Carl Valentin Spectra series Service Instructions Manual
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Carl Valentin Spectra series Service Instructions Manual

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Service instructions
Label printer
Spectra series
November 2008

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Summary of Contents for Carl Valentin Spectra series

  • Page 1 Service instructions Label printer Spectra series November 2008...
  • Page 2 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. Carl Valentin label printers comply with the following safety guidelines: EG Low-Voltage Directive (2006/95/EG) EG Electromagnetic Compatibility Directive (89/336/EWG)

  • Page 3: Table Of Contents

    Spectra series Table of contents Table of contents Table of contents................3 Notes on this document ............5 User notes ................5 Warnings ................. 5 Cross references ..............6 Safety instructions ..............7 General safety instructions............7 Safety handling when working with electricity ......9 Cleaning ................
  • Page 4 Table of contents Spectra series Error correction ..............51 Wiring plan ................59 Layout diagrams..............61 CPU ..................61 Power supply unit (revision G) ..........63 Memory card slot (option)............65 Compact Flash card slot (option) .......... 66 Input/output board (option) ............ 67 Input/output board 24V (option)..........

  • Page 5: Notes On This Document

    Vita 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 104/8 and 106/12. Information about operation of printer can be taken from our operating manual.

  • Page 6: Cross References

    Notes on this document Vita 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

    Spectra 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 Spectra 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

    Spectra 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 11: Cleaning

    Spectra series Cleaning Cleaning DANGER! Risk of death by electric shock! ⇒ Disconnect the label printer from power supply before performing any maintenance work. Cleaning schedule Cleaning task Frequency General cleaning (see section As necessary. 3.1, page 12). Cleaning print roller (see section Each time the label roll is 3.2, page 12).

  • Page 12: General Cleaning

    Cleaning Spectra series 3.1 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: Printhead

    Spectra series Cleaning 3.3 Printhead 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.

  • Page 14: Label Photocell

    Cleaning Spectra series 3.4 Label photocell CAUTION! 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 15: Replacing Components

    Spectra 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: Primary Fuse

    Replacing components Spectra series 4.2 Primary fuse Figure 4 1. Unplug the power plug from the filter block (A). Removing the primary fuse 2. Open cover (B). Lever it off laterally with a screwdriver. 3. Pull the fuse carrier (red) behind the cover outwards.

  • Page 17: Printhead (General)

    Spectra series Replacing components 4.4 Printhead (general) The printhead (4) is preinstalled on a head plate (1) and precisely aligned at the factory. Figure 6 Head plate Plug connection signal Plug connection tension Printhead Focal line Guiding Knurled screw CAUTION!

  • Page 18: Flat Type Printhead

    Replacing components Spectra series 4.5 Flat Type printhead Figure 7 1. Remove labels and transfer ribbon from the label printer. Removing the printhead 2. When printhead is closed, loosen the knurled screws (H). 3. Turn red lever (F) counter clockwise to lift up the printhead.

  • Page 19: Corner Type Printhead

    Spectra series Replacing components 4.6 Corner Type printhead Figure 8 1. Remove labels and transfer ribbon from the label printer. Removing the printhead 2. When printhead is closed, loosen the knurled screws (J). 3. Turn red lever (F) counter clockwise to lift up the printhead.

  • Page 20: Print Roller

    Replacing components Spectra series 4.7 Print roller Figure 9 1. Remove left printer cover. Removing the Loosen 3 screws at the lower left printer edge and 3 screws at the print roller chassis upper edge. 2. Remove the protective conductor at the inside of the printer cover.

  • Page 21: Label Photocell

    Spectra series Replacing components 4.8 Label photocell Soiling of the label photocell can also cause malfunctions. Before replacing the label photocell, check whether it is soiled and clean it if necessary (see chapter 3.4, page 14). Figure 10 1. Remove media from the printer.

  • Page 22: Cpu Pcb

    Replacing components Spectra series 4.9 CPU PCB Figure 11 1. If possible, save the printer configuration to a memory 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 Spectra series Replacing components 1. Place CPU PCB into the printer. Installing the CPU PCB 2. Secure PCB with the 5 fixing screws (D, Figure 11). 3. Fasten the 2 fixing screws (C, Figure 11) of the Centronics interface. 4. Insert all plug connections on the PCB.

  • Page 24: Power Supply

    Replacing components Spectra series 4.10 Power supply Figure 12 1. Unplug the printer from the electrical outlet. Removing the power supply 2. Remove left printer cover. Loosen 3 screws (A) at the lower left printer edge and 3 screws (B) at the chassis upper edge.

