Carl Valentin Vario III label printer Service Instructions

VARIO III

Service Instructions

Copyright by Carl Valentin GmbH / 7956045.1115

Information on the scope of delivery, appearance, performance, dimensions and weight reflect our knowledge at the time of printing.

We reserve the rights to make modifications.

All rights, including those regarding the translation, are reserved.

No part of this document may be reproduced in any form (print, photocopy or any other method) or edited, copied or distributed electronically without written permission from Carl Valentin GmbH.

Due to the constant further development of our devices discrepancies between manual and device can occur.

Please check www.carl-valentin.de for the latest update.

Trademarks

All named brands or trademarks are registered brands or registered trademarks of their respective owners and may not be separately labelled. It must not be concluded from the missing labelling that it is not a registered brand or a registered trademark.

Carl Valentin label printers comply with the following safety guidelines:

CE

EG Low-Voltage Directive (2006/95/EC)

EG Electromagnetic Compatibility Directive (2004/108/EC)

Carl Valentin GmbH

Postfach 3744

78026 Villingen-Schwenningen

Neckarstraße 78 – 86 u. 94

78056 Villingen-Schwenningen

Phone

Fax

E-Mail

Internet

+49 7720 9712-0

+49 7720 9712-9901 [email protected] www.carl-valentin.de

Vario III

11.15

Table of Contents

Table of Contents

Table of Contents ............................................................................. 3

1 Notes on this Document ....................................................... 5

1.1

User Notes ............................................................................... 5

1.2

Instructions .............................................................................. 5

1.3

Cross References .................................................................... 6

2 Safety Instructions ................................................................ 7

2.1

General Safety Instructions ..................................................... 7

2.2

Safety Handling When Working With Electricity ...................... 9

2.3

Environmentally-Friendly Disposal ........................................ 10

3 Connector Pin Assignment (Printer Rear) ........................ 11

4 Cleaning ............................................................................... 13

4.1

General Cleaning................................................................... 14

4.2

Cleaning the Transfer Ribbon Drawing Roller ....................... 14

4.3

Cleaning the Pressure Roller ................................................ 15

4.4

Cleaning the Printhead .......................................................... 16

4.5

Cleaning the Label Photocell ................................................. 17

5 Replacing Components ...................................................... 19

5.1

Tools List ............................................................................... 19

5.2

Replacing the Printhead ........................................................ 20

5.3

Adjusting the Print Position ................................................... 22

5.4

Replacing the Pressure Roller ............................................... 23

5.5

Replacing the Label Photocell ............................................... 24

5.6

Replacing the CPU PCB ....................................................... 25

5.7

Replacing the Power Supply ................................................. 27

5.8

Replacing the WLAN Module ................................................ 28

5.9

Replacing the Battery ............................................................ 29

6 Adjustments, settings and alignments ............................. 31

6.1

Adjusting the print mechanism .............................................. 31

6.2

Adjusting the Printhead ......................................................... 32

6.3

Adjusting Parallelism of Printhead ......................................... 33

6.4

Adjusting Pressure of Printhead ............................................ 34

6.5

Adjusting Pressure Balance Right/Left .................................. 34

6.6

Adjusting the ribbon rewinder/unwinder ................................ 35

6.7

Adjusting the Cutter Ledge .................................................... 36

6.8

Error Correction of Cutting Edge ........................................... 37

6.9

Oil and Lubricate ................................................................... 38

7 Refitting Options ................................................................. 39

7.1

I/O Plate ................................................................................. 39

7.2

Dispensing Unit ..................................................................... 40

7.3

Cutting Unit ............................................................................ 42

8 Error correction ................................................................... 45

9 Control inputs and outputs ................................................ 55

10 Wiring Plan ........................................................................... 61

10.1

CPU Component Placement Specification ............................ 62

11 Index ..................................................................................... 63

Service Instructions 3

Vario III

11.15

1 Notes on this Document

Notes on this Document

1.1 User Notes

This service manual is intended for qualified service and maintenance staff.

This manual contains information about hardware and mechanical part of the label printers.

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

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

1.2 Instructions

Basic information and warning references with the corresponding signal words for the danger level are as follows specified in this manual:

DANGER identifies an extraordinarily great and immediate danger which could lead to serious injury or even death.

WARNING identifies a possible danger would could lead to serious bodily injury or even death if sufficient precautions are not taken.

WARNING of cutting injuries.

Pay attention that cutting injuries caused by blades, cutting devices or sharp-edged parts are avoided.

WARNING of hand injuries.

Pay attention that hand injuries caused by closing mechanical parts of a machine/equipment are avoided.

WARNING of hot surfaces.

Pay attention so as not to come into contact with hot surfaces.

CAUTION indicates a potentially dangerous situation which could lead to moderate or light bodily injury or damage to property.

NOTICE gives you tips. They make a working sequence easier or draw attention to important working processes.

Gives you tips on protecting the environment.

⇒



Date

Handling instruction

Optional accessories, special fittings

Information in the display


Notes on this Document

Item numbers

Cross references to chapters and sections

References to other documents

Vario III

1.3 Cross References

References to specific items in a figure are marked with item numbers. They are identified with parentheses in the text, e.g. (9). If no figure number is provided, item numbers in the text always refer to the graphic directly above the text. If a reference is made to another graphic, the figure number is specified, e.g. (2, in figure 5).

For a cross reference to chapters and sections, the chapter number and page number are specified, e.g. a reference to this section: see chapter 1.3.2, on page 35).

References to other documents have the following form: See

'operating manual'.

6 Service Instructions 11.15

Vario III

Workplace and method of working

Clothing

Protective clothing

Safety Instructions

2 Safety Instructions

2.1 General Safety Instructions

⇒

Keep the area around the device clean during and after maintenance.

⇒

Work in a safety-conscious manner.

⇒

Store dismantled device parts in a safe place while maintenance is being performed.

CAUTION!

The drawing in of items of clothing by moving parts can lead to injuries.

⇒

If possible, do not wear clothing which could be caught by moving device parts.

⇒

⇒

Button or roll up shirt or jacket sleeves.

Tie or pin up long hair.

⇒

Tuck the ends of scarves, ties and shawls into your clothing or secure them with non-conductive clips.

DANGER!

Risk of death from increased flow of current via metals parts which come into contact with the device.

⇒

Do not wear clothing with metal parts.

⇒

Do not wear jewellery.

⇒

Do not wear glasses with a metal frame.

If a possible danger to your eyes is present, wear protective goggles, especially in the following cases:

• when knocking in or knocking out pins and similar parts with a hammer

• when using an electric drill

• when using spring hooks

• when loosening or inserting springs, snap rings and gripping rings

• when soldering

• when using solvents, cleaning agents or other chemicals

11.15 Service Instructions 7

Safety Instructions

Protective equipment

General safety instructions

Vario III

WARNING!

Risk of injury in case of missing or faulty protective equipment.

⇒

After performing maintenance work, attach all safety equipment (covers, safety precautions, ground cables etc.).

⇒

Replace faulty parts and those which have become unusable.

The label printer is designed for power supply systems of

110-230V. Connect the print module only to electrical outlets with a ground contact.

Couple the print module to devices using extra low voltage only.

Before making or undoing connections, switch off all devices involved

(computer, printer, accessories etc.).

Operate the print module in a dry environment only and do not get it wet (sprayed water, mist etc.).

