Carl Valentin C220 Operating instructions

Copyright by Carl Valentin GmbH / 7942525.0322
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.
The pneumatic applicator complies with the following safety
guidelines:
CE
Electromagnetic Compatibility Directive (2014/30/EU)
EG Machinery Directive (2006/42/EG)
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

C220 / C300 / C400
Table of Contents
03.22
Service Instructions
3
Table of Contents
1Introduction............................................................................ 5
1.1 General Instructions ................................................................ 5
1.2 General Safety Instructions..................................................... 6
1.3 Safety Labels........................................................................... 7
2Product Description .............................................................. 9
2.1 Applicator Overview................................................................. 9
2.2 Sensors ................................................................................. 12
2.3 Pneumatic.............................................................................. 13
3Maintenance and Cleaning................................................. 17
3.1 Tools...................................................................................... 17
3.2 Cleaning ................................................................................ 18
4Replacing Components ...................................................... 19
4.1 Dismantle the Cover.............................................................. 19
4.2 Stick the Slide Foil onto the Pad ........................................... 20
4.3 Replace the Valves................................................................ 21
4.4 Replace the PCB................................................................... 22
4.5 Replace the Cylinder............................................................. 23
4.6 Replace the lower end position sensor on the cylinder......... 24
4.7 Replace the upper end position sensor on the cylinder........ 25
5Troubleshooting .................................................................. 27
5.1 Sensor Labelling Position / Sensor Start Position................. 27
5.2 Functions of LEDs in the Applicator Electronics ................... 28
5.3 Pressure Measuring .............................................................. 29
5.4 Error Indications .................................................................... 30
6Block Diagram ..................................................................... 33
7Pneumatic plan.................................................................... 35
8Terminal Diagram of PCB................................................... 37
9Environmentally-Friendly Disposal ................................... 39
10 Index ..................................................................................... 41

Table of Contents
C220 / C300 / C400
4
Service Instructions
03.22

C220 / C300 / C400
Introduction
03.22
Service Instructions
5
1 Introduction
1.1 General Instructions
Important information and instructions in this document are
designated as follows:
DANGER identifies an extraordinarily great and immediate
danger which could lead to serious injury or even death.
WARNING identifies a possible danger 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
Date
Information in the display

Introduction
C220 / C300 / C400
6
Service Instructions
03.22
1.2 General Safety Instructions
WARNING!
Danger of injury by inadvertent move out of the cylinder.
Disconnect the printer from the power supply before
mounting the applicator.
Connect the compressed air only after mounting the
applicator to the printer.
•Only connect the device to other devices which have a protective
low voltage.
•Switch off all affected devices (computer, printer, accessories)
before connecting or disconnecting.
•The device may only be used in a dry environment, do not expose
it to moisture (sprays of water, mists, etc.).
WARNING!
In operation, moving parts are easily accessible. This
applies especially for the zone, where the pad is moved
between the starting and the labelling position.
During operation do not reach into that zone.
Keep long hair, loose clothes, and jewellery distant.
Before any manipulations in those areas, close the
shutoff valve.
WARNING!
Other unauthorized work on or modifications to the device
can also endanger operational safety.
Unauthorized interference with electronic modules or their
software can cause malfunctions.
Perform only those actions described in this operating
manual.
Work going beyond this may only be performed by
trained personnel or service technicians.
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.

C220 / C300 / C400
Introduction
03.22
Service Instructions
7
1.3 Safety Labels
1
2
Figure 1
CAUTION!
There is a risk of injury due to the movement of the pad
downwards and back up again.
Do not reach into the working area of the pad.
Keep hair, loose clothing, and items of jewellery out of
this area.
When incorporating the unit into the overall system,
safety precautions must be taken so that no-one is able
to reach into the working area.
1 = Cylinder is under pressure
A = Residual energy also possible
1 = when switched off
2 = Risk of crushing due to
1 = the movement of the pad

