Carl Valentin COMPA III Operating instructions

COMPA III
Service Instructions

Edition: 10/21 Part No. 7942025
Copyright
Copyright by Carl Valentin GmbH
Subject to 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.
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.
Topicality
Information on the scope of delivery, appearance, performance,
dimensions, and weight reflect our knowledge at the time of printing.
Due to constant further development of our products discrepancies
between documentation and product can occur.
Please check www.carl-valentin.de for the latest update.
Terms and Conditions
Deliveries and services are effected under the General Conditions of
Business of Carl Valentin GmbH
Licences
CE
Low-Voltage Directive (2014/35/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

Compa III
Table of Contents
10.21
Service Instructions
3
Table of Contents
1Notes on this Document....................................................... 5
1.1 User Notes............................................................................... 5
1.2 Instructions .............................................................................. 5
1.3 Cross References.................................................................... 6
2Safety Instructions ................................................................ 7
2.1 General Safety Instructions..................................................... 7
2.2 Safety Handling when Working with Electricity ..................... 10
3Printer Rear (Ports) ............................................................. 11
4Cleaning ............................................................................... 13
4.1 General Cleaning................................................................... 14
4.2 Clean the Pressure Roller ..................................................... 14
4.3 Clean the Printhead............................................................... 15
4.4 Clean the Label Photocell ..................................................... 16
5Replacing Components ...................................................... 19
5.1 Tool List................................................................................. 19
5.2 Replace the Printhead........................................................... 20
5.3 Adjust the Print Position ........................................................ 22
5.4 Replace the Pressure Roller and Dispenser Roller............... 23
5.5 Replace the Slipping Clutches .............................................. 24
5.6 Replace the Label Photocell.................................................. 26
5.7 Replace the CPU PCB .......................................................... 27
5.8 Replace the Power Supply Unit............................................. 28
5.9 Replace the Battery............................................................... 29
6Adjustments, Settings and Alignments ............................ 31
6.1 Adjust the Winding Torques .................................................. 31
6.2 Measure the Winding Torques at Ribbon Rewinder/Unwinder32
6.3 Measure the Torques at the Internal Rewinder..................... 34
6.4 Set the Winding Torque......................................................... 36
6.5 Adjust the Print Mechanism................................................... 37
6.6 Adjust the Position of Printhead............................................ 39
6.7 Adjust the Head Contact Pressure........................................ 41
6.8 Adjust the Transfer Ribbon Feed Path.................................. 42
6.9 Adjust the Belt Tension at Main Drive Motor......................... 44
7Retrofit with Options........................................................... 45
7.1 I/O Plate................................................................................. 45
7.2 Dispenser Unit with Photocell................................................ 46
7.3 Cutter..................................................................................... 47
8Error Correction................................................................... 49
9Control Inputs and Outputs................................................ 59
10 Wiring Plan........................................................................... 65
10.1 CPU Component Placement Specification............................ 66
11 Environmentally-Friendly Disposal ................................... 67
12 Index ..................................................................................... 69

Table of Contents
Compa III
4
Service Instructions
10.21

Compa III
Notes on this Document
10.21
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.
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 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

Notes on this Document
Compa III
6
Service Instructions
10.21
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, 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 III
Safety Instructions
10.21
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.
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
Workplace and
method of working
Clothing
Protective clothing

Safety Instructions
Compa III
8
Service Instructions
10.21
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 printer is designed for power supply systems from 100 … 240 V
AC. Connect the label printer only to electrical outlets with a ground
contact.
Couple the label printer to devices using extra low voltage only.
Before making or undoing connections, switch off all devices involved
(computer, printer, accessories etc.).
Operate the label printer in a dry environment only and do not get it
wet (sprayed water, mist etc.).
Do not use the label printer in an explosive atmosphere.
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.
CAUTION!
Risk of crushing when closing the cover.
When closing the cover, only touch it from the outside
and do not reach into the pivoting range of the cover.
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 and parts of it (e.g. 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.
Other unauthorized work or modifications to the direct print module
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.
Protective equipment
General safety
instructions

Compa III
Safety Instructions
10.21
Service Instructions
9
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.
DANGER!
Danger to life and limb from power supply!
Do not open the casing.

Safety Instructions
Compa III
10
Service Instructions
10.21
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.
Do 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 III
Printer Rear (Ports)
10.21
Service Instructions
11
3 Printer Rear (Ports)
A
B
C
D
F
G
H
I
E
Figure 1
A = Slot for CF card
B = USB interface
C = Switch On/Off
D = Serial RS-232 port
E = Power supply
F = USB host for USB keyboard and USB stick
G = Ethernet 10/100 interface
G = LED orange
G = Lighting = Connection active
G = Flashing = Data transfer
G = Off = No connection
G = LED green
G = Lighting = Speed 100 MBit
G = Off = Speed 10 MBit
H = USB host for USB keyboard and USB stick
I = Externel I/O (option)