Do not operate the label printer in explosive atmosphere and not in proximity of high voltage power lines.

Operate the label printer only in an environment protected against abrasive dust, swarf and other similar impurity.

If the label printer is operated with the cover open, ensure that clothing, hair, jewellery and similar personal items do not contact the exposed rotating parts.

The print unit can get hot during printing. Do not touch the printhead during operation. Cool down the print unit before changing material, removal or adjustment.

Carry out only the actions described in these operating instructions.

Any work beyond this may only be performed by the manufacturer or upon agreement with the manufacturer.

Unauthorized interference with electronic modules or their software can cause malfunctions.

Other unauthorized work or modifications to the label printer can endanger operational safety.

Always have service work done in a qualified workshop, where the personnel have the technical knowledge and tools required to do the necessary work.

There are warning stickers on the label printer that draw your attention to dangers. Therefore the warning stickers are not to be removed as then you and others cannot be aware of dangers and may be injured.

DANGER!

Danger to life and limb from power supply!

⇒

Do not open the casing.


Vario III Safety Instructions

Qualifications of personnel

General precautions to be heeded when beginning maintenance

Additional precautions to be heeded for devices with exposed energized parts

Tools

What to do in case an accident occurs

2.2 Safety Handling When Working With Electricity

⇒

The following work may only be performed by instructed and trained electricians:

• work on the electrical assemblies

• work on the device while it is open and connected to the power supply.

⇒

Locate the emergency-stop or power switch so that it can be actuated in case of an emergency.

⇒

Unplug the device from the electrical outlet before performing the following work:

• removing or installing power supply units

• working in the immediate vicinity of exposed power supply parts

• mechanical inspection of power supply parts

• modifying the device circuits.

⇒

Ensure that the device is de-energized.

⇒

Check the workplace for possible sources of danger, e.g. moist floors, defective extension cables, faulty protective conduction connections.

⇒

Give another person the task of remaining near the workplace.

This person must be familiar with the location and operation of the emergency-stop and power switches and switch off the power if danger arises.

⇒

Use only one hand while working on electrical circuits when a device is switched on. Hold the other hand behind your back or put it in your jacket pocket.

This prevents the electricity from flowing through your body.

⇒

To not use worn or damaged tools.

⇒

Use only tools and testing equipment that is suitable for the respective task.

⇒

Proceed in a very cautions and calm manner.

⇒

Avoid endangering yourself.

⇒

Switch the power off.

⇒

Request medical help (emergency physician).

⇒

Call for first aid if necessary.


Safety Instructions Vario III

2.3 Environmentally-Friendly Disposal

Manufacturers of B2B equipment are obliged to take back and dispose of old equipment that was manufactured after 13 August

2005. As a principle, this old equipment may not be delivered to communal collecting points. It may only be organised, used and disposed of by the manufacturer. Valentin products accordingly labelled can therefore be returned to Carl Valentin GmbH.

This way, you can be sure your old equipment will be disposed of correctly.

Carl Valentin GmbH thereby fulfils all obligations regarding timely disposal of old equipment and facilitates the smooth reselling of these products. Please understand that we can only take back equipment that is sent free of carriage charges.

Further information on the WEEE directive is available on our website www.carl-valentin.de.


Vario III

I

J

H

Figure 1

11.15

Connector Pin Assignment (Printer Rear)

3 Connector Pin Assignment (Printer Rear)

A

B

C

D

E

F

1

2

1 - LED orange

1 - Lighting = Connection active

1 - Flashing = Data transfer

1 - Off = No connection

2 - LED green

2 - Lighting: Speed 100 MBit

2 - Off: Speed 10 MBit

G

A Plug-in for CF card

B USB interface

C Serial interface RS-232

Pin 2 = TXD, Pin 3 = RXD, Pin 5 = GND, Pin 7 = CTS, Pin 8 = RTS

D Ethernet 10/100 interface

E USB host for USB keyboard and USB memory stick

F Parallel interface

G Switch On/Off

H Power supply

I External output/input (option)

J Winder connection

CAUTION!

The label printer can be damaged by non-compliant winders.

⇒

Attach only winders of Carl Valentin.


Vario III

Cleaning schedule

Cleaning

4 Cleaning

DANGER!

Risk of death by electric shock!

⇒

Disconnect the label printer from power supply before performing any maintenance work.

NOTICE!

When cleaning the label printer, personal protective equipment such as safety goggles and gloves are recommended.

Cleaning task

General cleaning (see chapter

4.1, page 14).

Cleaning transfer ribbon

drawing roller (see section 4.2, page 15).

Cleaning pressure roller (see

chapter 4.3, page 15).

Frequency

As necessary.

Each time the transfer ribbon is changed or when the printout is adversely affected.

Each time the label roll is changed or when the printout and label transport are adversely affected.

Cleaning printhead (see chapter

4.4, page 16).

Each time the transfer ribbon is changed or when the printout is adversely affected.

Cleaning label photocell (see

chapter 4.5, page 17).

When exchanging the label roll.

NOTICE!

The handling instructions for the use of Isopropanol (IPA) must be observed. In the case of skin or eye contact, immediately wash off the fluid thoroughly with running water. If the irritation persists, consult a doctor. Ensure good ventilation.


Cleaning Vario III

WARNING!

Risk of fire by easily inflammable label soluble!

⇒

When using label soluble, dust must be completely removed from the label printer and cleaned.

4.1 General Cleaning

CAUTION!

Abrasive cleaning agents can damage the label printer!

⇒

Do not use abrasives or solvents to clean the outer surface of the label printer.

⇒

Remove dust and paper fuzz in the printing area with a soft brush or vacuum cleaner.

⇒

Clean outer surfaces with an all-purpose cleaner.

4.2 Cleaning the Transfer Ribbon Drawing Roller

A soiled print roll can lead to reduced print quality and can affect transport of material.

1. Open printer cover.

2. Remove transfer ribbon from the label printer.

3. Remove deposits with roller cleaner and a soft cloth.

4. If the roller appears damaged, replace it.


Vario III Cleaning

4.3 Cleaning the Pressure Roller

A soiled pressure roller can lead to reduced print quality and can affect transport of material.

CAUTION!

Pressure roller can be damaged!

⇒

Do not use sharp or hard objects to clean the pressure roller.

A B C

Figure 2


2. Turn lever (C) counter clockwise to lift up the printhead (B).

3. Remove labels and transfer ribbon form the label printer.

4. Remove deposits with roller cleaner and a soft cloth.

5. Turn the roller (A) manually step by step to clean the complete roller (only possible when printer is switched off, as otherwise the step motor is full of power and the roller is kept in its position).


Cleaning Vario III

4.4 Cleaning the Printhead

Printing can cause accumulation of dirt at printhead e.g. by colour particles of transfer ribbon, and therefore it is necessary to clean the printhead in regular periods depending on operating hours, environmental effects such as dust etc.

CAUTION!

Printhead can be damaged!

⇒

Do not use sharp or hard objects to clean the printhead.

⇒

Do not touch protective glass layer of the printhead.

Figure 3


2. Turn lever (A, Figure 2) counter clockwise to lift up the printhead.

3. Remove labels and transfer ribbon from the label printer.

4. Clean printhead surface with special cleaning pen or a cotton swab dipped in pure alcohol.

5. Allow printhead to dry for 2-3 minutes before commissioning the printer.


Vario III Cleaning

4.5 Cleaning the Label Photocell

CAUTION!

