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Carl Valentin VARIO V Service Instructions Manual

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VARIO V
Service Instructions

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  • Page 1 VARIO V 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

    Vario V 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 ...... 9 Connector Pin Assignment (Printer Rear) ......
  • Page 4 Table of Contents Vario V Service Instructions 07.24...

  • Page 5: Notes On This Document

    Vario V 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 printer can be taken from our operating manual.

  • Page 6: Cross References

    Notes on this Document Vario V 1.3 Cross References References to specific items in a figure are marked with letters. They Drawings 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

    Vario V 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 Vario V 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

    Vario V 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 Instructions Vario V  Tools Do not use worn or damaged tools.  Use only tools and testing equipment that is suitable for the respective task.  What to do in case an Proceed in a very cautions and calm manner.

  • Page 11: Connector Pin Assignment (Printer Rear)

    USB 2.0 Hi-Speed Device (for connection PC) Ethernet 10/100 interface Serial interface RS-232 External output/input (option) Switch On/Off Power supply Winder connection CAUTION! The label printer can be damaged by non-compliant winders.  Attach only winders of Carl Valentin. 07.24 Service Instructions...
  • Page 12 Connector Pin Assignment (Printer Rear) Vario V Service Instructions 07.24...

  • Page 13: Cleaning

    Vario V Cleaning Cleaning DANGER! Risk of death by 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. NOTICE! When cleaning the label printer, personal protective equipment such as safety goggles and gloves are recommended.

  • Page 14: General Cleaning

    Cleaning Vario V WARNING! Risk of fire by easily inflammable label soluble!  When using label soluble, dust must be completely removed from the label printer and cleaned. 4.1 General Cleaning CAUTION! Abrasive cleaning agents can damage the label printer! ...

  • Page 15: Clean The Pressure Roller

    Vario V Cleaning 4.3 Clean the Pressure Roller A soiled pressure roller can lead to a reduced print quality and can affect the transport of material. CAUTION! Pressure roller can be damaged!  Do not use sharp or hard objects to clean the pressure roller.

  • Page 16: Clean The Printhead

    Cleaning Vario V 4.4 Clean the Printhead Printing can cause accumulation of dirt at the printhead e.g. by colour particles of the 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 17: Clean The Label Photocell

    Vario V Cleaning 4.5 Clean 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 be soiled with paper dust. This may affect the label scanning.
  • Page 18 Cleaning Vario V Service Instructions 07.24...

  • Page 19: Replacing Components

    Vario V 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 Tools List Some service work requires the following tools: •...

  • Page 20: Replace The Printhead

    Replacing Components Vario V 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 Vario V Replacing Components Figure 6 Remove the printhead 1. Open the printer cover. 2. Remove labels and transfer ribbon from the label printer. 3. When the printhead is closed, loosen the screws (D). 4. Turn the lever (B) counter clockwise to lift up the printhead.

  • Page 22: Adjust The Print Position

    Replacing Components Vario V 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 item Zero point adjustment is displayed.

  • Page 23: Replace The Pressure Roller

    Vario V Replacing Components 5.4 Replace the Pressure Roller Figure 7 Remove the 1. Open the printer cover. pressure roller 2. Turn the lever (A) counter clockwise to lift up the printhead. 3. Remove labels and transfer ribbon from the printer.

  • Page 24: Replace The Label Photocell

    Replacing Components Vario V 5.5 Replace 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, on page 17).

  • Page 25: Replace The Cpu Pcb

    Vario V Replacing Components 5.6 Replace the CPU PCB Figure 9 Remove the 1. If possible, save the printer configuration to a Compact Flash CPU PCB card. 2. Unplug the printer from the electrical outlet. 3. Remove the left printer cover.

  • Page 26: Replace The Power Supply

    Replacing Components Vario V Install the 1. Place the CPU PCB into the printer. CPU PCB 2. Secure the PCB to the chassis with two screw bolts (A) and four fixing screws (B). 3. Insert all plug connections on the PCB.
  • Page 27 Vario V Replacing Components 3. Remove the protective conductor at the inside of the printer cover. 4. Unplug all cable connections from the power supply (A). 5. Remove four fixing screws (B). 6. Remove the power supply unit (A). Install the 1.

  • Page 28: Replace The Battery

    Replacing Components Vario V 5.8 Replace the Battery DANGER! Danger of explosion due to improper replacement of the battery!  Use non-conductive tools.  Pay attention to polarity. Figure 11 1. Lift up the fixing bracket by means of a non-metallic device (e.g.

  • Page 29: Adjustments, Settings And Alignments

    Vario V 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 30: Adjust The Printhead

    Adjustments, Settings and Alignments Vario V 6.2 Adjust the Printhead CAUTION! The printhead assembly can be damaged. Attempting to adjust the printhead when the fixing screw (D, Figure 11) is tight can lead to defects at the printhead assembly. ...

  • Page 31: Adjust The Parallelism Of Printhead

    Vario V Adjustments, Settings and Alignments 6.3 Adjust the Parallelism of Printhead Figure 12 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 32: Adjust The Pressure Of Printhead

    Adjustments, Settings and Alignments Vario V 6.4 Adjust the Pressure of Printhead CAUTION! Damage of printhead by unequal use!  Only change the factory settings in exceptional cases. NOTICE! 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 33: Adjust The Ribbon Rewinder/Unwinder

    Vario V Adjustments, Settings and Alignments 6.6 Adjust the Ribbon Rewinder/Unwinder Figure 14 Due to the many different transfer ribbon variants regarding roller width, length and qualities it is necessary to provide the possibility to set the transfer ribbon tension.

