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Equipment Description 1-1

ICE Vulcan Service Manual

Introduction

This chapter contains the following topics:

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Equipment description

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About the manual

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Related publications

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Content presentation

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Abbreviations and acronyms

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Chapters in the manual

Equipment Description

The Vulcan is a smarter print and apply labeller that eliminates unscheduled downtime and
reduces costs and errors in case coding operations. The Label Printer Applicator is a simple,
reliable system with a minimum number of wear parts, and zero manual adjustments. Applying

Intelligent MotionTM technology ensures automatic and precise control of the entire system. In
addition, Direct Apply provides accurate placement of on-demand labels at high speed without
the need for an applicator (top or side applications only), enabling it to never miss a pack even
during build-back.

Vulcan maximizes uptime, increase productivity and remove the risk of mislabelled packages
by using the most intelligent and user friendly labelling system.

About the Manual

The Service Manual is intended for the use of technicians servicing the LPA. The Service Manual
contains the configuration, maintenance, and troubleshooting procedures.

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Summary of Contents for vulcan

Page 1: ...ICEVulcanServiceManual Vulcan Service Manual ...

Page 2: ...0 3 2 Limits for harmonic current emissions equipment input current 16A per phase IEC 61000 3 3 Limitation of voltage changes voltage fluctuations and flicker in public low voltage supply systems for equipment with rated current 16A per phase and not subject to conditional connection Low Voltage Directive 2006 95 EC Essential health and safety requirements relating to electrical equipment designed...

Page 3: ...ion of the use of certain hazardous substances RoHS EN 50581 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances Support and Training Contact Information If you have any questions or need assistance contact ICE on 01159 640144 Interactive Coding Equipment ICE Olympic House Willow Drive Sherwood Park Nottingham NG1...

Page 4: ...s you complete a Customer Training Course on the LPA For more information please contact us on 01159 640144 Interactive Coding Equipment ICE Olympic House Willow Drive Sherwood Park Nottingham NG15 0DP Web www interactivecoding co uk Note The manuals are intended to be supplements to and not replacements for ICE Customer Training ...

Page 5: ...nt Presentation 1 3 Positional References 1 3 Units of Measurement 1 3 Safety Information 1 4 Notes 1 5 Abbreviations and Acronyms 1 5 Chapters in the Manual 1 6 Chapter 2 Safety Introduction 2 2 Equipment Safety Guidelines 2 2 Comply with Electrical Codes 2 3 Electrical Power 2 4 Do Not Remove Warning Label 2 5 Grounding and Bonding 2 5 Printhead 2 6 Print Ribbon Safety Guidelines 2 6 Placement o...

Page 6: ... 3 19 Printhead 3 20 Chapter 4 Installation Tools and Supplies 4 3 Tools 4 3 Supplies 4 3 Unpacking and Inspecting the Labeller 4 3 Selection of a Suitable Installation Position 4 3 Positioning of Labeller Peel Tip 4 4 Installing the Label Applicator 4 5 Assembling the Stand 4 5 Mounting the LPA 4 9 Setting up the Production Line 4 11 Mounting the CLARiTY Display 4 13 Instating the Product Detecto...

Page 7: ...h Passwords 5 23 CLARiTY Power Saving 5 25 How to Configure the Job Settings 5 27 Job Creation and Settings 5 27 CLARiTY Configuration Settings 5 28 Managing Clones 5 31 How to Create a Clone 5 31 How to Restore a Clone 5 34 Chapter 6 Maintenance and Troubleshooting Maintenance 6 1 Preventive Maintenance Schedule 6 1 Replacement Instructions 6 2 Motor Calibration Wizard 6 4 Updating the CLARiTY Op...

Page 8: ...ave Setup Working with Master Slave 8 1 Master Slave Benefits 8 1 Master Slave Applications 8 2 Master Slave Terminology 8 2 LPA Terminology 8 2 Physical Installation 8 3 Software Configuration 8 4 Master Slave Basic and Advanced Configuration 8 5 Auto Changeover Mode 8 17 Using Master Slave Mode Group Job Select Mode 8 21 The Master LPA 8 21 The Slave LPAs 8 25 Using Master Slave Mode Group Contr...

Page 9: ...onnectors and Interface Specifications A 4 Appendix B CLARiTY Configuration Manager Introduction B 1 CLARiTY Configuration Manager B 2 Appendix C Main Board Test Points Main Board Test Points C 1 Appendix D Theory Of Printing Printing D 2 Appendix E Availability Overall Equipment Effectiveness Availability Tools E 1 Introduction E 1 Equipment Availability E 1 Operational Availability E 2 Availabil...

Page 10: ...ear parts and zero manual adjustments Applying Intelligent MotionTM technology ensures automatic and precise control of the entire system In addition Direct Apply provides accurate placement of on demand labels at high speed without the need for an applicator top or side applications only enabling it to never miss a pack even during build back Vulcan maximizes uptime increase productivity and remo...

Page 11: ...number 462470 21 Table 1 1 shows the list of language codes that you can use to identify the translated versions of this manual Note The availability of the Operator Manual is indicated by an asterisk Availability of the Service Manual is indicated by a plus sign For more information contact the ICE distributor or subsidiary Code Language Availability see note 01 English US 02 French 03 German 04 ...

Page 12: ...ormation like safety guidelines additional notes CLARiTY configuration manager terminologies and so on To help you identify the different types of information different writing styles are used in this manual Positional References Positions and directions like left right front rear to the right and to the left are with respect to the CLARiTY display when you see it from the front Units of Measureme...

Page 13: ...preceded by the word Warning They are always found before the step or information referring to the hazard For example Warning PERSONAL INJURY All electrical wiring and connections must comply with applicable local codes Consult the appropriate regulatory agency for further information Caution The caution statements indicate hazards or unsafe practices that result in equipment or property damage Th...

Page 14: ... for some functions to prevent any access that is not authorised Abbreviations and Acronyms Abbreviation Expansion AC Alternating Current I O Input Output LCD Liquid Crystal Display LED Light Emitting Diode LPA Label Printer Applicator POE Power Over Ethernet UI User Interface USB Universal Serial Bus WYSIWYG What You See Is What You Get Table 1 2 Abbreviations and Acronyms ...

Page 15: ...Y Operating System Contains the information on CLARiTY configuration manager 6 Maintenance and Troubleshooting Contains the information on replacement instructions service maintenance error messages its possible causes and the remedies 7 IPL Contains the illustrated parts list of orderable parts 8 Master Slave Setup Contains information about master slave setup 9 Appendix A Contains information ab...

Page 16: ...nt All available safety information should be observed and practised to operate the LPA safely and efficiently Warning PERSONAL INJURY Observe all safety and warning labels on the device for the safe operation of the system Warning PERSONAL INJURY Follow the installation and operating instructions at all times Only trained personnel should carry out maintenance or repair Adjustments should only be...

Page 17: ...r maintenance personnel should perform the installation or replacement procedures Qualified personnel are those who have successfully completed the training courses have sufficient experience with this equipment and are aware of the potential hazards to which they will be exposed Warning PERSONAL INJURY The LPA should be operated by an authorized personnel who can use the machine independently and...

Page 18: ...ear or finger rings while working with the equipment Caution EQUIPMENT DAMAGE Operate the LPA in an area where the environmental conditions outlined in Appendix A Specifications of this manual are met The LPA should be installed and operated on a stable solid base Caution EQUIPMENT DAMAGE The LPA should not be modified Only add accessories that are approved for the specific use by your supplier En...

Page 19: ...nt damage Warning PERSONAL INJURY There will be sections of the printer control board that will be permanently powered via the on board lithium battery therefore it is essential that the board should never be placed onto nor stored in or on any conductive surface including conductive plastic bags etc as this would flatten the battery and or potentially result in battery overheating The battery is ...

Page 20: ...Equipment Safety Guidelines 2 5 ICEVulcan ServiceManual manual ...

Page 21: ...50 Do Not Remove Warning Label Warning PERSONAL INJURY Do not under any circumstances remove or obstruct any warning caution or instruction labels present on the equipment If any part of these labels become damaged worn or removed they must be immediately replaced Grounding and Bonding Caution EQUIPMENT DAMAGE Always prevent static discharge from occurring Use proper Grounding and Bonding methods ...

Page 22: ...mpting to touch the printhead Warning PERSONAL INJURY Do not place your fingers under the printhead when the equipment is operating Print Ribbon Safety Guidelines Caution EQUIPMENT DAMAGE Print ribbons should be stored at a temperature range of 5 ºC to 40 ºC and at a non condensing humidity range of 20 to 85 Caution EQUIPMENT DAMAGE The use of incompatible ribbon can seriously damage your equipmen...

Page 23: ...00 of the National Electrical Code ANSI NFPA70 1993 Outside United States you must ensure compliance with all local regulations regarding the equipment placement in potentially hazardous locations Using Accessories To maintain regulatory approval for the equipment use only ICE approved accessories when attaching any device to the equipment Other Important Guidelines Warning PERSONAL INJURY Before ...

Page 24: ... eliminate the potential entanglement with the exposed rotating parts Cleaning Safety Guidelines Caution EQUIPMENT DAMAGE Do not apply excessive force to the printhead while cleaning as this can cause damage and can void the warranty Caution EQUIPMENT DAMAGE Use approved dealer cleaning supplies for cleaning Do not use high pressure air or cotton Equipment Handling Safety Guidelines Warning PERSON...

Page 25: ...precautions to prevent the LPA from tipping over when anchoring or moving the equipment Warning PERSONAL INJURY Only accessories provided by ICE are approved for the mounting of the LPA Follow the instructions provided for the mounting of the LPA onto the stands to ensure safe operation ...

Page 26: ...ICEVulcan ServiceManual Main Parts This chapter contains the following topics System Overview CLARiTYDisplay Labeller Printhead ...

Page 27: ...el Supply Mandrel 5 Conveyor 6 Dancer Arm 7 Vertical Stand with Conveyor U Base 8 Caster 9 CLARiTY Display 10 E Stop Button LPA 11 E stop Button Conveyor 12 Label Waste Mandrel 13 Printhead Components are not shown in the figure Figure 3 1 System Overview The main parts of the LPA are CLARiTYDisplay Labeller Printhead For more information on other integral parts of the LPA refer to Main Parts chap...

Page 28: ...ations of the packaging line and can be oriented horizontally or vertically CLARITY Display This display is a touch screen user interface connected to the main controller board via a communication power cable see Figure 3 2 The display has an LCD 6 5 display For more details on user interface refer to CLARiTY Operating System on page 5 1 1 3 2 1 Touch UI 2 Interconnecting Cable Communications Cabl...

Page 29: ...of the following main parts Main Controller Board for the LPA The main controller board is located behind the labeller unit The connector panel is directly mounted to the main controller board Figure 3 3 Main Controller Board Caution EQUIPMENT DAMAGE Care must be taken during servicing and handling to ensure that the connectors are not subjected to mechanical stress This may damage the main contro...

Page 30: ...cated near the peel tip assembly Gap Sensor and Print Roller PCB Figure 3 4 Gap Sensor and Print Roller PCB Ribbon and Printhead Sensor PCB The ribbon and printhead sensor PCB is located near printhead assembly 2 1 1 Ribbon and Printhead Sensor PCB 2 Motor Drive Cover Plate Removed Figure 3 5 Ribbon and Printhead Sensor PCB ...