Label photocell can be damaged!

⇒

Do not use sharp or hard objects or solvents to clean the label photocell.

The label photocell can become dirtied with paper dust and this can adversely affect label detection.

A

B

Figure 4


2. Turn lever (A, in Figure 2) counter clockwise to lift up the

printhead.


4. Blow out the photocell (A) with pressure gas spray.

Observe strictly the instructions on the spray can!

5. Clean the label photocell (A) additionally with a cleaning card (B) before soaked in pure alcohol. Move the cleaning card from one side to the other (see illustration).

6. Reload labels and transfer ribbon.


Vario III Replacing Components

5 Replacing Components

DANGER!

Risk of death via electric shock!

⇒

Before opening the housing cover, disconnect the device from the mains supply and wait approx. 2 - 3 minutes until the power supply unit has discharged.

5.1 Tools List

Some service work requires the following tools:

• Philips-head screwdriver, size 1

• Slot screwdriver, size 1

• Hexagonal wrench 2.5 mm

• Flat wrench size 0.5


Replacing Components

5.2 Replacing the Printhead

NOTICE!

The printhead (4) is preinstalled on a head plate (1) and aligned at the factory.

Vario III

A B

C

20

E

D

Figure 5

A Head plate

B Plug connection signal

C Plug connection tension

D Printhead

E Focal line

CAUTION!

The printhead can be damaged by static electricity discharges and impacts!

⇒

Set up printer on a grounded, conductive surface.

⇒

Ground your body, e.g. by wearing a grounded wristband.

⇒

Do not touch contacts on the plug connections (B, C).

⇒

Do not touch printing line (E) with hard objects or your hands.

11.15 Service Instructions


A

A

B

Removing the printhead

Installing the printhead

11.15

D E E D C

Figure 6


2. When printhead is closed, loosen the screws (D).

3. Turn lever (B) counter clockwise to lift up the printhead.

4. If the printhead (C) is not disengaged on the pressure roller, continue loosen the screws (D).

5. Remove the printhead carefully to the front until you can reach the plug connections.

6. Remove plug connections and then remove printhead (C).

1. Attach plug connections.

2. Position printhead in printhead mounting bracket in such a way that the pin is secured in the corresponding hole in the head plate.

3. Lightly keep printhead mounting bracket on the printer roller with one finger and check for correct positioning of the printhead.

4. Tighten again screws (D).

5. Reload labels and transfer ribbon.

6. Check resistance value on the type plate of printhead and if necessary change the value in the Service functions/heater

resistance.

7. Check the position of printout and if necessary adjust the print

position (see chapter 5.3).



Zero point adjustment in Y direction

Zero point adjustment in X direction

Vario III

5.3 Adjusting the Print Position

Press key to access the function menu.

Press key as long as you arrive the Service Functions menu.

Press key to select the menu.

Press key

adjustment.

as long as you arrive the menu item Zero point

Indication of value in 1/100 mm.

After replacing the printhead - the print cannot be continued at the same position on the label, the difference can be corrected in printing direction.

NOTICE!

The value for zero point adjustment is set ex works. After replacing the printhead, only service personnel are allowed to set this value anew.

Press key to arrive the next menu item.

Indication of value in 1/100 mm.

After replacing the printhead - the print cannot be continued at the same position on the label, the difference can be corrected across the printing direction.

NOTICE!

The value for zero point adjustment is set ex works. After replacing the printhead, only service personnel are allowed to set this value anew.


Vario III

5.4 Replacing the Pressure Roller


A

B

C

Removing the pressure roller

Installing the pressure roller

D G F E D

Figure 7

1. Turn lever (A) counter clockwise to lift up the printhead.

2. Remove labels and transfer ribbon from the printer.

3. Lift up approx. 3 - 4 mm the pins of the two-parts plastic rivet (D) with help from a tweezers or a small screwdriver. After pulling 2 rivets (D) the front plate (E) can be removed.

4. Unscrew 2 screws (C) at the bearing cover (B) and then remove the bearing cover (B).

5. Remove pressure roller (F) from the striker arm (G).

1. Press the pressure roller (F) into the striker arm (G).

Pay attention to the correct position of striker arm pins of the pressure roller (F).

2. Mount the bearing cover (B) with 2 screws (C) to the bottom side of sole plate.

3. At reassembly pay attention to a precise fitting of the pressure roller (F).

4. Remove the possible axial play of the pressure roller by interlocking the striker arm (G) and the mounted pressure roll (F).

5. Insert the pins of the plastic rivets (D) and install again the front plate (E).


Replacing Components Vario III

5.5 Replacing the Label Photocell

NOTICE!

Soiling of the label photocell can also cause malfunctions.

Before replacing the label photocell, check whether it is soiled

and clean it if necessary (see chapter 4.5, on page 17).

Removing label photocell

Installing the label photocell

24

A

B

C

D

Figure 8

1. Remove media from the printer.

2. Remove left printer cover.

Loosen two screws at the lower left printer edge and two screws at the chassis upper edge.

3. Remove the protective conductor at the inside of the printer cover.

4. Pull out the plug of the photocell connecting cable from the plug housing ST22 on the CPU.

5. Remove the cap (C) of the profile (A) with a screwdriver.

6. Loosen the red knurled knob (D) and pull the complete photocell unit outwards.

1. Guide the photocell cable through the aperture in the chassis.

2. Insert the photocell unit (B) from the cover side into the guiding and push up against direction of the left printer cover. Pay attention to the correct position of the sliding blocks.

3. Tighten the red knurled knob (D).

4. Apply again the cap (C) of the profile.

5. Connect the plug of the photocell connecting cable with the plug housing ST22 onto the CPU.

6. Connect the protective conductor to the inside of cover.

7. Install the left printer cover.

8. Adjust the label photocell.

Service Instructions 11.15

Vario III

A

A

A

A

5.6 Replacing the CPU PCB


B

B

Removing the

CPU PCB

Figure 9

1. If possible, save the printer configuration to a Compact Flash card.

2. Unplug the printer from the electrical outlet.




5. Detach all interface cables from the back of the printer.

6. Remove the memory card from the slot.

7. Unplug all side plug connections from the CPU PCB.

8. Remove the 4 screw bolts (A) at the parallel interface and 2 fixing bolts (B) from the CPU PCB.

9. Carefully remove the CPU PCB.



Installing the

CPU PCB

Vario III

1. Place CPU PCB into the printer.

2. Secure PCB to the chassis with the 4 screw bolts (A) and 2 fixing screws (B).

3. Insert all plug connections on the PCB.

4. Restore all interface connections on the back of the printer.


6. Mount again the left printer cover.

7. Connect the power cable at the rear of the printer.

8. Update the firmware if necessary.

9. Adjust the label photocell.

10. Load the printer configuration from the memory card if possible.

Otherwise, set the printer configuration via the operating panel.


Vario III

5.7 Replacing the Power Supply


A

Removing the power supply

Installing the power supply

11.15

C B B

Figure 10





4. Unplug all cable connections from power supply (A).

5. Remove 2 fixing screws (B) onto the printer bottom side.

6. Remove the power supply unit (A).

7. Unscrew 2 fixing screws at the power supply cover (C).

8. Remove the power supply cover (C) with isolation foil from the power supply (A).

1. Insert the power supply cover (C) with isolation foil above the new power supply (A).

2. Install the power supply cover (C) with 2 fixing screws at the power supply (A).

3. Insert the new power supply (A) and fix it with the screws (B).

CAUTION!

