Carl Valentin VARIO III series Operating instructions

VARIO III
Service Instructions

Copyright by Carl Valentin GmbH / 7956045.0314
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
Centronics®is a registered trademark of Data Computer Corporation.
Microsoft®is a registered trademark of Microsoft Corporation.
Windows 2000®, 2003®, XP®, Vista®, 7®, 8®, Windows ServerTM 2008,
Windows ServerTM 2008 R2, Windows ServerTM 2012 are registered
trademarks of Microsoft Corporation.
TrueTypeTM is a trademark of Apple Computer, Inc.
Zebra®and ZPL II®are registered trademarks of ZIH Corporation.
Carl Valentin label printers comply with the following safety guidelines:
CE EG Low-Voltage Directive (2006/95/EC)
EG Electromagnetic Compatibility Directive (2004/108/EC)
Carl Valentin GmbH
Postfach 3744
78026 Villingen-Schwenningen
Neckarstraße 78 – 86 u. 94
78056 Villingen-Schwenningen
Phone
Fax
[phone]
[phone]
E-Mail
Internet
[email protected]
www.carl-valentin.de

Vario III Series Table of Contents
03.14 Service Instructions 3
Table of Contents
Table of Contents............................................................................. 3
1Notes on this Document....................................................... 5
1.1User Notes............................................................................... 5
1.2Instructions .............................................................................. 5
1.3Cross References.................................................................... 6
2Safety Instructions................................................................ 7
2.1General Safety Instructions ..................................................... 7
2.2Safety Handling When Working With Electricity...................... 9
2.3Environmentally-Friendly Disposal........................................ 10
3Connector Pin Assignment (Printer Rear)........................ 11
4Cleaning ............................................................................... 13
4.1General Cleaning................................................................... 14
4.2Cleaning the Pressure Roller ................................................ 14
4.3Cleaning the Printhead.......................................................... 15
4.4Cleaning the Label Photocell................................................. 16
5Replacing Components ...................................................... 17
5.1Tools List ............................................................................... 17
5.2Replacing the Printhead ........................................................ 18
5.3Replacing the Pressure Roller............................................... 20
5.4Replacing the Label Photocell............................................... 21
5.5Replacing the CPU PCB ....................................................... 22
5.6Replacing the Power Supply ................................................. 24
5.7Replacing the WLAN module ................................................ 25
5.8Replacing the Battery ............................................................ 26
6Adjustments, settings and alignments ............................. 27
6.1Adjusting the print mechanism .............................................. 27
6.2Adjusting the Printhead ......................................................... 28
6.3Adjusting Parallelism of Printhead......................................... 29
6.4Adjusting Pressure of Printhead............................................ 30
6.5Adjusting Pressure Balance Right/Left.................................. 30
6.6Adjusting the ribbon rewinder/unwinder ................................ 31
6.7Adjusting the Cutter Ledge.................................................... 32
6.8Error Correction of Cutting Edge ........................................... 33
6.9Oil and Lubricate ................................................................... 34
7Refitting Options ................................................................. 35
7.1I/O Plate................................................................................. 35
7.2Dispensing Unit ..................................................................... 36
7.3Cutting Unit............................................................................ 38
8Error correction................................................................... 41
9Control inputs and outputs ................................................ 51
10Wiring Plan........................................................................... 57
10.1CPU Component Placement Specification............................ 58
11Index ..................................................................................... 59

Vario III Series Notes on this Document
03.14 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 103/8 T, 104/8, 107/12, 107/24 and 108/12 T.
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 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.
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
Datum Information in the display

Notes on this Document Vario III Series
6 Service Instructions 03.14
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

Vario III Series Safety Instructions
03.14 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 Vario III Series
8 Service Instructions 03.14
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 label printer is designed for power supply systems of
110-230V. Connect the print module only to electrical outlets with a
ground contact.
Couple the print module to devices using extra low voltage only.
Before making or undoing connections, switch off all devices involved
(computer, printer, accessories etc.).
Operate the print module in a dry environment only and do not get it
wet (sprayed water, mist etc.).
Do not operate the label printer in explosive atmosphere and not in
proximity of high voltage power lines.
Operate the label printer only in an environment protected against
abrasive dust, swarf and other similar impurity.
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 can get hot during printing. Do not touch the printhead
during operation. Cool down the print unit before changing material,
removal or adjustment.
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 label printer 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.
There are warning stickers on the label printer 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.
Protective equipment
General safety
instructions

Vario III Series Safety Instructions
03.14 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

Safety Instructions Vario III Series
10 Service Instructions 03.14
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.
Further information on the WEEE directive is available on our website
www.carl-valentin.de.

