Carl Valentin COMPA II User manual

COMPA II
Service Instructions

Copyright by Carl Valentin GmbH / 7952025B.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
[phone]
[phone]
E-Mail
Internet
[email protected]
www.carl-valentin.de

Compa II series Table of contents
11.15 Service instructions 3
Table of contents
Table of contents.............................................................................. 3
1Notes on this document ....................................................... 5
1.1User notes ............................................................................... 5
1.2Warnings ................................................................................. 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
3Printer Rear (Ports) ............................................................. 10
4Cleaning ............................................................................... 11
4.1General cleaning ................................................................... 12
4.2Cleaning the print roller ......................................................... 12
4.3Cleaning the printhead .......................................................... 12
4.4Cleaning the label photocell .................................................. 13
5Replacing components....................................................... 15
5.1Tool list .................................................................................. 15
5.2Replacing the printhead ........................................................ 15
5.3Adjusting the Print Position ................................................... 17
5.4Replacing the print roller and rewind assist roller ................. 18
5.5Replacing the slipping clutches ............................................. 19
5.6Replacing the label photocell ................................................ 21
5.7Replacing the CPU PCB ....................................................... 22
5.8Replacing the power supply unit ........................................... 23
5.9Replacing the WLAN module ................................................ 24
5.10Replacing the printhead FPGA.............................................. 25
5.11Replacing the battery ............................................................ 25
5.12Replacing the safety fuse ...................................................... 26
6Adjustments, settings and alignments ............................. 27
6.1Adjusting the winding torques ............................................... 27
6.2Measuring the winding torques at ribbon rewinder/unwinder 28
6.3Measuring the torques at the internal rewinder..................... 29
6.4Setting the winding torque..................................................... 30
6.5Adjusting the print mechanism .............................................. 31
6.6Adjusting the position of printhead ........................................ 33
6.7Adjusting the head contact pressure..................................... 34
6.8Adjusting the transfer ribbon feed path ................................. 35
6.9Adjusting the belt tension at main drive motor ...................... 36
6.10Adjusting the head switch...................................................... 37
7Refitting options.................................................................. 39
7.1I/O plate ................................................................................. 39
7.2Internal rewinder.................................................................... 40
7.3Cutter..................................................................................... 41
8Error correction................................................................... 43
9Control inputs and outputs ................................................ 53
10Wiring plan........................................................................... 59
10.1CPU component placement specification ............................. 60
11Environmentally-Friendly Disposal................................... 61
12Index ..................................................................................... 63

Compa II series Notes on this document
11.15 Service instructions 5
1 Notes on this document
1.1 User notes
This service manual is intended for qualified service and maintenance
staff.
This manual contains information about hardware and mechanical
part of the label printers 103/8 T, 104/8, 106/12, 106/24, 108/12 T,
162/12 and 162/12 T.
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 dealer.
1.2 Warnings
Warnings are presented with three signal words for the different levels
of danger.
DANGER identifies an extraordinarily great and immediate danger
which could lead to serious injury or even death.
WARNING identifies a possible danger would could lead to serious
bodily injury or even death if sufficient precautions are not taken.
CAUTION indicates a potentially dangerous situation which could lead
to moderate or light bodily injury or damage to property.
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.

Notes on this document Compa II series
6 Service instructions 11.15
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'.
Item numbers
Cross references to
chapters and sections
References to other
documents

Compa II series Safety instructions
11.15 Service instructions 7
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.
WARNING!
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.
Workplace and
method of working
Clothing

Safety instructions Compa II series
8 Service instructions 11.15
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 spring hooks
when loosening or inserting springs, snap rings and gripping rings
when soldering
when using solvents, cleaning agents or other chemicals
WARNING!
Risk of injury in case of missing or faulty protective
equipment.
After performing maintenance work, attach all safety
equipment (covers, safety precautions, ground cables
etc.).
Replace faulty parts and those which have become
unusable.
Protective clothing
Protective equipment

Compa II series Safety instructions
11.15 Service instructions 9
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.
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

Compa II series Printer Rear (Ports)
11.15 Service instructions 10
3 Printer Rear (Ports)
Figure 1
1 = Switch On/Off
2 = Power supply
3 = Plug-in for CF card
4 = USB interface
5 = Serial interface RS-232
5 = Pin 2 = TXD, Pin 3 = RXD, Pin 5 = GND,
5 = Pin 7 = CTS, Pin 8 = RTS
6 = Ethernet 10/100 interface
7 = USB host for USB keyboard and USB memory stick
8 = Parallel interface for Centronics
9 = External input/output (option)
6.1 - LED orange
6.1 - Lighting = Connection active
6.1 - Flashing = Data transfer
6.1 - Off = No connection
6.2 - LED green
6.2 - Lighting = Speed 100 MBit
6.2 - Off = Speed 10 MBit

