Carl Valentin VARIO III series Service Instructions Manual
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Carl Valentin VARIO III series Service Instructions Manual

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  • Page 1 VARIO III Service Instructions...
  • Page 2 Apple Computer, Inc. ® ® Zebra and ZPL II are registered trademarks of ZIH Corporation. Carl Valentin label printers comply with the following safety guidelines: EG Low-Voltage Directive (2006/95/EC) EG Electromagnetic Compatibility Directive (2004/108/EC) Carl Valentin GmbH Postfach 3744 78026 Villingen-Schwenningen Neckarstraße 78 –...

  • Page 3: Table Of Contents

    Vario III Series Table of Contents Table of Contents   Table of Contents ................3     Notes on this Document ............5 User Notes ................5     Instructions ................5     Cross References ..............6    ...

  • Page 5: Notes On This Document

    Vario III Series Notes on this Document Notes on this Document 1.1 User Notes This service manual is intended for qualified service and maintenance staff. This manual contains information about hardware and mechanical part of the label printers 103/8 T, 104/8, 107/12, 107/24 and 108/12 T.

  • Page 6: Cross References

    Notes on this Document Vario III Series 1.3 Cross References References to specific items in a figure are marked with item Item numbers numbers. They are identified with parentheses in the text, e.g. (9). If no figure number is provided, item numbers in the text always refer to the graphic directly above the text.

  • Page 7: Safety Instructions

    Vario III Series Safety Instructions Safety Instructions 2.1 General Safety Instructions  Workplace and Keep the area around the device clean during and after method of working maintenance.  Work in a safety-conscious manner.  Store dismantled device parts in a safe place while maintenance is being performed.
  • Page 8 Safety Instructions Vario III Series 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 III Series Safety Instructions 2.2 Safety Handling When Working With Electricity  Qualifications of The following work may only be performed by instructed and personnel trained electricians:  work on the electrical assemblies  work on the device while it is open and connected to the power supply.

  • Page 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 (Printer Rear)

    Vario III Series Connector Pin Assignment (Printer Rear) Connector Pin Assignment (Printer Rear) 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

    Vario III Series Cleaning Cleaning DANGER! Risk of death by electric shock!  Disconnect the label printer from power supply before performing any maintenance work. NOTICE! When cleaning the label printer, personal protective equipment such as safety goggles and gloves are recommended.

  • Page 14: General Cleaning

    Cleaning Vario III Series 4.1 General Cleaning CAUTION! Abrasive cleaning agents can damage the label printer!  Do not use abrasives or solvents to clean the outer surface of the label printer.  Remove dust and paper fuzz in the printing area with a soft brush or vacuum cleaner.

  • Page 15: Cleaning The Printhead

    Vario III Series Cleaning 4.3 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.

  • Page 16: Cleaning The Label Photocell

    Cleaning Vario III Series 4.4 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.

  • Page 17: Replacing Components

    Vario III Series Replacing Components Replacing Components DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.

  • Page 18: Replacing The Printhead

    Replacing Components Vario III Series 5.2 Replacing the Printhead NOTICE! The printhead (4) is preinstalled on a head plate (1) and aligned at the factory. Figure 5 Head plate Plug connection signal Plug connection tension Printhead Focal line CAUTION! The printhead can be damaged by static electricity discharges and impacts! ...
  • Page 19 Vario III Series Replacing Components Figure 6 1. Remove labels and transfer ribbon from the label printer. Removing the printhead 2. When printhead is closed, loosen the screws (D). 3. Turn lever (B) counter clockwise to lift up the printhead.

  • Page 20: Replacing The Pressure Roller

    Replacing Components Vario III Series 5.3 Replacing the Pressure Roller Figure 7 1. Turn lever (A) counter clockwise to lift up the printhead. Removing the pressure roller 2. Remove labels and transfer ribbon from the printer. 3. Lift up approx. 3 - 4 mm the pins of the two-parts plastic rivet (D) with help from a tweezers or a small screwdriver.

  • Page 21: Replacing The Label Photocell

    Vario III Series Replacing Components 5.4 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 4.4, on page 16).

