Carl Valentin FLEXICODE Series User manual

FLEXICODE
Operating Manual

Copyright by Carl Valentin GmbH / 7979005.1119
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 direct print modules comply with the following EU
directives:
CE
EU Low-Voltage Directive (2014/35/EU)
EU Electromagnetic Compatibility Directive (2014/30/EU)
Carl Valentin GmbH
Postfach 3744
78026 Villingen-Schwenningen
Neckarstraße 78 –86 u. 94
78056 Villingen-Schwenningen
Phone
Fax
[phone]
[phone]
E-Mail
Internet
[e-mail]
www.carl-valentin.de

Flexicode
Table of Contents
11.19
Operating Manual
3
Table of Contents
1Introduction............................................................................ 5
1.1 General Instructions ................................................................ 5
1.2 Intended Use........................................................................... 5
1.3 Safety Instructions................................................................... 6
1.4 Decommissioning and Dismantling ......................................... 7
2Machine Overview................................................................. 9
2.1 Figures................................................................................... 10
2.2 Continuous Mode .................................................................. 12
2.3 Intermittent Mode................................................................... 13
3Operating Conditions.......................................................... 15
4Technical Data ..................................................................... 19
4.1 Control Inputs and Outputs ................................................... 21
4.2 Pin Assignment of Encoder Socket ...................................... 30
5Installation and Initial Operation........................................ 31
5.1 Install the Print Mechanics at Machines................................ 32
5.2 Connect the Pneumatic Power Supply.................................. 34
5.3 Adjust the Pressure Power.................................................... 35
5.4 Connect the Direct Print Module ........................................... 36
5.5 Before Initial Operation.......................................................... 36
5.6 Print Control........................................................................... 37
5.7 Initial Operation ..................................................................... 37
5.8 Load Transfer Ribbon............................................................ 38
5.9 Increase the Clamping Force for Ribbon Roll ....................... 39
6Operation Panel................................................................... 41
6.1 Keyboard (Standard)............................................................. 41
6.2 Keyboard (Text Entry/User Guiding) ..................................... 42
7Function Menu..................................................................... 45
7.1 Menu Structure (Continuous Mode) ...................................... 45
7.2 Menu Structure (Intermittent Mode) ...................................... 48
7.3 Print Settings......................................................................... 51
7.4 Machine Parameters (Continuous Mode).............................. 52
7.5 Machine Parameters (Intermittent Mode).............................. 54
7.6 Layout.................................................................................... 56
7.7 Ribbon Save.......................................................................... 57
7.8 Ribbon Save (Continuous Mode) .......................................... 58
7.9 Ribbon Save (Intermittent Mode) .......................................... 62
7.10 Device Settings...................................................................... 64
7.11 I/O Parameters...................................................................... 67
7.12 Network ................................................................................. 68
7.13 Password............................................................................... 68
7.14 Interface................................................................................. 70
7.15 Emulation............................................................................... 71
7.16 Date & Time........................................................................... 72
7.17 Service Functions.................................................................. 73
7.18 Main Menu............................................................................. 76
7.19 Display During Printing.......................................................... 76
8Compact Flash Card / USB Memory Stick ........................ 77
8.1 General Information............................................................... 77
8.2 Display Structure................................................................... 77
8.3 Navigation.............................................................................. 78
8.4 Define User Directory............................................................ 79

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8.5 Load Layout........................................................................... 80
8.6 File Explorer .......................................................................... 81
8.7 Firmware Update................................................................... 86
8.8 Filter....................................................................................... 86
9Maintenance and Cleaning................................................. 87
9.1 General Cleaning................................................................... 87
9.2 Clean the Transfer Ribbon Drawing Roller ........................... 88
9.3 Clean the Printhead............................................................... 88
9.4 Replace the Printhead........................................................... 89
9.5 Angle Adjustment (Intermittent Mode)................................... 91
9.6 Print Quality Optimisation...................................................... 92
9.7 Cycle optimisation (Intermittent Mode).................................. 93
10 Signal Diagrams .................................................................. 95
10.1 Continuous Mode .................................................................. 95
10.2 Intermittent Mode................................................................... 99
11 Error Correction................................................................. 101
12 Additional Information ...................................................... 111
12.1 Column Printing................................................................... 111
12.2 Hotstart................................................................................ 112
13 Environmentally-Friendly Disposal ................................. 115
14 Index ................................................................................... 117

Flexicode
Introduction
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Operating Manual
5
1 Introduction
1.1 General 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.