Compa II series Cleaning
11.15 Service instructions 11
4 Cleaning
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.
Task Frequency
General cleaning (see chapter
4.1, on page 12).
As necessary.
Cleaning print roller (see
chapter 4.2, on page 12).
Each time the label roll is
changed or when the printout and
label transport are adversely
affected.
Cleaning printhead (see chapter
4.3, on page 12). Direct thermal printing: Each time the label roll is
changed.
Thermal transfer printing:
Each time the transfer ribbon is
changed or when the printout is
adversely affected.
Cleaning label photocell (see
chapter 4.4, on page 13).
When the label roll is changed.
WARNING!
Risk of fire by easily inflammable label soluble!
When using label soluble, dust must be completely
removed from the label printer and cleaned.
NOTICE!
For adjustments and simple installation work, use the
accompanying hexagonal wrench located in the bottom section
of the print unit.
No other tools are required for the work described here.
Cleaning schedule
Tools and
cleaning agents

Cleaning Compa II series
12 Service instructions 11.15
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 print roller
A soiled print roll can lead to reduced print quality and can affect
transport of material.
1. Turn lever (1, Figure 2) counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon form the label printer.
3. Remove deposits with roller cleaner and a soft cloth.
4. If the roller appears damaged, replace it (see chapter 5.3, on page
17).
4.3 Cleaning the printhead
Printing can cause accumulation of dirt at printhead e.g. by colour
particles of transfer ribbon, and therefore it is necessary to clean the
printhead in regular periods depending on operating hours,
environmental effects such as dust etc.
CAUTION!
Printhead can be damaged!
Do not use sharp or hard objects to clean the
printhead.
Do not touch protective glass layer of the printhead.
1. Turn lever (1, Figure 2) counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon from the label printer.
3. Clean printhead surface with special cleaning pen or a cotton
swab dipped in pure alcohol.
4. Allow printhead to dry for 2-3 minutes before commissioning the
printer.

Compa II series Cleaning
11.15 Service instructions 13
4.4 Cleaning the label photocell
CAUTION!
Label photocell can be damaged!
Do not use sharp or hard objects or solvents to clean
the label photocell.
The label photocell can become dirtied with paper dust and this can
adversely affect label detection.
Figure 2
1. Turn lever (1) counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon from the label printer.
3. Remove hexagonal wrench (5) from its retainer.
4. Press the latch (3) and slowly pull label photocell outwards via the
tab (4). Ensure that the label photocell cable is not tensioned by
this.
5. Clean label photocell and sensor units (2) with brush or cotton
swab soaked in pure alcohol.
6. Push label photocell back via tab (3) and set it.
7. Push hexagonal wrench (5) into retainer.
8. Reload labels and transfer ribbon.
Compa II 103 T, 104,
106 and 108 T

Cleaning Compa II series
14 Service instructions 11.15
Figure 3
1. Turn lever (1) counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon from the label printer.
3. Remove hexagonal wrench (7) from its retainer and remove the
rear cover of printer.
4. Slide the label photocell assembly onto the tab (5) toward the rear
cover until it stops and unplug the cable (2) from the plug on the
rear end of the label photocell (1).
5. Press the latch (6) and slowly pull label photocell outward via the
tab (5). That way the distance plate (3) is pushed out of label
photocell guide.
6. Clean label photocell and sensor units (4) with brush or cotton
swab soaked in pure alcohol.
7. Push label photocell back via tab (5).
8. Press the latch (6) and push the distance plate (3) into the guide
of the label photocell.
9. Reload labels and transfer ribbon.
Compa II 162 + 162 T

Compa II series Replacing components
11.15 Service instructions 15
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 Tool list
NOTICE!
For adjustments and simple installation work, use the
accompanying hexagonal wrench located in the bottom section
of the print unit.
Some service work requires other tools:
Philips-head screwdriver, size 1
Hexagonal wrench 1.5 mm
Torx screwdriver TX20
Snap ring pliers, ZGG 0
Spring scale 10 N
Spring scale 25 N
5.2 Replacing the printhead
NOTICE!
The printhead (7) is preinstalled on a head plate (1) and
aligned at the factory.
Figure 4
1 Head plate
2 Plug connection
3 Plug connection
4 Screw
5 Printing line
6 Pins
7 Printhead