Page 31: ...rive motor PCB is located near label drive motor 1 2 1 Label Drive Motor 2 Label Drive Motor PCB with Protective Cover Figure 3 6 Label Drive Motor PCB CLARiTY Display PCB The CLARiTY display PCB is located behind the LCD CLARiTY Display PCB Figure 3 7 CLARiTY Display PCB ...

Page 32: ...CB is located beside the pulley in the brake belt assembly 2 1 1 Pulley Removed 2 Supply Reel Hall Sensor PCB Figure 3 8 Supply Reel Hall Sensor PCB Dancer Arm Sensor PCB The dancer arm sensor PCB is located below the pulley in the brake belt assembly 1 2 1 Pulley Removed 2 Dancer Arm Sensor PCB ...

Page 33: ...Labeller 3 8 ICEVulcan ServiceManual Figure 3 9 Dancer Arm Sensor PCB ...

Page 34: ... Figure 3 10 Connector 4 Beacon 5 Product Detect 2 6 Product Detect 7 CLARiTY Display 8 Ethernet 9 Ethernet POE Ports Connectors Description Encoder Port for connecting a shaft encoder to the controller to tell the software how fast the substrate is traveling Serial Port IOIOI RS 232 SerialPort for connecting to PC PLC or other capable device Table 3 1 Controller Connections ...

Page 35: ... Product Detect 1 The product detector connector detects the product and informs the LPA when to print and apply the label on the product CLARiTY Display Port for Communicating with the CLARiTY Display and provides power to it Ethernet RJ 45portfor connectingthe printer to a TCP IP network Ethernet POE RJ 45portfor connectingthe printer to a TCP IP network device that requires Power Over Ethernet ...

Page 36: ...onnectors Encoder Figure 3 11 Encoder Pin Encoder Cable Pin Wire Color Function 1 1 Red 24 V ENC 2 2 Black 0 V QENC 3 3 White ENC AX 4 4 Green ENC BX 5 5 6 6 7 Link to Pin 8 Enc Present 8 Link to Pin 7 9 7 SHELL BRAID SHIELD CHASSIS Table 3 2 Encoder Pin ...

Page 37: ...E SEL BCD1 3 Red LINE SEL BCD2 4 Green LINE SEL BCD3 LINE INTERLOCK 5 Orange LINE STROBE 6 Blue IGNORE PACK 7 White Black 0 V IO 8 Red Black 24 V APPL 9 Green Black LINE INT LK COM 10 Orange Black LINE INT LK N C 11 Blue Black LINE INT LK N O 12 Black White REJECT OUT 13 Red White READY BUSY OUT 14 Green White 0 V 15 DRAIN WIRE 0 V Table 3 3 Input Output ...

Page 38: ...tion 1 Green 24 V 50 mA PNP 2 Yellow Not connected 3 Red 24 V 50 mA PNP 4 Amber 24 V 50 mA PNP 5 Black Not connected 6 0 V Table 3 4 Beacon Connection Power Cable RS232 Figure 3 14 RS232 Connection Scanner Cable Pin Wire Color Function 1 5 Brown GND 2 9 Blue 12 V DC 3 Table 3 5 RS232 Connection ...

Page 39: ... 4 Violet SENSOR 1 11 12 3 Red Blue RXD RS 232 SHELL BRAID SHIELD CHASSIS Table 3 5 RS232 Connection Continued Product Detect Figure 3 15 Product Detect Pin Sensor Cable Pin Wire Color Function 1 1 Red 24 V 2 White 3 3 Black 0 V 4 4 Green PNP OUTPUT 5 White 6 Blue 7 SHELL DRAIN WIRE CHASSIS Table 3 6 Product Detect Connection ...

Page 40: ...gh the printhead to the ribbon waste mandrel This forms the ribbon web Ribbon Supply Mandrel Black disc The ribbon supply mandrel with black disc holds the ribbon that is pre coated with ink During printing the ribbon is supplied to the thermal printhead where the ink is applied onto the labels 1 2 1 Ribbon Waste Mandrel 2 Ribbon Supply Mandrel Figure 3 16 Ribbon Mandrels ...

Page 41: ...el collects the waste ribbon that remains after the label has been printed The waste ribbon can be easily removed by using the pullout shaft in the ribbon waste mandrel which allows the core to be easily removed 1 2 1 Pullout Shaft 2 Ribbon Waste Mandrel Figure 3 17 Ribbon Mandrels ...

Page 42: ... disc holds the label roll in place on the mandrel The mandrel lock is used to retain the roll in place The mandrel lock indicates the locking and unlocking directions 1 2 1 Mandrel Lock 2 Label Supply Disc Figure 3 18 Label Supply Mandrel Dancer Arm The dancer arm is designed to absorb the change in tension of the label web during its movement through the LPA 1 2 1 Dancer Arm 2 Dancer Arm Roller ...

Page 43: ...b Idler Rollers Idler Rollers Figure 3 20 Idler Rollers Label Waste Mandrel The label waste mandrel winds the empty label backing waste that remains after the label has been printed and applied on the product The mandrel lock is used to hold and retain the roll in place and allows easy removal of the waste roll The mandrel lock indicates the locking and unlockingdirections Mandrel Lock Figure 3 21...

Page 44: ...PA can be stopped immediately by pressing the E Stop button When the E Stop button is pressed power to the label drive is removed and the LPA is stopped A fault message is displayed The E Stop button is fitted on the side wall of the machine see Figure 3 22 E stop button Figure 3 22 Emergency Stop Button Position The E Stop is reset by pulling out the E Stop button However the LPA will remain in f...

Page 45: ...s present on the equipment If any part of these labels become damaged worn or removed they must be immediately replaced Sensors The LPA is equipped with the following sensors to ensure correct operation of the system without manual intervention Label Gap Sensor The label gap sensor detects the gap between each label The LED item 2 Figure 3 24 displays the status of the sensor Refer to LED Indicato...

Page 46: ...e dots they get heated rapidly Thermal Transfer Print melts the ink on the ribbon The ink deposits on the label and quickly dries after the label leaves the printhead In Direct Thermal the color change of the label is directly caused by the heating elements without ribbon 1 4 2 3 1 Ribbon 2 Label 3 LED 4 Printhead Figure 3 25 Printhead For the printing theories refer to Appendix D Theory Of Printi...

Page 47: ... unauthorized personnel can damage the LPA and invalidate the warranty Warning PERSONAL INJURY Make sure that the mains electrical supply is within the range indicated by the label adjacent to the mains inlet of the labeller If the voltage ratings differ do not use the labeller until you consult your ICE supplier Use only the mains power cable supplied with the labeller This cable must terminate i...

Page 48: ...n it is connected to the mains electrical supply Observe all statutory electrical safety codes and practices Unless it is necessary to run the labeller disconnect the labeller from the mains electrical supply before removing the covers or attempting any service or repair activity The failure to follow this warning can cause death or personal injury Warning PERSONAL INJURY The LPA and stand compone...

Page 49: ...Illustrated Parts List for part numbers Selection of a Suitable Installation Position The LPA is available to print and apply labels in Right Hand or Left Hand directions and can be mounted vertically or horizontally Choose a suitable installation position based on the mounting requirement of the customer When choosing a suitable installation position for the labeller on the line make sure that it...

Page 50: ...on the printhead electrostatic charge and soiling caused by lacquer adhesive or other similar products used in the production process Warning PERSONAL INJURY The mains plug must remain accessible at all times because it serves as the main power disconnect Positioning of Labeller Peel Tip Identify a suitable position for the LPA according to the required product direction and the type of applicator...

Page 51: ...g procedure to assemble the Stand Note This procedure explains a typical horizontal left hand configuration A different configuration may require a different stand Make sure the installation is completed as per the requirement Note Additional stand instructions are available for different configurations 1 Remove the stand from the packaging in an area with sufficient room to build the stand close ...

Page 52: ... 1 Figure 4 2 and lowering the additional feet item 2 Figure 4 2 into position Note Do not over torque the locking bolts The stand will need to be adjusted later when the equipment is aligned to the conveyor 1 7 2 6 5 4 3 1 Mounting Fixture 2 Casters X4 3 Vertical Stand Fixing Location 4 Feet X4 5 Base 6 M6 Nuts X4 7 Stand Figure 4 1 Horizontal Stand H Base ...

Page 53: ...Installing the Label Applicator 4 8 ICEVulcan ServiceManual 2 1 1 Caster 2 Feet Figure 4 2 Caster and Feet ...

Page 54: ...ion on the base see Figure 4 3 and secure it using four M6 bolts washers and nuts item 6 Figure 4 1 on page 4 6 Figure 4 3 Horizontal Stand Location on H Base Warning There is only one location for the stand as shown in Figure 4 3 The LPA must be contained within the H base footprint as shown in Figure 4 4 on page 4 8 Note Refer to the Stand Instructions for more information ...

Page 55: ...of the H base 1 2 3 1 H Base 2 LPA 3 Indicates Containment Area Figure 4 4 LPA Contained Within H Base Footprint Warning PERSONAL INJURY Ensure that the stand has been assembled correctly and is secure i e casters locked before mounting the LPA to the stand Warning PERSONAL INJURY Follow the instructions on constructing the stands and mounting the LPA ...

Page 56: ...n moving equipment and loading labels 5 Mount the two stand bars item 4 Figure 4 5 to the LPA base item 1 There are three locations item 2 on the LPA base to mount stand bars choose the most appropriate locations for horizontal mounting 4 1 2 3 1 LPA Base 2 Location to Mount Stand Bars X3 3 M8 Screws X2 4 Stand Bars X2 Figure 4 5 LPA Base ...

Page 57: ... within the correct footprint as shown in Figure 4 4 on page 4 8 Secure it by tightening the M8 screws item 3 Figure 4 5 on page 4 9 8Tighten the M6 grub screws item 1 Figure 4 6 on the LPA 9When the LPA is secure in place raise the feet and unlock the casters Move the stand and LPA into position on the production line Note It is not recommended to transport the unit over long distances Warning PE...

Page 58: ... Production Line 12 Position the label applicator and the stand adjacent to the conveyor Use the height adjustments on the stand to position the printhead and the peel tip so that the label will be applied at the correct vertical location on the box Figure 4 7 Labeller on Line ...

Page 59: ...ble Make adjustments if necessary LPA Conveyor Figure 4 8 Level Check 14 Visually check to ensure that the plane of the peel tip runs perfectly parallel to the side of the box Peel Tip Figure 4 9 Peel Tip Alignment 15 Use the leveling feet to make any fine adjustments to the angle between the peel tip and the side of the box Otherwise use the leveling feet to secure the LPA and stand in ...

Page 60: ...Installing the Label Applicator 4 13 ICEVulcan ServiceManual place Use an adjustable wrench ...

Page 61: ...play Bracket Figure 4 10 CLARiTY Display Bracket Warning PERSONAL INJURY The CLARiTY display should be mounted in a convenient location to eliminate the potential entanglement with the exposed rotating parts 17 Mount the CLARiTY display on the bracket using the two button head screws with washers and metal washers 1 2 1 Button Head Screw with Washer x2 2 Metal Washer x2 Figure 4 11 CLARiTY Display...