Printer Rear (Ports)
Compa III
12
Service Instructions
10.21

Compa III
Cleaning
10.21
Service Instructions
13
4 Cleaning
DANGER!
Risk of death by electric shock!
Disconnect the label printer from the mains supply and
wait for a moment until the power supply unit has
discharged.
CAUTION!
Risk of injury when cleaning.
Pay attention to sharp edges.
NOTICE!
When cleaning the label printer, personal protective equipment
such as safety goggles and gloves are recommended.
Task
Frequency
General cleaning (see chapter
4.1, page 14).
As necessary.
Clean the pressure roller (see
chapter 4.2, page 14).
Each time the label roll is
changed or when the printout and
label transport are adversely
affected.
Clean the printhead (see
chapter 4.3, page 15).
Each time the transfer ribbon is
changed or when the printout is
adversely affected.
Clean the label photocell (see
chapter 4.4, page 16).
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.
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 plan

Cleaning
Compa III
14
Service Instructions
10.21
NOTICE!
For adjustments and simple installation work, use the
accompanying hexagonal wrench located in the upper section
of the print unit. No other tools are required for the work
described here.
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 the outer surfaces with an all-purpose cleaner.
4.2 Clean 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.
1. Turn the lever (3, Figure 5) counterclockwise to lift up the
printhead.
2. Remove labels and transfer ribbon.
3. Remove deposits with the roller cleaner and a soft cloth.
4. If the roller appears damaged, replace it (see chapter 5.4 Replace
the Pressure Roller and Dispenser Roller, page 23).
Tools and cleaning
agents

Compa III
Cleaning
10.21
Service Instructions
15
4.3 Clean 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 the lever (3, Figure 5) counterclockwise to lift up the
printhead.
2. Remove labels and transfer ribbon.
3. Clean the printhead surface with a special cleaning pen or a
cotton swab dipped in pure alcohol.
4. Before using the label printer, let the printhead dry for about two to
three minutes.

Cleaning
Compa III
16
Service Instructions
10.21
4.4 Clean 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 be soiled with paper dust. This may affect the
label scanning.
1
2
34
Figure 2
1. Remove labels and transfer ribbon.
2. Loosen the screw (5).
3. Press the locking (1) and slowly pull the label photocell outward
via the handle (3). Make sure that the photocell cable is not
stretched.
4. Clean the label photocell and the sensor slots (4) with a brush or a
cotton bud soaked in pure alcohol.
5. Push back the label photocell at the handle (3) and set it (see
operating manual).
6. Push the hexagon wrench (5) into the holder.
7. Reload labels and transfer ribbon.
Compa III 10X

Compa III
Cleaning
10.21
Service Instructions
17
1
2
34 5
Figure 3
DANGER!
Danger to life from mains voltage/electric shock!
Before maintenance work, disconnect the label
printer from the power supply and wait briefly until
the power supply unit has discharged.
The following work must be carried out by trained
service personnel!
1. Remove labels and transfer ribbon.
2. Loosen two hexagon socket screws on the upper cover edge and
then remove the left cover of printer.
3. Push the label photocell on the handle (3) as far as it will go in the
direction of the housing and pull the connection cable out of the
plug at the rear end of the label photocell.
4. Press the locking (1) and slowly pull the label photocell outward
via the handle (3). In this process, push the spacer plate (5) out of
the guiding of the photocell
5. Clean the label photocell and the sensor slots (4) with a brush or a
cotton bud soaked in pure alcohol.
6. Push the label photocell on the handle (3) towards the housing
wall.
7. Press the locking (1) and push the spacer plate (5) back into the
guiding of photocell.
8. Connect the connecting cable at the label photocell.
9. Mount again the left printer cover.
10. Adjust the label photocell.
11. Reload labels and transfer ribbon.
Compa III 162

Compa III
Replacing Components
10.21
Service Instructions
19
5 Replacing Components
DANGER!
Risk of death via electric shock!
Before opening the housing cover, disconnect the label
printer from the mains supply and wait for a moment 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 upper 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

Replacing Components
Compa III
20
Service Instructions
10.21
5.2 Replace the Printhead
CAUTION!
The printhead can be damaged by static electricity
discharges and impacts!
Set up the printer on a grounded, conductive surface.
Ground your body, e.g. by wearing a grounded
wristband.
Do not touch contacts on the plug connections (4, 5).
Do not touch printing line (6) with hard objects or your
hands.
1
7
221
6
3
4
5
3
9
8
Figure 4
1 =
Carrier
2 =
Screws for fixing the intermediate
layer at the printhead support
3 =
Screws for fixing the printhead at
the intermediate layer
4 =
Plug connection Signals
5 =
Plug connection Tension
6 =
Printing line
7 =
Thermal printhead
8 =
Intermediate layer
9 =
Guiding for transfer ribbon
NOTICE!
The intermediate layer (8) remains on the printer. Only the
printhead (7) is replaced.
CAUTION!
Danger of abrasion when removing/installing the printhead!
Pay attention to the toothing when the tear-off edge is
installed.