Carl Valentin Spectra II Service Manual Download

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Vario III Series

Notes on this Document

09.16

Service Instructions

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, 104/8, 106/12, 106/24, 107/12, 108/12,
160/12, 162/12 und 216/12.

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

If a problem arises that cannot be solved with help of this service of
manual, then please contact your responsible distributor.

1.2 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.

CAUTION

indicates a potentially dangerous situation

which could lead to moderate or light bodily injury or
damage to property.

NOTICE

gives you tips. They make a working sequence

easier or draw attention to important working processes.

Gives you tips on protecting the environment.



Handling instruction



Optional accessories, special fittings

Datum

Information in the display

Summary of Contents for Spectra II

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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: ...osition 23 5 6 Replacing the Pressure Roller 24 5 7 Replacing Label Photocell 25 5 8 Replacing the CPU PCB 26 5 9 Replacing the Power Supply 28 5 10 Replacing the WLAN Module 29 5 11 Replacing the I O FPGA 30 5 12 Replacing the Battery 30 6 Adjustments settings and alignments 31 6 1 Adjusting the print mechanism 31 6 2 Adjusting the Printhead Position Flat Type 32 6 3 Adjusting the Printhead Posit...

Page 4: ...Table of Contents Spectra II 4 Service Instructions 09 16 10 Wiring Plan 67 10 1 CPU Component Placement Specification 69 10 2 Power Electronics 70 11 Index 71 ...

Page 5: ...ions 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 CAUTION ind...

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: ...k 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 Do not wear clothing with metal parts Do not wear jewellery Do not wear glasses with a metal frame If a possible danger to your eyes is present wear protective goggles especially in the followi...

Page 8: ...printer is operated with the cover open ensure that clothing hair jewellery and similar personal items do not contact the exposed rotating parts The print unit can get hot during printing Do not touch the printhead during operation Cool down the print unit before changing material removal or adjustment Carry out only the actions described in these operating instructions Any work beyond this may on...

Page 9: ...e 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 in y...

Page 10: ...d 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 take back eq...

Page 11: ... input option B Winder connection C Switch On Off D Power supply E Parallel interface F USB host for USB keyboard and USB memory stick G Ethernet 10 100 interface H Serial interface RS 232 I USB interface J Plug in for CF card 1 LED orange 1 Lighting Connection active 1 Flashing Data transfer 1 Off No connection 2 LED green 2 Lighting Speed 100 MBit 2 Off Speed 10 MBit ...

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Page 13: ...on is changed or when the printout is adversely affected Cleaning pressure roller see chapter 4 2 page 14 Each time the label roll is changed or when the printout and label transport are adversely affected Cleaning printhead see chapter 4 4 page 16 Each time the transfer ribbon is changed or when the printout is adversely affected Cleaning label photocell see chapter 4 5 page 17 When exchanging th...

Page 14: ... and can affect transport of material 1 Open printer cover 2 Remove transfer ribbon from the label printer 3 Remove deposits with roller cleaner and a soft cloth 4 If the roller appears damaged replace it 4 2 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 t...

Page 15: ...jects to clean the print roller A B C Figure 2 1 Open printer cover 2 Turn lever A counter clockwise to lift up the printhead B 3 Remove labels and transfer ribbon form the label printer 4 Remove deposits with roller cleaner and a soft cloth 5 Turn the roller C manually step by step to clean the complete roller only possible when printer is switched off as otherwise the step motor is full of power...

Page 16: ...ffects such as dust etc CAUTION Printhead can be damaged Do not use sharp or hard objects to clean the printhead Do not touch protective glass layer of the printhead Figure 3 1 Open printer cover 2 Turn lever A in Figure 2 counter clockwise to lift up the printhead 3 Remove labels and transfer ribbon from the label printer 4 Clean printhead surface with special cleaning pen or a cotton swab dipped...

Page 17: ...affect label detection A B Figure 4 1 Open printer cover 2 Turn lever counter clockwise to lift up the printhead 3 Remove labels and transfer ribbon from the label printer 4 Blow out the photocell A with pressure gas spray Observe strictly the instructions on the spray can 5 Clean the label photocell A additionally with a cleaning card B before soaked in pure alcohol Move the cleaning card from on...

