Carl Valentin COMPA II Service Manual Download

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COMPA II

Service Instructions

Summary of Contents for COMPA II

Page 1: ...COMPA II Service Instructions ...

Page 2: ... between manual and device can occur Please check www carl valentin de for the latest update Trademarks All named brands or trademarks are registered brands or registered trademarks of their respective owners and may not be separately labelled It must not be concluded from the missing labelling that it is not a registered brand or a registered trademark Carl Valentin label printers comply with the...

Page 3: ...PU PCB 22 5 8 Replacing the power supply unit 23 5 9 Replacing the WLAN module 24 5 10 Replacing the printhead FPGA 25 5 11 Replacing the battery 25 5 12 Replacing the safety fuse 26 6 Adjustments settings and alignments 27 6 1 Adjusting the winding torques 27 6 2 Measuring the winding torques at ribbon rewinder unwinder 28 6 3 Measuring the torques at the internal rewinder 29 6 4 Setting the wind...

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Page 5: ...please contact your responsible dealer 1 2 Warnings Warnings are presented with three signal words for the different levels of danger 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 CAUTION indicates a ...

Page 6: ...e text always refer to the graphic directly above the text If a reference is made to another graphic the figure number is specified e g 2 in figure 5 For a cross reference to chapters and sections the chapter number and page number are specified e g a reference to this section see chapter 1 3 2 on page 35 References to other documents have the following form See operating manual Item numbers Cross...

Page 7: ...clothing by moving parts can lead to injuries If possible do not wear clothing which could be caught by moving device parts Button or roll up shirt or jacket sleeves Tie or pin up long hair Tuck the ends of scarves ties and shawls into your clothing or secure them with non conductive clips DANGER Risk of death from increased flow of current via metals parts which come into contact with the device ...

Page 8: ... when using spring hooks when loosening or inserting springs snap rings and gripping rings when soldering when using solvents cleaning agents or other chemicals 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 Pr...

Page 9: ...ctive extension cables faulty protective conduction connections Give another person the task of remaining near the workplace This person must be familiar with the location and operation of the emergency stop and power switches and switch off the power if danger arises Use only one hand while working on electrical circuits when a device is switched on Hold the other hand behind your back or put it ...

Page 10: ... interface RS 232 5 Pin 2 TXD Pin 3 RXD Pin 5 GND 5 Pin 7 CTS Pin 8 RTS 6 Ethernet 10 100 interface 7 USB host for USB keyboard and USB memory stick 8 Parallel interface for Centronics 9 External input output option 6 1 LED orange 6 1 Lighting Connection active 6 1 Flashing Data transfer 6 1 Off No connection 6 2 LED green 6 2 Lighting Speed 100 MBit 6 2 Off Speed 10 MBit ...

Page 11: ...ning printhead see chapter 4 3 on page 12 Direct thermal printing Each time the label roll is changed Thermal transfer printing Each time the transfer ribbon is changed or when the printout is adversely affected Cleaning label photocell see chapter 4 4 on page 13 When the label roll is changed WARNING Risk of fire by easily inflammable label soluble When using label soluble dust must be completely...

Page 12: ...eposits with roller cleaner and a soft cloth 4 If the roller appears damaged replace it see chapter 5 3 on page 17 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 CAUTION Printhead can ...

Page 13: ...ter clockwise to lift up the printhead 2 Remove labels and transfer ribbon from the label printer 3 Remove hexagonal wrench 5 from its retainer 4 Press the latch 3 and slowly pull label photocell outwards via the tab 4 Ensure that the label photocell cable is not tensioned by this 5 Clean label photocell and sensor units 2 with brush or cotton swab soaked in pure alcohol 6 Push label photocell bac...

Page 14: ... the rear cover until it stops and unplug the cable 2 from the plug on the rear end of the label photocell 1 5 Press the latch 6 and slowly pull label photocell outward via the tab 5 That way the distance plate 3 is pushed out of label photocell guide 6 Clean label photocell and sensor units 4 with brush or cotton swab soaked in pure alcohol 7 Push label photocell back via tab 5 8 Press the latch ...

