Carl Valentin COMPA III Service Instructions Manual
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Carl Valentin COMPA III Service Instructions Manual

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COMPA III
Service Instructions

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  • Page 1 COMPA III Service Instructions...
  • 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. Trademarks All named brands or trademarks are registered brands or registered trademarks of their respective owners and may not be separately labelled.

  • Page 3: Table Of Contents

    Compa III Table of Contents Table of Contents 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 ..... 10 Printer Rear (Ports) .............
  • Page 4 Table of Contents Compa III Service Instructions 10.21...

  • Page 5: Notes On This Document

    Compa III 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. Information about operation of printer can be taken from our operating manual.

  • Page 6: Cross References

    Notes on this Document Compa III 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 III 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 III 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 Compa III Safety Instructions 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 10: Safety Handling When Working With Electricity

    Safety Instructions Compa III 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: Printer Rear (Ports)

    Compa III Printer Rear (Ports) Printer Rear (Ports) Figure 1 A = Slot for CF card B = USB interface C = Switch On/Off D = Serial RS-232 port E = Power supply F = USB host for USB keyboard and USB stick...
  • Page 12 Printer Rear (Ports) Compa III Service Instructions 10.21...

  • Page 13: Cleaning

    Compa III Cleaning Cleaning DANGER! Risk of death by electric shock!  Disconnect the label printer from the mains supply and wait for a moment until the power supply unit has discharged. CAUTION! Risk of injury when cleaning.  Pay attention to sharp edges.

  • Page 14: General Cleaning

    Cleaning Compa III Tools and cleaning NOTICE! agents For adjustments and simple installation work, use the accompanying hexagonal wrench located in the upper section of the print unit. No other tools are required for the work described here. 4.1 General Cleaning...

  • Page 15: Clean The Printhead

    Compa III Cleaning 4.3 Clean 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.

  • Page 16: Clean The Label Photocell

    Do not use sharp or hard objects or solvents to clean the label photocell. The label photocell can be soiled with paper dust. This may affect the label scanning. Compa III 10X Figure 2 1. Remove labels and transfer ribbon. 2. Loosen the screw (5).
  • Page 17 Compa III Cleaning Compa III 162 Figure 3 DANGER! Danger to life from mains voltage/electric shock!  Before maintenance work, disconnect the label printer from the power supply and wait briefly until the power supply unit has discharged.  The following work must be carried out by trained service personnel! 1.

  • Page 19: Replacing Components

    Compa III Replacing Components Replacing Components DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the label printer from the mains supply and wait for a moment until the power supply unit has discharged. 5.1 Tool List...

  • Page 20: Replace The Printhead

    Replacing Components Compa III 5.2 Replace the Printhead CAUTION! The printhead can be damaged by static electricity discharges and impacts!  Set up the printer on a grounded, conductive surface.  Ground your body, e.g. by wearing a grounded wristband.
  • Page 21 Compa III Replacing Components Figure 5 Remove the printhead 1. Turn the lever (3) counterclockwise to lift up the printhead. 2. Remove labels and transfer ribbon. 3. Remove the hexagonal wrench (4) from its retainer. 4. Hold the printhead holder (2) on the pressure roller with one finger and unscrew the screws (1) with an Allen key until the printhead (7) is loose.

  • Page 22: Adjust The Print Position

    Replacing Components Compa III 5.3 Adjust the Print Position Press the key to access the function menu. Press the key until the menu Service Functions is displayed. Press the key to select the menu. Press the key until the menu Zero point adjustment is displayed Indication of value in 1/100 mm.

  • Page 23: Replace The Pressure Roller And Dispenser Roller

    Compa III Replacing Components 5.4 Replace the Pressure Roller and Dispenser Roller Figure 6 1. Turn the lever (1) counterclockwise to lift up the printhead. Remove the pressure roller/dispenser roller 2. Lift up the pressure system (7) from the dispenser roller.

  • Page 24: Replace The Slipping Clutches

    Replacing Components Compa III 5.5 Replace 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 25 Compa III Replacing Components Install the slipping 4 = Snap ring clutch on the rewinder 5 = Slipping clutch 6 = Coupling disks 7 = Winder axis 8 = Collar of belt wheel Figure 8 1. Slide the coupling (5) onto the winder axis (7).