Jamming of lines can cause short-circuits.

⇒

Do not jam lines under the power supply.

4. Connect all cable connections to the appropriate plug-in positions.


6. Mount again the left printer cover.



5.8 Replacing the WLAN Module

B

Removing the

WLAN module

Installing the

WLAN module

Vario III

B

CPU

D

E

F

G

A

D

I

L

B

H

H

C

F

J

K

G

K

Figure 11


2. Screw off the left printer cover.

3. Remove the CPU PCB (see chapter 5.6, page 25).

4. Remove hot melt glue from WLAN module (J) and then remove antenna cable (B) from WLAN module (J).

5. Remove connecting cable (L) from WLAN adapter (E).

6. Loosen screws (G) and washers (F) and dismount the WLAN adapter (E).

7. Dismount screws (K), spacer rings (H) and hex nuts (D) and remove WLAN module (J) from WLAN adapter (E).

1. Insert the new WLAN module (J) to the WLAN adapter (E) and fix it with screws (K), spacer rings (H) and hex nuts (D) at the WLAN adapter (E).

2. Mount the WLAN adapter (E) with screws (G) and washers (F) at the hexagon bolts (C).

3. Insert connection cable (L) in the WLAN adapter (E).

4. Connect antenna cable (B) with WLAN module (J) and fix the plug connectors with a drop of hot melt glue.

5. Install the CPU PCB (see chapter 5.6, pagee 25).

6. Install the left printer cover.



5.9 Replacing the Battery

DANGER!

Danger of explosion when exchanging the battery improper.

⇒

Pay attention to polarity.

A

Figure 12

1. Lift up the fixing bracket by means of a non-metallic device (e.g. plastic ruler).

2. Remove the battery.

3. Insert a new battery (CR 2032) into the support (A) and pay attention to position of polarity.

NOTICE!

The battery is responsible for the current supply of the real-time clock. After changing the battery the clock is to be set anew in menu Date/Time.


Vario III Adjustments, settings and alignments

6 Adjustments, settings and alignments

DANGER!


⇒


6.1 Adjusting the print mechanism

Major adjustment of the printing mechanism beyond format-based settings is only required if the printhead assembly has been removed or parts in this area have been replaced. Excluded from this is the replacement of the printhead, after which readjustment is generally not required.

The following print quality imperfections may indicate maladjustment of the printing mechanism:

• Print image too light

• Print image is spotty

• Print image lighter on one side

• Horizontal lines not parallel to the horizontal label edges

• Clear lateral drift of the transfer ribbon

NOTICE!

Print image errors can also arise from wrinkling of the transfer ribbon. This is why the transfer ribbon feed path and the head locking system should be checked before making adjustments to the printing mechanism (see 'operating manual').


Adjustments, settings and alignments

6.2 Adjusting the Printhead

Vario III

CAUTION!

The printhead assembly can be damaged.

Attempting to adjust the printhead when the fixing screw (D) is tight can lead to defects at the printhead assembly.

⇒

Always loosen the fixing screw (D) before adjusting the printhead.

Complete the following printhead settings to achieve the best possible print image:

⇒

Align the heating line with the highest point of the print roller.

Density of the print image is the greatest at this point.

⇒

Set the parallelism of horizontal lines with the edge of the label.

NOTICE!

Open and close the printhead locking device after each step of the adjustment.



6.3 Adjusting Parallelism of Printhead

A

A

B

D E

Figure 13

E D C

NOTICE!

An important characteristic for a high quality print is the parallelism of the focal line of the thermal printhead to the pressure roll. Because of the fact that the position of focal line of the printhead depends on fluctuations caused by production, it is necessary to adjust the parallelism.

1. Loosen the screws (D) with a hexagon key by approx. ¼ rotations.

2. Adjust the parallelism with the adjusting screws (E).

Clockwise = printhead moves forwards

Counter clockwise = printhead moves backwards

3. Adjust the parallelism as long as the printing result comes up to your full expectation.

4. Tighten again screws (D).

5. Start a print order with approx. 10 labels and control the correct passage of transfer ribbon.



6.4 Adjusting Pressure of Printhead

Vario III

CAUTION!

Damage of printhead by unequal use!

⇒

Change factory settings only in exceptional cases.

NOTICE!

Increasing the head contact pressure leads to an improvement of the print image density on the corresponding side and to a shifting of the ribbon feed path in the corresponding direction.

The selection of the smallest value can optimise the life cycle of printhead.

1. Turn pressure screws (A, Figure 13) to change the pressure of

printhead.

2. Turning the pressure screws (A, Figure 13) in clockwise direction

results in a pressure increase.

3. Turning the pressure screws (A, Figure 13) counter clockwise

results in a pressure decrease.

6.5 Adjusting Pressure Balance Right/Left

NOTICE!

After adjusting parallelism and no even strong pressure exists over the complete print width, use the eccentric (A) to set the balance.

A B

1. Loosen screw (B) with a screwdriver by approx. ¼ turn.

2. Turn the eccentric pin (A) in order to obtain a pressure balance. Adjust as long as the printout is perfect for the complete print width.

3. Tighten again screw (B).

34

Figure 14



6.6 Adjusting the ribbon rewinder/unwinder

11.15

A B

Figure 15

Due to the many different transfer ribbon variants regarding roller width, length and qualities it is necessary to provide the possibility to set transfer ribbon tension.

The transfer ribbon tension is to set in such way that no wrinkles in the ribbon appear but it is transported in the same way as the labels.

When using a too high ribbon tension this results usually in an excellent run of the transfer ribbon but this could lead to streaks onto the label or to a rip of ribbon particularly with narrow roles.

Ex factory the role tension is set to a transfer ribbon 110 mm width and standard quality. As approximate values for the factory setting the following can be accepted:

Transfer ribbon unwinder:

Distance of screw head (B) to roller face (A) = 2 mm

Transfer ribbon rewinder:

Distance of screw head (B) to roller face (A) = 4 mm

Tighten hex. head screw (B) = Increasing transfer ribbon tension

Loosen hex. head screw (B) = Reducing transfer ribbon tension

35 Service Instructions


6.7 Adjusting the Cutter Ledge

Vario III

CAUTION!

Risk of injury, particularly during maintenance, the cutter blades are sharp!

⇒

Switch off the before attaching the cutter!

⇒

The cutter may only be used when it is mounted on the printer!

⇒

Do not try to cut any materials which exceed the maximum width or thickness specifications.

⇒

Do NOT touch the area of the moving blades!

36

Figure 16

1. Remove 2 countersunk screws at the front plate and hang front plate out.

2. Unscrew screw (C) and remove front shaft.

3. Loosen counter nut on the rear of the adjusting screw (B).

4. Insert a piece of paper or labels between the lower plate (A) and fix cutter ledge. Move by hand the flexible cutter ledge (D) carefully upwards and control the cut.

The cutter has to start cutting approx. 5 mm from the left edge (of the fix cutter ledge).

