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Carl Valentin FLEXICODE Series Operating Manual

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FLEXICODE
Operating Manual

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  • Page 1 FLEXICODE Operating Manual...
  • Page 2 It must not be concluded from the missing labelling that it is not a registered brand or a registered trademark. Carl Valentin direct print modules comply with the following EU directives: EU Low-Voltage Directive (2014/35/EU)

  • Page 3: Table Of Contents

    Flexicode Table of Contents Table of Contents Introduction ................5 General Instructions ..............5 Intended Use ................5 Safety Instructions ..............6 Decommissioning and Dismantling ......... 7 Machine Overview ..............9 Figures ................... 10 Continuous Mode ..............12 Intermittent Mode ..............13 Operating Conditions ............
  • Page 4 Table of Contents Flexicode Load Layout ................80 File Explorer ................81 Firmware Update ..............86 Filter ..................86 Maintenance and Cleaning ..........87 General Cleaning..............87 Clean the Transfer Ribbon Drawing Roller ......88 Clean the Printhead ............... 88 Replace the Printhead ............

  • Page 5: Introduction

    Flexicode Introduction Introduction 1.1 General Instructions Basic information and warning references with the corresponding signal words for the danger level are as follows specified in this manual: DANGER identifies an extraordinarily great and immediate danger which could lead to serious injury or even death. WARNING identifies a possible danger would could lead to serious bodily injury or even death if sufficient precautions are not taken.

  • Page 6: Safety Instructions

    Introduction Flexicode The direct print module is solely intended to print suitable media which have been approved by the manufacturer. Any other or additional use is not intended. The manufacturer/supplier is not liable for damage resulting from misuse. Any misuse is at your own risk. Intended used includes heeding the operating manual, including the maintenance recommendations/regulations specified by the manufacturer.

  • Page 7: Decommissioning And Dismantling

    Introduction Flexicode Other unauthorized work or modifications to the direct print module can endanger operational safety. There are warning stickers on the direct print modules that draw your attention to dangers. Therefore the warning stickers are not to be removed as then you and others cannot be aware of dangers and may be injured.
  • Page 8 Introduction Flexicode Operating Manual 11.19...

  • Page 9: Machine Overview

    Flexicode Machine Overview Machine Overview The continuous and intermittent operating direct print module with high resolution is designed for installation in horizontal and vertical packaging machines. Convincing is the availability of left and right versions. Thanks to the separate control unit the direct print module can be integrated almost in each packaging process without any problems.

  • Page 10: Figures

    Machine Overview Flexicode 2.1 Figures Connection side of print mechanics Figure 1 Pneumatic connection Connecting cable (mechanics - control unit) Front of the print unit Figure 2 Lift sensor, internal Cover Spring catch Handle The cover (2) can be removed by the handle (4) with the spring catch (3) pressed down.
  • Page 11 Flexicode Machine Overview Connector assignment of control unit 12 - LED green 12 - Lighting = Speed 100 MBit 12 - Off = Speed 10 MBit 13 - LED orange 13 - Lighting = Connection active 13 - Flashing = Data transfer 13 - Off = No connection Figure 3...

  • Page 12: Continuous Mode

    Machine Overview Flexicode 2.2 Continuous Mode Please note that the material has sufficient adhesion at the pressure Material Speed transducer roll or encoder roll to permit the exact speed by the encoder. It is only possible to print when respecting the operating conditions, i.e.

  • Page 13: Intermittent Mode

    Flexicode Machine Overview 2.3 Intermittent Mode Print Principle Printhead Feed Packaging material Print surface Figure 6 After starting a print order the printhead moves against the print medium. Afterwards the printing carriage moves corresponding to the set or transferred layout length linear over the material which is to be printed.
  • Page 14 Machine Overview Flexicode Operating Manual 11.19...