Vario III Series Connector Pin Assignment (Printer Rear)
03.14 Service Instructions 11
3 Connector Pin Assignment (Printer Rear)
C
A
D
E
F
B
1
2
G
H
I
J
Figure 1
A Plug-in for CF card
B USB interface
C Serial interface RS-232
Pin 2 = TXD, Pin 3 = RXD, Pin 5 = GND, Pin 7 = CTS, Pin 8 = RTS
D Ethernet 10/100 interface
E USB host for USB keyboard and USB memory stick
F Parallel interface for Centronics
G Switch On/Off
H Power supply
I External output/input (option)
J Winder connection
1 - LED orange
1 - Lighting = Connection active
1 - Flashing = Data transfer
1 - Off = No connection
2 - LED green
2 - Lighting: Speed 100 MBit
2 - Off: Speed 10 MBit

Vario III Series Cleaning
03.14 Service Instructions 13
4 Cleaning
DANGER!
Risk of death by electric shock!
Disconnect the label printer from power supply
before performing any maintenance work.
NOTICE!
When cleaning the label printer, personal protective equipment
such as safety goggles and gloves are recommended.
Cleaning task Frequency
General cleaning (see chapter
4.1, page 14).
As necessary.
Cleaning 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.
Cleaning printhead (see chapter
4.3, page 15).
Each time the transfer ribbon is
changed or when the printout is
adversely affected.
Cleaning 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
schedule

Cleaning Vario III Series
14 Service Instructions 03.14
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 outer surfaces with an all-purpose cleaner.
4.2 Cleaning the Pressure Roller
A soiled pressure roller can lead to reduced print quality and can
affect transport of material.
CBA
Figure 2
1. Open printer cover.
2. Turn lever (C) counter clockwise to lift up the printhead (B).
3. Remove labels and transfer ribbon form the label printer.
4. Remove deposits with roller cleaner and a soft cloth.
5. Turn the roller (A) 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).

Vario III Series Cleaning
03.14 Service Instructions 15
4.3 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 3
1. Open printer cover.
2. Turn lever (A, Figure 2) 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 Vario III Series
16 Service Instructions 03.14
4.4 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.
AB
Figure 4
1. Open printer cover.
2. Turn lever (A, in Figure 2) 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.

Vario III Series Replacing Components
03.14 Service Instructions 17
5 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.
5.1 Tools List
Some service work requires the following tools:
Philips-head screwdriver, size 1
Slot screwdriver, size 1
Hexagonal wrench 2.5 mm
Flat wrench size 0.5

Replacing Components Vario III Series
18 Service Instructions 03.14
5.2 Replacing the Printhead
NOTICE!
The printhead (4) is preinstalled on a head plate (1) and
aligned at the factory.
B
E
C
A
D
Figure 5
A Head plate
B Plug connection signal
C Plug connection tension
D Printhead
E Focal line
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 (B, C).
Do not touch printing line (E) with hard objects or your
hands.

Vario III Series Replacing Components
03.14 Service Instructions 19
CDEED
B
A
A
Figure 6
1. Remove labels and transfer ribbon from the label printer.
2. When printhead is closed, loosen the screws (D).
3. Turn lever (B) counter clockwise to lift up the printhead.
4. If the printhead (C) is not disengaged on the pressure roller,
continue loosen the screws (D).
5. Remove the printhead carefully to the front until you can reach the
plug connections.
6. Remove plug connections and then remove printhead (C).
1. Attach plug connections.
2. Position printhead in printhead mounting bracket in such a way
that the pin is secured in the corresponding hole 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. Tighten again screws (D).
5. Reload labels and transfer ribbon.
6. Check resistance value on the type plate of printhead and if
necessary change the value in the Service functions/heater
resistance.
Removing the
printhead
Installing the
printhead

Replacing Components Vario III Series
20 Service Instructions 03.14
5.3 Replacing the Pressure Roller
A
DED
C
B
FG
Figure 7
1. Turn lever (A) counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon from the printer.
3. Lift up approx. 3 - 4 mm the pins of the two-parts plastic rivet (D)
with help from a tweezers or a small screwdriver. After pulling 2
rivets (D) the front plate (E) can be removed.
4. Unscrew 2 screws (C) at the bearing cover (B) and then remove
the bearing cover (B).
5. Remove pressure roller (F) from the striker arm (G).
1. Press the pressure roller (F) into the striker arm (G).
Pay attention to the correct position of striker arm pins of the
pressure roller (F).
2. Mount the bearing cover (B) with 2 screws (C) to the bottom side
of sole plate.
3. At reassembly pay attention to a precise fitting of the pressure
roller (F).
4. Remove the possible axial play of the pressure roller by
interlocking the striker arm (G) and the mounted pressure roll (F).
5. Insert the pins of the plastic rivets (D) and install again the front
plate (E).
Removing the
pressure roller
Installing the
pressure roller