Ice vulcan User manual

ICEVulcanServiceManual
Vulcan
Service Manual

For Customers in the European Union
This equipment displays the CE mark to indicate conformance to the following legislation:
EMC Directive 2004/108/EC
Essential health and safety requirements relating to electromagnetic
compatibility. CISPR22:2008 (Class A) Information Technology
Equipment - Radio
Disturbance Characteristics - Limits and
methods of measurement.
IEC 61000-6-2 Generic standards - Immunity for
industrial environments.
IEC 61000-6-4 Generic Emissions Standard for Heavy
Industrial Environments.
IEC 61000-3-2 Limits for harmonic current emissions
(equipment input current <=16A per phase).
IEC 61000-3-3 Limitation of voltage changes, voltage
fluctuations and flicker in public low voltage
supply systems for equipment with rated
current <=16A per phase and not subject to
conditional connection.
Low Voltage Directive 2006/95/EC
Essential health and safety requirements relating to electrical equipment designed
for use within certain voltage limits.
EN 60950-1 Safety requirements for information
technology equipment including electrical
business equipment
IEC 60950-1
Machinery Directive 2006/42/EC
EN 60204-1
IEC 60204-1
Safety of machinery - Electrical
equipment of machines.
EN ISO 12100 Safety standard for machinery.

ICE Vulcan Service Manual
EN ISO 13849-1 Safety requirements and guidance on the
principles for the design and integration of
safety-related parts of control systems
(SRP/CS), including the design of software.
RoHS Directive 2011/65/EC
Restriction of the use of certain hazardous substances (RoHS)
EN 50581 Technical documentation for the
assessment of electrical and electronic
products with respect to the restriction of
hazardous substances.
Support and Training
Contact Information
If you have any questions or need assistance, contact ICE on
01159 640144
Interactive Coding Equipment (ICE)
Olympic House
Willow Drive
Sherwood Park
Nottingham
NG15 0DP
Web: www.interactivecoding.co.uk

ICE Vulcan Service Manual
Customer Training
If you wish to perform your own service and maintenance on the LPA, ICE highly recommends
you complete a Customer Training Course on the LPA.
For more information, please contact us on
01159 640144
Interactive Coding Equipment (ICE)
Olympic House
Willow Drive
Sherwood Park
Nottingham
NG15 0DP
Web: www.interactivecoding.co.uk
Note: The manuals are intended to be supplements to (and not replacements for) ICE.
Customer Training.

ICE Vulcan Service Manual
Table of Contents
Compliance Information
For Customers in the U.S.A. ..........................................................................................................i
For Customers in Canada.............................................................................................................ii
For Customers in the European Union .........................................................................................ii
Support and Training
Contact Information ...................................................................................................................iv
Service Program..........................................................................................................................iv
Customer Training .......................................................................................................................v
Chapter 1 —Introduction
Equipment Description............................................................................................................1–1
About the Manual....................................................................................................................1–1
Related Publications ................................................................................................................1–2
Language Codes.......................................................................................................................1–2
Content Presentation ..............................................................................................................1–3
Positional References ..............................................................................................................1–3
Units of Measurement............................................................................................................ 1–3
Safety Information...................................................................................................................1–4
Notes........................................................................................................................................1–5
Abbreviations and Acronyms...................................................................................................1–5
Chapters in the Manual .......................................................................................................... 1–6
Chapter 2 —Safety
Introduction............................................................................................................................ 2–2
Equipment Safety Guidelines ................................................................................................. 2–2
Comply with Electrical Codes ..................................................................................................2–3
Electrical Power .......................................................................................................................2–4
Do Not Remove Warning Label ...............................................................................................2–5
Grounding and Bonding...........................................................................................................2–5
Printhead ................................................................................................................................ 2–6
Print Ribbon Safety Guidelines ................................................................................................2–6
Placement of the Equipment...................................................................................................2–7
Using Accessories.....................................................................................................................2–7
Other Important Guidelines ....................................................................................................2–7
Cleaning Safety Guidelines ......................................................................................................2–8
Equipment Handling Safety Guidelines .................................................................................. 2–8
Chapter 3 —Main Parts