5. Tighten counter nut on the rear of the adjusting screw (B).

6. Install front shaft and front plate.

7. Press key to test the cutter function.



6.8 Error Correction of Cutting Edge

If the cut is too far right please follow the steps:

1. Move the flexible cutter ledge (D) to the front.

2. Turn the adjusting screw (B) in clockwise direction until the correct value is reached.

3. Close again the cutter ledge.

4. Screw again the counter nut at the rear of the adjusting screw (B).

5. Install the front shaft and the front plate.


If the flexible cutter ledge (D) pushes from bottom to the fix cutter ledge please follow the steps:

1. Move the flexible cutter ledge (D) to the front.

2. Turn the adjusting screw (B) counter clockwise direction until the correct value is reached.

3. Screw again the counter nut at the rear of the adjusting screw (B).

4. Install the front shaft and the front plate.




6.9 Oil and Lubricate

Vario III

NOTICE!

Make sure when oiling and greasing that no lubricants deposit on photocells, electronic components, circuit boards, printhead and rolls.

Fett / Grease

Fett / Grease

Fett / Grease

Dünnflüssiges Öl

Low viscosity oil

Fett / Grease

Figure 17

Fett / Grease

In case that dust or other dirt is deposit you have to clean the lubrication at first with alcohol.

Apply rather in regular intervals (1-2 per year) a bit of lubricant, as only rarely too much. Otherwise the surplus of lubricant could settle on neighbouring components and disturb the functions.

In case those components should have run it because of lack of lubricant, exchange these as soon as possible so the functions of the components and the printer remain.

Install again all components which you have dismantled for the lubrication in the correct position.

Take care e.g. tensions of belt, springs etc.

Dünnflüssiges Öl

Low viscosity oil

Figure 18


Vario III Refitting Options

7 Refitting Options

DANGER!


⇒


7.1 I/O Plate

E

E

11.15

A

B

A

C

D

C

D

Figure 19

1. Remove the CPU PCB (see page 25).

2. Remove cover at the interface disruption from the chassis rear.

3. Screw hexagonal pillar (A) in the corresponding thread bolt at the chassis inside.

4. Install the I/O plate with fixing screws (E) at the disruption of chassis rear. Fix the I/O plate with cross-drive screws (D) and washers (C) onto the hexagonal pillars (A).

5. Insert the connecting cables for inputs/outputs corresponding to

the wiring plan (see chapter 9, page 55) into the appropriate plug-

in positions of the I/O plate.

6. Install the CPU PCB (see page 26).


Refitting Options

Dispensing unit without photocell

7.2 Dispensing Unit

Vario III

A

B

C

Figure 20

1. Remove winding plate (if mounted) and the subjacent square-end at the printer front.

2. Open the dispenser whip by pulling the dispenser axe to the left.

3. Mount the dispenser unit (B) with the enclosed screws (A + C) at the printer.

4. Engage again the dispensing whip.


Vario III

Dispensing unit with photocell

Refitting Options

11.15

A

B

C

Figure 21





4. Open the dispenser whip by pulling the dispenser axe to the left.

5. Place the dispenser unit (B) before the pressure roller. Guide the photocell cable through the visible chassis hole.

6. Mount the dispenser unit (B) with the enclosed screws (A + C) at the printer.

7. Insert the photocell cable corresponding to the wiring plan (see

chapter 9, page 55) into the appropriate plug-in positions of the

dispensing photocell.

8. Engage again the dispensing whip.

9. Connect the protective conductor to the inside of printer cover.

10. Mount again the printer cover.


Refitting Options Vario III

7.3 Cutting Unit

CAUTION!

Risk of injury, particularly during maintenance, the cutter blades are sharp!

⇒

Switch off the before attaching the cutter!

⇒

The cutter may only be used when it is mounted on the printer!

⇒

Do not try to cut any materials which exceed the maximum width or thickness specifications.

⇒

Do NOT touch the area of the moving blades!

42

A B C A D E E

Figure 22





4. Place the cutting unit before the printer and guide the connection cable through the visible chassis hole.


Vario III Refitting Options

F

G

H

G

Figure 23

5. Fix the cutting unit with the sole plates onto the spacer shafts (E).

6. Press the cutting unit onto the spacer shafts (E) backwards until it engages into the spacer shafts. For this purpose press the cutting unit a bit downwards.

7. Fix the cutting unit with the enclosed screws at the printer.

8. Insert front shaft into boring of the left sole plate of the cutting unit and fix with the screw at the printer.

9. Put the front plate (C) into the spacer shaft (D). Swing the front plate upwards and fix it with the enclosed screws (A) to the front shaft.

10. Mount the motor plate (H) with the washers and screws (G) at the printer chassis.

11. Insert the cutter cable and connection cable corresponding to the

wiring plan (see chapter 10, page 61) into the appropriate plug-in

positions of the PCB.

12. Connect the protective conductor to the inside of printer cover.

13. Mount again the printer cover.

14. Insert the protective plate on the spacer shaft (E) at the printer front.


Vario III Error correction

Error message

1 Line too high

2

3

4

5

6

7

8

9

Line too low

Character set

Unknown code type

Unvalid position

CV font

Vector font

Measuring label

No label found

10 No ribbon

11 COM FRAMING

12 COM PARITY

13 COM OVERRUN

8 Error correction

Cause

Line rises up completely or partly over the upper edge of label.

Line rises up completely or partly over the bottom edge of label.

Remedy

Move line down (increase Y value).

Check rotation and font.

Move line up (reduce X value).

Check rotation and font.

One res. several characters of the text is res. are not available in the selected font.

Change text.

Change font.

Selected code is not available. Check code type.

Selected position is not available.

Check position.

Selected font is not available.

Selected font is not available.

While measuring no label was found.

Set label length is too large.

No label available.

Soiled label photocell.

Labels not inserted correctly.

During the print order the ribbon roll becomes empty

(front printhead).

Defect at the transfer ribbon photocell (front photocell).

Stop bit error.

Check font.

Check font.

Check label length and if labels are inserted correctly.

Restart measuring anew.

Insert new label roll.

Check if labels are inserted correctly.

Clean the label photocell.

Change transfer ribbon.

Check transfer ribbon photocell

(service functions).

Parity error.

Loss of data at serial interface

(RS-232).

Check stop bits.

Check baud rate.

Check cable (printer and PC).

Check parity.

Check baud rate.


Check baud rate.



Error correction Vario III

Error message

14 Field numer

15 Length mask

16 Unknown mask

17 Missing ETB

Cause Remedy

Received line number is invalid at RS-232 and parallel interface.

Check sent data.

Check connection PC - printer.

Invalid length of received mask statement.

Check sent data.


Transferred mask statement is invalid.

No end of data found.

Check sent data.


Check sent data.


18 Invalid character One res. several characters of the text is res. are not available in the selected font.

Change text.

Change font.

19 Invalid statement

Unknown transferred data record.

20 Invalid check digit For check digit control the entered res. received check digit is wrong.

21 Invalid SC number

Check sent data.


Calculate check digit anew.

Check code data.

Selected SC factor is invalid for

EAN res. UPC.

Check SC factor.

22 Invalid number of digits

23 Check digit calculation

24 Invalid extension

25 Offset sign

Entered digits for EAN res.

UPC are invalid

< 12; > 13.

Check number of digits.

Selected check digit calculation is not available in the bar code.

Check calculation of check digit.

Check bar code type.

Check zoom factor. Selected zoom factor is not available.

Entered sign is not available. Check offset value.