Handling instruction

Optional accessories, special fittings
Datum
Information in the display
1.2 Intended Use
The direct print module is a state-of-the-art device which complies
with the recognized safety-related rules and regulations. Despite this,
a danger to life and limb of the user or third parties could arise and the
direct print module or other property could be damaged while
operating the device.
The direct print module may only be used while in proper working
order and for the intended purpose. Users must be safe, aware of
potential dangers and must comply with the operating instructions.
Faults, in particular those which affect safety, must be remedied
immediately.

Introduction
Flexicode
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Operating Manual
11.19
The direct print module is solely intended to print suitable media which
have been approved by the manufacturer. Any other or additional use
is not intended. The manufacturer/supplier is not liable for damage
resulting from misuse. Any misuse is at your own risk.
Intended used includes heeding the operating manual, including the
maintenance recommendations/regulations specified by the
manufacturer.
NOTICE!
The complete documentation is included in the scope of
delivery on CD ROM and can also currently be found in the
internet.
1.3 Safety Instructions
The direct print module is configured for a voltage of 230 V AC or
115 V AC (see type plate). It has to be plugged into a grounded
socket only.
Couple the direct 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 direct print module in a dry environment only and do not
get it wet (sprayed water, mist etc.).
Do not operate the direct print module in explosive atmosphere and
not in proximity of high voltage power lines.
Operate the direct print module only in an environment protected
against abrasive dust, swarf and other similar impurity.
Maintenance and servicing work can only be carried out by trained
personnel.
Operating personnel must be trained by the operator on the basis of
the operating manual.
Depending on use, ensure that clothing, hair, jewellery and similar
personal items do not contact the exposed rotating parts and/or the
moving parts (e.g. print carriage).
NOTICE!
With the open printing unit (due to construction) the requirements
of EN 60950-1/EN 62368-1 regarding fire protection casing are
not fulfilled. These must be ensured by the installation into the end
device.
The print unit and parts of it (e.g. motor, printhead) can get hot during
printing. Do not touch the printhead during operation. Cool down the
print unit before changing material, removal or adjustment.
Never use highly inflammable consumables.
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.

Introduction
Flexicode
11.19
Operating Manual
7
Other unauthorized work or modifications to the direct print module
can endanger operational safety.
There are warning stickers on the direct print modules 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.
CAUTION!
Two-pole fuse.
Before opening the housing cover, disconnect the
printing system from the mains supply and wait for a
moment until the power supply unit has discharged.
1.4 Decommissioning and Dismantling
NOTICE!
The decommissioning of printing system can only be carried out
by trained staff.
CAUTION!
Danger of injury by imprudent handling when lifting or placing
the printing system.
Do not underestimate the weight of the printing system
(6 kg).
Do not lift the printing system at the hood.
Protect the printing system against uncontrolled
movement.

Introduction
Flexicode
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Operating Manual
11.19

Flexicode
Machine Overview
11.19
Operating Manual
9
2 Machine Overview
The continuous and intermittent operating direct print module with
high resolution is designed for installation in horizontal and vertical
packaging machines. Convincing is the availability of left and right
versions. Thanks to the separate control unit the direct print module
can be integrated almost in each packaging process without any
problems.
Flexible labelling of packaging foil is effected either by means of
Windows printer driver included in delivery or by our proven design
software Labelstar Office/Labelstar PLUS.
With eight vector fonts, six bitmap fonts and six proportional fonts the
direct print module has a large selection at different font types. It can
be printed inverse, in italic format or 90 degrees turned fonts.
The handling of our durable direct print modules is easy and
comfortable. The parameter settings are made with the keys of the foil
keyboard. At each time the graphic display shows the current status.
By a new-developed electronics a maximum print speed up to 400
mm/s can be achieved.
Time-saving printer update is possible by interface.
As default, the direct print module is equipped with a parallel, serial,
USB and Ethernet interface. Additionally, the direct print module is
equipped with an USB Host that permits the connection of an external
USB keyboard and/or an USB memory stick. The direct print module
automatically recognizes by which interface it is controlled.
Thanks to the large number of options the direct print module can be
adapted to each task.

