Carl Valentin ILX Series Service Instructions Manual

Hide thumbs Also See for ILX Series:

Operating manual (126 pages)

Table Of Contents

Table of Contents

Quick Links

Need help?

Do you have a question about the ILX Series and is the answer not in the manual?

Questions and answers

Summary of Contents for Carl Valentin ILX Series

Page 2 It must not be concluded from the missing labelling that it is not a registered brand or a registered trademark. Carl Valentin printing systems comply with the following safety guidelines: EG Low-Voltage Directive (2006/95/EC)
Page 3: Table Of Contents
Table of Contents Table of Contents Table of Contents ................3 Notes on this Document ............5 User Notes ................5 Instructions ................5 Cross References ..............6 Safety Instructions ..............7 General Safety Instructions ............. 7 Safety Handling when Working with Electricity ....... 9 Environmentally-Friendly Disposal ........
Page 5: Notes On This Document
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 the electronics and the mechanical part of the printing system. Information about operation of the printing system can be taken from our operating manual.
Page 6: Cross References
Notes on this Document 1.3 Cross References Drawings References to specific items in a figure are marked with letters. They are identified with parentheses in the text, e.g. (A). If no figure number is provided, letters in the text always refer to the graphic directly above the text.
Page 7: Safety Instructions
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 Protective equipment 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.
Page 9: Safety Handling When Working With Electricity
Safety Instructions There are warning stickers on the printing systems 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 print unit must be integrated with the Emergency Stop circuit when it is incorporated into the overall machine.
Page 10: 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 11: Connector Pin Assignment (Back Side)
Connector Pin Assignment (Back Side) Connector Pin Assignment (Back Side) Right version (ILX 56/8, 80/8, 54/12, 81/12) Power supply Slot for CF card C USB interface D Serial interface RS-232 Ethernet 10/100 1 = LED orange Lighting = Connection active Flashing = Data transfer Off = No connection 2 = LED green...
Page 12 Connector Pin Assignment (Back Side) Right version (ILX 103/8, 104/8, 106/12, 108/12) Power supply Slot for CF card C USB interface D Serial interface RS-232 Ethernet 10/100 1 = LED orange Lighting = Connection active Flashing = Data transfer Off = No connection 2 = LED green Lighting = Speed 100 MBit Off = Speed 10 MBit...
Page 13: Cleaning
Cleaning Cleaning DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the printing system from the mains supply and wait for a moment until the power supply unit has discharged. NOTICE! When cleaning the printing system, personal protective equipment such as safety goggles and gloves are recommended.
Page 14: General Cleaning
Cleaning 4.1 General Cleaning CAUTION! Abrasive cleaning agents can damage the printing system!  Do not use abrasives or solvents to clean the outer surface of the printing system.  Remove dust and paper fuzz in the printing area with a soft brush or vacuum cleaner.
Page 15: Cleaning The Printer Roller
Cleaning 4.3 Cleaning the Printer Roller A soiled print roll can lead to reduced print quality and can affect transport of material. CAUTION! Printer roller can be damaged!  Do not use sharp or hard objects to clean the printer roller.
Page 16: Cleaning The Printhead
Cleaning 4.4 Cleaning the 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. CAUTION! Printhead can be damaged! ...
Page 17: Cleaning The Label Photocell
Cleaning 4.5 Cleaning the 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. ILX 56/8, 80/8, 54/12, 81/12 ILX 103/8, 104/8, 106/12, 108/12 Figure 7...
Page 18 Cleaning Service Instructions 11.18...
Page 19: Replacing Components
Replacing Components Replacing Components DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the printing system from the mains supply and wait for a moment until the power supply unit has discharged. 5.1 Tool List Some service work requires the following tools: ...
Page 20: Replacing The Printhead (General Information)
Replacing Components 5.2 Replacing the Printhead (General Information) NOTICE! The printhead (D) is preinstalled on a head plate (A) and precisely aligned at the factory. Do not loosen the screws (G) under any circumstances. ILX 56/8, 80/8, 54/12, 81/12 ILX 103/8, 104/8, 106/12, 108/12 Figure 8 Head plate Plug connection...
Page 21: Replacing The Printhead