  • Page 15: Operating Conditions

    Flexicode Operating Conditions Operating Conditions Before initial operation and during operation these operating conditions have to be observed to guarantee save and interference- free service of our direct print modules. Therefore please carefully read these operating conditions. Shipment and storage of our direct print modules are only allowed in original packing.
  • Page 16 Operating Conditions Flexicode Technical data of Power line voltage and power line frequency: See type plate power supply Allowable tolerance of power line voltage: +6 % … −10 % of nominal value Allowable tolerance of power line frequency: +2 % … −2 % of nominal value Allowable distortion factor of power line voltage: ≤...
  • Page 17 Flexicode Operating Conditions To avoid inadmissible heating, free air convection has to be ensured. Air convection Protection according IP: 20 Limit values Ambient temperature °C (operation): Min. +5 Max. +40 Ambient temperature °C (transport, storage): Min. −25 Max. +60 Relative air humidity % (operation): Max. 80 Relative air humidity % (transport, storage): Max.
  • Page 18 Operating Conditions Flexicode Operating Manual 11.19...

  • Page 19: Technical Data

    Flexicode Technical Data Technical Data Flexicode 53 Print resolution 300 dpi 50 … 400 mm/s Print speed Back speed max. 600 mm/s (intermittent mode only) Print width 53 mm Print length continuous mode: max. 3000 mm intermittent mode: max. 40 mm Frame passage width customized Printhead...
  • Page 20 Technical Data Flexicode Flexicode 53 Operation Panel Keys test print, function menu, quantity, CF Card, feed, enter, 4 x cursor LCD display graphic display 132 x 64 pixel Settings date, time, shift times 11 language settings (others on demand) print and device parameters, interfaces, password protection Monitoring Stop printing if end of ribbon / end of layout...

  • Page 21: Control Inputs And Outputs

    Flexicode Technical Data 4.1 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. 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...
  • Page 22 Technical Data Flexicode Configuration of D-Sub socket Figure 9 Cable identification Number Color white brown green yellow grey pink blue black violet grey-pink red-blue white-green brown-greed white-yellow yellow-brown white-grey grey-brown white-pink pink-brown white-blue brown-blue white-red brown-red white-black brown-black Operating Manual 11.19...
  • Page 23 Flexicode Technical Data Port 1 to Port 16 = Assignment for I/O Profile Std_Direct Port Description / Function 11 (Input) Print start 12 (Input) No function 13 (Input) Counter reset 14 (Input) No function 15 (Input) Error reset 16 (Input) No function 17 (Input) No function...
  • Page 24 Technical Data Flexicode Port 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. + 24 VDC 24 Volt DC output for external use.
  • Page 25 Flexicode Technical Data Port 1 to Port 16 = Assignment for I/O Profile StdFileSelDirect Port Description / Function 11 (Input) Print start 12 (Input) Error reset 13 (Input)* Number of the file to load Bit 0 (Input) 14 (Input)* Number of the file to load Bit 1 (Input) 15 (Input)* Number of the file to load Bit 2 (Input) 16 (Input)*...
  • Page 26 Technical Data Flexicode Port 1 to Port 16 = Assignment for I/O Profile SP_Direct0 Port Description / Function 11 (Input) Print start 12 (Input) No function 13 (Input) Counter reset 14 (Input) No function 15 (Input) Error reset 16 (Input) No function 17 (Input) No function...
  • Page 27 Flexicode Technical Data Plug Connector Technical data Type D-Sub connector High Density 26-pin. / connector Manufacturer W+P-Products Reference number 110-26-2-1-20 Output Voltages (connected with GND-PE) + 24 V / 1 A Fuse: Polyswitch / 30 V / 1 A + 5 V / 1 A Fuse: Polyswitch / 30 V / 1 A Port 1 - 15 Input...
  • Page 28 Technical Data Flexicode Example 1 Device connection to a machine with S7-300 SPS. Figure 10 Example 2 Device connection to a operating panel. Figure 11 Operating Manual 11.19...
  • Page 29 Flexicode Technical Data Device connection version if 'Option: 2. LED'. Example 3 Figure 12 Precautions When connecting a reed contact with a control input, the contact must have a switching capacity of min. 1 A in order to prevent the contact from sticking due to the inrush current.

  • Page 30: Pin Assignment Of Encoder Socket

    Technical Data Flexicode 4.2 Pin Assignment of Encoder Socket  5-pin connecting bushing, contacts according to DIN 45322 PIN1 = 5 VDC PIN2 = Encoder signal (channel A) PIN3 = Encoder signal (channel B) PIN4 = GND Operating voltage: 5 VDC Electrical data of encoder Output signal:...