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Page 19: ...ore opening the housing cover disconnect the device from the mains supply and wait approx 2 3 minutes until the power supply unit has discharged 5 1 Tools List Some service work requires the following tools Philips head screwdriver size 2 Screwdriver size 5 Allen wrench 1 5 mm 2 mm 2 5 mm Hexagonal wrench 3 mm Spring scale 50 N ...

Page 20: ... G Figure 5 A Head plate B Plug connection signal C Plug connection tension D Printhead E Focal line CAUTION The printhead can be damaged by static electricity discharges and impacts Set up printer on a grounded conductive surface Ground your body e g by wearing a grounded wristband Do not touch contacts on the plug connections B C Do not touch printing line D with hard objects or your hands ...

Page 21: ...ont until you can reach the plug connections 6 Remove plug connections and then remove printhead E 1 Attach plug connections 2 Position printhead E in printhead mounting bracket in such a way that the pin is secured in the corresponding hole in the head plate 3 Lightly keep printhead mounting bracket on the printer roller with one finger and check for correct positioning of the printhead 4 Tighten...

Page 22: ...efully to the front until you can reach the plug connections 6 Remove plug connections and then remove printhead F 1 Attach plug connections 2 Position printhead in printhead mounting bracket in such a way that the pin is secured in the corresponding hole in the head plate 3 Lightly keep printhead mounting bracket on the printer roller with one finger and check for correct positioning of the print...

Page 23: ... 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 printing ...

Page 24: ... remove the bearing cover B 5 Remove pressure roller E from the striker arm G 1 Press the pressure roller E into the striker arm G Pay attention to the correct position of striker arm pins of the pressure roller E 2 Mount the bearing cover B with 2 screws C to the bottom side of sole plate 3 At reassembly pay attention to a precise fitting of the pressure roller E 4 Remove the possible axial play ...

Page 25: ... knob C counter clockwise until the photocell A can be removed from the adjusting axis B 5 Unplug the cable from the plug on the rear end of the label photocell A 1 Connect the cable to the label photocell A 2 Place photocell A on the adjusting axis B and turn knurled knob C in clockwise direction until the photocell arrives at the desired position 3 Connect the protective conductor to the inside ...

Page 26: ...er Loosen two screws at the lower left printer edge and two screws at the chassis upper edge 4 Remove the protective conductor at the inside of the printer cover 5 Detach all interface cables from the back of the printer 6 Remove the memory card from the slot 7 Unplug all side plug connections from the CPU PCB 8 Remove the 4 screw bolts B at the parallel interface and 3 fixing bolts A from the CPU...

Page 27: ...all interface connections on the back of the printer 5 Connect the protective conductor to the inside of cover 6 Mount again the left printer cover 7 Connect the power cable at the rear of the printer 8 Update the firmware if necessary 9 Adjust the label photocell 10 Load the printer configuration from the memory card if possible Otherwise set the printer configuration via the operating panel Inst...

Page 28: ...he printer bottom side 5 Pivot the power supply B and the intermediate plate C from the printer 6 Disconnect the cable connections at the power supply B and remove the power supply 1 Establish the cable connections to the power supply 2 Insert the power supply and intermediate plate C into the printer and fix it with the fixing screws A CAUTION Jamming of lines can cause short circuits Do not jam ...

Page 29: ...washers H and dismount the WLAN adapter I 6 Dismount screws L spacer rings J and hex nuts F and remove WLAN module K from WLAN adapter I 1 Insert the new WLAN module K to the WLAN adapter I and fix it with screws L spacer rings J and hex nuts F at the WLAN adapter I 2 Mount the WLAN adapter I with screws G and washers H at support bracket B 3 Insert connection cable E in the WLAN adapter K 4 Conne...

Page 30: ...PGA into the support base 5 12 Replacing the Battery DANGER Danger of explosion when exchanging the battery improper Pay attention to polarity A Figure 13 1 Lift up the fixing bracket by means of a non metallic device e g plastic ruler 2 Remove the battery A 3 Insert a new battery CR 2032 into the support and pay attention to position of polarity NOTICE The battery is responsible for the current s...

Page 31: ...ing print quality imperfections may indicate maladjustment of the printing mechanism Print image too light Print image 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 lo...

Page 32: ...d NOTICE Open and close the printhead locking device after each step of the adjustment 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 B D E C F A A G I I H...

Page 33: ...ing of the ribbon feed path in the corresponding direction CAUTION Damage of printhead by unequal use Change factory settings only in exceptional cases The selection of the smallest value can optimise the life cycle of printhead 1 Turn pressure screws A Figure 14 to change the pressure of printhead 2 Turning the pressure screws A Figure 14 as far as they will go in clockwise direction results in a...