26 Offset value

27 Printhead temperature

28 Cutter error

29 Invalid parameter

Entered offset value is invalid. Check offset value.

Printhead temperature is too high.

Defective printhead sensing device.

Reduce contrast.

Change printhead.

With cut an error occurred.

Paper jam.

Check label run.

Check cutter run.

Entered data do not correspond to the characters allowed from the application identifier.

Check code data.


Vario III

Error message

30 Application

Identifier

31 HIBC definition

Error correction

32 System clock

33 No CF interface

34 No print memory

35 Printhead open

36 BCD invalid format

37 BCD overflow

38 BCD division

39 FLASH ERROR

40 Length command

41 No drive

42 Drive error

43 Not formatted

44 Delete current directory

45 Path too long

Cause Remedy

Selected application identifier is not available in GS1-128.

Check code data.

Check definition of HIBC code. F Missing HIBC system sign.

Missing primary code.

Real Time Clock function is selected but the battery is empty.

Defective RTC.

Interrupted connection CPU -

CF card.

Defective CF card interface.

No print CF found.

Change battery.

Change RTC component.

Check connection CPU - CF card interface.

Check CF card interface.

Check CF assembly on CPU.

Close the printhead and start print order anew.

Check entered format.

At start of a print order the printhead is open.

BCD error

Invalid format for the calculation of Euro variable.

BCD error


BCD error


Flash component error.



Invalid length of the received command statement.

Run a software update.

Change CPU.

Check data sent.


Insert CF card correctly. CF card not found / not correctly inserted.

Impossible to read CF card

(faulty).

CF Card not formatted.

Check CF card, if necessary change it.

Format CF card.

Change directory. Attempt to delete the actual directory.

Too long indication of path. Indicate a shorter path.

11.15 47 Service Instructions


Error message

46 Drive writeprotected

Cause Remedy

Memory card is write-protected. Deactivate write protection.

47 Directory not file

54 File/directory exists

Correct your entry.

48 File already open

49 No file/directory

50 Invalid file name

51 Internal file error

52 Root full

Attempt to change a file during an access is active.

Select another file.

File does not exist on CF card. Check file name.

File name contains invalid characters.

Internal file system error.

The max. number (64) of main directory entries is reached.

Correct entry of name, remove special characters.

Please contact your distributor.

Delete at least one main directory entry and create subdirectories.

53 Drive full

Attempt to indicate a directory as file name.

Maximum CF capacity is reached.

The selected file/directory already exists.

Use new CF Card, delete no longer required files.

Check name, select a different name.

55 File too large

During copying procedure not enough memory space onto target drive available.

56 No update file

Errors in update file of firmware.

57 Invalid graphic file The selected file does not contain graphic data.

58 Directory not empty

Attempt to delete a not empty directory.

Use a larger target card.

Start update file anew.

Check file name.

Delete all files and subdirectories in the desired directory.

59 No interface

No CF card drive found.

60 No CF card No CF card is inserted.

Check connection of CF card drive.

Contact your distributor

Insert CF card in the slot.

61 Webserver error

62 Wrong FPGA

63 End position

Error at start of web server.

The direct print module is equipped with the wrong

FPGA.



The label length is too long.

The number of labels per cycle is too much.

Check label length res. the number of labels per cycle.



Error message

64 Zero point

65 Compressed air

Cause

Defective photocell.

Remedy

Change photocell.

Pressure air is not connected. Check pressure air.

66 External releaser

67 Row too long

68 Scanner

69 Scanner NoRead

70 Scanner data

71 Invalid page

External print release signal is missing.

Wrong definition of column width res. number of columns.

The connected bar code scanner signals a device error.

Check input signal.

Reduce the column width res. correct the number of columns.

Check the connection scanner/printer.

Check scanner (dirty).

Bad print quality.

Printhead completely soiled or defective.

Print speed too high.

Increase contrast.

Clean printhead or exchange (if necessary).

Reduce print speed.

Scanned data does not correspond to the data which is to print.

Exchange printhead.

As page number either 0 or a number > 9 is selected.

Select a number between 1 and 9.

72 Page selection

73 Page not defined

74 Format user guiding

Wrong format for customised entry.

75 Format date/time Wrong format for date/time.

76 Hotstart CF

A page which is not available is selected.

Check the defined pages.

The page is not defined. Check the print definition.

No CF card found.

Check the format string.

Check the format string.

If option hotstart was activated, a CF card must be inserted.

Switch off the printer before inserting the memory card.

77 Flip/Rotate

78 System file

79 Shift variable

Selection of print of several columns and also mirror/rotate.

It is only possible to select one of both functions.

Not possible. Loading of temporary hotstart files.

Faulty definition of shift times

(overlapping times).

Check definition of shift times.

80 GS1 Databar

General GS1 Databar error.

81 IGP error Protocol error IGP.

Check definition and parameter of GS1 Databar code.

Check sent data.



Error message

82 Time generation

83 Transport protection

84 No font data

Both DPM position sensors

(start/end) are active.

Displace zero point sensor

Check sensors in service functions menu

Font and web data is missing. Run a software update.

85 No layout ID

86 Layout ID

Label ID definition is missing.

Scanned data does not correspond to defined ID.

Define label ID onto the label.

Wrong label loaded from CF card.

87 RFID no label

Cause Remedy

Printing creation was still active at print start.

Reduce print speed.

Use printers' output signal for synchronisation.

Use bitmap fonts to reduce generating time.

88 RFID verify

89 RFID timeout

RFID unit cannot recognise a label.

Error while checking programmed data.

Displace RFID unit or use an offset.

Faulty RFID label.

Check RFID definitions

Error at programming the RFID label.

Label positioning.

Faulty label.

90 RFID data

91 RFID tag type

92 RFID lock

Faulty or incomplete definition of RFID data.

Check RFID data definitions.

Definition of label data does not correspond with the used label.

Check storage partitioning of used label type

Error at programming the RFID label (locked fields).

Check RFID data definitions.

Label was already programmed.

93 RFID programming

94 Scanner timeout

Error at programming the RFID label.

Check RFID definitions.

The scanner could not read the bar code within the set timeout time.

Defective printhead.

Wrinkles in transfer ribbon.

Scanner wrong positioned.

Timeout time too short.

Check printhead.

Check transfer ribbon.

Position scanner correctly, corresponding to the set feeding.

Select longer timeout time.

50 11.15 Service Instructions


Error message

95 Scanner layout difference

96 COM break

97 COM general

98 No software printhead FPGA

99 Load software printhead FPGA

100 Upper position

101 Lower position

102 Vacuum plate empty

103 Start signal

104 No print data

105 Printhead

106 Invalid Tag type

107 RFID invalid

108 GS1-128 invalid

109 EPC parameter

Cause

Scanner data does not correspond to bar code data.

Serial interface error.

Serial interface error.

Remedy

Check adjustment of scanner.

Check scanner settings / connection.

Check settings for serial data transmission as well as cable

(printer-PC).

Check settings for serial data transmission as well as cable

(printer-PC).

No printhead-FPGA data available.

Error when programming printhead-FPGA.

Sensor signal up is missing

(option APL 100).

Please contact your responsible distributor.


Check input signals / compressed-air supply.

Sensor signal down is missing

(option APL 100).


Sensor does not recognise a label at vacuum plate

(option APL 100).

Print order is active but device not ready to process it.