Machine Overview
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Operating Manual
11.19
2.1 Figures
2
1
1
2
Figure 1
1 =
Pneumatic connection
2 =
Connecting cable (mechanics - control unit)
4
1
32
Figure 2
1 =
Lift sensor, internal
2 =
Cover
3 =
Spring catch
4 =
Handle
The cover (2) can be removed by the handle (4) with the spring catch
(3) pressed down.
NOTICE!
No print job can be initiated when the cover is removed.
An internal cover sensor (1) checks the status of the cover (open/
closed). This sensor does not satisfy the requirements of a standard-
compliant safety switch (see chapter 1.3, on page 6).
Connection side of
print mechanics
Front of the print unit

Flexicode
Machine Overview
11.19
Operating Manual
11
1 2 3 4 5 6 7
8 9 10 11
1312
Figure 3
1 =
Parallel interface
2 =
Connecting cable (mechanics - control unit)
3 =
USB host for USB keyboard and USB memory stick
4 =
Encoder connection
5 =
USB interface
6 =
External inputs/outputs
7 =
CF card slot
8 =
Touch Panel connection
9 =
Ethernet interface
10 =
RS 232 interface
11 =
Power supply with switch
Connector assignment
of control unit
12 - LED green
12 - Lighting = Speed 100 MBit
12 - Off = Speed 10 MBit
13 - LED orange
13 - Lighting = Connection active
13 - Flashing = Data transfer
13 - Off = No connection

Machine Overview
Flexicode
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Operating Manual
11.19
2.2 Continuous Mode
Please note that the material has sufficient adhesion at the pressure
transducer roll or encoder roll to permit the exact speed by the
encoder.
It is only possible to print when respecting the operating conditions,
i.e. the speed has to be observed.
Figure 4
After starting a print order the printhead moves against the print
medium. The feed of material is registered by the encoder and then
evaluated. The printhead is in start position as long as the printing
onto the moving material is finished and then it moves back to its
home position.
Figure 5
NOTICE!
In case the encoder is connected to the counter-pressure roll
or the encoder roll you have to observe that the material has
sufficient adhesion at the pressure roll or encoder roll to
guarantee an exact speed by the encoder.
Material Speed
Print Principle
Material Guiding

Flexicode
Machine Overview
11.19
Operating Manual
13
2.3 Intermittent Mode
Lift
Print surface
Feed
Packaging material
Printhead
Figure 6
After starting a print order the printhead moves against the print
medium. Afterwards the printing carriage moves corresponding to the
set or transferred layout length linear over the material which is to be
printed. After the print procedure the printhead again lifts up and the
printing carriage moves again to the starting position.
The direct print module has a print length of 40 mm maximum. The
print start position is in a difference of approx. 40 mm to the side
panel.
ca.40mm max. 40mm
A B
Figure 7
A: Start position
B: End position
Print Principle
Print Position

Machine Overview
Flexicode
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Operating Manual
11.19

Flexicode
Operating Conditions
11.19
Operating Manual
15
3 Operating Conditions
Before initial operation and during operation these operating
conditions have to be observed to guarantee save and interference-
free service of our direct print modules.
Therefore please carefully read these operating conditions.
Shipment and storage of our direct print modules are only allowed in
original packing.
Installation and initial operation of direct print modules is only allowed
if operating conditions were fulfilled.
Initial operation, programming, operation, cleaning and service of our
direct print modules are only recommended after careful study of our
manuals.
Operation of direct print modules is only allowed by especially trained
persons.
NOTICE!
Perform trainings regularly. Content of the training are chapter 3
(Operating Conditions), chapter 5.8 (Load Transfer Ribbon) and
chapter 9 (Maintenance and Cleaning.
These indications are also valid for someone else's equipment
supplied by us.
Only use original spare and exchange parts.
Please contact the manufacturer with respect to spare/wear parts.
The installation place of direct print module should be even, free of
vibration and currents of air are to be avoided.
The direct print modules have to be installed to ensure optimal
operation and servicing.
The installation of the power supply to connect our direct print
modules has to be effected according to the international rules and
regulations, especially the recommendations of one of the three
following commissions:
•International Electronic Commission (IEC)
•European Committee for Electro technical Standardisation
(CENELEC)
•Verband Deutscher Elektrotechniker (VDE)
Our direct print modules are constructed according to VDE and have
to be connected to a grounded conductor. The power supply has to be
equipped with a grounded conductor to eliminate internal interfering
voltage.
Conditions for
installation place
Installation of
power supply