Page 62: ...nt the product detector to the conveyor upstream of the label applicator Note Position the product detector as needed for the application and the production line Product Detector Figure 4 12 Product Detector 19 Connect the external shaft encoder if used to the DB 9 port on the side of the applicator ...

Page 63: ... 4 16 ICEVulcan ServiceManual Cable Connections 20 Make the cable connections as shown in Figure 4 13 and Figure 4 14 on page 4 16 4 3 2 1 1 Beacon 2 Mains Power Lead 3 Product Detect 2 4 CLARiTY Display Figure 4 13 Cable Connections ...

Page 64: ...tor connectors are available Make sure that the product detector connector is plugged into the Product Detect 1 port Note Do not place excessive strain on the beacon cable before mounting the beacon Display TCP IP Network TCP IP Network with PoE RS 232 Connection External Device I O Beacon Barcode Scanner Encoder Product Detect Sensor Figure 4 14 Wiring Connection ...

Page 65: ...olves following procedures Loading a label roll on to the label supply disc mandrel Loading a ribbon roll on to the ribbon supply mandrel D C B A A Gap Sensor B Peel Tip C Ribbon D Label Figure 4 15 Left Hand Webbing Diagram D A Gap Sensor B Peel Tip C Ribbon D Label C B Items not shown in picture ...

Page 66: ...Installing the Label Applicator 4 19 ICEVulcan ServiceManual Figure 4 16 Right Hand Webbing Diagram ...

Page 67: ...he mandrel lock in the direction indicated on the lock on the supply mandrel see Figure 4 17 Remove the label supply disc Unlock Lock Note Left Hand unit shown Figure 4 17 Mandrel Lock 22 Fit the label roll to the label supply mandrel Ensure that the label supply is placed onto the mandrel so that the labels feed in the direction indicated on the supply disc 1 2 1 Label Supply Mandrel 2 Label Supp...

Page 68: ...e label routing Thread the label web as shown in Figure 4 15 on page 4 17 and Figure 4 16 on page 4 17 i e route the labels around each of the rollers in turn as shown on the webbing diagram Ensure that the labels are threaded through the label gap sensor and around the peel tip 3 2 1 1 Label Around Peel Tip 2 Label Gap Sensor 3 Label Figure 4 19 Label Around Peel Tip 25 Unlock the waste mandrel b...

Page 69: ...web is secure Note If the mandrel lock is not secured the label speed will not be accurate 28 Place the supply disc on the supply mandrel and lock it if not already completed For information on removing the ribbon and labels from the LPA refer to How to Replace Label and Ribbon Web on page 6 30 Loading a Ribbon Roll on to the Ribbon Supply Mandrel 29 Remove the new ribbon from its packaging 30 Unw...

Page 70: ...bbon Supply Ink Side Down Figure 4 22 Loading Ribbon Around Printhead Note Ensure that the ink side of the ribbon is facing the label after the ribbon is routed through the printhead Refer to the webbingdiagram for the correct web path see Figure 4 15 on page 4 17 and Figure 4 16 on page 4 17 33 Load the fresh waste core onto the waste mandrel and ensure that the ribbon runs in the direction of th...

Page 71: ...ed position 1 2 1 Pullout Shaft 2 Waste Ribbon Mandrel Figure 4 23 Pullout Shaft 35 Wind excess ribbon onto the waste mandrel ensuring that the ribbon is not torn or wrinkled 1 4 2 3 1 Ribbon Waste Mandrel 2 Printhead 3 Ribbon Supply Ink Side Down 4 Ribbon Supply Mandrel Figure 4 24 Loading Ribbon Around Printhead Caution EQUIPMENT DAMAGE Turn the waste mandrel only to provide tension in the ribbo...

Page 72: ...6 CLARiTY Display Power On Setting up the User Interface 38 In the CLARiTY Display navigate to Tools Setup Control Installation Wizard The Installation Wizard dialog box appears 39 Follow the on screen instructions provided by the Installation Wizard and touch Next when ready to progress For information on Installation Wizard refer to Operator Manual In case of an error touch Back to return to the...

Page 73: ...Installing the Label Applicator 4 24 ICEVulcan ServiceManual correct the error Touch Cancel to exit from the wizard ...

Page 74: ...e Parameters altered when running through the installation wizard are saved on selection Selecting Cancel will exit the user from the wizard it will not reset any parameter to the previous value Note If the LPA is setup offline to confirm operation it may be necessary to restart the installation wizard to ensure that the online setup is correct ...

Page 75: ...power saving How to configure job settings Managing Clones For more information on the user interface refer to Operator Manual Getting started with the CLARiTY CLARiTY is an icon based operator control system It has an easy to use touch screen and most areas of the display are active that is touching an area on the screen is like pressing a button on a traditional control panel All technical aspec...

Page 76: ...ton 3 Current Job Details Bar 4 Consumables 5 Ribbon 6 Labels 7 Print Position 8 PerformanceInformation 9 Print Button 10 System Control Buttons 11 Home Button 12 Job Select Button Figure 5 1 CLARiTY Home Page Warning PERSONAL INJURY The LPA starts printing if you touch the status bar when the LPA is in OFFLINE mode Make sure that you do not touch the status bar if the LPA is not required to run ...

Page 77: ...st that the Operator should be aware of but do not keep the system from printing Fault Conditions exist to keep the system from printing Allows the user to toggle between offline and running mode enabling or disabling printing Allows the user to access the current warning and fault screens if any present Tools Button Opens the Tools menu when selected Current Job Details Page Displays the informat...

Page 78: ...o access Labels page by navigating to Consumables Labels Percentage Percentage of label available Estimated Empty Time Estimated time by when the label will empty based on the current job and the production rate Estimated Time Remaining Estimated time remaining based on the current job and the production rate Last Changed Date and time when the label was last changed ...

Page 79: ...when the ribbon will empty based on the current job and the production rate Estimated Time Remaining Estimated time remaining based on the current job and the production rate Last Changed Date and time when the ribbon was last changed Print Position Opens the Print Position menu when selected Permits the user to set the label position on the product print position X and print position Y on the lab...

Page 80: ...n is only present if option is enabled on the printer using CLARiTY ConfigurationManager System Control Buttons Permits the user to switch off or switch on the LPA It also allows the user to change the LPA between RUNNING and OFFLINE modes Home Button Returns the user to the Home screen as shown in Figure 5 1 on page 5 2 Job Select Button Permits the user to select the required job from the list F...

Page 81: ...on is ideal This can lead to a large and cumbersome menu tree on the LPA s user interface that users have to work with Most LPA variables are set during the installation process The variables are set to values that tailor the LPA to the application Once set these variables only need to be changed when the application for the LPA changes ...

Page 82: ... LPA for review comparison modification Updating the system software Saving retrieving language files Saving retrieving job font and graphics files Snapshot of CLARiTY screens Figure 5 2 CLARiTY Configuration Manager As a result the CLARiTY user interface retains the availability of a small number of operating variables for the user to change It also provides an increased level of LPA system integ...

Page 83: ... 2 Click on the CD drive 3 Select CLARiTY Configuration Manager on the CD Index File Downloads page appears 4 Run the CLARiTYConfig exe file Follow the on screen instructions to install the software The software is installed in the PC and is ready for use How to Connect the CLARiTY Configuration Manager to the LPA Note When you connect the CLARiTY Configuration Manager to the LPA the first connect...

Page 84: ...reports the message Connection Active and the new printer icon turns green If the status displays Not connected disable or quit the other applications running on the PC that are using the serial port Check that the baud rate settings on the Configuration Manager matches with the LPA s baud rate 5 Click the Upload button see Figure 5 4 The progress of the operation is displayed in the status panel ...

Page 85: ...and Restoring a USB Archive on a CLARiTY LPA on page 5 17 How to Connect the CLARiTY Configuration Manager to the LPA using an Ethernet cable The following components are required to connect the LPA to CLARiTY Configuration Manager via Ethernet cable Correct Ethernet cable If connection is being made directly between the PC and the LPA a crossed Ethernet cable must be used If the connection is bei...

Page 86: ... an office LAN consult with your IT manager before assigning IP addresses to your PC If you are making a direct connection you may specify any IP address 1 Open the PC Ethernet port properties and select Use the following IP address Then specify the new address for example 10 27 55 130 in Figure 5 5 and the subnet mask Usually 255 255 255 0 Figure 5 5 IP Address Settings on the PC Note The screen ...

Page 87: ...rs 4 Set the BinaryCommsNetworkPort parameter to 3001 5 Set the IP address to be in the same range as the PC port for example 10 27 55 131 in Figure 5 5 on page 5 11 and click Apply Note The LPA IP address should not be the same as the IP address of the PC 6 Set the Subnet mask to match that of your PC port 7 Right click on the New Coder 1 icon and click the Download button to download the paramet...

Page 88: ...nto the LPA Figure 5 7 New Coder Settings 9 Click the Apply button and the new settings are activated and the coder icon turns green 10 Click the Upload button The progress of the operation is displayed in the status panel This uploads the LPA parameters set to the PC The list of folders containing the configuration parameters appears in the parameter listing in the right hand frame of the Configu...

Page 89: ...e following tasks to change the value of a parameter 1 Click the required parameter from the parameter list The current value is displayed in the Value box at the bottom of the screen 2 Change the value to the required value using the mouse and the keyboard 3 Click the Apply button The value displayed in the parameters list is updated to reflect the change Note Event parameters do not have values ...

Page 90: ...word The Default password is password Figure 5 9 CLARiTY Change Password How to Save the Changes in the LPA Do the following tasks to make the changes effective 1 Click the Printer icon in the left hand pane to open the LPA controls at the bottom pane of the window 2 Click the Download button to update the LPA with the changes that you have made to the parameters A dialog box opens with the messag...

Page 91: ...swords when changes are downloaded to the LPA or select Update Passwords to update the passwords only Figure 5 10 CLARiTY Save Password Change How to Archive the Current Parameters The set of parameters can also be saved as an archive and are stored on the PC The archive can be loaded into the Configuration Manager and downloaded to the LPA again at a later date to revert to the archived set of pa...

Page 92: ... panel and right click on it 2 Choose Load from the pop up menu The archived parameters are displayed on the right hand pane 3 Click the Printer icon from the left hand panel and click the Download button to load the archive of parameters to the LPA Caution EQUIPMENT DAMAGE If the CLARiTY user interface is used within a network Ethernet IP or TCP IP the Power over Ethernet PoE setting must be deac...

Page 93: ...e file or keep the default name and press OK 5 Once the screen indicates the Archive was created successfully press OK 6 Remove the USB memory stick from the LPA Editing the Archive in CLARiTY Configuration Manager Do the following tasks to edit the archive in CLARiTY Configuration Manager 1 Insert the USB memory stick into a USB port of the computer running CLARiTY Configuration Manager 2 Locate ...

Page 94: ... 12 Load Archive File 5 Make the required changes to the setting on the right hand side of the CLARiTY Configuration Manager window 6 Right click on the name of the archive file and select Save 7 Select OK after confirming that the correct archive has been selected Figure 5 13 Confirm Archive Replacement ...