Page 15: ...tments and simple installation work use the accompanying hexagonal wrench located in the bottom section of the print unit Some service work requires other tools Philips head screwdriver size 1 Hexagonal wrench 1 5 mm Torx screwdriver TX20 Snap ring pliers ZGG 0 Spring scale 10 N Spring scale 25 N 5 2 Replacing the printhead NOTICE The printhead 7 is preinstalled on a head plate 1 and aligned at th...

Page 16: ...with one finger and screw out screw 8 with the hexagonal wrench and remove it and the washer 5 Swivel printhead mounting bracket 9 upwards 6 Remove printhead from the printhead mounting bracket 9 if necessary 7 Loosen both plug connections 2 3 on the printhead and set printhead down on a clean soft surface 1 Attach plug connections 2 3 2 Position printhead in printhead mounting bracket 9 in such a...

Page 17: ...e can be corrected in printing direction NOTICE The value for zero point adjustment is set ex works After replacing the printhead only service personnel are allowed to set this value anew Press key to arrive the next menu item Indication of value in 1 100 mm After replacing the printhead the print cannot be continued at the same position on the label the difference can be corrected across the prin...

Page 18: ...hexagonal wrench 6 Remove side plate 2 Figure 7 1 Pull print roller 7 and rewind assist roller 8 from the shafts 9 10 on the housing 2 Clean shafts 9 10 of the rollers see expanded view at shaft 10 3 Slide print roller 7 and rewind assist roller 8 onto their respective shafts and turn slightly until the hexagon of the shaft engages in the hexagon socket of the print roller 4 Set side plate 2 Figur...

Page 19: ...der coupling Change the slipping clutch when it can no longer be set Removal and installation of the slipping clutch is also required for replacement of a winder 1 Unplug the printer from the electrical outlet 2 Remove the rear cover of the printer 3 Remove the snap ring 1 4 Pull coupling or brake 2 from the winder axis 4 Figure 9 5 Ensure that the pin 4 Figure 23 remains on the winder axis when p...

Page 20: ... side as far as possible see chapter 5 6 on page 21 and install the rear cover of the printer 1 Snap ring 2 Brake 3 Lever 4 Pin 5 Winder acis 6 Spring Figure 10 1 Slide the brake 2 onto the winder axis 5 in such a way that it fits on the hexagonal profile of the pin 4 2 Ensure that the lever 3 grasps between the two ends of the spring 6 3 Secure the snap ring 1 4 Adjust the coupling see chapter 6 ...

Page 21: ...ate 7 7 Pull out the label photocell 1 via the tab 4 toward the cover side Compa II 162 162 T That way the distance plate 3 is pushed out of label photocell guide 1 Insert the label photocell 1 into the guide from the cover side and slide it onto the tab 5 toward the rear cover until it stops Compa II 162 162 T Push the distance plate 3 into the guide of the label photocell 2 Remount the side plat...

Page 22: ...PU PCB 8 Carefully remove the CPU PCB 1 Place CPU PCB 2 onto the retainers 1 2 Secure the PCB with three screws 3 3 Insert all plug connections on the PCB 4 Pull the label photocell toward the cover side as far as possible see chapter 5 6 on page 21 and install the rear cover of the printer 5 Restore all interface connections on the back of the printer 6 Connect the power cable at the rear of the ...

Page 23: ...two screws on the back of the printer 7 8 Hold the power supply unit firmly at the metal bracket 4 and remove the two screws 2 9 Remove the power supply unit 1 Insert the power supply unit and secure the PCB with two screws 2 2 Secure the metal bracket 4 of the power supply unit to the back of the printer with two screws 7 3 Connect the power supply unit cable to the power supply output 1 4 Insert...

Page 24: ...Remove connecting cable E from WLAN adapter F 7 Dismount screws J spacer rings K and hex nuts L and remove WLAN module M from WLAN adapter F 1 Insert the new WLAN module M to the WLAN adapter F and fix it with screws J spacer rings K and hex nuts L at the WLAN adapter F 2 Insert connection cable E in the WLAN adapter F 3 Connect antenna cable B with WLAN module M and fix the plug connectors with a...