  • Page 31: Installation And Initial Operation

    Flexicode Installation and Initial Operation Installation and Initial Operation Unpack/pack the direct CAUTION! print module Danger of injury by imprudent handling when lifting or placing the printing system.  Do not underestimate the weight of the printing system (6 kg). ...

  • Page 32: Install The Print Mechanics At Machines

    Installation and Initial Operation Flexicode 5.1 Install the Print Mechanics at Machines Installation with NOTICE! mounting frame With the open printing unit (due to construction) the requirements of EN 60950-1/EN 62368-1 regarding fire protection casing are not fulfilled. These must be ensured by the installation into the end device.
  • Page 33 Flexicode Installation and Initial Operation Required space for 1 90 outgoing cable Figure 14 NOTICE! The well-thought-out housing concept provides multiple possibilities for the cable outgoing. With small space requirements the cables can be directed upwards, downwards and to the side. 11.19 Operating Manual...

  • Page 34: Connect The Pneumatic Power Supply

    Installation and Initial Operation Flexicode 5.2 Connect the Pneumatic Power Supply The pneumatic power supply for the printhead mechanics has to be made available a minimum continuous pressure of 4 … 6 bars in front of the pressure regulator. The maximum pressure in front of the pressure regulator is 7 bars and 4 bars after the pressure regulator.

  • Page 35: Adjust The Pressure Power

    Flexicode Installation and Initial Operation 5.3 Adjust the Pressure Power The pressure power of the printhead can be set with the pressure regulator. The values are indicated in the following table: NOTICE! If the pressure power is too low then the printhead has no more contact to the counter-pressure plate.

  • Page 36: Connect The Direct Print Module

    Installation and Initial Operation Flexicode 5.4 Connect the Direct Print Module The direct print module is prepared according to standard for a mains Connect to the voltage of 230 V AC / 50 … 60 Hz. Optionally a mains voltage can be power supply used by 115 V AC / 50 …...

  • Page 37: Print Control

    Flexicode Installation and Initial Operation 5.6 Print Control As the direct print module is always in control mode, print orders can only be transmitted but not started via the existing interfaces (serial, parallel, USB or Ethernet). The print is started by a start signal to the ‘print start-control input’.

  • Page 38: Load Transfer Ribbon

    Installation and Initial Operation Flexicode 5.8 Load Transfer Ribbon NOTICE! As for the electrostatic unloading the thin coating of the thermal printhead or other electronic parts can be damaged, the transfer ribbon should be antistatic. The use of wrong materials can lead to printer malfunctions and the guarantee can expire.

  • Page 39: Increase The Clamping Force For Ribbon Roll

    Flexicode Installation and Initial Operation 5.9 Increase the Clamping Force for Ribbon Roll NOTICE! We recommend the use of high-quality transfer ribbon with a cardboard core. A sample ribbon roll is included in the scope of delivery. The clamping force of transfer ribbon roll placed on the rewinding/unwinding unit is designed for this quality.
  • Page 40 Installation and Initial Operation Flexicode Operating Manual 11.19...

  • Page 41: Operation Panel

    Flexicode Operation Panel Operation Panel 6.1 Keyboard (Standard) Function Back to the main menu. Start a test print. Delete a stopped print order. Change to the function menu. In function menu: one menu item back. Change to the quantity (number of pieces) menu. Press the keys to select the number of layouts that should be printed.

  • Page 42: Keyboard (Text Entry/User Guiding)

    Operation Panel Flexicode 6.2 Keyboard (Text Entry/User Guiding) The control unit of the print module is equipped with an alphanumeric character block which allows the user to enter parameters and customised variables without the connection of an external keyboard. Each key contains letters and similar to the use of a mobile phone (like sms) a direct and time-saving input is possible.
  • Page 43 Flexicode Operation Panel Function Back to the main menu. Start a test print. Delete a stopped print order. Not yet in use. Delete the character at the cursor position. If the cursor is between the last character then the last character is deleted.
  • Page 44 Operation Panel Flexicode Operating Manual 11.19...