Page 95: ...LARiTY Parameter Archives 3 Locate the desired archive from the list on the screen and select it 4 Select the Restore Archive button at the bottom of the screen 5 Select Yes if you are sure that you want to continue with the restore process after reading the message on the LPA s screen 6 Select Yes or No depending on whether or not you want to restore the network settings from the archive 7 Select...

Page 96: ...for configuration are shown for output activation and or deactivation The options for selection are listed in Table 5 2 Options Consumables are Low Consumables are not Low Job Allocation Aborted Job Allocation Complete Job Update Queue is Empty Job Update Queue is Full Job Update Queue is High Job Update Queue is Low Job Update Queue is Not Empty Job Update Queue is Not Full Job Update Queue is No...

Page 97: ...t Data is Not Ready Print Data is Ready Print Failed Print Signal Ignored Reject Product Table 5 2 External Output 1 3 Options Continued Status of the Warning Beacon in Typical Setup The external outputs 1 3 are evaluated with reference to the status of the warning beacon see Figure 5 14 CLARiTY is Offline CLARiTY is Online CLARiTY enters warning CLARiTY Fault Figure 5 14 Various Indications of th...

Page 98: ...tional features of the CLARiTY User Interface to be protected by different user access levels During installation you can set the standard normal or advanced password selection using CLARiTY Configuration Manager The default password option is Disabled see Figure 5 15 Protection may be globally enabled or disabled Figure 5 15 Password Note If you do not want to have password protection select Disa...

Page 99: ...on password for the level of user Advanced Passwords This is a fully configurable option that allows individual users to be setup for bespoke access either as an individual or part of an access group with individual passwords To set up the passwords navigate to UserInterfaces Passwords Enable Passwords Select the required password Figure 5 16 Figure 5 16 Advanced Password Configuration Note To dow...

Page 100: ...This section describes the behaviour of the CLARiTY display in the various power saving states It is possible to set the power saving mode of the CLARiTY display There are four modes None Minimal High Full The default power saving mode is set to Full Figure 5 17 Power Saving Modes ...

Page 101: ...r 1 minute of inactivity User interface turns off after a further 14 minutes of inactivity Activity User touching the screen USB keyboard input Printing Raising of a warning e g the moment the LPA transitions from No Error into Warning Presence of an error Power Saving Mode 3 Full User interface dims after 1 minute of inactivity User interface turns off after a further 14 minutes of inactivity Act...

Page 102: ...ttings are specific to the active print job CIFF File For information on creating jobs in CLARiSOFT refer to the CLARiSOFT Manual P N 462458 or the Operator Manual Note Ensure that the image width and height settings are set so that the image is created and saved in the orientation as needed to print onto the label During job creation if the image needs to be rotated go to File Properties Image Or...

Page 103: ... the permitted queue is configurable The LPA prints the current job until the number of products printed equals the allocation count sent by the CLARiTY display at which point it stops When one allocation batch has been completed the next job is automatically selected by the LPA if there is a pending job in the queue If there is no pending job in the queue the LPA will not execute any further prin...

Page 104: ... LPA When allocations are enabled it is possible to view the job queue at the CLARiTY panel in two different ways Do the following tasks to view the job queue 1 Touch the Current job details bar on the home screen to access the Job Preview page Job Queue Button Figure 5 19 Job Preview Page 2 Touch the Job Queue button to display the Image Update Queue page You can view the queue of jobs and the pr...

Page 105: ...ls Diagnostics Control Image Update Auto Print Mode Auto print triggering mode allows the LPA to print and apply the label at specific intervals on athe substrate Auto print trigger can be setup from the system configuration wizard during start up Once the LPA is placed in Running mode the LPA will print as setup until the CLARiTY display is placed in Offline or Shutdown mode ...

Page 106: ...l Managing Clones How to Create a Clone 1 Navigate to Tools Setup Control see Figure 5 21 Figure 5 21 Control Page Note The options CLARiTY Printer Clones and CLARiTY Update are not visible until a memory stick is inserted into the printer 2 Touch CLARiTY Printer Clones ...

Page 107: ...there are no previous clones available to restore you will see the message as shown in the Figure 5 22 Touch Create Clone Figure 5 22 Create Clone 4 After selecting Create Clone you can then rename the clone if you wish Then touch OK Figure 5 23 Create Clone ...

Page 108: ...s bar screen appears while the clone is being created Figure 5 24 Clone Creating Screen 6 The clone is successfully created and the completion status screen appears see Figure 5 25 Select OK to exit from the screen Figure 5 25 Successful Clone Creation Message Screen ...

Page 109: ... be carried out when print mode is disabled that is printer Offline or Shutdown mode 1 Navigate to Tools Setup Control CLARITY Printer Clones to restore a clone 2 Touch the required file and touch Restore Clone Figure 5 26 Restore Clone 3 The confirmation pages appears Touch Yes Figure 5 27 Confirmation Message Screen 1 ...

Page 110: ... Managing Clones 5 35 ICEVulcan ServiceManual 4 Touch Yes Figure 5 28 Confirmation Message Screen 2 5 Displays the below screen with progress bar while the clone is being restored Figure 5 29 Restoring Clone ...

Page 111: ...Rev AA Managing Clones 5 36 ICEVulcan ServiceManual The clone has been successfully restored Figure 5 30 Successful Clone Restore Message Screen ...

Page 112: ...s CLARiTY display faults I O faults Label web faults For more information on maintenance refer to Operator Manual Maintenance Preventive Maintenance Schedule MaintenanceItem MaintenanceMethod MaintenanceInterval Printhead Clean with 70 Isopropyl alcohol With every ribbon change Print roller and ribbon roller Clean with 70 Isopropyl alcohol With every ribbon change or when dust adhesive is present ...

Page 113: ...r as required Belts Visual inspection for wear Every six months 500 Rolls Clean dust and debris from internal components Clean with air canned air only Do not use high pressure shop air As required Verify that all modules and accessories are securely fastened Visual inspection Once monthly For systems using tamp applicator module Check filter regulator for water or oil collection Visual Inspection...

Page 114: ...d Printhead Sensor PCB Printhead Cable Guide Printhead Belt Printhead Motor Printhead Cable Main PCB and SD Card Label Drive Belt Label Drive Motor Label Drive Motor PCB CLARiTY Display LCD and PCB Power Supply Ribbon Drive Motor Brake Belt Brake Motor Supply Reel Hall Sensor PCB Dancer Arm Sensor PCB Dancer Arm Springs Rewind Cord and Supply Gripper Flaps Supply Assembly Vertical Stand H Base Hor...

Page 115: ...otor Calibration Wizard During the LPA build the ribbon and the printhead motors are calibrated and the calibration is stored in the PCB When the PCB or the motors are changed the calibration data is no longer valid and recalibration is required When the PCB is changed the installation wizard will start on the LPA power ON and the calibration process is part of this procedure When the printhead or...

Page 116: ...librate Ribbon Motors Do the following tasks to calibrate ribbon motors Note Remove the label or ribbon fitted to the mandrels before starting calibration procedure 1Navigate to Operations CharacterizeRibbonMotors Figure 6 1 Characterize Ribbon Motors ...

Page 117: ...nMotors confirmation screen appears Figure 6 2 Characterize Ribbon Motors Confirmation 3 Select Yes 4 The LPA will begin calibration of the ribbon motor The mandrels will start to rotate at various speeds during this procedure 5 The mandrels will stop rotating when the calibration is complete ...

Page 118: ...rinthead Motors Do the following tasks to calibrate printhead motors Note Remove the label or ribbon fitted to the mandrels before starting calibration procedure 1 Navigate to Operations CharacterizePrintheadPosition Figure 6 3 Characterize Printhead Position ...

Page 119: ...ition confirmation screen appears Figure 6 4 Characterize Printhead Position Confirmation 3 Select Yes 4 The LPA will begin calibration of the printhead motor The mandrels will start to rotate at various speeds during this procedure 5 The mandrels will stop rotating when the calibration is complete ...

Page 120: ...PA behavior The LPA should be used only when a valid part number appears in the part number window There are two ways of performing a CLARiTY Update 1 Connecting the LPA to a PC that runs CLARiTY Configuration manager 2 Inserting a USB memory stick containing the update file into the LPA Before performing a CLARiTY Update it is strongly recommended that a parameter archive is saved using CLARiTY C...

Page 121: ... the progress of the download can be followed in the Progress pane of the CLARiTY Configuration Manager screen 5 Once the download is completed the CLARiTY Update of the LPA starts and the CLARiTY screen indicates the progress of the update Note It is very Important to ensure that the power to the LPA is not removed during the update process or the flash card in the LPA may get corrupted When the ...

Page 122: ...stored in a root directory called CLARiTYupdate 2 Connect the stick to the CLARiTY Operator Interface via the USB port see Figure 6 6 USB Port Figure 6 6 USB Location 3 If the CLARiTY Configuration Manager parameter called Prompt On CLARiTY Update Detect is set to Yes when the device is connected to the CLARiTY Operator Interface a confirmation page appears 4 If the parameter is set to No navigate...

Page 123: ...l of the LPA Figure 6 7 CLARiTY Update Page 6 Touch OK a confirmation page appears Figure 6 8 Figure 6 8 CLARiTY Confirmation Page Caution EQUIPMENT DAMAGE Make sure that the equipment is switched ON during the update process If not the flash card in the equipment may get corrupted 7 Touch Yes and the LPA starts to update the software ...

Page 124: ...der and the CLARiTY Home page appears Figure 6 9 CLARiTY Update Complete 8 Check the software part number in the Diagnostics screen to check that the update is successful Note For information on maintaining CLARiTY display printhead and labeller refer to Maintenance Chapter of Operator Manual ...

Page 125: ...the engineer support personnel through a number of tests for each element of the machine Follow the on screen instructions for each of the tests Figure 6 10 Machine Test Wizard Note Where a test passes the next test begins Where a test fails recommended remedial actions will be provided Once resolved re run the wizard until all elements have passed each test A summary of test results will be provi...

Page 126: ...asks 1 Run the machine test wizard Note Ribbon and labels must be removed from the LPA before starting the wizard 2 Perform the specific tests for the parts Table 6 3 lists the tests included in the wizard in order of execution Sl No Test Name 1 E Stop Test 2 Dancer Arm Test 3 Label Supply Brake Test 4 Supply Rotation Sensor Test 5 Gap Sensor Calibration 6 Gap Sensor Test 7 Print Roller Test Table...

Page 127: ...ection Test 13 Ribbon Supply Mandrel Test 14 Ribbon Supply Test 15 Ribbon Supply Direction Test 16 Ribbon Rewind Mandrel Test 17 Ribbon Rewind Test 18 Ribbon Rewind Direction Test 19 Printhead Pivot Test Table 6 3 List of Tests included in Wizard Continued 3Follow the on screen instructions to fix any found issues Figure 6 12 Machine Test Wizard 4 Close the machine test wizard ...

Page 128: ...red Bright Red No Label material is detected Route the label web correctly Flashing Red Ribbon and Label detected indicating that the ribbon is threaded incorrectly and is detected by the label gap sensor Route the ribbon web correctly Green Label is detected No operator action required Table 6 4 LED Status ...