  • Page 25: Printhead Fpga

    Spectra series Replacing components 4.11 Printhead FPGA 1. Remove defective FPGA (B) from PLCC support base with a suitable displacement pincer. 2. Pay attention to polarity and press the new FPGA into the support base. 4.12 I/O FPGA 1. Separate the I/O plate (if available) from the CPU.

  • Page 27: Adjustments, Settings And Alignments

    Spectra 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: Position Of Printhead (Flat Type)

    Adjustments, settings and alignments Spectra series 5.2 Position of printhead (Flat Type) Complete the following printhead settings to achieve the best possible print image: ⇒ Align the heating line with the highest point of the print roller. Density of the print image is the greatest at this point.
  • Page 29 Spectra series Adjustments, settings and alignments After adjusting parallelism and no even strong pressure exists over Pressure balance the complete print width, by means of a plate (C, Figure 14) you can right/left set the balance as follows: 1. Loosen screw (D, Figure 14) about one quarter turn.

  • Page 30: Position Of Printhead (Corner Type)

    Adjustments, settings and alignments Spectra series 5.3 Position of printhead (Corner Type) Complete the following printhead settings to achieve the best possible print image: ⇒ Align the heating line with the highest point of the print roller. Density of the print image is the greatest at this point.
  • Page 31 Spectra series Adjustments, settings and alignments After adjusting parallelism and no even strong pressure exists over Pressure balance the complete print width, by means of a plate (C, Figure 15) you can right/left set the balance as follows: 1. Loosen screw (D, Figure 15) about one quarter turn.

  • Page 32: Transfer Ribbon Feed Path

    Adjustments, settings and alignments Spectra series 5.4 Transfer ribbon feed path Adjust the transfer ribbon feed path by changing the head contact pressure. Increasing the head contact pressure with the screws (A) shifts the ribbon feed path in the corresponding direction. Possibly arising formation of wrinkles can be eliminated by bowing the printhead.

  • Page 33: Ribbon Rewinder/Unwinder

    Spectra series Adjustments, settings and alignments 5.5 Ribbon rewinder/unwinder Figure 17 Due to the many different transfer ribbon variants regarding roller width, length and qualities it is necessary to provide the possibility to set transfer ribbon tension. The transfer ribbon tension is to set in such way that no wrinkles in the ribbon appear but it is transported in the same way as the labels.

  • Page 34: Head Photocell

    Adjustments, settings and alignments Spectra series 5.6 Head photocell The head photocell prevents printing from occurring when the printhead is open. Figure 18 1. Unplug the printer from the electrical outlet. 2. Remove left printer cover. Loosen 3 screws at the lower left printer edge and 3 screws at the chassis upper edge.

  • Page 35: Cutter Ledge

    Spectra series Adjustments, settings and alignments 5.7 Cutter ledge Figure 19 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 36 Adjustments, settings and alignments Spectra series If the cut is incorrect, the pressure between cutter shaft (A) and cutter ledge (B) is to be increased as described below: 1. Remove the right side cover of the cutter unit. Remove the 3 screws of the hexagon head bolts (H).

  • Page 37: Angle Of Aperture (Cutter Unit)

    Spectra series Adjustments, settings and alignments 5.8 Angle of aperture (cutter unit) CAUTION! Risk of injury, particularly during maintenance, the cutter blades are sharp! Figure 20 If the labels show dog-ears after the cutting procedure or if a paper jam occurred then the angle of aperture (F) is to be increased.

  • Page 38: Pressure Curve (Ribbon Save)

    Adjustments, settings and alignments Spectra series 5.9 Pressure curve (ribbon save) If the ribbon save function is activated and the printhead is not enough lifted up from the label material, then the pressure curve is to be adjusted anew. The pressure curve is onto the shaft of the ribbon save motor (A).
  • Page 39 Spectra series Adjustments, settings and alignments The sketch (see Figure 22) shows from behind the shaft of ribbon save motor (A) with pressure curve (B) and disc (C). The bearing ring (D) with the attached sole plate (E) is underneath.

  • Page 40: Supporting Bar (Ribbon Save)

    Adjustments, settings and alignments Spectra series 5.10 Supporting bar (ribbon save) Figure 23 If the transfer ribbon save function is active and a paper jam occurs or if the print position onto the label is incorrect, this could be traced back to an inadequate adjustment of the supporting bar (A).

  • Page 41: Oil And Lubricate

    Spectra series Adjustments, settings and alignments 5.11 Oil and Lubricate Make sure when oiling and greasing that no lubricants deposit on photocells, electronic components, circuit boards, printhead and rolls. A = Grease B = Low viscosity oil C = Oil...