Replacing Components 5.3 Replacing the Printhead ILX 56/8, 80/8, 54/12, 81/12 Figure 9 Removing the 1. Remove labels and transfer ribbon from the printing systam. printhead 2. When printhead is closed, loosen the fixing screw (E). 3. Turn lever (B) counter clockwise to lift up the printhead (C). 4.
Page 22 Replacing Components ILX 103/8, 104/8, 106/12, 108/12 Figure 10 Removing the 1. Remove labels and transfer ribbon from the printing systam. printhead 2. When printhead is closed, loosen the knurled screw (C). 3. Turn lever (A) counter clockwise to lift up the printhead (B). 4.
Page 23: Adjusting The Print Position
Replacing Components 5.4 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 24: Replacing Pressure Roller
Replacing Components 5.5 Replacing Pressure Roller ILX 56/8, 80/8, 54/12, 81/12 Figure 11 Removing the pressure 1. Remove device cover. roller 2. Remove the protective conductor at the inside of the cover. 3. Turn lever (A) counter clockwise to lift up the printhead. 4.
Page 25 Replacing Components ILX 103/8, 104/8, 106/12, 108/12 Figure 12 Removing the pressure 1. Turn lever (A) counter clockwise to lift up the printhead. roller 2. Remove labels and transfer ribbon from the printing system. 3. Remove the two screws (C) at the bearing cover (B) and remove the bearing cover (B).
Page 26: Replacing The Label Photocell
Replacing Components 5.6 Replacing the Label Photocell NOTICE! 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 4.5, page 17). ILX 56/8, 80/8, 54/12, 81/12 A B C Figure 13...
Page 27 Replacing Components ILX 103/8, 104/8, 106/12, 108/12 Figure 14 Removing label 1. Remove labels and transfer ribbon from the printing systam. photocell 2. Remove the cover 3. Remove the protective conductor at the inside of the cover. 4. Remove protective disc (B). 5.
Page 28: Replacing The Pcb Cpu
Replacing Components 5.7 Replacing the PCB CPU ILX 56/8, 80/8, 54/12, 81/12 ILX 103/8, 104/8, 106/12, 108/12 Figure 15 Removing the NOTICE! CPU PCB Save the configuration of the printing system onto a CF card. 1. Unplug the printing system from the electrical outlet. 2.
Page 29 Replacing Components Installing the 1. Place CPU PCB into the printing system. CPU PCB 2. Secure PCB with the four screw bolts (A) and two fixing screws (B). 3. Insert all plug connections on the PCB. 4. Restore all interface connections on the back of the printing system.
Page 30: Replacing The Power Supply
Replacing Components 5.8 Replacing the Power Supply ILX 56/8, 80/8, 54/12, 81/12 Figure 16 1. Unplug the printing system from the electrical outlet. Removing the power supply 2. Remove the CPU PCB (see chapter 5.6, page 26). 3. Unplug all cable connections from power supply (B). 4.
Page 31 Replacing Components ILX 103/8, 104/8, 106/12, 108/12 Figure 17 Removing the 1. Unplug the printing system from the electrical outlet. power supply 2. Remove the CPU PCB (see chapter 5.6, page 26). 3. Unplug all cable connections from power supply (B). 4.
Page 32: Replacing The Pcb Control Inputs/Outputs
Replacing Components 5.9 Replacing the PCB Control Inputs/Outputs ILX 56/8, 80/8, 54/12, 81/12 ILX 103/8, 104/8, 106/12, 108/12 Figure 18 Removing the PCB NOTICE! assembly group Save the configuration of the printing system onto a CF card. 1. Unplug the print module from the electrical outlet. 2.
Page 33 Replacing Components Installing PCB control 1. Insert the connection cable corresponding to the marking of PCB inputs/outputs and/or the wiring plan (see chapter 9, page 55) into the plug-in positions of the PCB control inputs/outputs (B). 2. Fix the PCB inputs/outputs (B) with the hexagonal bolts (A) at the connection plate.
Page 34: Replacing The Power Electronics
Replacing Components 5.10 Replacing the Power Electronics Figure 19 Removing the power electronics 1. Unplug the print module from the electrical outlet. 2. Detach all interface cables from the back of the print module. 3. Remove the protective conductor at the inside of the cover. 4.
Page 35: Replacing Applicator Prearrangement (Option)
Replacing Components 5.11 Replacing Applicator Prearrangement (Option) ILX 56/8, 80/8, 54/12, 81/12 Figure 20 1. Unplug the print module from the electrical outlet. Removing the applicator 2. Remove the device cover. prearrangement 3. Remove the protective conductor at the inside of the cover. 4.
Page 36 Replacing Components ILX 103/8, 104/8, 106/12, 108/12 Figure 21 Removing the 1. Unplug the print module from the electrical outlet. applicator 2. Remove the device cover. prearrangement 3. Remove the protective conductor at the inside of the cover. 4. Remove the power electronics (see chapter 5.10, page 33). 5.
Page 37: Replacing The Battery
Replacing Components 5.12 Replacing the Battery DANGER! Danger of explosion when exchanging the battery improper!  Use non-conductive tools.  Pay attention to polarity. Figure 22 1. Lift up the fixing bracket by means of a non-metallic device (e.g. plastic ruler). 2.
