Warnings ....................5 Winding torques Adjusting ..................27 Measuring (internal rewinder) ............29 Measuring (ribbon rewinder ............28 Measuring (ribbon unwinder ............28 Setting .....................
  • Page 66 Carl Valentin GmbH Neckarstraße 78 – 86 u. 94 . 78056 Villingen-Schwenningen Phone +49 (0)7720 9712-0 . Fax +49 (0)7720 9712-9901 info@carl-valentin.de . www.carl-valentin.de...

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