Carl Valentin Vario II series User manual

Service Manual - English
Vario II Series
79.55.023 • September 2002
All rights reserved.
Carl Valentin GmbH • Neckarstraße 78 – 82 & 94 • 78056 Villingen-Schwenningen
[e-mail] • www.valentin-carl.de

Table of contents
1
WIRING PLANS .........................................................................................................1
Electronics...............................................................................................................................................1
CPU............................................................................................................................2
Plan of components.................................................................................................................................2
Jumper plan.............................................................................................................................................3
Components and plug-in positions..........................................................................................................3
POWER UNIT (REVISION B).....................................................................................4
Plan of components.................................................................................................................................4
Components and plug-in positions..........................................................................................................4
MEMORY CARD SLOT (OPTION).............................................................................5
Plan of components.................................................................................................................................5
Components and plug-in positions..........................................................................................................6
INPUT/OUTPUT PLATE (OPTION)............................................................................7
Plan of components.................................................................................................................................7
Jumper plan.............................................................................................................................................8
Components and plug-in positions..........................................................................................................8
ETHERNET (OPTION)...............................................................................................9
Plan of components.................................................................................................................................9
Components and plug-in positions..........................................................................................................9
CONNECTIONS BACK PANEL................................................................................10
MEASURING POINTS POWER UNIT......................................................................11
Voltage supply...................................................................................................................................... 11
Printhead voltage* ................................................................................................................................ 12
Printhead voltage* ................................................................................................................................ 12
Tranformer voltage*.............................................................................................................................. 12
Feed motor ........................................................................................................................................... 13
Motor signals ........................................................................................................................................ 14

Table of contents
2
MEASURING POINTS CPU.....................................................................................16
Voltage supply...................................................................................................................................... 16
Clock Signal: RESET............................................................................................................................ 16
Clock Signal: Systemclock ................................................................................................................... 17
Printhead signals.................................................................................................................................. 18
MEASURING POINTS PHOTOCELLS ....................................................................19
Label photocell transmission................................................................................................................ 19
Label photocell reflexion....................................................................................................................... 19
Transfer ribbon control photocell (TCR)............................................................................................... 20
Dispenser photocell (option)................................................................................................................. 20
EXCHANGE OF DEFECTIVE COMPONENTS........................................................21
Exchange of fuse.................................................................................................................................. 21
CPU...................................................................................................................................................... 23
Printhead FPGA*.................................................................................................................................. 24
Input/Output FPGA*.............................................................................................................................. 24
Batterie*................................................................................................................................................ 24
Power unit............................................................................................................................................. 25
OPTIONS .................................................................................................................26
Refit memory card slot.......................................................................................................................... 26
Refint input/output plate........................................................................................................................ 27
Refit RS-485 and RS-422 plate............................................................................................................ 30
Refit Ethernet plate............................................................................................................................... 31
Refit dispenser...................................................................................................................................... 32
Refit cutter ............................................................................................................................................ 33
Adjust cutter ledge................................................................................................................................ 35
MECHANIC ..............................................................................................................37
Exchange of printhead.......................................................................................................................... 37
Adjustment of printhead Flat Type KF.................................................................................................. 38
Adjust rewinder / unwinder................................................................................................................... 40
Exchange pressure roll......................................................................................................................... 41
Exchange / clean label photocell.......................................................................................................... 43
Oil and Lubricate .................................................................................................................................. 44

Table of contents
3
CONNECTION PLAN INTERFACES .......................................................................45
Centronics............................................................................................................................................. 45
RS-232.................................................................................................................................................. 45
RS-485 and RS-422............................................................................................................................. 46
Ethernet (Option).................................................................................................................................. 47
INDEX ......................................................................................................................49

Service Manual
1
WIRING PLANS
Electronics

Service Manual
2
CPU
Plan of components

Service Manual
3
Jumper plan
JP1
JP2
JP3
JP4
BOOT 1-2 open closed 1-2
STANDARD 2-3 open open 1-2
JP5 JP7 JP8 JP9
BOOT
closed open 1-2 1-2
STANDARD
closed closed 2-3 2-3
Components and plug-in positions
Components:
P1 Sensibility label photocell tranmission
P2 Sensibility label photocell reflexion
P3 Sensibility dispenser photocell
U1; U2 FLASH component
U3 32bit RISC processor
U5; U6 DRAM
U8 RESET component
U10 RTC
U11 INPUT/OUTPUT FPGA
U13 RS-232 component
U14 USB component
U20 Printhead FPGA
U28 serial EEPROM
Plug-in positions
ST1 Bus plug (Ethernet)
ST7 Label photocell reflexion
ST8 Dispenser photocell
ST11 Printhead open/closed
ST12 Ribbon savings photocell (option)
ST13 Connection to power unit
ST14 Label photocell transmission
ST15 Ribbon control
ST16, 17, 19 Dispensing I/O, RS-485, RS-422 (option)
ST20 Memory Card (Option)
ST21 Foil keyboard
ST22 Printhead KCE107/12 or KCE 160/12
ST23 Printhead RH108/12 or RH162/12
ST24 LCD display