Page 129: ... dancer arm or a faulty dancer arm home position sensor You can view the sensor state at Tools Diagnostics Printhead Inputs If the problem persists please call your local service representative The machine will not run until this fault is resolved Once resolved and ready press the Clear button below Fault E5008 IntegraMotor VoltsOutOfRange LabelDriveFault The label drive motor power safety system ...

Page 130: ...ty Power off the machine and check that the printhead cables are not damaged and are firmly plugged into the printhead Power on and attempt to resume printing This fault will only clear when the tempera ture sensor readings are within the working range 10 C to 65 C You can check the readings at Tools Diagnostics Printhead Inputs If the problem persists please call your local service representative...

Page 131: ...ted dancer arm or a faulty dancer arm position sensor You can view the reading of the dancer arm position at Tools Diagnostics Printhead Inputs If the problem persists please call your local service representative The machine will not run until this fault is resolved Once resolved and ready press the Clear button below Fault Table 6 5 CLARiTY Error Messages Continued ...

Page 132: ...tdow n Ribbon Drive Fault The ribbon drive fault may be caused by a faulty main circuit board or the ribbon motors or the connec tions between them Power off the machine and check the con nections then re try If the problem persists please call your local service representative The machine will not run until this fault is resolved Once resolved and ready press the Clear button below Fault E5023 In...

Page 133: ...ence Ribbon Feed Fault This fault may be caused by an object obstructing or chang ing the ribbon path check that the ribbon path is correct and that the rollers can rotate freely without obstruc tion This fault may also be due to a fault with the ribbon roller sensor Check this sensor at Tools Diagnostics Printhead lnputs Once resolved and ready press Clear but ton and re try If the problem still ...

Page 134: ...rinthead force drive has a fault This may be caused by a faulty main circuit board Power off the machine and replace the main circuit board then re try If the problem persists please call your local service representative The machine will not run until this fault is resolved Fault Table 6 5 CLARiTY Error Messages Continued ...

Page 135: ...ve has a fault This may be caused by a faulty main circuit board or the printhead force motor or the con nectionsbetweenthem Power off the machine and check the con nections then re try If the problem persists please call your local service representative The machine will not run until this fault is resolved Fault E5032 IntegraPrintheadPosi tion Printhead Position Fault This fault may be caused by...

Page 136: ...machine is config ured to accept This can be caused by products being too close together or if the product sensor is faulty or is being falsely triggered by an obstruction or similar You can check the product sensor input at Tools Diagnostics Printhead Inputs If the problem persists or you wish to pur chase a spare product sensor please call your local service representative Once resolved and read...

Page 137: ...under the printhead then re try If the problem persists please call your local service representative Once resolved and ready press the Clear button below Fault E5038 CrashStop Dancer Arm Fault The dancer arm is not movingfreely Thisfault may be caused by an obstructed dancer arm or a faulty dancer arm position sensor You can view the reading of the dancer arm position at Tools Diagnostics Printhe...

Page 138: ...rinthead Positioning Error Check that the printhead print roller and bumpers are fitted If everything is fitted correctly and the prob lem persists check the Printhead Position Sensor at Tools Diagnostics Printhead Inputs If no input is detected and the problem per sists please call your local service repre sentative Once resolved and ready press the Clear button below Fault E5041 IntegraLabelDriv...

Page 139: ...ntative The machine will not run until this fault is resolved Fault E5044 BrakeControlOpenCir cuit Label Supply Brake Fault The label supply brake fault may be caused by a faulty cir cuit board or the brake motor or the connec tions between them Power off the machine and check the con nections then re try If the problem persists please call your local service representative The machine will not ru...

Page 140: ...ep Label Feed Fault If the problem persists replace the print roller sensor or call your local service repre sentative The machine will not run until this fault is resolved Once resolved and ready press the Clear button below Fault Table 6 5 CLARiTY Error Messages Continued ...

Page 141: ...d ready press the Clear button below Fault E5051 IntegraNoPrinthead Incompatible Print head An incompatible printhead has been detected Power off the machine and replace with a compatible printhead Power on to resume operation If the problem persists or if you wish to pur chase spare parts please call your local ser vice representative for further support The machine will not run until this fault ...

Page 142: ...s or if you wish to pur chase spare parts please call your local ser vice representative for further support The machine will not run until this fault is resolved Fault E5055 RewindCalibration Label Waste Mandrel Not Locked If there is a restriction stopping you from fully closing the waste mandrel and this fault persists please call your local service repre sentative for further support and refer...

Page 143: ...being falsely triggered by an obstruc tion or similar or possi bly the sensor is faulty You can check the pad sensor input at Tools Diagnostics Options Applicator Inputs and Outputs If the problem persists or you wish to purchase a spare sensor please call your local service representative Once resolved and ready press the Clear button below Fault E5102 TampCylinderPositio n Error Applicator Cylin...

Page 144: ...Rev AA Troubleshooting 6 31 ICEVulcan ServiceManual Table 6 5 CLARiTY Error Messages Continued ...

Page 145: ... in barcodes which cannot be scanned It can also be caused by physical obstruction of the scan ner or a hardware fault in the printhead or scanner Check that labels are being applied correctly to the product Check that the applied label is not wrinkled on the product Check that the printhead is clean and printing visibly clear barcodes If possible verify the printed barcodes with a separate barcod...

Page 146: ... barcode in its field of view check the mounting and configuration of the scanner This could also be due to a print error or a communications error with the scanner or a hardware fault with the scanner Power off and check cabling between labeller and scanner then re try If the problem persists please call your local service representative Once resolved and ready press the Clear button below Fault ...

Page 147: ...damaged touch screen Replace LCD display CLARiTY screen not displayed Faulty Remote User Interface PCBA Replace PCBA Faulty RUI cable assembly Replace cable RUI connectors not inserted correctly Power off and insert cable correctly Faulty main control board P N 604795 Replace main control board Backlight faulty Replace LCD display External I O supply short circuit Remove external sensors encoder e...

Page 148: ...ible Cause Solution Dancer Arm hits end stops Brake belt worn or broken Review error message for further detail Replace belt Brake motor fault Review error message for further detail Replace motor Brake Motor Drive system fault Review error message for further detail Table 6 9 Label Web Faults ...

Page 149: ...assemblies and other separate parts Illustrations Table 7 1 on page 7 1 shows the symbols used to indicate the different levels of main assemblies in a system and the sub assemblies under the main assembly Main Assembly Sub Assembly 1 Sub Assembly 2 Sub Assembly 3 Further explosion Sub Assembly 4 Table 7 1 Symbols Representation Assemblies Alphabets An alphabet is assigned to the main assemblies o...

Page 150: ...igure 7 1 Note The numbers assigned to main assemblies can be used only for one time Printer A B C D E F 1 G H J E F G E F G 1 2 3 1 2 3 2 3 4 5 Figure 7 1 Graphical Representation of the Different Subassemblies and Parts Notes Notes provide useful information Some examples for note are as follows Note To order this item use part number of item 9 in this table Note This screw is a part of printhea...

Page 151: ...sembly 7 32 ICEVulcan ServiceManual LPA Assembly C A B Figure 7 2 LPA Assembly Table 7 2 shows the assemblies of the Vulcan LPA Assembly Item Description A LPA B CLARiTY Display C Printhead Table 7 2 LPA Assemblies ...

Page 152: ...Rev AA LPA 7 4 ICEVulcan ServiceManual LPA A Figure 7 3 LPA Item No Description A Label Printer Applicator Table 7 3 Label Printer Applicator Power Supply Assembly 2 1 Figure 7 4 Power Supply Assembly ...

Page 153: ...o Part Number Description Quantity 1 406347 Spare LPA 48V Power Supply Assembly 1 Table 7 4 48 V Power Supply Assembly 2 Figure 7 6 150 V Power Supply Assembly Item No Part Number Description Quantity 2 406348 Spare LPA 150V Power Supply Assembly 1 Table 7 5 150 V Power Supply Assembly ...

Page 154: ...rt Number Description Quantity 3 406349 Spare LPA Label Drive Motor 1 Table 7 6 Label Drive Motor Brake Motor Assembly 4 5 Figure 7 8 Brake Motor Assembly Item No Part Number Description Quantity 4 406351 Spare LPA Brake Motor Assembly 5 406362 Spare LPA Access Plate 1 Table 7 7 Brake Motor Assembly ...

Page 155: ... Spares Part Number Description Quantity 406343 Spare LPA Fuse Pack of 10 Table 7 8 Additional LPA Spares LPA PCB 7 6 Figure 7 9 LPA PCB Item No Part Number Description Quantity 6 406341 Spare LPA Main PCB 1 7 406342 Spare LPA SD Card 1 Table 7 9 LPA PCB ...

Page 156: ...em No Part Number Description Quantity 8 406331 Spare LPA RH Brake Belt Assembly 406332 Spare LPA LH Brake Belt Assembly Table 7 10 Brake Belt Assembly Label Drive Belt 9 Figure 7 11 Label Drive Belt Item No Part Number Description Quantity 9 406334 Spare LPA Label Drive Belt 1 Table 7 11 Label Drive Belt ...

Page 157: ...m No Part Number Description Quantity 10 406337 Spare LPA Supply Disc Assembly Table 7 12 Supply Disc Assembly Supply Assembly 11 Figure 7 13 Supply Assembly Item No Part Number Description Quantity 11 406345 Spare LPA RH Supply Assembly 406346 Spare LPA LH Supply Assembly Table 7 13 Supply Assembly ...

Page 158: ...14 Supply Gripper Flaps Item No Part Number Description Quantity 12 406353 Spare Supply Gripper Flaps Table 7 14 Supply Gripper Flaps Label Roller 13 13 Figure 7 15 Label Roller Item No Part Number Description Quantity 13 406354 Spare LPA Label Roller Table 7 15 Label Roller ...

Page 159: ...Rev AA LPA 7 11 ICEVulcan ServiceManual Rewind Cord 14 Figure 7 16 Rewind Cord Item No Part Number Description Quantity Rewind Assembly 14 406359 Spare LPA Rewind Cord Pack of 10 Table 7 16 Rewind Cord ...

Page 160: ...Roller Item No Part Number Description Quantity 15 406360 Spare Dancer Arm Roller Pack of 5 Table 7 17 Dancer Arm Roller Dancer Arm Spring 16 Figure 7 18 Dancer Arm Spring Item No Part Number Description Quantity 16 406361 Spare Dancer Arm Spring Pack of 5 Table 7 18 Dancer Arm Spring ...

Page 161: ...epper PCB Item No Part Number Description Quantity 17 406336 Spare LPA Label Drive Stepper PCB 1 Table 7 19 Label Drive Stepper PCB Dancer Arm Sensor PCB 18 Figure 7 20 Dancer Arm Sensor PCB Item No Part Number Description Quantity 18 406355 Spare LPA Dancer Arm Sensor PCB 1 Table 7 20 Dancer Arm Sensor PCB ...

Page 162: ...ly Reel Hall Sensor PCB Item No Part Number Description Quantity 19 406356 Spare LPA Supply Reel Hall Sensor PCB 1 Table 7 21 Supply Reel Hall Sensor PCB CLARiTY Display B Figure 7 22 CLARiTY Display Item No Part Number Description B 406338 Spare 6 5 CLARiTY User Interface Table 7 22 CLARiTY Display ...