  • Page 43: Refitting Options

    Spectra 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 44: Compact Flash Card Slot

    Refitting options Spectra series 6.2 Compact Flash card slot 1. Remove left printer cover. Loosen 3 screws (A) at the lower left printer edge and 3 screws (B) at the chassis upper edge. 2. Remove the protective conductor at the inside of the printer cover.

  • Page 45: Internal Rewinder

    Spectra series Refitting options 6.3 Internal rewinder Figure 28 1. Remove left printer cover. Loosen 3 screws at the lower left printer edge and 3 screws at the chassis upper edge. 2. Remove the protective conductor at the inside of the printer cover.

  • Page 46: Ethernet Interface

    Refitting options Spectra series 6.4 Ethernet interface Figure 29 1. Remove left printer cover. Loosen 3 screws (A) at the lower left printer edge and 3 screws (B) at the chassis upper edge. 2. Remove the protective conductor at the inside of the printer cover.

  • Page 47: I/O Plate

    Spectra series Refitting options 6.5 I/O plate Figure 30 1. Remove left printer cover. Loosen 3 screws at the lower left printer edge (A) and 3 screws (B) at the chassis upper edge. 2. Remove the protective conductor at the inside of the printer cover.

  • Page 48: Dispensing Unit

    Refitting options Spectra series 6.6 Dispensing unit Figure 31 1. Remove tear off edge (if mounted) at the front of printer. Dispensing unit without photocell 2. For an easier handling, remove front plate (if mounted) which is fixed at the printer base.

  • Page 49: Cutting Unit

    Spectra series Refitting options 6.7 Cutting unit 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 50: Guiding For Leporello Fold Material

    Refitting options Spectra series 6.8 Guiding for Leporello fold material Figure 33 At the printer rear you can find a breakout (A) for externally supplied label material. 1. Place the setup-kit for Leporello guiding (D) as illustrated above in front of the breakout.

  • Page 51: Error Correction

    Spectra series Error correction Error correction Line rises up completely or partly Move line down (increase Y over the upper edge of layout. value). Check rotation and font. Line rises up completely or partly Move line up (reduce Y value).
  • Page 52 Error correction Spectra series Loss of data at serial interface Check baud rate. (RS-232). Check cable (printer and PC). Received line number is invalid Check sent data. at RS-232 and Centronics. Check connection PC - printer. Invalid length of received mask Check sent data.
  • Page 53 Spectra series Error correction Printhead temperature is too Reduce contrast. high. Change printhead. Defective printhead sensing device. With cut an error occurred. Check layout run. Paper jam. Check cutter run. Entered data do not correspond Check code data. to the characters allowed from the application identifier.
  • Page 54 Error correction Spectra series Invalid length of the received Check data sent. command statement. Check connection PC - printer. Memory card not found / not Insert memory card correctly. correctly inserted. Impossible to read memory card Check memory card, if (faulty).
  • Page 55 Spectra series Error correction The selected file/directory Check name, select a different already exists. name. During copying procedure not Use a larger target card. enough memory space onto target drive available. Errors in update file of firmware. Start update file anew.
  • Page 56 Error correction Spectra series The connected bar code Check the connection scanner signals a device error. scanner/printer. Check scanner (dirty). Bad print quality. Increase contrast. Printhead completely soiled or Clean printhead or exchange (if defective. necessary). Print speed too high.
  • Page 57 Spectra series Error correction Protocol error IGP. Check sent data. Printing creation was still active Reduce print speed. at print start. Use printers' output signal for synchronisation. Use bitmap fonts to reduce generating time. Both DPM position sensors Displace zero point sensor (start/end) are active.
  • Page 58 Error correction Spectra series The scanner could not read the bar code within the set timeout time. Defective printhead. Check printhead. Wrinkles in transfer ribbon. Check transfer ribbon. Scanner wrong positioned. Position scanner correctly, Timeout time too short. corresponding to the set feeding.

  • Page 59: Wiring Plan

    Spectra series Wiring plan Wiring plan Spectra 107, 108, 160, 162 Figure 34 1108 Service instructions...
  • Page 60 Wiring plan Spectra series Spectra 216 Figure 35 Service instructions 1108...

  • Page 61: Layout Diagrams

    Spectra series Layout diagrams Layout diagrams 9.1 CPU Figure 36 1108 Service instructions...
  • Page 62 Layout diagrams Spectra series Jumper plan open closed closed open open for Spectra 107, BOOT 108, 160, 162 open open closed open closed* STANDARD JP10 JP11 JP12 JP13 JP14 open open BOOT open 1-2* STANDARD Jumper plan open closed closed...