  • Page 45: Function Menu

    Flexicode Function Menu Function Menu 7.1 Menu Structure (Continuous Mode) Print Settings Contrast Transfer Ribbon Control X Displacement Maschine Parameters Mode Print Offset Print Position Layouts/Cycle Check Material Speed Resolution/Material Feed Material Speed Print length Layout Settings Column printing Material selection Flip layout Rotate layout Alignment...
  • Page 46 Function Menu Flexicode I/O Parameters I/O Port 1-8 I/O Port 9-16 Debounce Not Ready: Error I/O Profile Network IP Address Netmask Standard Gateway Speed/Duplex DHCP Printer Name MAC Address Password Operation Network Interface COM1 Baud Parity Data Bits Stop Bit Start Sign Stop Sign Data Memory...
  • Page 47 Flexicode Function Menu Service Functions Photocell Parameters Paper Counter Heater Resistance Printhead Temperature Transfer ribbon Print Examples Input Output Online/Offline Transfer Ribbon Prior Warning Write log files to memory card CF Card / USB Stick Load Layout Change Directory Load File Save Layout Save Configuration Delete File...

  • Page 48: Menu Structure (Intermittent Mode)

    Function Menu Flexicode 7.2 Menu Structure (Intermittent Mode) Print Settings Speed Contrast Transfer Ribbon Control X Displacement Maschine Parameters Mode Back Speed Print Offset Print Position Layouts/Cycle Layout Settings Print length Column printing Material selection Flip layout Rotate layout Alignment Ribbon Save Operating Mode Transfer Ribbon Correction...
  • Page 49 Flexicode Function Menu I/O Parameters I/O Port 1-8 I/O Port 9-16 Debounce Start signal delay Not ready: Error Save signal I/O Profile Network IP Address Netmask Standard Gateway Speed/Duplex DHCP Printer Name MAC Address Password Operation Network Interface COM1 Baud Parity Data Bits Stop Bit...
  • Page 50 Function Menu Flexicode Date/Time Set Date/Time Summertime Start of Summertime - Format Start of Summertime - Date Start of Summertime - Time End of Summertime - Format End of Summertime - Date End of Summertime - Time Time Shifting Service Functions Photocell Parameters Paper Counter Heater Resistance...

  • Page 51: Print Settings

    Flexicode Function Menu 7.3 Print Settings Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key to select the menu Print settings. Indication of print speed in mm/s (see Technical Data, page 19). The Speed (intermittent print speed can be determined for each print order anew.

  • Page 52: Machine Parameters (Continuous Mode)

    Function Menu Flexicode 7.4 Machine Parameters (Continuous Mode) Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Machine parameters is displayed. Press the key to select the menu.
  • Page 53 Flexicode Function Menu Press the key to move to the next menu item. Indication of distance of the layout (res. the first layout in case more Print offset layouts per cycles are to be printed) to the zero point of machine. Settings possible either in mm or ms.

  • Page 54: Machine Parameters (Intermittent Mode)

    Function Menu Flexicode Press the key to move to the next menu item. Encoder resolution / material feed per encoder rotation Resolution Indication of resolution of used encoder and material feed per rotation of encoder in mm. These settings help measuring the material speed. The material feeding per encoder rotation corresponds for instance, in a 1:1 translation between the encoder and the roller, to the roller circumference.
  • Page 55 Flexicode Function Menu Press the key to move to the next menu item. Indication of back speed of print mechanics after print end in mm/s. Back speed Each cycle of the machine consists of printing and return to the zero point of machine.

  • Page 56: Layout

    Function Menu Flexicode 7.6 Layout Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Layout is displayed. Press the key to select the menu. Print length Indication of way the print mechanics has to move.

  • Page 57: Ribbon Save

    Flexicode Function Menu 7.7 Ribbon Save Ribbon save = maximum exploitation of transfer ribbon Layout Transfer ribbon w/o ribbon save Layout ribbon save Field ribbon save Transfer ribbon with ribbon save Procedure In principle the ribbon save is achieved by the way that the transfer ribbon in phases in those no printing is effected stopped or decelerated.