Page 34: ...an be damaged Attempting to adjust the printhead when the fixing screw J and HI is tight can lead to defects at the printhead assembly Always loosen the fixing screw J or H before adjusting the printhead NOTICE Open and close the printhead locking device after each step of the adjustment B D E C F A A J I G H H G I J Figure 15 An important characteristic for a high quality print is the parallelism...

Page 35: ...eve a pressure balance turn the excentric bolt D Figure 15 as long as the printing result comes up to your full expectation 3 Tighten again screw C Figure 15 4 Start a print order with approx 10 labels and control the correct passage of transfer ribbon 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 f...

Page 36: ...th of a turn Only turn the adjustment screw D as far as is absolutely necessary A A C B C B D Figure 16 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 roller is from the disk of the rewinder 2 If the ribbon runs inward or outward turn the corresponding screw B after loosening the screw C clockwise in small increments ...

Page 37: ...e labels When using a too high ribbon tension this results usually in an excellent run of the transfer ribbon but this could lead to streaks onto the label or to a rip of ribbon particularly with narrow roles Ex factory the role tension is set to a transfer ribbon 110 mm width and standard quality As approximate values for the factory setting the following can be accepted Transfer ribbon unwinder ...

Page 38: ...ews at the chassis upper edge 3 Lock printhead 4 Slightly loosen the fixing screws A of the photocell B 5 Shift the photocell B in the hole sideways in such way that the plate D extends slightly into the centre of photocell into the fork 6 Tighten again the screws A 7 If this measure should not be sufficient the plate D can be also shifted by loosening the screws C 8 Install again the left printer...

Page 39: ...or thickness specifications Do NOT touch the area of the moving blades 1 Loosen screws C and remove front plate D of the cutter unit 2 Loosen hex socket head screws E and remove cutter unit 3 Place the cutter unit in front of the printer and make sure that the connecting cable has to be connected 4 Insert the power plug and switch on the printer 5 Insert paper or labels from behind through the ins...

Page 40: ... F 3 Turn the spacer pillar F slightly downwards with a flat spanner size 8 4 Tighten again the 2 screws A 5 Start a single cut In the main menu of printer of if a print order has been stopped press key to start a single cut In case the quality of the cut is not sufficient then repeat the above mentioned steps If the pressure is too strong this could result in an increased ware Therefore select th...

Page 41: ...en the angle of aperture F is to be increased 1 Remove the 3 countersink screws D 2 Remove the right cover of cutter unit The reflexion photocell E scans the screw head B onto the belt drive A 3 If the angle of aperture is too small the photocell has to be turned slightly in clockwise direction Loosen the screw C Keep the distance of 5 mm between photocell and screw head 4 Place the cover onto the...

Page 42: ...then the pressure curve is to be adjusted anew The pressure curve is onto the shaft of the ribbon save motor A A Figure 21 1 Remove left printer cover Loosen 3 screws at the lower left printer edge and 3 screws at the chassis upper edge 2 Remove the protective conductor at the inside of the printer cover B G H C D E F A Adjusting position Printing position Printing notch Adjusting notch Adjusting ...

Page 43: ...t with pressure curve and disk from the lift to the right until a slight resistance can be noticed If the slot in the disk can be moved slightly to the right and to the left out of the photocell A then the pressure curve is adjusted correctly 11 If the gap should not be in the range of the photocell the following causes are possible The wrong notch on the pressure curve was used for the adjustment...

Page 44: ...onnection with the beneath positioned transport roller is responsible for the label feed if printhead is lifted up The pressure of the supporting bar should be the same as the value for the printhead The factory setting corresponds to an average for standard labels For very narrow extremely smooth or thick labels a different setting is necessary Use the threaded pins A to change the pressure Press...

Page 45: ...you have to clean the lubrication at first with alcohol Apply rather in regular intervals 1 2 per year a bit of lubricant as only rarely too much Otherwise the surplus of lubricant could settle on neighbouring components and disturb the functions In case those components should have run it because of lack of lubricant exchange these as soon as possible so the functions of the components and the pr...

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Page 47: ...t the chassis upper edge 2 Remove the protective conductor at the inside of the printer cover 3 At the print mechanics side remove both of the label unwinding disks A B 4 Unscrew 4 screws C and remove cover sheet for the rewinder 5 Push the supporting plate with motor K of the set up kit from behind through the chassis aperture and fix the rewinder with the countersink screws C 6 Insert the motor ...