  • Page 63: Power Supply Unit (Revision G)

    Spectra series Layout diagrams 9.2 Power supply unit (revision G) Figure 37 1108 Service instructions...
  • Page 64 Layout diagrams Spectra series Motor driver 'internal winder' (option) Component overview Motor driver feed motor Motor driver ribbon save motor (option) Motor driver ribbon motor (option ribbon save) Motor driver cutter motor (option) Control component printhead heater voltage Voltage control 5V...

  • Page 65: Memory Card Slot (Option)

    Spectra series Layout diagrams 9.3 Memory card slot (option) Figure 38 Data bus driver Component overview Switching transistor for memory card voltage Connection CPU Plug-in positions 1108 Service instructions...

  • Page 66: Compact Flash Card Slot (Option)

    Layout diagrams Spectra series 9.4 Compact Flash card slot (option) Figure 39 STP1 Connection CPU Plug-in positions Service instructions 1108...

  • Page 67: Input/Output Board (Option)

    Spectra series Layout diagrams 9.5 Input/output board (option) Figure 40 Jumper plan Only valid for complete equipped I/O board. Function Jumper position JP6 RS-422 full duplex RS-485 half duplex EPLD component Component overview Optocoupler outputs 1-4 (Output1) Optocoupler outputs 5-8 (Output2)

  • Page 68: Input/Output Board 24V (Option)

    Layout diagrams Spectra series 9.6 Input/output board 24V (option) Figure 41 Jumper plan Only valid for complete equipped I/O board. Function Jumper position JP6 RS-422 full duplex RS-485 full duplex EPLD component Component overview Optocoupler outputs 1-4 (Output1) Optocoupler outputs 5-8 (Output2)

  • Page 69: Ethernet (Option)

    Spectra series Layout diagrams 9.7 Ethernet (option) Figure 42 Ethernet processor Component overview Reset inverter Voltage control 3.3V Connection bus male connector CPU Plug-in positions 1108 Service instructions...

  • Page 71: Pin Assignment Interfaces

    Spectra series Pin assignment interfaces 10 Pin assignment interfaces 10.1 Centronics Figure 43 Signal STROBE DATA1-8 BUSY PERROR SELECT AUTOFD 15-16 VCC1284 (4,7V) 19-30 INIT FAULT 33-35 SELECTIN 10.2 RS-232 Figure 44 Signal 1108 Service instructions...

  • Page 72: Rs-485 And Rs-422 (Option)

    Pin assignment interfaces Spectra series 10.3 RS-485 and RS-422 (option) Figure 45 PIN at Function RS-422 Function RS-485 D-SUB (full duplex) (half duplex) female connector TxD− TxD+ TxD (RTxD)− TxD (RxD)+ RxD− RxD+ Service instructions 1108...

  • Page 73: Ethernet (Option)

    Spectra series Pin assignment interfaces 10.4 Ethernet (option) Figure 46 PIN RJ45 Description female connector TX− RX− 10.5 USB 1.0 Figure 47 Signal D− 1108 Service instructions...

  • Page 75: Index

    Spectra series Index 11 Index Adjustments, settings, alignments Angle of aperture ................37 Cutter ledge ................35, 36 Head photocell................34 Oil and lubricate................41 Pressure curve (ribbon save) ........... 38, 39 Print mechanism ................27 Printhead position (Corner Type) ........... 30 Printhead position (Flat Type) ............

  • Page 76: Service Instructions

    Index Spectra series Component overview ..............62 CPU PCB, replacing ..............22, 23 Jumper plan ..................62 Layout diagram ................61 Plug-in positions ................62 Cutter ledge, adjusting ..............35, 36 Cutting unit, refit ................. 49 Dispensing unit, refit................48 Electricity, safety handling..............
  • Page 77 Spectra series Index Leporello guiding, refit ................ 50 Lubricate and oil ................. 41 Measuring points, power supply unit..........64 Memory card slot (option) Component overview ..............65 Layout diagram ................65 Plug-in positions ................65 Refit....................43 Notes Document ..................5 User ....................
  • Page 78 Index Spectra series Refit options Compact Flash card slot ..............44 Cutting unit..................49 Dispensing unit ................48 Ethernet interface ................46 I/O plate ..................47 Internal rewinder ................45 Leporello guiding ................50 Memory card slot ................43 Rewinder (internal), refit ..............45 Rewinder, adjusting................

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