  • Page 58: Ribbon Save (Continuous Mode)

    Function Menu Flexicode 7.8 Ribbon Save (Continuous Mode) Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Ribbon save is displayed. Press the key to select the menu.
  • Page 59 Flexicode Function Menu −xx mm = The feedback can be made smaller. It causes loss of transfer ribbon but the number of cycles is increased. If the value is increased to the complete backfeed length then the direct print module sets automatically the max. value and no more backfeed is accomplished.
  • Page 60 Function Menu Flexicode Press the key to move to the next menu item. Expert parameters This menu item is password protected. Enter the password, press the to confirm the input and the following parameters are indicated: PhDownT = printhead down time in ms: Printhead down time This is used from ribbon save algorithm for the calculation of start time of printhead downwards movement.
  • Page 61 Flexicode Function Menu Press the key to move to the next menu item. FieldRS = field ribbon saving: Field ribbon saving Off: Field ribbon save mode Off. PHOnly: Only the printhead is moved. The transfer ribbon is not stopped. Normal: Field ribbon save is executed only if the transfer ribbon motor is completely stopped.

  • Page 62: Ribbon Save (Intermittent Mode)

    Function Menu Flexicode 7.9 Ribbon Save (Intermittent Mode) Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Ribbon save is displayed. Press the key to select the menu.
  • Page 63 Flexicode Function Menu Press the key to move to the next menu item. This menu item is password protected. Enter password, press the key Expert parameters to confirm the input and the following parameters are indicated: Printhead down time PhDownT = printhead down time in ms: This is used from ribbon save algorithm for the calculation of start time of printhead downwards movement.

  • Page 64: Device Settings

    Function Menu Flexicode 7.10 Device Settings Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Device settings is displayed. Press the key to select the menu. Off: The complete print memory is deleted.
  • Page 65 Flexicode Function Menu Press the key to move to the next menu item. Selection of language the display indicates texts in the graphic Language display. At the moment the following languages are available: German, English, French, Spanish, Finnish, Czech, Portuguese, Dutch, Italian, Danish, Polish, Greek, Hungarian, Russian, Chinese (option), Ukrainian, Turkish, Swedish, Norwegian.
  • Page 66 Function Menu Flexicode Press the key to move to the next menu item. On: A new print order is only printed after confirmation at the device. Layout confirmation An already active continuing print order is printed as long as the confirmation is effected at the device.

  • Page 67: I/O Parameters

    Flexicode Function Menu 7.11 I/O Parameters Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu IO parameters is displayed. Press the key to select the menu. I/O Port 1-8 and Definition of port functions: I/O Port 9-16...

  • Page 68: Network

    Function Menu Flexicode Press the key to move to the next menu item. Selection of the available configurations Std_Direct (factory setting), I/O Profile StdFileSelDirect, SP_Direct0 or Old_Direct0. The corresponding assignment is indicated in chapter 4.1, page 21. 7.12 Network Switch on the control unit and the display shows the main menu. Press the key to access the function menu.
  • Page 69 Flexicode Function Menu Operation Entering a 4-digit numeric password. Password Press the key to move to the next menu item. Protection Printer settings can be changed (contrast, speed, operating mode, ...). The password protection prevents modifications at the printer settings. configuration Press the key to move to the next menu item.

  • Page 70: Interface

    Function Menu Flexicode 7.14 Interface Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Interface is displayed. Press the key to select the menu. COM1 / Baud / COM1: P / D / S...

  • Page 71: Emulation

    Press the key until the menu Emulation is displayed. Press the key to select the menu. Protocol CVPL: Carl Valentin Programming Language ® ZPL: Zebra Programming Language ® Change between CVPL protocol and ZPL II protocol.

  • Page 72: Date & Time

    Function Menu Flexicode 7.16 Date & Time Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Date/Time is displayed. Press the key to select the menu. Setting of The upper line of display shows the current date, the second line the date and time...