  • Page 34: Adjust The Cutter Ledge

    Adjustments, Settings and Alignments Vario V 6.7 Adjust the Cutter Ledge CAUTION! Risk of injury, particularly during maintenance, the cutter blades are sharp!  Switch off the printer before attaching the cutter!  The cutter may only be used when it is mounted on the printer! ...

  • Page 35: Error Correction Of Cutter Ledge

    Vario V Adjustments, Settings and Alignments 5. Tighten the counter nut on the rear of the adjusting screw (C). 6. Install front shaft and front plate. 7. Press the key to test the cutter function. 6.8 Error Correction of Cutter Ledge If the cut is too far right please follow the steps: 1.

  • Page 36: Oil And Lubricate

    Adjustments, Settings and Alignments Vario V 6.9 Oil and Lubricate NOTICE! Make sure when oiling and greasing that no lubricants deposit on photocells, electronic components, circuit boards, printhead and rolls. Öl, Oil, Huile Fett, Grease, Graisse Figure 16 In case that dust or other dirt is deposit you have to clean the lubrication at first with alcohol.

  • Page 37: Retrofit With Options

    Vario V 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 38: Dispenser Unit

    Retrofit with Options Vario V 7.2 Dispenser Unit Dispenser unit without photocell Figure 18 1. Remove winding plate (if mounted) and the subjacent square-end at the printer front. 2. Open the dispensing whip by pulling the dispensing axe to the left.
  • Page 39 Vario V Retrofit with Options Dispenser unit with photocell Figure 19 1. Remove the left printer cover. Loosen two screws at the lower left printer edge and two screws at the chassis upper edge. 2. Remove the protective conductor at the inside of printer cover.

  • Page 40: Cutting Unit

    Retrofit with Options Vario V 7.3 Cutting Unit CAUTION! Risk of injury, particularly during maintenance, the cutter blades are sharp!  Switch off the printer befoere attaching the cutter!  The cutter may only be used when it is mounted on the printer! ...
  • Page 41 Vario V Retrofit with Options Figure 21 5. Fix the cutting unit with the sole plates onto the spacer shafts (E). 6. Push the cutting unit back until it engages into the spacer shafts. For this purpose press the cutting unit a bit downwards.
  • Page 42 Retrofit with Options Vario V Service Instructions 07.24...

  • Page 43: Error Correction

    Vario V 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 X value).
  • Page 44 Error correction Vario V 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 45 Vario V 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 46 Error correction Vario V 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 47 Vario V 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 48 Error correction Vario V 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 49 Vario V 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 50 Error correction Vario V 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 51 Vario V 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.
  • Page 52 Error correction Vario V Error message Cause Remedy Script failure LUA script is incorrect. Check the script. 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.

  • Page 53: Control Inputs And Outputs

    Vario V Control Inputs and Outputs Control Inputs and Outputs By means of a maximum of 16 control inputs and outputs which, in the following, are also referred to as ports, different functions of the printer system can be triggered and operating states can be displayed.
  • Page 54 Control Inputs and Outputs Vario V Configuration of D-Sub socket Figure 23 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 55 Vario V 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 56 Control Inputs and Outputs Vario V Port 1 to Port 16 = Assignment for I/O Profile StdFileSelLabel Identification Description / Function Port 1 Print start and cut (Input) Port 2 Error reset (Input) Port 3 Number of the file to load Bit 0 (Input)
  • Page 57 Vario V Control Inputs and Outputs Technical data Plug Connector 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...
  • Page 58 Control Inputs and Outputs Vario V Example 1 Device connection to a machine with S7-300 SPS. Figure 24 Device connection to a operating panel. Example 2 Figure 25 Service Instructions 07.24...
  • Page 59 Vario V Control Inputs and Outputs Example 3 Device connection version if 'Option: 2. LED'. Figure 26 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 60 Control Inputs and Outputs Vario V Service Instructions 07.24...

  • Page 61: Wiring Plan

    Vario V Wiring Plan 10 Wiring Plan Figure 27 07.24 Service Instructions...
  • Page 62 Wiring Plan Vario V Figure 28 Service Instructions 07.24...

  • Page 63: Cpu Component Placement Specification

    Vario V Wiring Plan 10.1 CPU Component Placement Specification Figure 29 07.24 Service Instructions...
  • Page 64 Wiring Plan Vario V Figure 30 Service Instructions 07.24...

  • Page 65: 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 66 Environmentally-Friendly Disposal Vario V Service Instructions 07.24...

  • Page 67: Index

    Vario V Index 12 Index adjustments, settings, alignments cutter ledge ................34, 35 oil and lubricate ................36 print mechanism ................29 printhead position ................30 printhead, parallelism ..............31 printhead, pressure ................. 32 printhead, pressure balance ............32 rewinder ..................33 rnwinder ..................
  • Page 68 Index Vario V label photocell cleaning ..................17 replacing ..................24 notes document ..................5 user ....................5 oil and lubricate .................. 36 parallelism, adjusting ................31 power supply, replacing ..............27 pressure balance, adjusting ............... 32 pressure roller cleaning ..................15 replacing ..................
  • Page 70 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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