Page 25: ...y attention to polarity and press the new FPGA into the support base 5 11 Replacing the battery DANGER Danger of explosion when exchanging the battery improper Pay attention to polarity Figure 15 1 Lift up the fixing bracket by means of a non metallic device e g plastic ruler 2 Remove the defective battery 3 Insert a new battery into the support A and pay attention to position of polarity ...

Page 26: ... of complete power supply voltages Figure 16 1 Remove left printer cover Unscrew two screws at the upper left printer edge 2 Remove CPU PCB see chapter 5 7 on page 22 3 Replace secondary safety fuse on the power supply 4 Install CPU PCB see chapter 5 7 on page 22 and recreate plug connexion 5 Attach again the left printer cover ...

Page 27: ...e a sufficiently tightened label strip The winding axes of the rewinder are not actively driven by the belts during label backfeed but rather solely by the pull of the print roller The torque required to decouple the rewinder from the belt drive is implemented via a brake in the winding reel which works in both directions The measured clockwise torque is the sum of the coupling torque and the torq...

Page 28: ...e rear cover 2 Remove the transfer ribbon from the printer 3 Attach the test collar 3 to the winder 4 4 Turn the knurled nut counter clockwise to clamp the test collar 5 Wind the cord attached to the test collar around the test collar several times 6 Secure spring scale 10 N 1 at the end of the cord and move the spring scale upward vertically until the winder begins turning 7 If the drive belt at ...

Page 29: ...rom the electrical outlet and remove the rear cover 2 Remove the label media from the printer 3 Push the cord 2 under a bracket of the internal rewinder 3 and wind it around the rewinder 4 Secure 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 Otherwise ...

Page 30: ... cover 2 Press the knurled ring 1 of the slipping clutch toward the housing wall The lock 2 of the knurled ring is released 3 Turn the knurled ring to the desired position while pushing it 4 Release the knurled ring in the desired position 5 Ensure that the tabs of the lock are located completely in the grooves of the setting value 6 Measure the winding torque again and compare it to the setpoint ...

Page 31: ...is spotty Print image lighter on one side Horizontal lines not parallel to the horizontal label edges Clear lateral drift of the transfer ribbon NOTICE Print image errors can also arise from wrinkling of the transfer ribbon This is why the transfer ribbon feed path and the head locking system should be checked before making adjustments to the printing mechanism see operating manual Adjustment of t...

Page 32: ...ger in such a way that the adjustment screws are accessible through the holes of the square axis 4 Loosen the screw 1 for the printhead bowing with a hexagonal wrench 1 5 mm and turn it counter clockwise until turning becomes perceptibly easier This should occur after a maximum of a half a rotation When the label printer is prepared for adjustment continue with the adjustment of the printhead posi...

Page 33: ...crews 3 before adjusting the printhead Figure 21 NOTICE Open and close the printhead locking device after each step of the adjustment 1 Check the alignment of printhead in the adjustment windows 1 Compa II 162 162 T Check the alignment of printhead at the slides 5 2 If the printhead is not aligned properly loosen the screw 3 about one quarter turn 3 If the printhead is not aligned properly use the...

Page 34: ...ntact 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 Figure 22 1 Turn the adjustment screws 1 counter clockwise until turning becomes perceptibly easy 2 The contrast value in function menu is to be reduced in the printer configuration until the print image is only barely recognizable Und...

Page 35: ...y turn the adjustment screw 1 as far as is absolutely necessary Figure 23 1 Check the transfer ribbon feed path The wound up ribbon should be the same distance from the disk of the winder as the supply roll is from the disk of the rewinder 2 If the ribbon runs inward or outward turn the corresponding screw 3a or 3b clockwise in small increments 3 Wait until the ribbon feed path has stabilized afte...