Page 48: ...signated slot see wiring plan on page 63 1 Remove left printer cover Loosen 3 screws at the lower left printer edge and 3 screws at the chassis upper edge 2 Remove the protective conductor at the inside of the printer cover 3 Remove covers C at the interface disruptions from the chassis rear 4 Fix the support angle F with protective disks E and hexagon nut D at the connecting plate 5 Place the inp...

Page 49: ... rocker 1 Remove tear off edge if mounted at the front of printer 2 For an easier handling remove front plate if mounted which is fixed at the printer base 3 Pull the knurled knob A to open the dispenser rocker 4 Place the dispensing unit B before the pressure roller Introduce the photocell cable D between the chassis and the left supporting plate of the dispenser downwards 5 Fix the dispensing un...

Page 50: ... if mounted which is fixed at the printer base 3 If pre assembled remove front plate C of cutting unit A 4 Hold the cutting unit slightly inclined on the right side in front of the pressure roller so that the threaded holes of the aluminium profile have approximately the same height as the through holes at the cutting unit 5 Press the cutting unit backwards at the left side 6 Fix the cutting unit ...

Page 51: ...xternally supplied label material 1 Place the setup kit for Leporello guiding D as illustrated above in front of the breakout 2 Fix the Leporello guiding with the enclosed screws A and slot nuts at the rear 3 Adjust the label guiding C according to material width 4 The supplied label material should be aligned as parallel as possible to the centre panel of the printer ...

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Page 53: ... 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 the label photocell ...

Page 54: ...the 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 Ch...

Page 55: ...rinthead 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 update Ch...

Page 56: ...ger 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 file ...

Page 57: ... 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 Check th...

Page 58: ...r 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 label...

Page 59: ... 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 Check ...

Page 60: ...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 customized entry...

Page 61: ... 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 Print speed is too slow Increase the s...

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Page 63: ...splayed 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 and ...

Page 64: ...ence 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 all control outputs VDC...

Page 65: ...nnector 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 5 VD...

Page 66: ...Control inputs and outputs Spectra II 66 Service Instructions 09 16 Device connection to a machine with S7 300 SPS Figure 33 Device connection to a operating panel Figure 34 Example 1 Example 2 ...

Page 67: ...nter 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 connected ...

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Page 69: ...Spectra II Wiring Plan 09 16 Service Instructions 67 10 Wiring Plan Figure 36 ...

Page 70: ...Wiring Plan Spectra II 68 Service Instructions 09 16 Figure 37 ...

Page 71: ...pectra II Wiring Plan 09 16 Serviceanleitung 69 10 1 CPU Component Placement Specification Figure 38 JP1 Debug JP2 write protection Boot sector Programming closed closed Delivery closed open Jumper plan ...

Page 72: ...Wiring Plan Spectra II 70 Service Instructions 09 16 10 2 Power Electronics Figure 39 ...

Page 73: ...dule 13 Pressure roller cleaning 15 Printhead cleaning 16 Component plan Power electronics 70 Component plan CPU 69 Component replacing Battery 30 CPU PCB 26 27 I O FPGA 30 Label photocell 25 Power supply 28 Pressure roller 24 Printhead 20 Printhead Corner Type 22 Printhead Flat Type 21 Tools list 19 WLAN module 29 Connector pin assignment printer rear 11 Control inputs and outputs 64 CPU Componen...

Page 74: ...ronics component plan 70 Power supply replacing 28 Pressure curve adjusting 42 43 Pressure roller Replacing 24 Print mechanism adjusting 31 Print position adjusting 23 Printhead Corner Type parallelism 34 35 Corner Type pressure 35 Corner Type pressure balance 35 Flat Type parallelism 32 Flat Type pressure 33 Flat Type pressure balance 33 Replacing 20 Replacing Corner Type 22 Replacing Flat Type 2...

Page 75: ...working with electricity 9 Safety instructions 8 Clothing 7 Protective clothing 7 Protective equipment 8 Workplace 7 Supporting bar adjusting 44 T Tools list 19 Transfer ribbon feed path adjusting 36 U Unwinder adjusting 37 W Wiring plan 67 68 WLAN module replacing 29 ...

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Carl Valentin Spectra II, Service Manual

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