Replacing components Compa II series
16 Service instructions 11.15
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 (2, 3).
Do not touch printing line (5) with hard objects or your
hands.
Figure 5
1. Turn lever (10) counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon from the label printer.
3. Remove hexagonal wrench (11) from its retainer.
4. Lightly keep printhead mounting bracket (9) on the print roller with
one finger and screw out screw (8) with the hexagonal wrench
and remove it and the washer.
5. Swivel printhead mounting bracket (9) upwards.
6. Remove printhead from the printhead mounting bracket (9) if
necessary.
7. Loosen both plug connections (2, 3) on the printhead and set
printhead down on a clean, soft surface.
1. Attach plug connections (2, 3).
2. Position printhead in printhead mounting bracket (9) in such a way
that the pins (6) are secured in the corresponding holes in the
printhead mounting bracket (9).
3. Lightly keep printhead mounting bracket (9) on the print roller with
one finger and check for correct positioning of the printhead
mounting bracket (9).
4. Screw in screw (8) with washer with the hexagonal wrench and
tighten it.
5. Reload labels and transfer ribbon.
Removing the
printhead
Installing the printhead

Compa II series Replacing components
11.15 Service instructions 17
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 as long as you arrive the menu item Zero point
adjustment.
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.
Zero point adjustment
in Y direction
Zero point adjustment
in X direction

Replacing components Compa II series
18 Service instructions 11.15
5.4 Replacing the print roller and rewind assist roller
Figure 6
1. Turn lever (1) counter clockwise to lift up the printhead.
2. Lift the pinch roller (5) off the rewind assist roller.
3. Remove labels and transfer ribbon from the label printer.
4. Loosen screws (4) on plate (6) with hexagonal wrench by several
turns and remove plate (6).
5. Unscrew screws (3a, b, c) of the side plate (2) with hexagonal
wrench.
6. Remove side plate (2).
Figure 7
1. Pull print roller (7) and rewind assist roller (8) from the shafts (9,
10) on the housing.
2. Clean shafts (9, 10) of the rollers (see expanded view at shaft 10).
3. Slide print roller (7) and rewind assist roller (8) onto their
respective shafts and turn slightly until the hexagon of the shaft
engages in the hexagon socket of the print roller.
4. Set side plate (2, Figure 6) in place and screw it down with the
screws (3a, b, c, Figure 6) by tightening the screws in order a-b-c..
5. Set plate (6, Figure 6) in place and tighten screws (4, Figure 6)
with hexagonal wrench.
Removing the
side plate
Removing and
installing rollers

Compa II series Replacing components
11.15 Service instructions 19
5.5 Replacing the slipping clutches
The rewinder for the transfer ribbon and the internal rewinder are
coupled to slipping clutches in the main drive. The supply hub of the
transfer ribbon is braked with a slipping clutch during printing.
Figure 8
1 = Transfer ribbon supply hub: brake
2 = Transfer ribbon take up hub: coupling
3 = Internal rewinder: coupling
Change the slipping clutch when it can no longer be set. Removal and
installation of the slipping clutch is also required for replacement of a
winder.
1. Unplug the printer from the electrical outlet.
2. Remove the rear cover of the printer.
3. Remove the snap ring (1).
4. Pull coupling or brake (2) from the winder axis (4, Figure 9).
5. Ensure that the pin (4, Figure 23) remains on the winder axis
when pulling the brake off. Reattach the pin to the winder axis if it
has been pulled off. The axis profile is shaped in such a way that
the pin only fits on the winder axis in one way.
Removing the
slipping clutch

Replacing components Compa II series
20 Service instructions 11.15
1 = Snap ring
2 = Slipping clutch
3 = Coupling disks
4 = Winder axis
5 = Collar of belt wheel
Figure 9
1. Slide coupling (2) onto the winder axis (4).
2. Align grooves in the coupling disks (3) with the guides in the collar
of the belt wheel (5).
3. Slide coupling further until it stops.
4. Secure the snap ring (1).
5. Adjust the coupling (see chapter 6.1, on page 27).
6. Pull the label photocell toward the cover side as far as possible
(see chapter 5.6, on page 21) and install the rear cover of the
printer.
1 = Snap ring
2 = Brake
3 = Lever
4 = Pin
5 = Winder acis
6 = Spring
Figure 10
1. Slide the brake (2) onto the winder axis (5) in such a way that it
fits on the hexagonal profile of the pin (4).
2. Ensure that the lever (3) grasps between the two ends of the
spring (6).
3. Secure the snap ring (1).
4. Adjust the coupling (see chapter 6.1, on page 27).
5. Pull the label photocell toward the cover side as far as possible
(see chapter 5.6, on page 21) and install the rear cover of the
printer.
Installing the slipping
clutch on the rewinder
Installing the brake
on the transfer ribbon
supply hub