Carl Valentin ILX Series Operating instructions

Copyright by Carl Valentin GmbH / 7974025A.1118
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 printing systems comply with the following safety
guidelines:
CE
EG Low-Voltage Directive (2006/95/EC)
EG Electromagnetic Compatibility Directive (2004/108/EG)
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

ILX
Table of Contents
11.18
Service Instructions
3
Table of Contents
Table of Contents............................................................................. 3
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 ....................... 9
2.3 Environmentally-Friendly Disposal........................................ 10
3Connector Pin Assignment (Back Side) ........................... 11
4Cleaning ............................................................................... 13
4.1 General Cleaning................................................................... 14
4.2 Cleaning the Transfer Ribbon Drawing Roller....................... 14
4.3 Cleaning the Printer Roller .................................................... 15
4.4 Cleaning the Printhead.......................................................... 16
4.5 Cleaning the Label Photocell................................................. 17
5Replacing Components ...................................................... 19
5.1 Tool List................................................................................. 19
5.2 Replacing the Printhead (General Information)..................... 20
5.3 Replacing the Printhead........................................................ 21
5.4 Adjusting the Print Position ................................................... 23
5.5 Replacing Pressure Roller..................................................... 24
5.6 Replacing the Label Photocell............................................... 26
5.7 Replacing the PCB CPU ....................................................... 28
5.8 Replacing the Power Supply ................................................. 30
5.9 Replacing the PCB Control Inputs/Outputs........................... 32
5.10 Replacing the Power Electronics........................................... 34
5.11 Replacing Applicator Prearrangement (Option) .................... 35
5.12 Replacing the Battery............................................................ 37
6Adjustments, Settings and Alignments ............................ 39
6.1 Adjusting the Print Mechanism.............................................. 39
6.2 Adjusting the Position of Printhead ....................................... 40
6.3 Adjusting the Head Contact Pressure ................................... 44
6.4 Adjusting the Transfer Ribbon Feed Path............................. 46
6.5 Adjusting the Ribbon Rewinder/Unwinder............................. 48
6.6 Ölen und Fetten..................................................................... 49
7Error correction ................................................................... 51
8Control inputs and outputs ................................................ 61
9Connection Plans ................................................................ 55
9.1 Wiring Plan ILX5X/8X, right version...................................... 55
9.2 Wiring Plan ILX 5X/8X, left version ....................................... 56
9.3 Wiring Plan ILX 10X, right version......................................... 57
9.4 Wiring Plan ILX 10X, left version........................................... 58
9.5 CPU Layout Diagram............................................................. 59
10 Index ..................................................................................... 61

ILX
Notes on this Document
11.18
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 the electronics and the
mechanical part of the printing system.
Information about operation of the printing system can be taken from
our operating manual.
If a problem arises that cannot be solved with help of this service
instructions, then please contact your responsible dealer.
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 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
Date
Information in the display

Notes on this Document
ILX
6
Service Instructions
11.18
1.3 Cross References
References to specific items in a figure are marked with letters. They
are identified with parentheses in the text, e.g. (A). If no figure number
is provided, letters 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. (A, 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'.
Drawings
Cross references to
chapters and sections
References to other
documents

ILX
Safety Instructions
11.18
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
ILX
8
Service Instructions
11.18
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 printing system is designed for power supply systems of
110 … 230V. Connect the printing system only to electrical outlets
with a ground contact.
Couple the printing system to devices using extra low voltage only.
Before making or undoing connections, switch off all devices involved
(computer, printer, accessories etc.).
Operate the printing system in a dry environment only and do not get
it wet (sprayed water, mist etc.).
Do not operate the printing system in explosive atmosphere and not in
proximity of high voltage power lines.
Operate the printing system 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.
If the printing system is operated with the cover open, ensure that
clothing, hair, jewellery and similar personal items do not contact the
exposed rotating parts.
NOTICE!
With the printing system (due to construction) the requirements of
EN60950-1 regarding fire protection casing are not fulfilled.
These must be ensured by the installation into the end device.
The printing system 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.
Other unauthorized work or modifications to the printing system can
endanger operational safety.
Protective equipment
General safety
instructions