Check start signal.

Print data outside the defined label.

Selection of wrong module type

(design software).

Check selected module type.

Check selection of left/right version.

No original printhead is used. Check the used printhead.

Contact your distributor.

Wrong Tag type.

Tad data do not match the Tag type in the printer.

Adapt data or use the correct

Tag type.

RFID module is not activated.

No RFID data can be processed.

Activate RFID module or remove RFID data from label data.

Transferred GS1-128 bar code is invalid.

Verify bar code data (see GS1-

128 bar code specification).

Error at EPC calculation. Verify data (see EPC specification).


Error correction

Error message

110 Housing open

111 EAN.UCC code

112 Print carriage

113 Applicator error

114 Left position

115 Right position

116 Print position

117 XML parameter

118 Invalid variable

119 No ribbon

120 Wrong directory

121 No label found

122 IP occupied

Vario III

Cause Remedy

When starting the print order the housing cover is not closed.

Close the housing cover and start the print order anew.

Transferred EAN.UCC code is invalid.

Printing carriage does not move.

Error while using applicator.

Left final position switch is not in correct position.

Verify bar code data (see corresponding specification).

Check gear belt (possibly broken).

Check applicator.

Check LEFT final position switch for correct function and position.

Check function of pneumatics for cross traverse.

Right final position switch is not in correct position.

Check RIGHT final position switch for correct function and position.

Check function of pneumatics for cross traverse.

The print position is not correct. Check TOP and RIGHT final position switch for correct function and position.

Check pneumatics for function

The parameters in the XML file are not correct.


Transferred variable is invalid with customized entry.

During the print order the ribbon roll becomes empty

(rear printhead).

Defect at the transfer ribbon photocell (rear photocell).

Invalid target directory when copying.

Select correct variable without customized entry and transfer it.


Check transfer ribbon photocell

(service functions).

No label found at the rear printhead (DuoPrint).



The IP address was already assigned.

Target directory must not be within the source directory.

Check target directory.




Assign a new IP address.


Vario III

Error message

123 Print asynchronous

124 Speed too slow

125 DMA send buffer

Error correction

Cause Remedy

The label photocell do not work in the order as it is expected according to print data.

Check label size and gap size.

Check label photocell settings. The settings of the photocell are not correct.

Settings of label size and gap size are not correct.

No label found at the rear printhead.

Check correct loading of label material.




Print speed is too slow.



Increase the speed of customers' machine.

Communication problem HMI. Restart the printer.

126 UID conflict

127 Module not found

128 No release signal

129 Wrong firmware

Configuration RFID programming faulty.

Run RFID initialising.

RFID module not available. Check the RFID module connection.


No print release by higher-level control (customer machine).

Activate release signal at the higher-level control.

Firmware does not match the used printer type.

Use firmware that fits to the printer type.


130 Language missing

131 Wrong material

132 Invalid mark-up tag

133 Script not found

Language file for the set printer language is not available.


Label material does not fit to printing data.

Invalid mark-up formatting characters in text.

User label material with suitable label and/or gap length.

Correct the formatting characters in the text.

LUA script file not found. Check the file name.

11.15 53 Service Instructions


Error message

134 Script failure

Cause

LUA script is incorrect.

Remedy

Check the script.

135 Script user error Error in LUA script user input. Correct the input value.

136 No reprint available No label data for reprinting available.

137 Printhead short circuit

138 Too little ribbon

Send new label data to the printer.

Electrical short at the printhead. Check the used printhead.

Transfer ribbon ends.




Vario III

Printer, internal circuitry

Control inputs and outputs

9 Control inputs and outputs

By means of a maximum of 16 control inputs and outputs which, in the following, are also referred to as ports, different functions of the printer system can be triggered and operating states can be displayed.

The ports are provided by means of a D-Sub bushing (26pin HD) at the rear panel of the printer system and are galvanically isolated from protective earth (PE) by means of an optocoupler semi-conductor route.

Each port can be configured as input and as output. This function however, is predefined in the printer software and cannot be changed by the user.

The following parameters can be changed and set by using the menu: debounce times and high or low active.

11.15

Figure 24



Configuration of

D-Sub socket

Vario III

Figure 25

Port 1 to Port 16 = Assignment for I/O Profile 'Std_Label'

Identification Pin Description / Function

Port 1

Port 2

Port 3

Port 4

10

1

11

2

Print start and cut (Input)

Reprint last printed label (Input)

Counter Reset (Input)

Option applicator only: Start application (Input)

Port 5

Port 6

Port 7

Port 8

Port 9

Port 10

12

3

13

4

15

6

Error reset (Input)

Cancel all print jobs (Input)

Label end sensor (Input)

External release signal (Input)

Error (Output)

Print order activ (Output)

Port 11

Port 12

Port 13

Port 14

Port 15

Port 16

COM/VDC for Inputs

VDC for

Outputs

COM for

Outputs

GND-PE

16

7

17

8

18

9

19

20

5,14

21,22

23,24

Dispenser photocell: Label exists at dispenser photocell (Output)

Single print (Output)

Ready (Output)

Option applicator only: Ready for application (Output)

Option scanner only: Bar code not readable (Output)

Prior warning for transfer ribbon end (Output)

Common reference potential of all control inputs. 'COM/VDC for

Inputs' is usually connected with the (-) terminal of the control voltage and the control inputs are switched to active (+).

By means of the option '2nd LED', 'COM/VDC for Inputs' can optionally be connected with the (+) terminal of the control voltage.

Then, the control inputs are switched to active (-).

Common supply connection of all control outputs. 'VDC for Outputs' must be connected with the (+) terminal of the control voltage.

Never leave 'VDC for Outputs' open even if no output is used.

Common reference potential of all control outputs. 'COM for Outputs' must be connected with the (-) terminal of the control voltage.

Never leave 'COM for Outputs' open even if no output is used.

'GND-PE' is the reference potential of the '+5 VDC EXT' and '+24

VDC EXT' voltages provided by the printer system.

'GND-PE' is printer internally connected with protective earth (PE).


Vario III

Identification Pin

+ 5 VDC

EXT

25

+ 24 VDC

EXT

Technical data

26


Description / Function

5 Volt DC output for external use. Max. 1 A.

This voltage is provided from direct print module and can be used e.g. as control voltage. Never apply any external voltage to this output.

24 Volt DC output for external use. Max. 1 A.

This voltage is provided from direct print module and can be used e.g. as control voltage. Never apply any external voltage to this output.

Plug Connector

Type D-Sub connector High Density

26-pin. / connector

Manufacturer

Reference number

W+P-Products

110-26-2-1-20

Output Voltages (connected with GND-PE)

Fuse: Polyswitch / 30 V / 1 A

Fuse: Polyswitch / 30 V / 1 A

+ 24 V / 1 A

+ 5 V / 1 A

Port 1 - 15

Input

Tension

Impedance

Output

Tension

Impedance

Current max.

5 VDC … 24 VDC

47Ω + (100nF || 10 kΩ)

5 VDC … 24 VDC

47Ω + (100nF || 10 kΩ || 47Ω)

High +15 mA

Low -15 mA

Port 16

Input

Tension

Impedance

Output

Tension

Impedance

Current max.