  • Page 26: Replace The Label Photocell

    5. Unscrew the screw (2). 6. Press the locking (1) and slowly pull the label photocell outwards by the handle (3). Compa III 162: That way the distance plate (4) is pushed out of label photocell guide. Install the label 1.

  • Page 27: Replace The Cpu Pcb

    Compa III Replacing Components 5.7 Replace the CPU PCB Figure 11 Remove the 1. If possible, save the printer configuration to a CompactFlash card. CPU PCB 2. Unplug the printer from the electrical outlet. 3. Detach all interface cables from the back of the printer.

  • Page 28: Replace The Power Supply Unit

    Replacing Components Compa III 5.8 Replace the Power Supply Unit Figure 12 1. Unplug the printer from the electrical outlet. Remove the power supply unit 2. Remove the CPU PCB (see chapter 5.7, Replace the CPU PCB, page 27). 3. Remove the front panel at the bottom left (5).

  • Page 29: Replace The Battery

    Compa III Replacing Components 5.9 Replace the Battery DANGER! Danger of explosion due to improper replacement of the battery!  Use non-conductive tools.  Pay attention to polarity. Figure 13 1. Lift up the fixing bracket by means of a non-metallic device (e.g.
  • Page 30 Replacing Components Compa III Service Instructions 10.21...

  • Page 31: Adjustments, Settings And Alignments

    Compa III Adjustments, Settings and Alignments Adjustments, Settings and Alignments DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the label printer from the mains supply and wait for a moment until the power supply unit has discharged.

  • Page 32: Measure The Winding Torques At Ribbon Rewinder/Unwinder32

    = radius of test collar (30 mm) Setpoints for transfer Clockwise ribbon rewinder = 12.9 … 14.4 Ncm = 4.3 … 4.8 N Compa III (all): Counterclockwise = 2.1 … 3.0 Ncm = 0.7 … 1.0 N Compa III (all): Any direction...
  • Page 33 Compa III Adjustments, Settings and Alignments 5. Wind the cord attached to the test collar several times clockwise around the test collar. 6. Secure spring scale [10 N] (1) at the end of the cord and move the spring scale upward vertically until the transfer ribbon rewinder begins turning.

  • Page 34: Measure The Torques At The Internal Rewinder

    = radius of test collar (20 mm) Clockwise Setpoints for internal transfer ribbon = 28 … 32 Ncm = 14 … 16 N Compa III (alle): rewinder Counterclockwise = 8 … 12 Ncm = 4 … 6 N Compa II 162: Figure 15 1.
  • Page 35 Compa III Adjustments, Settings and Alignments 4. Secure the spring scale [25 N] (1) at the end of the cord. 5. Move the spring scale (1) upward vertically until the winder begins turning. 6. If the drive belt is also moving, hold it in place during the measurement.

  • Page 36: Set The Winding Torque

    Adjustments, Settings and Alignments Compa III 6.4 Set 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 37: Adjust The Print Mechanism

    Compa III Adjustments, Settings and Alignments 6.5 Adjust 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 38 Adjustments, Settings and Alignments Compa III Prepare the label printer for adjustment Figure 17 1. Load labels and transfer ribbon which extend across the entire printing width. 2. Move the transfer ribbon deflection to the central position (1) with the screw (2).

  • Page 39: Adjust The Position Of Printhead

    (2) and the transfer ribbon guiding (3). 2. If the printhead is not aligned properly, loosen the screw (1) about a quarter turn. Compa III 162: Loosen the screws (6) a quarter turn. 10.21 Service Instructions...
  • Page 40 Compa III 3. Align the parallelism of the printhead with the screw (4). Turning clockwise moves the printhead forward. Compa III 162: Turning clockwise moves the printhead backwards. 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 (4).