ILX
Safety Instructions
11.18
Service Instructions
9
There are warning stickers on the printing systems 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.
The print unit must be integrated with the Emergency Stop circuit
when it is incorporated into the overall machine.
All isolating safety equipment must be installed before starting-up the
machine.
DANGER!
Danger to life and limb from power supply!
Do not open the casing.
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.
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.
Qualifications of
personnel
General precautions to
be heeded when
beginning maintenance

Safety Instructions
ILX
10
Service Instructions
11.18
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.
2.3 Environmentally-Friendly Disposal
Manufacturers of B2B equipment are obliged to take back and
dispose of old equipment that was manufactured after 13 August
2005. As a principle, this old equipment may not be delivered to
communal collecting points. It may only be organised, used and
disposed of by the manufacturer. Valentin products accordingly
labelled can therefore be returned to Carl Valentin GmbH.
This way, you can be sure your old equipment will be disposed of
correctly.
Carl Valentin GmbH thereby fulfils all obligations regarding timely
disposal of old equipment and facilitates the smooth reselling of these
products. Please understand that we can only take back equipment
that is sent free of carriage charges.
The electronics board of the printing system is equipped with a
battery. This must only be discarded in battery collection containers or
by public waste management authorities.
Further information on the WEEE directive is available on our website
www.carl-valentin.de.
Additional precautions
to be heeded for
devices with exposed
energized parts
Tools
What to do in case an
accident occurs

ILX
Connector Pin Assignment (Back Side)
11.18
Service Instructions
11
3 Connector Pin Assignment (Back Side)
Right version (ILX 56/8, 80/8, 54/12, 81/12)
D
B
E
F
G
C
H
I
A
1
2
Figure 1
A
Power supply
B
Slot for CF card
C
USB interface
D
Serial interface RS-232
E
Ethernet 10/100
1 =
LED orange
Lighting = Connection active
Flashing = Data transfer
Off = No connection
2 =
LED green
Lighting = Speed 100 MBit
Off = Speed 10 MBit
F
USB host for USB keyboard and
USB memory stick
G
Parallel interface
H
External output/input
I
Power On/Off switch
Left version (ILX 56/8, 80/8, 54/12, 81/12)
D
B
E
F
G
C
I
H
A
1
2
Figure 2
A
Power supply
B
Slot for CF card
C
USB interface
D
Serial interface RS-232
E
Ethernet 10/100
1 =
LED orange
Lighting = Connection active
Flashing = Data transfer
Off = No connection
2 =
LED green
Lighting = Speed 100 MBit
Off = Speed 10 MBit
F
USB host for USB keyboard and
USB memory stick
G
Parallel interface
H
External output/input
I
Power On/Off switch
NOTICE!
For installing the options e.g. unwinder, applicator are different
fixing points available. If you require drawings, send us an email
to [e-mail].

Connector Pin Assignment (Back Side)
ILX
12
Service Instructions
11.18
Right version (ILX 103/8, 104/8, 106/12, 108/12)
D
B
E
F
G
C
I
H
A
1
2
Figure 3
A
Power supply
B
Slot for CF card
C
USB interface
D
Serial interface RS-232
E
Ethernet 10/100
1 =
LED orange
Lighting = Connection active
Flashing = Data transfer
Off = No connection
2 =
LED green
Lighting = Speed 100 MBit
Off = Speed 10 MBit
F
USB host for USB keyboard and
USB memory stick
G
Parallel interface
H
External output/input
I
Power On/Off switch
Left version (ILX 103/8, 104/8, 106/12, 108/12)
D
B
E
F
G
C
I
H
A
1
2
Figure 4
A
Power supply
B
Slot for CF card
C
USB interface
D
Serial interface RS-232
E
Ethernet 10/100
1 =
LED orange
Lighting = Connection active
Flashing = Data transfer
Off = No connection
2 =
LED green
Lighting = Speed 100 MBit
Off = Speed 10 MBit
F
USB host for USB keyboard and
USB memory stick
G
Parallel interface
H
External output/input
I
Power On/Off switch
NOTICE!
For installing the options e.g. unwinder, applicator are different
fixing points available. If you require drawings, send us an email
to [e-mail].