Page 36: ...the belt Tension the toothed belt in such a way that it cannot rub against the label photocell Figure 24 1 Unplug the printer from the electrical outlet 2 Remove the rear cover 3 Loosen the three fixing screws 4 of the main drive motor 3 4 Swivel the main drive motor 3 in such a way that the toothed belt 2 is tensioned tightly between the motor and the print roller 1 5 Tighten the fixing screws 4 ...

Page 37: ...rinter from the electrical outlet 2 Remove the rear cover 3 Lock printhead 4 Slightly loosen the fixing screws 3 of the head switch 2 5 Move the head switch housing and switching lever 1 to a parallel position see magnified cut out 6 Screw down the head switch in this position 7 Pull the label photocell toward the cover side as far as possible see chapter 5 6 on page 21 and install the rear cover ...

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Page 39: ...supply unit has discharged 7 1 I O plate A B Figure 26 1 Remove the CPU PCB see chapter 5 7 on page 22 2 Remove cover at the interface disruption from the chassis rear 3 Fix the I O plate B with fixing screws A at the aft disruption 4 Insert the connecting cables for inputs outputs corresponding to the wiring plan see chapter 10 on page 59 into the appropriate plug in positions of the I O plate 5 ...

Page 40: ...nter cover Unscrew two screws at the upper left printer edge 3 Remove black protective cap in order to use the opening for the internal rewinding unit 4 Mount the single components of internal rewinding unit in illustrated order from front through the chassis opening 5 Build the illustrated course of belt 6 Attach again the printer cover ...

Page 41: ...r Do not try to cut any materials which exceed the maximum width or thickness specifications Do NOT touch the area of the moving blades 1 Open the right printer cover 2 Remover lower front plate 3 Insert cutter unit with guiding pilots in the appropriate guiding holes Take care of plug in connector 4 Fix cutter unit with knurled screw at chassis 5 Tighten front plate with enclosed hex nut and wash...

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Page 43: ...not available Check font 7 Vector font Selected font is not available Check font 8 Measuring label While measuring no label was found Set label length is too large Check label length and if labels are inserted correctly Restart measuring anew 9 No label found No label available Soiled label photocell Labels not inserted correctly Insert new label roll Check if labels are inserted correctly Clean t...

Page 44: ...e entered res received check digit is wrong Calculate check digit anew Check code data 21 Invalid SC number Selected SC factor is invalid for EAN res UPC Check SC factor 22 Invalid number of digits Entered digits for EAN res UPC are invalid 12 13 Check number of digits 23 Check digit calculation Selected check digit calculation is not available in the bar code Check calculation of check digit Chec...

Page 45: ...he printhead and start print order anew 36 BCD invalid format BCD error Invalid format for the calculation of Euro variable Check entered format 37 BCD overflow BCD error Invalid format for the calculation of Euro variable Check entered format 38 BCD division BCD error Invalid format for the calculation of Euro variable Check entered format 39 FLASH ERROR Flash component error Run a software updat...

Page 46: ...longer required files 54 File directory exists The selected file directory already exists Check name select a different name 55 File too large During copying procedure not enough memory space onto target drive available Use a larger target card 56 No update file Errors in update file of firmware Start update file anew 57 Invalid graphic file The selected file does not contain graphic data Check fi...

Page 47: ...ange printhead 71 Invalid page As page number either 0 or a number 9 is selected Select a number between 1 and 9 72 Page selection A page which is not available is selected Check the defined pages 73 Page not defined The page is not defined Check the print definition 74 Format user guiding Wrong format for customised entry Check the format string 75 Format date time Wrong format for date time Chec...

Page 48: ... or use an offset 88 RFID verify Error while checking programmed data Faulty RFID label Check RFID definitions 89 RFID timeout Error at programming the RFID label Label positioning Faulty label 90 RFID data Faulty or incomplete definition of RFID data Check RFID data definitions 91 RFID tag type Definition of label data does not correspond with the used label Check storage partitioning of used lab...

Page 49: ... down is missing option APL 100 Check input signals compressed air supply 102 Vacuum plate empty Sensor does not recognise a label at vacuum plate option APL 100 Check input signals compressed air supply 103 Start signal Print order is active but device not ready to process it Check start signal 104 No print data Print data outside the defined label Selection of wrong module type design software C...

