Carl Valentin Spectra series Operating instructions

Service instructions
Label printer
Spectra series
November 2008

Copyright by Carl Valentin GmbH / 79880251108
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.
Carl Valentin label printers comply with the following safety guidelines:
CE EG Low-Voltage Directive (2006/95/EG)
EG Electromagnetic Compatibility Directive (89/336/EWG)
Carl Valentin GmbH
Postfach 3744 D-78026 Villingen-Schwenningen
Neckarstraße 78-80 D-78056 Villingen-Schwenningen
Phone 07720 / 97 12-0
Fax 07720 / 99 49-871
E-mail [email protected]
www.valentin-carl.de

Spectra series Table of contents
1108 Service instructions 3
Table of contents
Table of contents.............................................................................. 3
1Notes on this document ....................................................... 5
1.1 User notes ............................................................................... 5
1.2 Warnings ................................................................................. 5
1.3 Cross references ..................................................................... 6
2Safety instructions................................................................ 7
2.1 General safety instructions...................................................... 7
2.2 Safety handling when working with electricity ......................... 9
3Cleaning ............................................................................... 11
3.1 General cleaning ................................................................... 12
3.2 Print roller .............................................................................. 12
3.3 Printhead ............................................................................... 13
3.4 Label photocell ...................................................................... 14
4Replacing components....................................................... 15
4.1 Tool list .................................................................................. 15
4.2 Primary fuse .......................................................................... 16
4.3 Secondary fuse...................................................................... 16
4.4 Printhead (general)................................................................ 17
4.5 Flat Type printhead................................................................ 18
4.6 Corner Type printhead .......................................................... 19
4.7 Print roller .............................................................................. 20
4.8 Label photocell ...................................................................... 21
4.9 CPU PCB............................................................................... 22
4.10 Power supply ......................................................................... 24
4.11 Printhead FPGA .................................................................... 25
4.12 I/O FPGA ............................................................................... 25
4.13 Battery ................................................................................... 25
5Adjustments, settings and alignments ............................. 27
5.1 Print mechanism.................................................................... 27
5.2 Position of printhead (Flat Type) ........................................... 28
5.3 Position of printhead (Corner Type) ...................................... 30
5.4 Transfer ribbon feed path ...................................................... 32
5.5 Ribbon rewinder/unwinder..................................................... 33
5.6 Head photocell....................................................................... 34
5.7 Cutter ledge ........................................................................... 35
5.8 Angle of aperture (cutter unit)................................................ 37
5.9 Pressure curve (ribbon save) ................................................ 38
5.10 Supporting bar (ribbon save)................................................. 40
5.11 Oil and Lubricate ................................................................... 41
6Refitting options.................................................................. 43
6.1 Memory card slot ................................................................... 43
6.2 Compact Flash card slot........................................................ 44
6.3 Internal rewinder.................................................................... 45
6.4 Ethernet interface .................................................................. 46
6.5 I/O plate ................................................................................. 47
6.6 Dispensing unit ...................................................................... 48
6.7 Cutting unit ............................................................................ 49
6.8 Guiding for Leporello fold material ........................................ 50

Table of contents Spectra series
4 Service instructions 1108
7Error correction ................................................................... 51
8Wiring plan........................................................................... 59
9Layout diagrams.................................................................. 61
9.1 CPU ....................................................................................... 61
9.2 Power supply unit (revision G) .............................................. 63
9.3 Memory card slot (option)...................................................... 65
9.4 Compact Flash card slot (option) .......................................... 66
9.5 Input/output board (option) .................................................... 67
9.6 Input/output board 24V (option)............................................. 68
9.7 Ethernet (option).................................................................... 69
10 Pin assignment interfaces.................................................. 71
10.1 Centronics ............................................................................. 71
10.2 RS-232 .................................................................................. 71
10.3 RS-485 and RS-422 (option)................................................. 72
10.4 Ethernet (option).................................................................... 73
10.5 USB 1.0 ................................................................................. 73
11 Index ..................................................................................... 75

Vita series Notes on this document
1108 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 104/8 and 106/12.
Information about operation of printer can be taken from our operating
manual.
If a problem arises that cannot be solved with help of this service of
manual, then please contact your responsible 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 Vita series
6 Service instructions 1108
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

Spectra series Safety instructions
1108 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.
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.
Workplace and
method of working
Clothing

Safety instructions Spectra series
8 Service instructions 1108
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

Spectra series Safety instructions
1108 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

Spectra series Cleaning
1108 Service instructions 11
3 Cleaning
DANGER!
Risk of death by electric shock!
⇒Disconnect the label printer from power supply
before performing any maintenance work.
Cleaning task Frequency
General cleaning (see section
3.1, page 12).
As necessary.
Cleaning print roller (see section
3.2, page 12).
Each time the label roll is
changed or when the printout and
label transport are adversely
affected.
Cleaning printhead (see section
3.3, page 13). 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
section 3.4, page 14).
When exchanging the label roll.
WARNING!
Risk of fire by easily inflammable label soluble!
⇒When using label soluble, dust must be completely
removed from the label printer and cleaned.
Cleaning schedule

Cleaning Spectra series
12 Service instructions 1108
3.1 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.
3.2 Print roller
A soiled print roll can lead to reduced print quality and can affect
transport of material.
Figure 1
1. Open printer cover.
2. Turn red lever (B) counter clockwise to lift up the printhead (A).
3. Remove labels and transfer ribbon form the label printer.
4. Remove deposits with roller cleaner and a soft cloth.
5. Turn the roller (C) manually step by step to clean the complete
roller (only possible when printer is switched off, as otherwise the
step motor is full of power and the roller is kept in its position).