Service Manual
4
POWER UNIT (REVISION B)
Plan of components Components and plug-in positions
Components:
U1
U2
U3
U4
Z1
F1
T3
control component printhead heater voltage
voltage control 5 V
voltage control 24 V
motor driver feed motor
bridge-connected rectifier
secondary fuse 10 A/T
P canal MOS-FET 100V/50A printhead voltage
Plug-in positions:
ST1
ST3
ST4
ST5
ST6
ST7
ST10
motor plug cutter motor (option)
motor plug 'internal winder' (option)
fan
motor plug feed motor
toroidal transformer
connection to CPU
heater voltage printhead
Measuring points:
5V
24V
40V
GND
voltage for CPU VCC
heater voltage printhead VDK
input voltage VIN
mass

Service Manual
5
MEMORY CARD SLOT (Option)
Plan of components

Service Manual
6
Components and plug-in positions
Components:
U3 data bus driver
Q1 switching transistor for memory card voltage
Plug-in positions:
JP1 connection to CPU

Service Manual
7
INPUT/OUTPUT PLATE (OPTION)
Plan of components

Service Manual
8
Jumper plan
Only valid for complete equipped I/O plate
Function Jumper position JP6
RS-422
full duplex 2-1
RS-485
half duplex 2-3
Components and plug-in positions
Components:
U1 EPLD component
U2 Optocoupler outputs 1-4 (Output1)
U3 Optocoupler outputs 5-8 (Output2)
U4 Optocoupler inputs 1-4 (Input1)
U5 Optocoupler inputs 5-8 (Input2)
U6 driver inputs
U7 Driver RS-422 / RS-485
U8 Optocoupler DTR/DIR
U9 Optocoupler TXD1
U10 Optocoupler RXD1
U11 Voltage transformer 5V ±5V
U20, 21 Interface component RS422 / RS485
Plug-in position:
ST1 Outputs 1-4 (Output1)
ST2 Outputs 5-8 (Output2)
ST3 Inputs 1-4 (Input 1)
ST4 Inputs 5-8 (Input2)
ST5 RS-485 / RS-422
ST 16, 17, 19 Connection to CPU

Service Manual
9
ETHERNET (Option)
Plan of components Components and plug-in positions
Components:
U1
U5
U6
TR1
ethernet processor
reset inverter
voltage control 3.3V
transformer
Plug-in positions:
ST1 connection bus plug CPU

Service Manual
10
CONNECTIONS BACK PANEL
A = Output (option)
B = Input (option)
C = USB
D = Connection PC keyboard
E = Memory card interface (option)
F= Centronics
G = RS-232
H = Ethernet (option)
I = RS-422/RS-485 (connection)
J = Winder connection

Service Manual
11
MEASURING POINTS POWER UNIT
Voltage supply
Attention: Unplug the printer!
Only experienced staff is allowed to open the printer and to proceed measuring.
The main measuring points are between ST3 (cut sensor) and SST7 (transformer input)
Measuring point Description Correct value Notes
5V VCC 5V
24V VDK The printhead
voltage depends on
3 factors (see below)
40V VIN 40V
GND GND 0V
1. factor = Contrast (the higher the contrast, the higher the printhead voltage)
2. factor = Printhead resistance (the higher the resistance, the higher the printhead voltage)
3. factor = Printhead temperature (the higher the temperature, the lower the printhead voltage)

Service Manual
12
Printhead voltage*
The printhead voltage depends on the following 3 factors:
1. factor = Contrast (the higher the contrast, the higher the printhead voltage)
2. factor = Printhead resistance (the higher the resistance, the higher the printhead voltage)
3. factor = Printhead temperature (the higher the temperature, the lower the printhead voltage)
The measured voltages are approximate values and therefore fluctuations from printer to printer can
be possible:
Contrast Measured printhead voltage
printhead voltage: 1265
printhead temperature: 22°C
Measured printhead voltage
printhead voltage: 1330
printhead temperature: 22°C
10% ≈ 22,78V ≈ 23,26V
100% ≈ 23,69V ≈ 24,17V
200% ≈ 24,66V ≈ 25,15V
Tranformer voltage*
Measuring point Description Correct value Notes
ST7 PIN1 und 4;
PIN2 und 3 28V1 /28V2 ~ 30V voltage alternating current VAC
* Attention: Unplug the printer!
Only experienced staff is allowed to open the printer and to proceed measuring.

Service Manual
13
Feed motor
Attention: Unplug the printer!
Only experienced staff is allowed to open the printer and to proceed measuring.
Measuring point Description Correct value Notes
ST9 PIN28;
D18 anode FD_EA release motor driver phase A
ST9 PIN31;
D19 anode FD_EB release motor driver phase B
ST9 PIN32;
R106 FD_C control input motor current
ST9 PIN19;
D17 anode FD_PA input signal motor driver phase A
ST9 PIN33
D20 anode FD_PB input signal motor driver phase B
ST9 PIN30
U15 PIN1 or PIN13 SYNC ≈ 28kHz synchronisation motor driver
Schematic drawing of feed signals

Service Manual
14
Motor signals
Winder motor (option)*
Measuring point Description Correct value Notes
D23 Cathode
24V
24V
D23 Anode
GND
0V
T10 releases D23 anode.
For feed motor the mass is switched
through. Winder motor runs
Motor current and input signals phase A and B are analog to feed motor.
Cutter motor (option)*
Measuring point Description Correct value Notes
D22 Kathode 24V 24V
ST7 PIN39 und PIN40 VCC 5V
ST7 PIN25 CUT_Home
ST7 PIN29 Cutsensor
ST5 PIN1 und PIN2 GND 0V
Attention:Unplug the printer!
Only experienced staff is allowed to open the printer and to proceed measuring.