Page 50: ...matics for cross traverse 116 Print position The print position is not correct Check TOP and RIGHT final position switch for correct function and position Check pneumatics for function 117 XML parameter The parameters in the XML file are not correct Please contact your responsible distributor 118 Invalid variable Transferred variable is invalid with customized entry Select correct variable without...

Page 51: ...The settings of the photocell are not correct Check label photocell settings Settings of label size and gap size are not correct Check correct loading of label material No label found at the rear printhead Insert new label roll Soiled label photocell Clean the label photocell Labels not inserted correctly Check if labels are inserted correctly 124 Speed too slow The print speed is too slow Increas...

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Page 53: ...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 route Each port can be configured as input and as output This function however is predefined in the printer software and cannot be changed by the user The following parameters can be changed an...

Page 54: ...nputs 19 Common reference potential of all control inputs COM VDC for Inputs is usually connected with the terminal of the control voltage and the control inputs are switched to active By means of the option 2nd LED COM VDC for Inputs can optionally be connected with the terminal of the control voltage Then the control inputs are switched to active VDC for Outputs 20 Common supply connection of al...

Page 55: ...n 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 Tension 5 VDC 24 VDC Impedance 47Ω 100nF 10 kΩ Output Tension 5 VDC 24 VDC Impedance 47Ω 100nF 10 kΩ 47Ω Current max High 15 mA Low 15 mA Port 16 Input Tension 5 VDC 24 VDC Impedance 100nF 10 kΩ Output Tension ...

Page 56: ...Control inputs and outputs Compa II series 56 Service instructions 11 15 Device connection to a machine with S7 300 SPS Figure 30 Device connection to a operating panel Figure 31 Example 1 Example 2 ...

Page 57: ...e printer s internal voltages 5 VDC EXT or 24 VDC EXT is used an external fuse e g 0 5 AF should be additionally installed to protect the printer electronics In the event of an inductive load an antiparallel connected diode for instance must be used to discharge the induction energy In order to minimise the influence of leakage currents at control outputs a resistor must depending on what is conne...

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Page 59: ...Compa II series Wiring plan 11 15 Service instructions 59 10 Wiring plan Figure 33 ...

Page 60: ...g plan Compa II series 60 Service instructions 11 15 10 1 CPU component placement specification Figure 34 JP1 Debug JP2 Write protection Boot sector Programming closed closed Delivery closed open Jumper plan ...

Page 61: ... 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 Carl Valentin GmbH thereby fulfils all obligations regarding timely disposal of old equipment and facilitates the smooth reselling of these products Please understand that we can only tak...

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Page 63: ...g Cleaning schedule 11 Label photocell 13 14 Print roller 12 Printhead 12 Component plan CPU 60 Component replacing Battery 25 CPU PCB 22 Label photocell 21 Power supply unit 23 Print roller 18 Printhead 15 16 Printhead FPGA 25 Rewind assist roller 18 Safety fuse 26 Slipping clutch 19 20 Tool list 15 WLAN module 24 Control inputs and outputs 54 CPU Component plan 60 CPU PCB replacing 22 Jumper pla...

Page 64: ... mechanism adjusting 31 32 Print position adjusting 17 Print roller Cleaning 12 Replacing 18 Printhead Cleaning 12 Position adjusting 33 Printhead FPGA replacing 25 Replacing 15 16 R Refit options Cutter 41 I O plate 39 Internal rewinder 40 Rewind assist roller replacing 18 Rewinder internal refitting 40 S Safety fuse replacing 26 Safety handling when working with electricity 9 Safety instructions...

Page 65: ...tions 65 T Tool list 15 Transfer ribbon feed path adjusting 35 W Warnings 5 Winding torques Adjusting 27 Measuring internal rewinder 29 Measuring ribbon rewinder 28 Measuring ribbon unwinder 28 Setting 30 Wiring plan 59 WLAN module replacing 24 ...

Page 66: ...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 ...

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Carl Valentin COMPA II, Service Manual

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