Page 163: ... 23 CLARiTY LCD Item No Part Number Description Quantity 1 404326 Spare 6 5 CLARiTY LCD 1 Table 7 23 CLARiTY LCD CLARiTY Display PCB 2 Figure 7 24 CLARiTY Display PCB Item No Part Number Description Quantity 2 406340 Spare LPA 6 5 CLARiTY PCB 1 Table 7 24 CLARiTY Display PCB ...

Page 164: ...anual Printhead Assembly C 1 Figure 7 25 Printhead Assembly Item No Part Number Description Quantity C 406315 Spare LPA 107 Printhead Assembly 1 Printhead 1 2 406321 Spare LPA Printhead Bumper Assembly Table 7 25 Printhead Assembly Items are not shown ...

Page 165: ...16 LPA 107mm Print Roller Assembly Table 7 26 Print Roller Assembly Printhead Mount Assembly 4 Figure 7 27 Printhead Mount Assembly Item No Part Number Description Quantity 4 406109 Integra RH Narrow Printhead Mount Assembly 406110 Integra LH Narrow Printhead Mount Assembly 406317 LPA RH 107mm Printhead Mount Assembly 406318 LPA LH 107mm Printhead Mount Assembly Table 7 27 Printhead Mount Assembly...

Page 166: ...m No Part Number Description Quantity 5 406320 Spare LPA Peel Tip Assembly 1 Table 7 28 Peel Tip Assembly Ribbon Sensor Roller Assembly 6 Figure 7 29 Ribbon Sensor Roller Assembly Item No Part Number Description Quantity 6 406319 Spare LPA Ribbon Sensor Roller Assembly Table 7 29 Ribbon Sensor Roller Assembly ...

Page 167: ...tem No Part Number Description Quantity 7 406322 Spare LPA RH Analogue Gap Sensor Assembly 406323 Spare LPA LH Analogue Gap Sensor Assembly Table 7 30 Gap Sensor Assembly Printhead Cable Guide 8 Figure 7 31 Printhead Cable Guide Item No Part Number Description Quantity 8 406328 Spare LPA Printhead Cable Guide 1 ...

Page 168: ...Rev AA Printhead Assembly 7 20 ICEVulcan ServiceManual Table 7 31 Printhead Cable Guide ...

Page 169: ...ead Belt Item No Part Number Description Quantity 9 406333 Spare LPA Printhead Belt 1 Table 7 32 Printhead Belt Printhead Motor Assembly 10 Figure 7 33 Printhead Motor Assembly Item No Part Number Description Quantity 10 406352 Spare LPA Printhead Motor Assembly 1 Table 7 33 Printhead Motor ...

Page 170: ...y RH 1 406388 LPA Wipe down assembly LH Table 7 34 Wipe Down Printhead PCB Gap Sensor and Print Roller Sensor PCB 12 Figure 7 35 Gap Sensor and Print Roller Sensor PCB Item No Part Number Description Quantity 12 406324 Spare LPA RH Gap Sensor and Print Roller Sensor PCB 1 406325 Spare LPA LH Gap Sensor and Print Roller Sensor PCB Table 7 35 Gap Sensor and Print Roller Sensor PCB ...

Page 171: ...head Sensor PCB Printhead Cables 14 14 Figure 7 37 Printhead Cables Table 7 37 Printhead Cables Item No Part Number Description Quantity 13 406326 Spare LPA RH Ribbon and Printhead Sensor PCB 1 406327 Spare LPA LH Ribbon and Printhead Sensor PCB Item No Part Number Description Quantity 14 406357 Spare LPA RH Printhead Cable 1 406358 Spare LPA LH Printhead Cable ...

Page 172: ...o Part Number Description Quantity 15 406329 Spare LPA Leaf Springs Pack of 16 16 406363 Spare LPA 107mm Ribbon Guide Roller Pack of 5 Table 7 38 Ribbon Items are not shown Ribbon Drive Motor 17 17 Figure 7 39 Ribbon Drive Motor Item No Part Number Description Quantity 17 406350 Spare LPA Ribbon Drive Motor 2 ...

Page 173: ...Rev AA Printhead Assembly 7 23 ICEVulcan ServiceManual Table 7 39 Ribbon Drive Motor ...

Page 174: ...lack Ribbon Disc Item No Part Number Description Quantity 18 406330 Spare LPA Black Ribbon Disc Pack of 5 Table 7 40 Black Ribbon Disc Easy Off Mandrel 19 Figure 7 41 Easy Off Mandrel Item No Part Number Description Quantity 19 406376 Easy Off Mandrel Refurb Kit Table 7 41 Easy Off Mandrel ...

Page 175: ...s 7 25 ICEVulcan ServiceManual Accessories Stands Vertical Stand H Base 1 Figure 7 42 Vertical Stand H Base Item No Part Number Description Quantity 1 406389 LPA Vertical Stand H Base 1 Table 7 42 Vertical Stand H Base ...

Page 176: ...ries 7 26 ICEVulcan ServiceManual Horizontal Stand H Base 2 Figure 7 43 Horizontal Stand Direct Apply Item No Part Number Description Quantity 2 406391 LPA Horizontal Stand H Base 1 Table 7 43 Horizontal Stand H Base ...

Page 177: ...cal Stand with Integral Conveyor U Base 3 Figure 7 44 Vertical Stand with Integral Conveyor U Base Item No Part Number Description Quantity 3 406390 LPA Vertical Stand with Integral Conveyor U Base 1 Table 7 44 Vertical Stand with Integral Conveyor U Base ...

Page 178: ...ntegral Conveyor U Base 1 Table 7 45 Horizontal Stand with Integral Conveyor U Base Additional Accessories Part Number Description Quantity 405450 LPA Encoder Assembly 1 406384 LPA Status Beacon Assembly 1 406386 LPA Product Detect Sensor Assembly 1 406394 LPA Pack Handling Kit 1 406395 LPA Barcode Scanner Kit Serial 1 406421 LPA Barcode Scanner Kit PoE 1 406501 CLARiTY Support Tube Assembly 1 Tab...

Page 179: ... Cable Assembly 1 506086 High Speed RUI Cable 3 m 1 506148 High Speed RUI Cable 1 m 1 506149 High Speed RUI Cable 5 m 1 Table 7 47 Accessories Cables Cables Part Number Description 406314 Internal I O Cable Assembly 406374 Spare RH LPA Cable Kit 406375 Spare LH LPA Cable Kit 406379 LPA External I O Cable Table 7 48 Cables ...

Page 180: ...ed LPA setup time A single point of setup reduces the setup time Reduced human errors Only one entry of data rather than several entries reduces the possibility of setup mistakes by human error Cost effective A lower cost coding solution when multiple LPAs are required to fulfil a coding application through the use of the Slave LPA without LCD Cost reduction and effective usage of space All these ...

Page 181: ...ntial Operator errors when inputting variable data All other functions are performed at each local LPA s LCD panel Group Control Allows connection of one standard with LCD acting as the Master to up to three Slave without LCD LPAs All Job selection Setup Diagnostics and Error reporting are performed at the Master LPA only Auto Changeover Allows the connection of two LPAs Two LPAs are setup in auto...

Page 182: ...terconnection cable may be used to connect directly between the Ethernet ports of the two LPAs All other cables e g I O cable must be connected in the same way as the standalone LPAs When more than two LPAs are to be connected together or connection to a network is required a Printer Connection Box complete with ethernet patch cables is required The Connection Box allows up to four LPAs one Master...

Page 183: ...s and encoder lead 1 4 3 2 1 Encoder Lead 2 Network Connector 3 Ethernet Ports 4 Integral I O Cables Figure 8 1 Printer Connection Box Software Configuration To configure Master Slave mode CLARiTY Configuration Manager is required The LPAs may be configured using a serial cable or a network connection However this manual assumes that a standard Null Modem cable part number 400720 is being used ...

Page 184: ...ed if the group is to be connected to a wider area network Note If a LPA has previously been configured to Advanced Configuration mode this setting is saved as the standard default configuration for the LPA Basic Configuration Configuring the Slave LPAs To configure the slave LPA proceed as follows 1 EstablishcommunicationsbetweenCLARiTYConfigurationManager and the first Slave LPA How to Connect t...

Page 185: ...tively starting with One it is not permissible to have two Slave LPAs numbered One and Three Slave LPAs connected to the same network require individual Slave numbers 4 Select the option to be taken in the event of communication failure between the Master LPA and Slave LPA from the drop down list The three options available are No Action ignore the condition Raise a Warning message and continue op...

Page 186: ...sabled greyed out as shown in Figure 8 4 Disabled Job Button Figure 8 4 CLarity Home page After a short period of time the Slave LPA may raise a Warning or Fault message depending on the setting you chosen in Action if connection to the Master is lost to indicate that the Master LPA is absent as shown in Figure 8 5 and Figure 8 6 Figure 8 5 Warning Message ...

Page 187: ...ssage can be cleared from the Slave LPA screen Repeat the above steps to install the remaining Slave LPAs in the group Basic Configuration Configuring the Master LPA To configure the master LPA proceed as follows 1 EstablishcommunicationsbetweenCLARiTYConfigurationManager and the master LPA How to Connect the CLARiTY Configuration Manager to the LPA using an RS232 connection on page 5 8 ...

Page 188: ...n when the icon turns green and Select Set as Master from the list as shown in Figure 8 7 Figure 8 7 CLARiTY Config Master Setup A configure master printer dialog box appears Figure 8 8 3 2 1 Names Fields 2 Check Boxes 3 Master Slave Level Drop Down List 1 Figure 8 8 Configure Master LPA Dialog Box ...

Page 189: ...Master Slave level has been selected the OK button becomes available 6Click OK button to program the LPA with the selected configuration Connecting the LPAs Together To connect the LPAs proceed as follows 1If the LPAs are not already connected they may be connected together as described Physical Installation on page 8 3 After a few seconds any Faults and or Warnings messages on the Master and Slav...

Page 190: ...lly assigned addresses The Subnet Mask used on the network and port number for Master Slave communications is also required The default port number is 3002 and in most situations it is not necessary to change this number Change it only if you are instructed to do so by the IT department To avoid confusion the same port number should be used for all Slave LPAs Advanced Configuration Configuring the...

Page 191: ...he icon turns green and Select Set as Slave from the list as shown in Figure 8 9 Figure 8 9 CLARiTY Config Slave Setup If the LPA has not been assigned an IP address or configured in advanced mode previously a configure slave printer dialog box appears Figure 8 10 Figure 8 10 Configure Slave LPA Dialog Box ...

Page 192: ...e condition Raise a Warning message and continue operation Raise a Fault message and suspend operation stop printing 6 Touch OK to configure the Slave LPA Once the slave LPA is configured on a Standard LPA the JOB button on the screen of CLARiTY is disabled greyed out as shown in Figure 8 4 on page 8 7 After a short period of time the Slave LPA may raise a Warning or Fault message depending on the...

Page 193: ... follows 1 EstablishcommunicationsbetweenCLARiTYConfigurationManager and the master LPA How to Connect the CLARiTY Configuration Manager to the LPA using an RS232 connection on page 5 8 2 Right click on the New Printer icon when the icon turns green and Select Set as Master from the list as shown in Figure 8 12 Figure 8 12 CLARiTY Config Master Setup ...