  • Page 22: Replacing The Cpu Pcb

    Replacing Components Vario III Series 5.5 Replacing the CPU PCB Figure 9 1. If possible, save the printer configuration to a Compact Flash Removing the card. CPU PCB 2. Unplug the printer from the electrical outlet. 3. Remove left printer cover.
  • Page 23 Vario III Series Replacing Components 1. Place CPU PCB into the printer. Installing the CPU PCB 2. Secure PCB to the chassis with the 4 screw bolts (A) and 2 fixing screws (B). 3. Insert all plug connections on the PCB.

  • Page 24: Replacing The Power Supply

    Replacing Components Vario III Series 5.6 Replacing the Power Supply Figure 10 1. Unplug the printer from the electrical outlet. Removing the power supply 2. Remove left printer cover. Loosen two screws at the lower left printer edge and two screws at the chassis upper edge.

  • Page 25: Replacing The Wlan Module

    Vario III Series Replacing Components 5.7 Replacing the WLAN Module Figure 11 1. Unplug the printer from the electrical outlet. Removing the WLAN module 2. Screw off the left printer cover. 3. Remove the CPU PCB (see chapter 5.5, page 22).

  • Page 26: Replacing The Battery

    Replacing Components Vario III Series 5.8 Replacing the Battery DANGER! Danger of explosion when exchanging the battery improper.  Pay attention to polarity. Figure 12 1. Lift up the fixing bracket by means of a non-metallic device (e.g. plastic ruler).

  • Page 27: Adjustments, Settings And Alignments

    Vario III Series Adjustments, settings and alignments Adjustments, settings and alignments DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.

  • Page 28: Adjusting The Printhead

    Adjustments, settings and alignments Vario III Series 6.2 Adjusting the Printhead CAUTION! The printhead assembly can be damaged. Attempting to adjust the printhead when the fixing screw (D) is tight can lead to defects at the printhead assembly.  Always loosen the fixing screw (D) before adjusting the printhead.

  • Page 29: Adjusting Parallelism Of Printhead

    Vario III Series Adjustments, settings and alignments 6.3 Adjusting Parallelism of Printhead Figure 13 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 30: Adjusting Pressure Of Printhead

    Adjustments, settings and alignments Vario III Series 6.4 Adjusting Pressure of Printhead CAUTION! Damage of printhead by unequal use!  Change factory settings only 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 31: Adjusting The Ribbon Rewinder/Unwinder

    Vario III Series Adjustments, settings and alignments 6.6 Adjusting the ribbon rewinder/unwinder Figure 15 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 32: Adjusting The Cutter Ledge

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

  • Page 33: Error Correction Of Cutting Edge

    Vario III Series Adjustments, settings and alignments 6.8 Error Correction of Cutting Edge If the cut is too far right please follow the steps: 1. Move the flexible cutter ledge (D) to the front. 2. Turn the adjusting screw (B) in clockwise direction until the correct value is reached.

  • Page 34: Oil And Lubricate

    Adjustments, settings and alignments Vario III Series 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. In case that dust or other dirt is deposit...

  • Page 35: Refitting Options

    Vario III Series Refitting Options Refitting Options DANGER! Risk of death via electric shock!  Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.

  • Page 36: Dispensing Unit

    Refitting Options Vario III Series 7.2 Dispensing Unit Dispensing unit without photocell Figure 20 1. Remove winding plate (if mounted) and the subjacent square-end at the printer front. 2. Open the dispenser whip by pulling the dispenser axe to the left.
  • Page 37 Vario III Series Refitting Options Dispensing unit with photocell Figure 21 1. Remove 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 the printer cover.

  • Page 38: Cutting Unit

    Refitting Options Vario III Series 7.3 Cutting Unit CAUTION! Risk of injury, particularly during maintenance, the cutter blades are sharp!  Switch off the before attaching the cutter!  The cutter may only be used when it is mounted on the printer! ...
  • Page 39 Vario III Series Refitting Options Figure 23 5. Fix the cutting unit with the sole plates onto the spacer shafts (E). 6. Press the cutting unit onto the spacer shafts (E) backwards until it engages into the spacer shafts. For this purpose press the cutting unit a bit downwards.