Operating Conditions
Flexicode
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Operating Manual
11.19
Power line voltage and power line frequency: See type plate
Allowable tolerance of power line voltage:
+6 % … −10 % of nominal value
Allowable tolerance of power line frequency:
+2 % … −2 % of nominal value
Allowable distortion factor of power line voltage: ≤ 5 %
In case your net is infected (e.g. by using thyristor controlled
machines) anti-interference measures have to be taken. You can use
one of the following possibilities:
•Provide separate power supply to our direct print modules.
•In case of problems please connect capacity-decoupled isolation
transformer or similar interference suppressor in front of our direct
print modules.
All connecting lines have to be guided in shielded lines. Shielding has
to be connected on both sides to the corner shell.
It is not allowed to guide lines parallel to power lines. If a parallel
guiding cannot be avoided a distance of at least 0.5 m has to be
observed.
Temperature of lines between: −15 … +80 °C.
It is only allowed to connect devices which fulfil the request 'Safety
Extra Low Voltage' (SELV). These are generally devices which are
checked corresponding to EN 60950/EN 62368-1.
The data cables must be completely protected and provide with metal
or metallised connector housings. Shielded cables and connectors are
necessary, in order to avoid radiant emittance and receipt of electrical
disturbances.
Allowable lines
Shielded line:
4 x 2 x 0,14 mm² ( 4 x 2 x AWG 26)
6 x 2 x 0,14 mm² ( 6 x 2 x AWG 26)
12 x 2 x 0,14 mm² (12 x 2 x AWG 26)
Sending and receiving lines have to be twisted in pairs.
Maximum line length:
with interface V 24 (RS-232C) - 3 m (with shielding)
with parallel interface - 3 m (with shielding)
USB - 3 m
Ethernet - 100 m
Technical data of
power supply
Anti-interference
measures
Connecting lines to
external machines
Installation of
data lines

Flexicode
Operating Conditions
11.19
Operating Manual
17
To avoid inadmissible heating, free air convection has to be ensured.
Protection according IP: 20
Ambient temperature °C (operation): Min. +5 Max. +40
Ambient temperature °C (transport, storage): Min. −25 Max. +60
Relative air humidity % (operation): Max. 80
Relative air humidity % (transport, storage): Max. 80
(bedewing of printers not allowed)
We do not take any responsibility for damage caused by:
•Ignoring our operating conditions and operating manual.
•Incorrect electric installation of environment.
•Building alterations of our printers.
•Incorrect programming and operation.
•Not performed data protection.
•Using of not original spare parts and accessories.
•Natural wear and tear.
When (re)installing or programming our direct print modules please
control the new settings by test running and test printing. Herewith you
avoid faulty results, reports and evaluation.
Only specially trained staff is allowed to operate the direct print
modules.
Control the correct handling of our products and repeat training.
We do not guarantee that all features described in this manual exist in
all models. Caused by our efforts to continue further development and
improvement, technical data might change without notice.
By further developments or regulations of the country illustrations and
examples shown in the manual can be different from the delivered
model.
Please pay attention to the information about admissible print media
and the notes to the printer maintenance, in order to avoid damages
or premature wear.
We endeavoured to write this manual in an understandable form to
give and you as much as possible information. If you have any queries
or if you discover errors, please inform us to give us the possibility to
correct and improve our manual.
Air convection
Limit values
Guarantee

Operating Conditions
Flexicode
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Operating Manual
11.19