Introduction
C220 / C300 / C400
8
Service Instructions
03.22

C220 / C300 / C400
Product Description
03.22
Service Instructions
9
2 Product Description
2.1 Applicator Overview
4
6
7
8
10
11
13
3
1
2
5
9
12
Figure 2
1 =
Tube
18 =
Lower cylinder throttle valve
2 =
Energy chain
19 =
Labelling sensor (lower end position sensor)
3 =
Knurled screw for attaching the
applicator to the printer
10 =
Pad retainer
4 =
Upper cylinder throttle valve
11 =
Top plate (customized)
5 =
Sensor start position (upper and
position sensor)
12 =
Suction plate (customized)
6 =
Stopper for operating mode Blow on
13 =
Blow tube
7 =
Lift cylinder

Product Description
C220 / C300 / C400
10
Service Instructions
03.22
14
15
19181716
Figure 3
14 =
Throttle valve vacuum
15 =
Throttle valve support air
16 =
Connector applicator –printer
17 =
Connector compressed air
18 =
Shut-off valve compressed air
19 =
Pneumatic maintenance unit

C220 / C300 / C400
Product Description
03.22
Service Instructions
11
20
21
22
23 24 25
Figure 4
20 =
Valve lift cylinder
21 =
Valve blow air
22 =
Valve vacuum / support air
23 =
Valve block
24 =
PCB applicator control
25 =
Vacuum generator

Product Description
C220 / C300 / C400
12
Service Instructions
03.22
2.2 Sensors
The contact of the pad onto the product or the reaching of the release
position is detected by a Hall-sensor. For which purpose the
displacement of the adapter bolt in relation to the sensor is used.
The start position is the upper end position of cylinder and the position
of the pad which takeover the label from printer. This position will be
detected via a Hall-sensor in interaction with a magnet mounted inside
cylinder.
The correct transfer of a label will be checked by the vacuum sensor.
It also checks that there is no longer a label on the pad in case the
return movement. This sensor is integrated to the applicator PCB.
The pressure sensor controls the pressure air. This sensor is
integrated to the applicator PCB.
Sensor labelling
position
Sensor start
position
Sensor vacuum
Sensor pressure

C220 / C300 / C400
Product Description
03.22
Service Instructions
13
2.3 Pneumatic
A cylinder with stroke of 220-400 mm is used for the transport of
labels between the peel-off edge of the printer and the labelling
position.
The movement of cylinder is controlled by a control valve on the valve
block.
The speed of movement can be changed by two throttle valves
mounted at cylinder.
The label will be transported by a pad. The pad must be appropriate to
the size of label.
During the label transport a vacuum is applied on the pad.
In operating mode 'blow on' in the lower final position the label is
applied by a high pressure.
The vacuum at the pad is produced by a vacuum generator. The
vacuum generator is controlled by control valve on the valve block.
The low pressure can be adjusted by a throttle valve.
Air is blown from below (supporting air) through a blow tube onto the
label to support the transfer of the label from the printer to the pad.
The blow tube is adjustable concerning the blowing direction.
The supporting air is connected by the magnet valve (support air). The
power of the supporting air can be adjusted by a throttle valve at the
valve block.
The pneumatic maintenance unit is offered as an option for the
applicator. The important components of the pneumatic maintenance
unit are a pressure reducer with manometer, a water separator with
micro filter and a main connector for compressed air.
The distribution of the compressed air to the various pneumatic units
is made in the valve block.
On the valve block is mounted the control valve for support air and
vacuum with their throttle valves and the control valves for the lift
cylinder and blow air.
Cylinder
Pad
Vacuum generator
Blow tube
Pneumatic
maintenance unit
Valve block

Product Description
C220 / C300 / C400
14
Service Instructions
03.22
NOTICE!
For adjustments of certain applicator functions, release the
control valves in the pneumatic system.
The control valves are accessible only with dismounted cover.
3
4
1197 10862 11
5
1
Figure 5
Loosen screws (1) and remove cover (2).
The compressed air control valves can be controlled manually
with integrated switch (6 - 11).
Three-way valve (3) to control the lift cylinder
If the printer is switched on the valve will controlled by electronics and
the tamp will hold in the upper end position (home position). If the
valve switched the tamp will move in the lower end position (labelling
position). In normal labelling operation the movement back in the
upper end position will start by a signal from labelling sensor (lower
end position sensor).
NOTICE!
The switching by hand of this valve has only a result in case
of a switched off printer.
Switching the valve by hand over switch 6 the tamp will move down up
to the lowest possible position because no control is made by the
sensor.
Switching the valve by hand over switch 7 the tamp will move up.
Control valves