Page 39: Adjustments, Settings And Alignments
Adjustments, Settings and Alignments Adjustments, Settings and Alignments DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the printing system from the mains supply and wait for a moment until the power supply unit has discharged.
Page 40: Adjusting The Position Of Printhead
Adjustments, Settings and Alignments 6.2 Adjusting the Position of Printhead 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 41 Adjustments, Settings and Alignments Parallelism NOTICE! An important characteristic for a high quality print is the parallelism of the focal line of the thermal printhead to the pressure roll. Because of the fact that the position of focal line of the printhead depends on fluctuations caused by production, it is necessary to adjust the parallelism.
Page 42 Adjustments, Settings and Alignments ILX 103/8, 104/8, 106/12, 108/12 Figure 24 Parallelism NOTICE! An important characteristic for a high quality print is the parallelism of the focal line of the thermal printhead to the pressure roll. Because of the fact that the position of focal line of the printhead depends on fluctuations caused by production, it is necessary to adjust the parallelism.
Page 43 Adjustments, Settings and Alignments Pressure balance NOTICE! right/left After adjusting parallelism and no even strong pressure exists over the complete print width, by means of a plate (B, Figure 24) you can set the balance. 1. Loosen screw (C, Figure 24) with a screwdriver by approx. ¼ rotations.
Page 44: Adjusting The Head Contact Pressure
Adjustments, Settings and Alignments 6.3 Adjusting the Head Contact Pressure ILX 56/8, 80/8, NOTICE! 54/12, 81/12 Change the head contact pressure with the screw (B). Increasing the head contact pressure leads to an improvement of the print image density. A B C D E Figure 25 1.
Page 45 Adjustments, Settings and Alignments ILX 103/8, 104/8, NOTICE! 106/12, 108/12 Change the head contact pressure with the screws (A) at the inside and outside of the printhead. Increasing the head contact pressure leads to an improvement of the print image density on the corresponding side and to a shifting of the ribbon feed path in the corresponding direction.
Page 46: Adjusting The Transfer Ribbon Feed Path
Adjustments, Settings and Alignments 6.4 Adjusting the Transfer Ribbon Feed Path ILX 56/8, 80/8, Adjust the transfer ribbon feed path by changing the head contact 54/12, 81/12 pressure. Increasing the head contact pressure with the screw (A) shifts the ribbon feed path. A B C D E Figure 27 1.
Page 47 Adjustments, Settings and Alignments ILX 103/8, 104/8, Adjust the transfer ribbon feed path by changing the head contact 106/12, 108/12 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 48: Adjusting The Ribbon Rewinder/Unwinder
Adjustments, Settings and Alignments 6.5 Adjusting the Ribbon Rewinder/Unwinder ILX 56/8, 80/8, 54/12, 81/12 ILX 103/8, 104/8, 106/12, 108/12 Figure 29 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.
Page 49: Ölen Und Fetten
Adjustments, Settings and Alignments 6.6 Ölen und Fetten NOTICE! Make sure when oiling and greasing that no lubricants deposit on photocells, electronic components, circuit boards, printhead and rolls. ILX 56/8, 80/8, 54/12, 81/12 ILX 103/8, 104/8, 106/12, 108/12 Figure 30 Fett Fett Fett...
Page 50 Adjustments, Settings and Alignments In case that dust or other dirt is deposit you have to clean the lubrication at first with alcohol. Apply rather in regular intervals (1-2 per year) a bit of lubricant, as only rarely too much. Otherwise the surplus of lubricant could settle on neighbouring components and disturb the functions.
Page 51: Error Correction
Error correction Error correction Error message Cause Remedy Line too high Line rises up completely or Move line down (increase Y partly over the upper edge of value). label. Check rotation and font. Line too low Line rises up completely or Move line up (reduce Y value).
Page 52 Error correction Error message Cause Remedy Field numer Received line number is invalid Check sent data. at RS-232 and parallel Check connection PC - printer. interface. Length mask Invalid length of received mask Check sent data. statement. Check connection PC - printer. Unknown mask Transferred mask statement is Check sent data.
Page 53 Error correction Error message Cause Remedy Invalid parameter Entered data do not correspond Check code data. to the characters allowed from the application identifier. Application Selected application identifier is Check code data. Identifier not available in GS1-128. HIBC definition F Missing HIBC system sign. Check definition of HIBC code.
Page 54 Error correction Error message Cause Remedy Delete current Attempt to delete the actual Change directory. directory directory. Path too long Too long indication of path. Indicate a shorter path. Drive write- Memory card is write-protected. Deactivate write protection. protected Directory not file Attempt to indicate a directory Correct your entry.