  • Page 73: Service Functions

    Flexicode Function Menu 7.17 Service Functions NOTICE! So that the distributor res. the manufacturer in case of service can offer fast support the necessary information such as selected parameters can be taken directly from the service functions menu of the device. Switch on the control unit and the display shows the main menu.
  • Page 74 Function Menu Flexicode Press the key to move to the next menu item. Selection of the used transfer ribbon length (300 m, 450 m, 600 m). Ribbon With smaller ribbons, a higher number of cycles can be reached. Press the key to move to the next menu item.
  • Page 75 Flexicode Function Menu Online: Data can be received by interface. The keys of the foil keyboard are only active, if you changed in the Offline mode with the Offline: The keys of the foil keyboard are still active but received data are not processed.

  • Page 76: Main Menu

    Function Menu Flexicode 7.18 Main Menu Switch on the control unit and the display shows the main menu. The main menu shows information such as device type, current date and time, version number of firmware and the used FPGA. The selected display is shown for a short time, then the indication returns to the first information.

  • Page 77: Compact Flash Card / Usb Memory Stick

    Flexicode Compact Flash Card / USB Memory Stick Compact Flash Card / USB Memory Stick 8.1 General Information On the back side of the label printer is the slot for the CF card and the USB port for inserting the USB memory stick. The mass storage menu (memory menu) permits the access to CF cards or USB memory sticks attached to the printer.

  • Page 78: Navigation

    Compact Flash Card / USB Memory Stick Flexicode 8.3 Navigation The memory menu is operated with the keys of the foil keyboard of the control unit or with different function keys of an attached USB keyboard. Return to the previous menu. Function Load layout: Change to the File Explorer.

  • Page 79: Define User Directory

    Flexicode Compact Flash Card / USB Memory Stick 8.4 Define User Directory NOTICE! A user directory is to be defined: • before using and/or navigating through the memory menu. • if formatting of CF card is effected at PC and thus the STANDARD directory was not created automatically.

  • Page 80: Load Layout

    Compact Flash Card / USB Memory Stick Flexicode Press the key to access the memory menu. Press the key to call the File Explorer. Press the keys to select the directory. Press the key to display all available functions. Select the function Set as user dir and press the key to confirm the selection.

  • Page 81: File Explorer

    Flexicode Compact Flash Card / USB Memory Stick 8.6 File Explorer The File Explorer is the file manager of the printing system. The File Explorer provides the main functions for the user interface of memory menu. In the user directory, press the key to access the File Explorer.
  • Page 82 Compact Flash Card / USB Memory Stick Flexicode Loads a file. This can be a configuration saved before, a layout, etc. Load file Press the key to access the memory menu. Press the key to call the File Explorer. Press the keys to select the file.
  • Page 83 Flexicode Compact Flash Card / USB Memory Stick Saves the complete, current printer configuration under the selected Save configuration name. Press the key to access the memory menu. Press the key to call the File Explorer. Press the key to move to the menu Save file. Select the function Save configuration and press the key confirm the selection.
  • Page 84 Compact Flash Card / USB Memory Stick Flexicode Formats irrevocably the memory card. Format memory card NOTICE! USB sticks cannot be formatted at the printer! Press the key to access the memory menu. Press the key to call the File Explorer. Select the drive which is to format with the navigation keys.
  • Page 85 Flexicode Compact Flash Card / USB Memory Stick Creates a duplicate of the original file and/or the original directory to Copy memory card make changes independently of the original. Press the key to access the memory menu. Press the key to call the File Explorer.

  • Page 86: Firmware Update

    Compact Flash Card / USB Memory Stick Flexicode 8.7 Firmware Update Starting from firmware version 1.58, updates can be performed via the memory menu. Both the USB stick as well as the CF card can be used for this. Procedure On the CF card / USB memory stick a directory is created in which the necessary update files are stored (firmware.prn, data.prn).

  • Page 87: Maintenance And Cleaning

    Flexicode Maintenance and Cleaning Maintenance and Cleaning DANGER! Risk of death by 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 label printer, personal protective equipment such as safety goggles and gloves are recommended.

  • Page 88: Clean The Transfer Ribbon Drawing Roller

    Maintenance and Cleaning Flexicode 9.2 Clean the Transfer Ribbon Drawing Roller A soiled drawing roller can lead to reduced print quality and can affect transport of material. Figure 18 1. Remove the cover. 2. Remove transfer ribbon from the direct print module. 3.