  • Page 41: Error Correction

    Vario III Series Error correction Error correction Error message Cause Remedy Line rises up completely or Move line down (increase Y Line too high partly over the upper edge of value). label. Check rotation and font. Line rises up completely or Move line up (reduce X value).
  • Page 42 Error correction Vario III Series Error message Cause Remedy Received line number is invalid Check sent data. Field numer at RS-232 and Centronics. Check connection PC - printer. Invalid length of received mask Check sent data. Length mask statement. Check connection PC - printer.
  • Page 43 Vario III Series Error correction Error message Cause Remedy Selected application identifier is Check code data. Application not available in GS1-128. Identifier F Missing HIBC system sign. Check definition of HIBC code. HIBC definition Missing primary code. Real Time Clock function is Change battery.
  • Page 44 Error correction Vario III Series Error message Cause Remedy Memory card is write-protected. Deactivate write protection. Drive write- protected Attempt to indicate a directory Correct your entry. Directory not file as file name. Attempt to change a file during Select another file.
  • Page 45 Vario III Series Error correction Error message Cause Remedy Defective photocell. Change photocell. Zero point Pressure air is not connected. Check pressure air. Compressed air External print release signal is Check input signal. External releaser missing. Wrong definition of column Reduce the column width res.
  • Page 46 Error correction Vario III Series Error message Cause Remedy Printing creation was still active Reduce print speed. Time generation at print start. Use printers' output signal for synchronisation. Use bitmap fonts to reduce generating time. Both DPM position sensors Displace zero point sensor Transport protection (start/end) are active.
  • Page 47 Vario III Series Error correction Error message Cause Remedy Scanner data does not Check adjustment of scanner. Scanner layout correspond to bar code data. difference Check scanner settings / connection. Serial interface error. Check settings for serial data COM break transmission as well as cable (printer-PC).
  • Page 48 Error correction Vario III Series Error message Cause Remedy When starting the print order Close the housing cover and Housing open the housing cover is not closed. start the print order anew. Transferred EAN.UCC code is Verify bar code data (see EAN.UCC code...
  • Page 49 Vario III Series Error correction Error message Cause Remedy The label photocell do not work Check label size and gap size. Print asynchronous in the order as it is expected according to print data. The settings of the photocell Check label photocell settings.

  • Page 51: Control Inputs And Outputs

    Vario III Series 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 52 Control inputs and outputs Vario III Series Configuration of D-Sub socket Figure 25 Identification Description / Function Port 1 Print start (Input) Port 2 Cut (Input) Port 3 Counter Reset (Input) Port 4 External synchronisation of label position (Input) Port 5...
  • Page 53 Vario III Series 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 print module and can be used e.g. as control voltage. Never apply any external voltage to this output.
  • Page 54 Control inputs and outputs Vario III Series Device connection to a machine with S7-300 SPS. Example 1 Figure 26 Device connection to a operating panel. Example 2 Figure 27 Service Instructions 03.14...
  • Page 55 Vario III Series Control inputs and outputs Device connection version if 'Option: 2. LED'. Example 3 Figure 28 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 57: Wiring Plan

    Vario III Series Wiring Plan 10 Wiring Plan Figure 29 03.14 Service Instructions...

  • Page 58: Cpu Component Placement Specification

    Wiring Plan Vario III Series 10.1 CPU Component Placement Specification Figure 30 Jumper plan JP1 (Debug) JP2 (write-protection) closed closed Boot sector Programming closed open Delivery Service Instructions 03.14...

  • Page 59: Index

    Vario III Series Index 11 Index A  Adjustments, settings, alignments Cutter ledge ..................32 Cutting edge ................... 33 Oil and lubricate ................34 Print mechanism ................27 Printhead position ................28 Printhead, parallelism ..............29 Printhead, pressure ................ 30 Printhead, pressure balance ............30 Rewinder ..................
  • Page 60 Index Vario III Series J  Jumper plan CPU ................58 L  Label photocell Cleaning ..................16 Replacing ..................21 N  Notes Document ..................5 User ....................5 O  Oil and lubricate ................. 34 P  Parallelism, adjusting ................. 29 Power supply, replacing ..............24 Pressure balance, adjusting ...............
  • Page 62 Carl Valentin GmbH Neckarstraße 78 – 86 u. 94 . 78056 Villingen-Schwenningen Phone +49 (0)7720 9712-0 . Fax +49 (0)7720 9712-9901 info@carl-valentin.de . www.carl-valentin.de...

This manual is also suitable for:

103/8 t107/12107/24108/12 t104/8

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