5 VDC … 24 VDC

100nF || 10 kΩ

5 VDC … 24 VDC

100nF || 10 kΩ

High +500 mA (Darlington BCP56-16)

Low - 500 mA (Darlington BCP56-16)

Optocoupler

Output

Input

Input

Option 2nd LED

TCMT4106, CTR 100% - 300%, Vishay or

TLP281-4(GB), CTR 100% - 600%, Toshiba


TLP281-4(GB), CTR 100% - 600%, Toshiba


TLP280-4, CTR 33% - 300%, Toshiba



Example 1

Device connection to a machine with S7-300 SPS.

Vario III

Example 2

Figure 26

Device connection to a operating panel.

58

Figure 27


Vario III

Example 3


Device connection version if 'Option: 2. LED'.

Precautions

Figure 28

When connecting a reed contact with a control input, the contact must have a switching capacity of min. 1 A in order to prevent the contact from sticking due to the inrush current. As an alternative, a suitable resistor can be connected in series.

If one of the printer’s internal voltages '+5 VDC EXT' or '+24 VDC

EXT' is used, an external fuse e.g. 0.5 AF, should be additionally installed to protect the printer electronics.

In the event of an inductive load, an antiparallel connected diode, for instance, must be used to discharge the induction energy.

In order to minimise the influence of leakage currents at control outputs, a resistor must, depending on what is connected, be installed in parallel with the load.

In order to avoid any damages to the printing system, the max. output currents must not be exceeded or outputs shorted.


Vario III

10 Wiring Plan

Wiring Plan

Figure 29


Wiring Plan

10.1 CPU Component Placement Specification

Vario III

Figure 30

Jumper plan

Boot sector

Programming

Delivery

JP1 (Debug)

closed closed

JP2 (write-protection) closed open


Vario III

11.15

Index

11 Index

A

Adjustments, settings, alignments

Cutter ledge .................................................................................... 36

Cutting edge ................................................................................... 37

Oil and lubricate .............................................................................. 38

Print mechanism ............................................................................. 31

Printhead position ........................................................................... 32

Printhead, parallelism ..................................................................... 33

Printhead, pressure ........................................................................ 34

Printhead, pressure balance ........................................................... 34

Rewinder ......................................................................................... 35

Unwinder ......................................................................................... 35

B

Battery, replacing ............................................................................... 29

C

Cleaning

Cleaning schedule .......................................................................... 13

General cleaning ............................................................................. 14

Label photocell ................................................................................ 17

Pressure roller, cleaning ................................................................. 14

Printhead ........................................................................................ 16

Component plan CPU ........................................................................ 62

Component replacing

Battery............................................................................................. 29

CPU PCB .................................................................................. 25, 26

Label photocell ................................................................................ 24

Power supply .................................................................................. 27

Pressure roller ................................................................................ 23

Printhead .................................................................................. 20, 21

Tools list .......................................................................................... 19

WLAN module ................................................................................. 28

Connector pin assignment, printer rear .............................................. 11

Control inputs and outputs ................................................................. 56

CPU

Component plan ............................................................................. 62

CPU PCB, replacing ................................................................. 25, 26

Jumper plan .................................................................................... 62

Cutter ledge, adjusting ....................................................................... 36

Cutting edge, adjusting....................................................................... 37

Cutting unit, refit ........................................................................... 42, 43

D

Dispensing unit, refit ..................................................................... 40, 41

E

Electricity, safety handling .................................................................... 9

Environmentally-friendly disposal ....................................................... 10

Error messages/Error corrections 45, 46, 47, 48, 49, 50, 51, 52, 53, 54

I

I/O plate, refit ...................................................................................... 39

Inputs/outputs ............................................................................... 55, 57

Instructions ........................................................................................... 5


Index

64

Vario III

J

Jumper plan CPU ............................................................................... 62

L

Label photocell

Cleaning .......................................................................................... 17

Replacing ........................................................................................ 24

M

Maintenance/cleaning

Ribbon drawing roller, cleaning ...................................................... 14

N

Notes

Document ......................................................................................... 5

User .................................................................................................. 5

O

Oil and lubricate ................................................................................. 38

P

Parallelism, adjusting ......................................................................... 33

Power supply, replacing ..................................................................... 27

Pressure balance, adjusting ............................................................... 34

Pressure roller

Cleaning .......................................................................................... 15

Replacing ........................................................................................ 23

Pressure, adjusting ............................................................................. 34

Print position, adjusting ...................................................................... 22

Printhead

Cleaning .......................................................................................... 16

Parallelism, adjusting ...................................................................... 33

Position, adjusting ........................................................................... 32

Pressure balance adjusting ............................................................ 34

Pressure, adjusting ......................................................................... 34

Replacing .................................................................................. 20, 21

R

Refit options

Cutting unit ................................................................................ 42, 43

Dispensing unit ......................................................................... 40, 41

I/O plate .......................................................................................... 39

Rewinder, adjusting ............................................................................ 35

S

Safety handling when working with electricity ...................................... 9

Safety instructions ................................................................................ 8

Clothing ............................................................................................. 7

Protective clothing ............................................................................ 7

Protective equipment ........................................................................ 8

Workplace ......................................................................................... 7

T

Tools list ............................................................................................. 19

U

Unwinder, adjusting ............................................................................ 35


Vario III Index

W

Wiring plan ......................................................................................... 61

WLAN module, replacing.................................................................... 28


Carl Valentin GmbH

Neckarstraße 78 – 86 u. 94 . 78056 Villingen-Schwenningen

Phone +49 7720 9712-0 . Fax +49 7720 9712-9901 [email protected] . www.carl-valentin.de

Carl Valentin Vario III label printer Service Instructions

Assistant Bot

VARIO III

1 Notes on this Document

1.1 User Notes

1.2 Instructions

1.3 Cross References

2 Safety Instructions

2.1 General Safety Instructions

2.2 Safety Handling When Working With Electricity

2.3 Environmentally-Friendly Disposal

3 Connector Pin Assignment (Printer Rear)

4 Cleaning

4.1 General Cleaning

4.2 Cleaning the Transfer Ribbon Drawing Roller

4.3 Cleaning the Pressure Roller

4.4 Cleaning the Printhead

4.5 Cleaning the Label Photocell

5 Replacing Components

5.1 Tools List

5.2 Replacing the Printhead

5.3 Adjusting the Print Position

5.4 Replacing the Pressure Roller

5.5 Replacing the Label Photocell

5.6 Replacing the CPU PCB

5.7 Replacing the Power Supply

5.8 Replacing the WLAN Module

5.9 Replacing the Battery

6 Adjustments, settings and alignments

6.1 Adjusting the print mechanism

6.2 Adjusting the Printhead

6.3 Adjusting Parallelism of Printhead

6.4 Adjusting Pressure of Printhead

6.5 Adjusting Pressure Balance Right/Left

6.6 Adjusting the ribbon rewinder/unwinder

6.7 Adjusting the Cutter Ledge

6.8 Error Correction of Cutting Edge

6.9 Oil and Lubricate

7 Refitting Options

7.1 I/O Plate

7.2 Dispensing Unit

7.3 Cutting Unit

8 Error correction

9 Control inputs and outputs

10 Wiring Plan

10.1 CPU Component Placement Specification

11 Index

A

B

C

D

E

I

J

L

M

N

O

P

R

S

T

U

W

Key Features

Frequently Answers and Questions

How do I clean the printhead?

What tools do I need to replace the pressure roller?

How do I adjust the cutter ledge?

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