  • Page 41: Adjust The Head Contact Pressure

    Compa III Adjustments, Settings and Alignments 6.7 Adjust the Head Contact Pressure NOTICE! Change the head contact pressure with the screws (1a) and (1b) 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 42: Adjust The Transfer Ribbon Feed Path

    Adjustments, Settings and Alignments Compa III 6.8 Adjust the Transfer Ribbon Feed Path Adjust the transfer ribbon feed path by changing the head contact pressure and adjusting the transfer ribbon deflection. Increasing the head contact pressure with the screws (2) shifts the ribbon feed path in the corresponding direction.
  • Page 43 Compa III Adjustments, Settings and Alignments 3. Wait until the ribbon feed path has stabilized after each step of the adjustment. 4. Check the ribbon feed path for wrinkles. 5. If wrinkles arise on the inside, turn the screw (1) counterclockwise.

  • Page 44: Adjust The Belt Tension At Main Drive Motor

    Adjustments, Settings and Alignments Compa III 6.9 Adjust 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 45: Retrofit With Options

    Compa III Retrofit with Options Retrofit with Options DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the label printer from the mains supply and wait for a moment until the power supply unit has discharged.

  • Page 46: Dispenser Unit With Photocell

    Retrofit with Options Compa III 7.2 Dispenser Unit with Photocell Figure 23 1. Unscrew the screw (3) and remove the front panel at bottom left (4). 2. Align the dispenser unit with photocell (2) with the fixing lugs in the front panel towards the top and push the guiding pins into the provided guide holes (5).

  • Page 47: Cutter

    Compa III Retrofit with Options 7.3 Cutter CAUTION! Risk of injury, particularly during maintenance, the cutter blades are sharp!  Switch off before attaching the cutter!  The cutter may only be used when it is mounted on the printer! ...
  • Page 48 Retrofit with Options Compa III Service Instructions 10.21...

  • Page 49: Error Correction

    Compa III 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 50 Error Correction Compa III 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 51 Compa III 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 52 Error Correction Compa III 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 53 Compa III 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 54 Error Correction Compa III 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 55 Compa III 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 56 Error Correction Compa III 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 57 Compa III Error Correction Error message Cause Remedy Print asynchronous The label photocell does not Check label size and gap size. work in the order as it is expected according to print data. The settings of the photocell Check label photocell settings.
  • Page 58 Error Correction Compa III 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.

  • Page 59: Control Inputs And Outputs

    Compa III 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 60 Control Inputs and Outputs Compa III Configuration of D-Sub socket Figure 26 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...
  • Page 61 Compa III Control Inputs and Outputs 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) Port 3 Counter Reset (Input)
  • Page 62 Control Inputs and Outputs Compa III 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 63 Compa III Control Inputs and Outputs Example 1 Device connection to a machine with S7-300 SPS. Figure 27 Example 2 Device connection to a operating panel. Figure 28 10.21 Service Instructions...
  • Page 64 Control Inputs and Outputs Compa III Example 3 Device connection version if 'Option: 2. LED'. Figure 29 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 65: Wiring Plan

    Compa III Wiring Plan 10 Wiring Plan Figure 30 10.21 Service Instructions...

  • Page 66: Cpu Component Placement Specification

    Wiring Plan Compa III 10.1 CPU Component Placement Specification Figure 31 Jumper plan JP1 (Debug) JP2 (Write-protection) Boot sector closed closed Programming Delivery closed open Service Instructions 10.21...

  • Page 67: 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 68 Environmentally-Friendly Disposal Compa III Service Instructions 10.21...

  • Page 69: Index

    Compa III Index 12 Index adjustments, settings, alignments belt tension (main drive motor) ............44 head contact pressure ..............41 print mechanism ............... 37, 38 printhead position ..............39, 40 transfer ribbon feed path..............42 winding torques ............. 31, 32, 34, 36 assembly drawings ................
  • Page 70 Index Compa III I/O plate, retrofit .................. 45 instructions ................... 5 jumper plan, CPU ................66 label photocell replacing ..................26 notes document ..................5 user ....................5 power supply unit, replacing ............... 28 pressure roller, replacing ..............23 print mechanism, adjusting............37, 38 print position, adjusting ...............
  • Page 72 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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