  • Page 89: Replace The Printhead

    Flexicode Maintenance and Cleaning 9.4 Replace the Printhead CAUTION! The printhead can be damaged by static electricity discharges and impacts!  Set up the device on a grounded, conductive surface.  Ground your body, e.g. by wearing a grounded wristband. ...
  • Page 90 Maintenance and Cleaning Flexicode Figure 20 1. Fix the printhead flat rod (E) with the screws (C) to the printhead. Install the printhead Ensure the correct position of the flat rod (see illustration). 2. Insert the connection assembly to the new printhead. 3.

  • Page 91: Angle Adjustment (Intermittent Mode)

    Flexicode Maintenance and Cleaning 9.5 Angle Adjustment (Intermittent Mode) Figure 21 The installation angle of the printhead is default 26° to the print surface. However, manufacturing tolerances of printhead and mechanics can require another angle. CAUTION! Damage of printhead by unequal use! Higher wastage of ribbon by faster ripping.

  • Page 92: Print Quality Optimisation

    Maintenance and Cleaning Flexicode 9.6 Print Quality Optimisation The following table shows some possibilities to improve the print quality. Generally you have to note: the higher the print speed the lower the print quality. Problem Possible solution • Regular inferior print quality Increase the contrast •...

  • Page 93: Cycle Optimisation (Intermittent Mode)

    Flexicode Maintenance and Cleaning 9.7 Cycle optimisation (Intermittent Mode) NOTICE! Number of cycle is a complete print cycle per time unit. Figure 22 In case of 'time critical' applications you have the possibility with a good selection of different device parameters to increase the effective print speed and it this way the clock cycle.
  • Page 94 Maintenance and Cleaning Flexicode Operating Manual 11.19...

  • Page 95: Signal Diagrams

    Flexicode Signal Diagrams 10 Signal Diagrams 10.1 Continuous Mode NOTICE! The line 'data receipt' indicates when the direct print module receives data. Number of layouts per print order: 1 Dispenser mode: Dynamic Data memory: standard Ribbon save: On Trigger input print start: increasing slope In 'dispenser mode: dynamic' the layout distance onto the material is Layout not determined by the layout length but by the time between start...
  • Page 96 Signal Diagrams Flexicode Number of layouts per print order: 1 Data memory: extended Ribbon save: On Trigger input print start: increasing slope Layout For a better comparison we used the same layouts as before. Data receipt As soon as the generation of the layout is finished a new one is send to the direct print module.
  • Page 97 Flexicode Signal Diagrams Number of layouts per print order: 3 Data memory: Off/standard/extended Ribbon save: On Trigger input print start: increasing slope Layout/generation with The use of printer variables means that each layout is different and the direct print module has to generate several parts of the layout module variables anew, e.g.
  • Page 98 Signal Diagrams Flexicode Dispenser Mode: Static Number of layouts per print order: 4 Data memory: Off/standard/extended Ribbon save: On Trigger input print start: level High Layout 4 layouts with counter. Print start/print In 'dispenser mode: static' the level of the start impulse is recognised as valid start signal.

  • Page 99: Intermittent Mode

    Flexicode Signal Diagrams 10.2 Intermittent Mode Single item processing Continuous mode 11.19 Operating Manual...
  • Page 100 Signal Diagrams Flexicode Operating Manual 11.19...