Flexicode
Technical Data
11.19
Operating Manual
19
4 Technical Data
Flexicode 53
Print resolution
300 dpi
Print speed
50 … 400 mm/s
Back speed
max. 600 mm/s (intermittent mode only)
Print width
53 mm
Print length
continuous mode: max. 3000 mm
intermittent mode: max. 40 mm
Frame passage width
customized
Printhead
Corner Type
Acoustic Emission
Average sound power level
69 dB(A) - Measuring distance 1 m
Transfer Ribbon
Ink
outside / inside
Roll diameter
max. 82 mm
Core diameter
25,4 mm / 1"
Length
max. 450 m
Width
max. 55 mm
Dimensions (width x height x depth)
Print mechanics
without mounting frame
190 mm x 180 mm x 208 mm
with mounting frame
depends on passage width
Control unit
242 mm x 117 mm x 220 mm
(connecting cable set to mechanics 2.5 m
Weight
Print mechanics
6,0 kg
Electronics with cable
3.7 kg
Electronics
Processor
High Speed 32 Bit
RAM
16 MB
Slot
Compact Flash card type I
Battery cache
for Real-Time clock (storage of data with shut-down)
Warning signal
acoustic signal when error
Interfaces
Serial
RS-232C (up to 115.200 Baud)
Parallel
SPP
USB
2.0 High Speed Slave
Ethernet
10/100 Base T, LPD, RawIP-Printing, DHCP, HTTP, FTP
2 x USB Master
connection for external USB keyboard and memory stick
Connection Values
Pneumatic connection
6 bar dry and free of oil
Air consumption typical*
* hub 1,5 mm
150 cycle/min
6 bar operating pressure
150 ml/min
Nominal voltage
230 V AC / 50 … 60 Hz 1,5 A
115 V AC / 50 … 60 Hz 3 A (Option)
Fuse values
2x T4A 250 V
Operation Data
Temperature
5 … 40 °C
Humidity
max. 80 % (non-condensing)

Technical Data
Flexicode
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Operating Manual
11.19
Flexicode 53
Operation Panel
Keys
test print, function menu, quantity, CF Card, feed, enter, 4 x cursor
LCD display
graphic display 132 x 64 pixel
Settings
date, time, shift times
11 language settings (others on demand)
print and device parameters, interfaces, password protection
Monitoring
Stop printing if
end of ribbon / end of layout
Status report
extensive status print with information about settings
e.g. print length counter, runtime counter,
photocell interface and network parameters
printout of all internal fonts and all supported bar codes
Fonts
Font types
6 Bitmap fonts, 8 Vector fonts/TrueType fonts, 6 proportional fonts
other fonts on demand
Character sets
Windows 1250 up to1257, DOS 437, 850, 852, 857
all West and East European Latin, Cyrillic, Greek
and Arabic (option) characters are supported
other character sets on demand
Bitmap fonts
size in width and height 0,8 … 5,6
zoom 2 … 9, orientation 0°, 90°, 180°, 270°
Vector fonts/
TrueType fonts
size in width and height 1 … 99 mm
variable zoom
orientation 0°, 90°, 180°, 270°
Font attributes
depending on character font - bold, Italic, inverse, vertical
Font width
variable
Bar Codes
1D bar codes
CODABAR, Code 128, Code 2/5 interleaved, Code 39, Code 39
extended, Code 93, EAN 13, EAN 8, EAN ADD ON, GS1-128,
Identcode, ITF 14, Leitcode, Pharmacode, PZN 7 Code, PZN 8 Code,
UPC-A, UPC-E
2D bar codes
Aztec Code, CODABLOCK F, DataMatrix, GS1 DataMatrix,
MAXICODE, PDF 417, QR Code
Composite bar codes
GS1 DataBar Expanded, GS1 DataBar Limited, GS1 DataBar
Omnidirectional, GS1 DataBar Stacked, GS1 DataBar Stacked
Omnidirectional, GS1 DataBar Truncated
all bar codes are variable in height, module width and ratio.
orientation 0°, 90°, 180°, 270°.
Optionally with check digit and human readable line.
Software
Configuration
ConfigTool
Process control
NiceLabel
Design software
Labelstar Office Lite, Labelstar Office
Windows printer driver
Windows 7®- Windows 10®32/64 Bit,
Windows Server 2008®(R2) - Windows Server 2019®
Technical details are subject to change.