Page 194: ...rviceManual A configure master printer dialog box appears Figure 8 13 3 2 1 Master Slave Level Drop Down List 2 Check Boxes 1 3 Names Fields Figure 8 13 Configure Master LPA Dialog Box 3 Click on the Advanced button to change to advanced configuration ...

Page 195: ...Check boxes on the left hand side of the dialog box indicate how many Slaves are to be connected 5 Click on the check boxes to select the slave LPAs The dialog box allows only the selection of consecutively numbered Slaves starting with Slave 1 6 Enter the IP address network subnet mask and the port number of the slave LPA and the master in their Address field Subnet Mask field and Port field resp...

Page 196: ...ish communications between CLARiTY Configuration Manager and LPA 2 3 How to Connect the CLARiTY Configuration Manager to the LPA using an RS232 connection on page 5 8 2 Right click on the New Printer icon when the icon turns green and Select Multiple Machine Modes Set as Machine 2 3 from the list as shown in Figure 8 15 Figure 8 15 Set as Machine 2 3 ...

Page 197: ...8 7 After a short period of time LPA 2 3 may raise a Warning or Fault message depending on the setting you chosen in Action if connection to the Master is lost to indicate that LPA 1 is absent as shown in Figure 8 5 on page 8 7 and Figure 8 6 on page 8 8 Once LPA 1 has been configured and communication established between LPAs the warning message can be cleared from LPA 2 3 screen Note Only one LP...

Page 198: ...aster Slave 8 19 ICEVulcan ServiceManual 2 Right click on the New Printer icon when the icon turns green and Select Multiple Machine Modes Set as Machine 1 from the list as shown in Figure 8 17 Figure 8 17 Set as Machine 1 ...

Page 199: ...f Printer 1 Printer 2 and Printer 3 if required Note The Check boxes on the left hand side of the dialog box indicate how many Slaves are to be connected 5 Click on the check boxes to select LPA 2 3 The dialog box allows only the selection of consecutively numbered Slaves starting with Slave 1 6 Enter the IP address network subnet mask and the port number of the LPA 2 3 and LPA 1 in their IP Addre...

Page 200: ...blem persists repeat the configuration steps to ensure that the Master and Slaves LPAs have been configured with the correct IP addresses subnet masks and port numbers 4 If operating under Group Control mode any Faults and or Warnings present on the Slave LPAs is reported on the Master LPA CLARiTY screen then they must be cleared at the Master LPA Using Master Slave Mode Group Job Select Mode The ...

Page 201: ...aster LPA s CLARiTY as shown in Figure 8 19 and Figure 8 20 Figure 8 19 Fault State Figure 8 20 Fault State Details In the example shown Figure 8 19 and Figure 8 20 communication has been lost between the Master and Slave LPA This fault can be cleared when the communications are re established or when the Slave LPA is unassigned ...

Page 202: ...e printhead page You can see the list of LPAs connected to the Master as shown in Figure 8 21 Note The Master LPA is always listed first followed by the Slaves Figure 8 21 Printhead Diagnostics Note If the Master and Slave LPAs have been given a Name as described in Configure the Master LPA CLARiTY reflects these changes as in Figure 8 21 ...

Page 203: ... This allows a Slave Absent fault to be cleared at the Master CLARiTY so that the Master and other Slave LPAs can continue operation Note When a Slave LPA is unassigned the Master is unable to send commands to the Slave LPA and ignores any information sent from the Slave LPA Un assigning a Slave LPA is a useful when a LPA is removed from the production line for maintenance and the rest of the LPAs...

Page 204: ...d other software packages e g CLARiSOFT Using Master Slave Mode Group Control Mode Group Control mode allows Slave LPAs to be controlled from the Master LPA CLARiTY interface In addition to the parameters available in Group Job Select mode additional Setup and Diagnostics CLARiTY pages are available for setup and diagnostics information The Master LPA In Group Control mode the CLARiTY Operator int...

Page 205: ...rameters If Set up information is selected any parameters edited would be saved in the selected Slave LPA If a Slave LPA raises a Fault or Warning the message is displayed on the Master LPA CLARiTY The Fault is also displayed on the Slave CLARiTY if it is a Standard LPA When viewing the details of the error screen on the Master CLARiTY the name of the Slave LPA raising the error is displayed e g L...

Page 206: ...aster LPA has been assigned a single Slave LPA The Consumables bar for each LPA assigned is displayed on the screen of the Master LPA Figure 8 25 Master and Slave Consumables Consumables information on an individual LPA can be viewed further by pressing the chosen LPAs consumable bar ...

Page 207: ...ne and Print Position buttons are disabled Job selection and Online Offline changes may only be initiated at the Master LPA Standard LPAs in Slave mode accepts communications from CLARiTY Configuration Manager and other packages e g CLARiSOFT All other operations are initiated from the Master LPA Slave LPAs no CLARiTY accepts communications from CLARiTY Configuration Manager and other packages e g...

Page 208: ...A is deleted from the Master Slave group and begins to function as a standalone LPA Note If the Slave LPAs are Standard LPAs the JOB button is enabled and the Slave s Job database is empty or contains only the last Job selected The Master Slave group database is held by the Master LPA Therefore if a LPA is disabled from the Master Slave network and becomes a stand alone unit any additional Jobs re...

Page 209: ...on on page 5 8 2 Right click on the New Printer icon when the icon turns green and Select Disable Master Slave mode from the list as shown in Figure 8 27 Figure 8 28 CLARiTY Config Master Disabling A confirmation box appears asking you to confirm this action 3 Click Yes do one of the following Replace the Master LPA with a new LPA containing identical configuration parameters and ensure the old Ma...

Page 210: ...green and Select Multiple Machine Modes Disable Multiple Machine Mode from the list as shown in Figure 8 29 Figure 8 29 CLARiTY Config LPA 2 3 Disabling A confirmation box appears asking you to confirm this action 3 Click Yes and LPA 2 3 is deleted from the Auto Changeover group and begins to function as a standalone LPA Note If LPA 2 3 is Standard LPA the JOB button is enabled and LPA 2 3 s Job d...

Page 211: ...TY Configuration Manager to the LPA using an RS232 connection on page 5 8 2 Right click on the New Printer icon when the icon turns green and Select Multiple Machine Modes Disable Multiple Machine Mode from the list as shown in Figure 8 27 Figure 8 30 CLARiTY Config LPA 1 Disabling A confirmation box appears asking you to confirm this action 3 Click Yes 4 Replace LPA 1 with a new LPA containing id...

Page 212: ...8 in Specifications This chapter contains information about the following topics Technicaldrawings Technicalspecifications Electricalspecifications Systemspecifications Technical Drawings CLARiTY Display 184 6 mm 49 9 mm 7 3 in 1 9 in Figure A 1 CLARiTY Display Dimensions ...

Page 213: ... ICEVulcan ServiceManual 313 8 mm 12 3 in 587 5 mm 23 1 in Label Printer Applicator 12 9 mm 0 5 in 335 mm 13 2 in 93 mm 672 6 mm 26 5 in 118 mm 3 7 in 4 6 in 726 mm 28 6 in Figure A 2 LPA RH with Direct Apply ...

Page 214: ...iTY Display CLARiTY Operati ng System 184 6 49 9 147 1 kg 8 4 TFT SVGA LPA with Direct Apply 819 313 8 587 5 40 kg witha roll of labels Table A 1 Technical Specification Electrical Specifications Voltage 100 240 VAC 90 264 V max Current 3 85 1 6 A Frequency 50 60 Hz Power 48V 250W Control board TTO power 150V 175 W Main drive power Fuse 2 x T10AH250V Table A 2 Electrical Specifications ...

Page 215: ... to 500 mm s Throughput Up to 350 packs per minute depending upon line speed and pack size Table A 3 System Specifications External Connectors and Interface Specifications Connector Specification Product Sensor 1 and 2 M12 A coding 4POS female IO D Sub 15POS Female Encoder D Sub 9POS Female Beacon M16 DIN 6POS Female LED based beacon RS232 Serial D Sub 9POS male Ethernet RJ45 Ethernet PoE RJ45 Rem...

Page 216: ...A 4 SystemSpecifications Rev AA ICEVulcan ServiceManual Clarity Configuration Manager Introduction CLARiTY Configuration Manager lists all the configurable parameters of the LPA ...

Page 217: ...r code 0 260 Consecutive NoReadLimit 3 0 214748364 7 Consecutive WrongRead Limit 1 214748364 7 DelayBefore Gate 0 0 1000 DelayType 0 Time in ms 1 1 Distance in mm GateTimeout 500 0 5000 PHds 1 Consumables Ribbon Colour 0 Black 2 1 White 2 Other Ribbon Width 91 55 110 Ribbon Widthin mm ImageInform a tion MirroredIm age 0 No 1 Select if image is be reversed 1 Yes PrintOrienta tion 0 0 degree 1 Set O...

Page 218: ...nits If there is no encoder enter fixed product or line speed in mm sec or ft sec FixedSpeed Products 0 External Encoder 1 Select Fixed Speed Printing if no encoder avaiable 1 Fixed Speed Printing GapSensor GapSensor ToBeakDis tance 400 100 5000 distance in mm GapSensor Type 0 Array 2 1 Auxiliary 2 Point Ignored PrintsBehav iour 0 Ignore 2 Select the required printer behaviourwhen prints are misse...

Page 219: ...B 4 Rev AA ICEVulcan ServiceManual LabelRepeat Distance 500 5 5000 Table B 1 CLARiTY Configuration Manager Continued ...

Page 220: ... for the print trigger 1 Negative Edge Trigger ProductSens or2Trigger 0 PositiveEdge Trigger 1 Select either the positive or negatitive edge that is used for the print trigger 1 Negative Edge Trigger ProductSens or2TriggerDis tance 0 0 3000 mm inches Distance between prod uct sensor and specific appli cator i e to label applicator or barcode reader ProductSens or2Usage 0 None 2 Is print repeat mod...

Page 221: ...1474 Set up the external output 1 Output2 Config see Table 5 2 1 21474 21474 Set up the external output 2 Output3 Config see Table 5 2 2 21474 21474 Set up the external output 3 PrinterConfigu ration Horizontal PrintRegistra tion 0 1000 3000 PrintDark ness 75 0 100 PrintForce 50 0 100 PrintRoller Width 0 110mm 2 1 76mm 2 Requires Set ting PrintSensor ToApplica torDistance 0 0 3000 PrintingMode 0 T...

Page 222: ...terSet 0 ASCII 2 1 UTF8 2 Unicode DateCodes Day Of Month Codes 1 2 3 4 5 0 2048 Set up required date and time codes Day of Week Codes A B C D E 0 512 Hour Codes A B C D E 0 1024 Minute Codes AG AH A I AJ 0 4096 Month Codes JA FE M R AL MA 0 512 Week Of Year Codes 1 2 3 4 5 0 4096 Year of Decade Codes A B C D E 0 512 Job Orientation 0 0deg 3 1 90deg 2 180deg 4 270deg Table B 1 CLARiTY Configuration...