Spectra series Cleaning
1108 Service instructions 13
3.3 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 2
1. Open printer cover.
2. Turn red lever (B, in Figure 1) 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.

Cleaning Spectra series
14 Service instructions 1108
3.4 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 3
1. Open printer cover.
2. Turn red lever (B, in Figure 1) counter clockwise to lift up the
printhead.
3. Remove labels and transfer ribbon from the label printer.
4. Blow out the photocell (A) with pressure gas spray.
Observe strictly the instructions on the spray can!
5. Clean the label photocell (A) additionally with a cleaning card (B)
before soaked in pure alcohol. Move the cleaning card from one
side to the other (see illustration).
6. Reload labels and transfer ribbon.

Spectra series Replacing components
1108 Service instructions 15
4 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.
4.1 Tool list
Some service work requires the following tools:
•Philips-head screwdriver, size 2
•Screwdriver, size 5
•Allen wrench 1,5 mm / 2 mm / 2,5 mm
•Hexagonal wrench 3 mm
•Spring scale 50 N

Replacing components Spectra series
16 Service instructions 1108
4.2 Primary fuse
Figure 4
1. Unplug the power plug from the filter block (A).
2. Open cover (B).
Lever it off laterally with a screwdriver.
3. Pull the fuse carrier (red) behind the cover outwards.
4. Remove the micro fuse 2AT.
1. Insert the micro fuse 2AT into the fuse carrier (red).
2. Plug the fuse carrier into the line filter block (A).
3. Close the cover (B).
4. Connect the power cable.
4.3 Secondary fuse
Figure 5
1. Remove left printer cover.
Loosen two screws at the lower left
printer edge and three screws at the
chassis upper edge.
2. Remove the protective conductor at
the inside of the printer cover.
3. Replace secondary fuse (A) on the
power supply.
4. Mount again the printer cover.
Removing the
primary fuse
Installing the
primary fuse

Spectra series Replacing components
1108 Service instructions 17
4.4 Printhead (general)
The printhead (4) is preinstalled on a head plate (1) and
precisely aligned at the factory.
Figure 6
1 Head plate
2 Plug connection signal
3 Plug connection tension
4 Printhead
5 Focal line
6 Guiding
7 Knurled screw
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.

Replacing components Spectra series
18 Service instructions 1108
4.5 Flat Type printhead
Figure 7
1. Remove labels and transfer ribbon from the label printer.
2. When printhead is closed, loosen the knurled screws (H).
3. Turn red lever (F) counter clockwise to lift up the printhead.
4. If the printhead (G) is not disengaged on the pressure roller,
continue loosen the knurled screws (H).
5. Remove the printhead carefully to the front until you can reach the
plug connections.
6. Remove plug connections and then remove printhead (G).
1. Attach plug connections.
2. Position printhead in printhead mounting bracket in such a way
that the pins are secured in the corresponding holes 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. Screw in screw (H) and tighten it.
5. Check resistance value on the type plate of printhead and if
necessary change the value in the service functions/heater
resistance.
6. Reload labels and transfer ribbon.
Removing the
printhead
Installing the
printhead

Spectra series Replacing components
1108 Service instructions 19
4.6 Corner Type printhead
Figure 8
1. Remove labels and transfer ribbon from the label printer.
2. When printhead is closed, loosen the knurled screws (J).
3. Turn red lever (F) counter clockwise to lift up the printhead.
4. If the printhead (G) is not disengaged on the pressure roller,
continue loosen the knurled screws (J).
5. Remove the printhead carefully to the front until you can reach the
plug connections.
6. Remove plug connections and then remove printhead (G).
1. Attach plug connections.
2. Position printhead in printhead mounting bracket in such a way
that the pins are secured in the corresponding holes 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. Screw in screw (J) and tighten it.
5. Check resistance value on the type plate of printhead and if
necessary change the value in the service functions/heater
resistance.
6. Reload labels and transfer ribbon.
Removing the
printhead
Installing the
printhead

Replacing components Spectra series
20 Service instructions 1108
4.7 Print roller
Figure 9
1. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
2. Remove the protective conductor at the inside of the printer cover.
3. Loosen screws (A) and remove tear off edge (if mounted) before
the pressure roller.
4. Turn red lever (E) clockwise to lift up the printhead.
5. Loosen pins (F) from belt pulley (G) on the print roller (D).
6. Remove protective disc (C) and ball bearing (B).
7. Pull print roller (D) through the drillings outwards.
8. Hold the belt pulley (G).
1. Insert the new print roller (D) through the drillings and the belt
pulley (G).
2. Mount protective disc (C) and ball bearing (B).
3. When reassembling the belt pulley (G), a pin must meet the milled
surface of roller axe.
4. Tighten pins (F) strongly.
The roller has to be installed precisely.
5. Connect the protective conductor to the inside of cover.
6. Mount again the printer cover.
Removing the
print roller
Installing the
print roller