ILX
Cleaning
11.18
Service Instructions
13
4 Cleaning
DANGER!
Risk of death via electric shock!
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.
NOTICE!
When cleaning the printing system, personal protective
equipment such as safety goggles and gloves are
recommended.
Task
Frequency
General cleaning
(see chapter 4.1, page 14).
As necessary.
Cleaning transfer ribbon
drawing roller (see section 4.2,
page 14).
Each time the transfer ribbon is
changed or when the printout is
adversely affected.
Cleaning print roler
(see chapter 4.3, page 14).
Each time the label roll is
changed or when the printout and
label transport are adversely
affected.
Cleaning printhead
(see chapter 4.4, page 16).
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 4.5, page 17).
When the label roll is changed.
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 printing system and cleaned.
Cleaning schedule

Cleaning
ILX
14
Service Instructions
11.18
4.1 General Cleaning
CAUTION!
Abrasive cleaning agents can damage the printing system!
Do not use abrasives or solvents to clean the outer
surface of the printing system.
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 Transfer Ribbon Drawing Roller
A soiled print roll can lead to reduced print quality and can affect
transport of material.
1. Open cover of printing system.
2. Remove labels and transfer ribbon form the printing system.
3. Remove deposits with roller cleaner and a soft cloth.
4. If the roller appears damaged, replace it.

ILX
Cleaning
11.18
Service Instructions
15
4.3 Cleaning the Printer Roller
A soiled print roll can lead to reduced print quality and can affect
transport of material.
CAUTION!
Printer roller can be damaged!
Do not use sharp or hard objects to clean the printer
roller.
ILX 56/8, 80/8, 54/12, 81/12
ILX 103/8, 104/8, 106/12, 108/12
D
A
B
C
C
D
A
B
Figure 5
1. Turn lever (A) counter clockwise to lift up the printhead (B).
2. Remove labels and transfer ribbon form the printing system.
3. Remove deposits with roller cleaner and a soft cloth.
4. Turn the roller (C + D) manually step by step to clean the
complete roller (only possible when printing system is switched
off, as otherwise the step motor is full of power and the roller is
kept in its position).

Cleaning
ILX
16
Service Instructions
11.18
4.4 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.
Figure 6
1. Turn the lever (A, in Figure 5) anticlockwise to lift up the
printhead.
2. Remove labels and transfer ribbon.
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
printing system.

ILX
Cleaning
11.18
Service Instructions
17
4.5 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.
ILX 56/8, 80/8, 54/12, 81/12
ILX 103/8, 104/8, 106/12, 108/12
AB
A
B
Figure 7
1. Turn lever counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon from the printing system.
3. Blow out the photocell (A) with pressure gas spray.
Observe strictly the instructions on the spray can!
4. 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).
5. Reload the labels and transfer ribbon.

Cleaning
ILX
18
Service Instructions
11.18

ILX
Replacing Components
11.18
Service Instructions
19
5 Replacing Components
DANGER!
Risk of death via electric shock!
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.
5.1 Tool List
Some service work requires the following tools:
Philips-head screwdriver, size 1
Hexagonal wrench 1.5 mm
Hexagonal wrench 2.5 mm
Spring scale 10 N
Spring scale 25 N

Replacing Components
ILX
20
Service Instructions
11.18
5.2 Replacing the Printhead (General Information)
NOTICE!
The printhead (D) is preinstalled on a head plate (A) and
precisely aligned at the factory. Do not loosen the screws (G)
under any circumstances.
ILX 56/8, 80/8, 54/12, 81/12
ILX 103/8, 104/8, 106/12, 108/12
EDFG
BA C
G
B
FE
C
A
DG
Figure 8
A
Head plate
B
Plug connection
C
Plug connection
D
Printhead
E
Focal line
F
Guiding
G
Screw
CAUTION!
The printhead can be damaged by static electricity
discharges and impacts!
Set up printing system on a grounded, conductive
surface.
Ground your body, e.g. by wearing a grounded
wristband.
Do not touch contacts on the plug connections (B, C).
Do not touch printing line (E) with hard objects or your
hands.