Page 55 Error correction Error message Cause Remedy Wrong FPGA The direct printing system is Please contact your distributor. equipped with the wrong FPGA. End position Check label length res. the The label length is too long. number of labels per cycle. The number of labels per cycle is too much.
Page 56 Error correction Error message Cause Remedy System file Loading of temporary hotstart Not possible. files. Shift variable Faulty definition of shift times Check definition of shift times. (overlapping times). GS1 Databar General GS1 Databar error. Check definition and parameter of GS1 Databar code. IGP error Protocol error IGP.
Page 57 Error correction Error message Cause Remedy Scanner timeout 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, corresponding to the set Timeout time too short.
Page 58 Error correction Error message Cause Remedy Invalid Tag type Wrong Tag type. Adapt data or use the correct Tag type. Tad data do not match the Tag type in the printer. RFID invalid RFID module is not activated. Activate RFID module or remove RFID data from label No RFID data can be data.
Page 59 Error correction Error message Cause Remedy No ribbon During the print order the Change transfer ribbon. ribbon roll becomes empty. Check transfer ribbon photocell Defect at the transfer ribbon (service functions). photocell. Wrong directory Invalid target directory when Target directory must not be copying.
Page 60 Error correction Error message Cause Remedy No release signal No print release by higher-level Activate release signal at the control (customer machine). higher-level control. Wrong firmware Firmware does not match the Use firmware that fits to the used printer type. printer type.
Page 61: Control Inputs And Outputs
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 printing system can be triggered and operating states can be displayed.
Page 62 Control inputs and outputs Configuration of D-Sub socket Figure 33 Port 1 to Port 16 = Assignment for I/O Profile 'Std_Label' Identification Description / Function Port 1 Print start (Input) Port 2 Reprint last printed label (Input) Port 3 Counter Reset (Input) Port 4 Option applicator only: Start application (Input) Port 5...
Page 63 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 printing system and can be used e.g. as control voltage. Never apply any external voltage to this output. + 24 VDC 24 Volt DC output for external use.
Page 64 Control inputs and outputs Example 1 Device connection to a machine with S7-300 SPS. Figure 34 Example 2 Device connection to a operating panel. Figure 35 Service Instructions 11.18...
Page 65 Control inputs and outputs Example 3 Device connection version if 'Option: 2. LED'. Figure 36 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 67: Connection Plans
Connection Plans Connection Plans 9.1 Wiring Plan ILX5X/8X, right version Figure 37 11.18 Service Instructions...
Page 68: Wiring Plan Ilx 5X/8X, Left Version
Connection Plans 9.2 Wiring Plan ILX 5X/8X, left version Figure 38 Service Instructions 11.18...
Page 69: Wiring Plan Ilx 10X, Right Version
Connection Plans 9.3 Wiring Plan ILX 10X, right version Figure 39 11.18 Service Instructions...
Page 70: Wiring Plan Ilx 10X, Left Version
Connection Plans 9.4 Wiring Plan ILX 10X, left version Figure 40 Service Instructions 11.18...
Page 71: Cpu Layout Diagram
Connection Plans 9.5 CPU Layout Diagram Figure 41 Jumper plan JP1 (Debug) JP2 (Write- protection) Boot sector closed closed Programming Delivery closed open 11.18 Service Instructions...
Page 73: Index
Index 10 Index Adjustments, settings, alignments Head contact pressure .............. 44, 45 Oil and lubricate ................ 49, 50 Print mechanism ................39 Printhead position ............40, 41, 42, 43 Rewinder ..................48 Transfer ribbon feed path ............... 46 Unwinder ..................48 Applicator prearrangement (option), replacing ......
Page 74 Index Head contact pressure, adjusting ..........44, 45 Inputs/outputs ................61, 63 Instructions ................... 5 Jumper plan, CPU ................59 Label photocell Cleaning ..................17 Replacing .................. 26, 27 Layout diagram, CPU ................. 59 Oil and lubricate ................49, 50 PCB control inputs/outputs, replacing ..........
Page 75 Index Wiring plan ILX 10X, left version ............58 Wiring plan ILX 10X, right version ............57 Wiring plan ILX 5X/8X, left version ............. 56 Wiring plan ILX 5X/8X, right version ..........55 11.18 Service Instructions...

This manual is also suitable for:

Ilx 56/8 Ilx 80/8 Ilx 81/12 Ilx 103/8 Ilx 104/8 Ilx 54/12 ... Show all