  • Page 101: Error Correction

    Flexicode Error Correction 11 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 102 Error Correction Flexicode Error message Cause Remedy Field number Received line number is invalid. Check sent data. Check connection PC - printer. 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 103 Flexicode Error Correction Error message Cause Remedy Application Selected application identifier is Check code data. Identifier not available in GS1-128. HIBC definition Missing HIBC system sign. Check definition of HIBC code. Missing primary code. System clock Real Time Clock function is Change battery.
  • Page 104 Error Correction Flexicode Error message Cause Remedy Drive write- Memory card is write-protected. Deactivate write protection. protected Directory not file Attempt to indicate a directory Correct your entry. as file name. File already open Attempt to change a file during Select another file.
  • Page 105 Flexicode Error Correction Error message Cause Remedy Zero point Defective photocell. Change photocell. Compressed air Pressure air is not connected. Check pressure air. External release External print release signal is Check input signal. missing. Column too wide Wrong definition of column Reduce the column width res.
  • Page 106 Error Correction Flexicode Error message Cause Remedy Time generation Printing creation was still active Reduce print speed. at print start. Use printers' output signal for synchronization. Use bitmap fonts to reduce generating time. Transport protection Both DPM position sensors Displace zero point sensor (start/end) are active.
  • Page 107 Flexicode Error Correction Error message Cause Remedy Scanner layout Scanner data does not Check adjustment of scanner. difference correspond to bar code data. Check scanner settings / connection. COM break Serial interface error. Check settings for serial data transmission as well as cable (printer-PC).
  • Page 108 Error Correction Flexicode Error message Cause Remedy Housing open When starting the print order Close the housing cover and the housing cover is not closed. start the print order anew. EAN.UCC code Transferred EAN.UCC code is Verify bar code data (see invalid.
  • Page 109 Flexicode Error Correction Error message Cause Remedy Print asynchronous The label photocell do not work Check label size and gap size. in the order as it is expected according to print data. The settings of the photocell Check label photocell settings. are not correct.
  • Page 110 Error Correction Flexicode Error message Cause Remedy Script user error Error in LUA script user input. Correct the input value. No reprint available No label data for reprinting Send new label data to the available. printer. Printhead short Electrical short at the printhead. Check the used printhead.

  • Page 111: Additional Information

    Flexicode Additional Information 12 Additional Information 12.1 Column Printing With this direct print module several columns can be printed, i.e. the information of one column can be printed several times (depending on its width) on a layout. Caused by this the use of the complete print width is possible and the generating time is enormously reduced.

  • Page 112: Hotstart

    Additional Information Flexicode 12.2 Hotstart NOTICE! The data is saved onto CF card. Therefore the CF card is a condition for the Hotstart menu item. The function Hotstart contains e.g. that in case of a power failure the currently loaded layout can be further processed without any loss of data.
  • Page 113 Flexicode Additional Information Start print order In case at switching off the direct print module a print order was active, then a print start is released automatically and the required res. actual number of printed layouts is refreshed. In case the print order was stopped at switching off the direct print module, it is again set to the stopped mode after switching on the direct print module anew.
  • Page 114 Additional Information Flexicode Operating Manual 11.19...

  • Page 115: Environmentally-Friendly Disposal

    Carl Valentin GmbH zurückgegeben werden. Die Altgeräte werden daraufhin fachgerecht entsorgt. Die Carl Valentin GmbH nimmt dadurch alle Verpflichtungen im Rahmen der Altgeräteentsorgung rechtzeitig wahr und ermöglicht damit auch weiterhin den reibungslosen Vertrieb der Produkte. Wir können nur frachtfrei zugesandte Geräte zurücknehmen.
  • Page 116 Environmentally-Friendly Disposal Flexicode Operating Manual 11.19...

  • Page 117: Index

    Flexicode Index 14 Index clamping force (ribbon roll), increase ..........39 column printing ................. 111 compact flash card change directory ................81 copying.................... 85 define user directory ..............79, 80 delete file ..................83 display structure ................77 filter ....................86 firmware update ................
  • Page 118 Index Flexicode machine parameters (continuous mode) ......52, 53, 54 machine parameters (intermittent mode) ........54, 55 main menu ..................76 network ................... 68 password .................. 68, 69 print settings ................... 51 ribbon save ..................57 ribbon save (continuous mode) ........58, 59, 60, 61 ribbon save (intermittent mode) ..........
  • Page 119 Index Flexicode pneumatic power supply, connecting ..........34 pressure power, adjusting ..............35 print control ..................37 print unit, front ..................10 safety instructions ................6, 7 scope of delivery ................31 signal diagrams continuous mode ............95, 96, 97, 98 intermittent mode ................
  • Page 120 Carl Valentin GmbH Neckarstraße 78 86 u. 94 . 78056 Villingen-Schwenningen Phone +49 7720 9712-0 . Fax +49 7720 9712-9901 info@carl-valentin.de . www.carl-valentin.de...

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