C220 / C300 / C400
Product Description
03.22
Service Instructions
15
Double two-way valve (4) for blow air
In the operation mode 'Blow on' the label will blow up to the product.
In the operating modes 'Stamp on' and 'Roll on' the blow air is
switched on for a short time after each application to avoid
contaminations within the vacuum channels.
For all described functions both valves will be controlled parallel.
By pressing the keys 8 or 9 the blow air is only switched on by one of
both internal valves.
Double two-way valve (5) for vacuum / supporting air
The two internal valves serve the vacuum nozzle for connecting an in
this way for creating the negative pressure at the tamp and
independent of this for connecting the support air at the blow tube for
the label transfer.
By pressing switch 10 the vacuum is switched on and by pressing
switch 11 the supporting air is switched on.

Product Description
C220 / C300 / C400
16
Service Instructions
03.22

C220 / C300 / C400
Maintenance and Cleaning
03.22
Service Instructions
17
3 Maintenance and Cleaning
3.1 Tools
For Assemblies
Tools
Size
Cylinder plunger
Combination wrench
25.5 mm
Throttle valve
29.0 mm
Guide rod
10.0 mm
L-connector (valve block in
maintenance guiding)
14.0 mm
Lift cylinder
20.0 mm
Valve block, energy track
Hexagon wrench
22.0 mm
PCB
22.5 mm
Adjustment guiding block
25.0 mm
Throttle valves
Screwdriver for
slotted screws
22.5 mm
Valves on the valve block
Crosstip screwdriver
PH 0
Sensors (labelling sensor +
sensor start position)
PH 2
Works at PCB
Wrist grounding
Pressure measurement
Manometer
to approx. 5 bar
Cloth soft brush, multi-purpose cleaner (without solvent)

Maintenance and Cleaning
C220 / C300 / C400
18
Service Instructions
03.22
3.2 Cleaning
CAUTION!
Abrasive cleaning agents can damage the applicator!
Do not use abrasives or solvents to clean the outer
surface of the label printer.
1
Figure 6
Clean the outside surfaces with multipurpose cleaner.
Remove dust particles and label splits with a soft brush or a
vacuum cleaner.
The ideal takeover and handling of the label can be achieved by
cleaning the surface of slide foil (1) at regular intervals.

C220 / C300 / C400
Replacing Components
03.22
Service Instructions
19
4 Replacing Components
WARNING!
Risk of injury by uncontrolled functions of the applicator.
Disconnect the printer power supply.
Close the compressed air supply before the work.
4.1 Dismantle the Cover
NOTICE!
Dismantle the cover to arrive the components installed on the
carrier plate.
3 22
1
Figure 7
1. Loosen the screw (2).
2. Remove the screw (1).
3. Remove the panel (3) in direction of arrow.
NOTICE!
Before starting the normal operation mount the cover again.

Replacing Components
C220 / C300 / C400
20
Service Instructions
03.22
4.2 Stick the Slide Foil onto the Pad
1
2
2
3
Figure 8
1. Dismount the pad unit (2).
2. Remove the slide foil (1) completely.
3. Clear the surface from remains of glue.
4. Remove covering foil from the slide foil (1).
5. Put the slide foil (1) with its adhesive side onto the pad (2). Press
the slide foil firmly on the pad.
6. Cut off overlapping parts of the slide foil (1) according to the
broken line of the pad (2).
7. Punch the slide foil (1) on the pad (2) using the punch pin (3)
appropriate to the hole pattern on the wearing slide foil.
8. Punch the hole completely by turning the pin.
9. Mount the pad unit (2).