Page 223: ...dMapping Printhead1 2 1 4 Printhead2 2 1 4 Printhead3 3 1 4 Printhead4 4 1 4 Printer Codes Equipment Reference 1 0 255 Factory Refer ence 1 0 255 Line Reference 1 0 255 ResetPrintLimitOn Startup 0 No 1 1 Yes Shift Codes Number Of Shifts 0 0 168 Number Set up shift requirement Start Of Day 00 00 00 23 59 59 23 59 59 Start Of Hour Of Week 00 00 00 167 00 00 167 00 00 TimerCodeEncryp tion ABCDEFGHIJ ...

Page 224: ...ct Update 2 Transmit on Print Update Queue MaxQueue Length 1 1 20 Number Operations Apply Trigger CalibrateGapSen sor Trigger CharacterizePrint headPosition Trigger CharacterizeRib bonMotors Trigger CycleApply Trigger CycleDispense Trigger CycleDispenseAn dApply Trigger Dispense Trigger DispenseAndApply Trigger GenerateLogFiles Trigger PrintLabel Trigger TestPrint Trigger Table B 1 CLARiTY Configu...

Page 225: ...14400 8 19200 9 38400 10 56000 11 57600 12 115200 FlowControl 0 None 2 1 Software 2 Hardware Usage 0 None 6 1 Text Commu nications 2 CLARiTY 3 ZPL Emula tion 4 SATO Emula tion 5 Transmitted Field 6 Barcode Scanner Database Location 0 Local 1 Select the required loca tion for the job files 1 Remote EnableUserTest Print 0 No 1 1 Yes Table B 1 CLARiTY Configuration Manager Continued ...

Page 226: ...nts 0 No 1 1 Yes LoggingMode 0 None 2 1 Normal 2 Advanced PowerSaving Mode 0 None 3 1 Minimal 2 High 3 Full SATO BarcodeSizing 0 Favour Smaller Bar codes 2 1 Balanced 2 Favour Larger Bar codes DeleteCRLF 0 No 1 1 Yes Resolution 0 203 dpi 2 1 300 dpi 2 600 dpi FontCodePage 0 22 22 FontSpaceDe fault 0 1 1 Table B 1 CLARiTY Configuration Manager Continued ...

Page 227: ... 9999 9999 YOrigin 0 9999 9999 Label Width UseSATOV alue 0 Emulation Value 1 1 Use Printer Value Width 107 1 9999 PrintLimitMode 0 Unlimited Prints 1 1 Use SATO supplied print limit PrintMode 0 Download Only 3 1 Download Select 2 Download Select Delete after use 3 Select Only don t use Data base ProtocolCom mandCodes 0 Standard 1 1 Alternate ServiceInformation AddressLine1 0 255 AddressLine2 0 255...

Page 228: ...to show the job description if providedfor the print job 1 Yes TCPIP BarcodeScan ner IPAddress 0 0 0 0 7 15 Network Port 2111 1 65535 Protocol 0 Disabled 2 1 Enabled Recrive 2 Enabled Transmit Response Port 1025 1 65535 BinaryCom msNetwork Port 3001 0 256000 DefaultGate way 0 15 IPAddress 0 0 0 0 7 15 SATOEmula tion NetworkPort 1024 1 65535 Protocol 0 None 2 1 Status 3 2 Status 4 ResponsePort 1025...

Page 229: ...e ZipherASCII CommsProto col xml 0 200 USB PromptOn CLARiTYData FileDetect 0 No 1 Select yes to prompt ifprinter detects a CLARiTY Data file on the usb 1 Yes PromptOn CLARiTYPa rameterArchiv eDetect 0 No 1 Select yes to prompt ifprinter detects a CLARiTY archive file on the usb 1 Yes PromptOn CLARiTYPrint erCloneDetect 0 No 1 Select yes to prompt ifprinter detects a CLARiTY printerclonefile on the...

Page 230: ...orA A 1 1 DriveMapping ForB B 1 1 DriveMapping ForE E 1 1 DriveMapping ForR R 1 1 EmulationRes olution 0 203 dpi 2 1 300 dpi 2 600 dpi LabelConfigu ration HorizontalField Offset Horizontal Shift 0 9999 9999 UseZE BRAValue 0 Use Emula tion Value 1 1 Use Printer Value LabelLength Length 107 1 9999 UseZE BRAValue 0 Use Emula tion Value 1 1 Use Printer Value LabelOrigin UseZE BRAValue 0 Use Emula tion...

Page 231: ... Printer Value VerticalShift 0 120 120 PrintLimitMode 0 Unlimited Prints 1 1 Use ZPL sup plied print limit PrintMode 0 Download Only 3 1 Download Select 2 Download Select Delete after use 3 Select Only don t use Data base Resoluition Scale Factor 0 1 1 User Inter faces CLARiTY HomeScreen Preview 0 No 1 1 Yes Language English 0 100 Enter the required lan guage Measuremen tUnits 0 Metric 1 Select un...

Page 232: ...bled 2 Select the pre ferred pass word level 1 Normal 2 Advanced Recalibrate Touchscreen TouchToEdit Enabled 0 Disable 1 1 Enable CLARiTYConfig Archive Not Archived 0 100 LastUpdated 05 30 2012 10 02 37 0 100 WebServer Enabled 0 No 1 Select yes to enable Web Server 1 Yes Table B 1 CLARiTY Configuration Manager Continued ...

Page 233: ...v AA Main Board Test Points C 1 Main Board Test Points Note All references are made as viewed from the front side of the PCB unless mentioned TP344 TP347 TP346 Figure C 1 Main Board Test Points Rear View ...

Page 234: ...ICEVulcanServiceManual TP29 TP30 TP35 TP42 TP33 TP37 TP40 TP64 TP81 TP77 TP41 TP165 TP208 TP304 TP319 TP320 TP329 TP333 TP342 TP381 Figure C 2 Main Board Test Points Front View ...

Page 235: ...C 2 Main Board Test Points Rev AA ...

Page 236: ... left segment of PCB 3 25 3 35 V TP304 5V bottom left segment of PCB 4 75 5 25 V TP320 12V bottom left segment of PCB 11 75 12 25 V TP329 24V bottom left segment of PCB 23 5 24 5 V TP40 2V6 just to right of U16 2 45 2 75 V TP37 1Y8A just to top right of U16 1 75 1 95 V TP33 3V3U just to top right of U16 3 15 3 45 V TP30 1Y2D just above L2 1 15 1 35 V TP29 1Y8 just to top left of U16 1 70 1 90 V TP...

Page 237: ...ed to one side is used as the printing media The printhead presses the thermal transfer ribbon onto the substrate item 2 with the ink side of ribbon in contact with the substrate Print elements heat small areas of the ribbon and this transfers the ink to the target substrate The printhead and the substrate move relative to each other The print elements are programmable and controlled to create an ...

Page 238: ...FS and Horizontal Form Fill Seal HFFS or flow wrap machines Continuous motion printing has the following features The substrate item 3 Figure D 2 moves while the printhead item 4 is stationary Speed of the substrate is monitored by an encoder The ribbon and the substrate speeds are matched by the ribbon drive The printhead pushes the substrate against a rotating print roller item 2 4 RIBBON FEED 3...

Page 239: ...ows two basic availability metrics simultaneously EquipmentAvailability OperationalAvailability Equipment availability is the same and equal or more than operational availability Note Operational Availability can be changed between two separate production time proxies as required by the user Power On and Running mode Please see Operational Availability on page E 2 for further details Equipment Ava...

Page 240: ...cleared If the equipment is powered down in a equipment fault state the downtime counter continues until equipment is powered on and the fault is cleared Operational Availability Operational Availability 1 OperationDowntime Production Time The Production Time Proxy allows the availability calculation to change between customer selected operating modes either Running or Power On The production time...

Page 241: ...unter starts The equipment remains in this operation fault state until the fault is cleared If the equipment is powered down in a operation fault state the downtime counter continues until equipment is powered on and the fault is cleared Availability Page Access the Availability page by navigating to Home Performance Availability The availability page displays the equipment availability and operat...

Page 242: ...r information on how to export to USB stick All data can be exported to USB for further interrogation Refer to the Operator Manual for complete information on How to use Availability tools Figure E 1 Availability Touch to view the Fault Pareto page for the selected availability data The page displays the fault type downtime and fault frequency see Figure E 2 and Figure E 3 on page E 5 ...

Page 243: ...ure E 2 Fault Pareto For Equipment Availability Figure E 3 Fault Pareto for Operational Availability The Fault pareto screens show all faults their duration and the frequencies for the period being viewed This will help to identify any ongoing issues that might indicate a training issue or bad performer Each fault can be selected for further detail on the fault time and also on when each event occ...

Page 244: ... date time and duration of the fault Figure E 4 Event The Event page will show for each fault the date time and duration of that fault for the time period selected Each event can be selected for further detail Touch to view the Parameters page see Figure E 5 Parameters page displays the values of each parameter for the particular downtime Figure E 5 Parameters Page ...

Page 245: ... that shows all alarms warnings and status indicators of the equipment Selecting event log from this page will show the event log for the event time Touch Go to Event Log to view Event log page see Figure E 6 on page E 7 You can also view this page by navigating through Tools Diagnostics Printhead The Event log retains all activities happening for a six month period It can be useful to check other...

Page 246: ...ServiceManual Touch on the Event message for detailed description of the fault and where available the parameter page can be selected Each fault description takes the user to a more detailed of the fault likely causes and correction actions Figure E 7 Event log diagnostics ...

Page 247: ... AvailabilityMetrics Event Log Do the following tasks to export the data to the USB stick 1 Insert USB stick to the external USB connector Note Export To USB button is activated only when a USB stick is inserted Note Ensure that the USB stick does not have any previous exported data as you will be asked to overwrite the files see Figure E 8 Figure E 8 Overwrite Files 2 Export to USB ...

Page 248: ... Home page navigate to Performance Availability see Figure E 1 on page E 4 b Select Export to USB c Confirmation page will be displayed see Figure E 9 Figure E 9 Export Availability Metrics Confirmation d Select OK e On completion success page will be displayed Figure E 10 Export Success f Select OK and remove the USB stick ...

Page 249: ...gate to Tools Diagnostics Printhead Event Log see Figure E 6 on page E 7 b Select Export to USB c Confirmation page will be displayed see Figure E 11 Figure E 11 Export Event Log Confirmation d Select OK e On completion success page will be displayed Figure E 12 Export Success f Select OK and remove the USB stick ...

Page 250: ...ceManual 3 The files can be exported into Microsoft EXCEL or other spreadsheet tools and can be used to create graphs and logs for use in monitoring the equipment performance see Figure E 13 Figure E 13 Exported Data in Microsoft EXCEL ...

Page 251: ... advancing the label liner It is a part of the print engine and is electronically controlled by the control card inside the back cover Idler Roller These are the rollers that guide the label liner along its thread path Job or Image Job is the set of characters that is required to be marked on the product label Label Job or Image Label Length This is the overall length of the label from leading edg...

Page 252: ...e laser system BCD mode Line Select Refresh the Print Memory The print memory is updated automatically within CLARiTY Rewind Roll This is the mandrel provided to store the spent label web Tamp Application Module This is a label applicator that uses an air cylinder that extends to apply the label on to the object and retracts to its home position The label is dispensed onto a tamp pad through the a...

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