ICE Vulcan Service Manual
System Overview .................................................................................................................... 3–2
CLARITY Display ................................................................................................................. 3–3
Labeller .............................................................................................................................. 3–4
Main Controller Board for the LPA .................................................................................... 3–4
Gap Sensor and Print Roller Sensor PCB............................................................................ 3–5
Ribbon and Printhead Sensor PCB..................................................................................... 3–5
Label Drive Motor PCB....................................................................................................... 3–6
CLARiTY Display PCB .......................................................................................................... 3–6
Supply Reel Hall Sensor PCB .............................................................................................. 3–7
Dancer Arm Sensor PCB..................................................................................................... 3–7
Connectors......................................................................................................................... 3–8
Ribbon Web ..................................................................................................................... 3–14
Label Web ........................................................................................................................ 3–16
Emergency Stop (E-Stop) ................................................................................................. 3–18
Sensors............................................................................................................................. 3–19
Printhead ......................................................................................................................... 3–20
Chapter 4 —Installation
Tools and Supplies ............................................................................................................. 4–3
Tools................................................................................................................................... 4–3
Supplies.............................................................................................................................. 4–3
Unpacking and Inspecting the Labeller ............................................................................. 4–3
Selection of a Suitable Installation Position ...................................................................... 4–3
Positioning of Labeller/Peel Tip......................................................................................... 4–4
Installing the Label Applicator ........................................................................................... 4–5
Assembling the Stand ........................................................................................................ 4–5
Mounting the LPA.............................................................................................................. 4–9
Setting up the Production Line ........................................................................................ 4–11
Mounting the CLARiTY Display ........................................................................................ 4–13
Instating the Product Detector........................................................................................ 4–14
Cable Connections ........................................................................................................... 4–15
Loading the Web.............................................................................................................. 4–17
Turning On the Machine.................................................................................................. 4–23
Setting up the User Interface .......................................................................................... 4–23
Chapter 5 —CLARiTY Operating System
Getting started with the CLARiTY ...................................................................................... 5–1

ICE Vulcan Service Manual
Using the Home Page ........................................................................................................ 5–2
How to Configure the LPA ................................................................................................. 5–6
CLARiTY Configuration Manager ....................................................................................... 5–6
How to Connect the CLARiTY Configuration
Manager to the LPA ........................................................................................................... 5–8
How to Edit the Parameters ............................................................................................ 5–14
How to Save the Changes in the LPA............................................................................... 5–15
How to Archive the Current Parameters ......................................................................... 5–16
How to Load a Saved Archive .......................................................................................... 5–17
Creating, Editing and Restoring a USB Archive on a
CLARiTY LPA ..................................................................................................................... 5–17
How to Set the External Outputs..................................................................................... 5–21
External Outputs.............................................................................................................. 5–21
Working with Passwords ................................................................................................. 5–23
CLARiTY Power Saving ..................................................................................................... 5–25
How to Configure the Job Settings .................................................................................. 5–27
Job Creation and Settings ................................................................................................ 5–27
CLARiTY Configuration Settings ....................................................................................... 5–28
Managing Clones ............................................................................................................. 5–31
How to Create a Clone..................................................................................................... 5–31
How to Restore a Clone ................................................................................................... 5–34
Chapter 6 —Maintenance and Troubleshooting
Maintenance...................................................................................................................... 6–1
Preventive Maintenance Schedule.................................................................................... 6–1
Replacement Instructions.................................................................................................. 6–2
Motor Calibration Wizard.................................................................................................. 6–4
Updating the CLARiTY Operating System .......................................................................... 6–9
Troubleshooting............................................................................................................... 6–14
Diagnostics Wizard .......................................................................................................... 6–14
LED Indicator Description ................................................................................................ 6–17
CLARiTY Error Messages .................................................................................................. 6–18
Barcode Scanner Faults and Warnings ............................................................................ 6–27
Job File Faults and Warnings ........................................................................................... 6–28
CLARiTY Display Faults..................................................................................................... 6–28
I/O Faults ......................................................................................................................... 6–28
Label Web Faults ............................................................................................................. 6–29

ICE Vulcan Service Manual
Chapter 7 —Illustrated Parts List
How to Read the IPL .......................................................................................................... 7–1
Illustrations ........................................................................................................................ 7–1
Notes.................................................................................................................................. 7–2
LPA Assembly..................................................................................................................... 7–3
LPA ..................................................................................................................................... 7–4
Label Web .......................................................................................................................... 7–8
CLARiTY Display................................................................................................................ 7–14
Printhead Assembly......................................................................................................... 7–16
Ribbon.............................................................................................................................. 7–23
Accessories ...................................................................................................................... 7–25
Stands .............................................................................................................................. 7–25
Additional Accessories..................................................................................................... 7–28
Accessories Cables........................................................................................................... 7–29
Cables............................................................................................................................... 7–29
Chapter 8 —Master Slave Setup
Working with Master/Slave............................................................................................... 8–1
Master/Slave Benefits ....................................................................................................... 8–1
Master/Slave Applications................................................................................................. 8–2
Master/Slave Terminology ................................................................................................ 8–2
LPA Terminology................................................................................................................ 8–2
Physical Installation ........................................................................................................... 8–3
Software Configuration ..................................................................................................... 8–4
Master/Slave Basic and Advanced Configuration ............................................................. 8–5
Auto-Changeover Mode .................................................................................................. 8–17
Using Master/Slave Mode - Group Job Select Mode ...................................................... 8–21
The Master LPA................................................................................................................ 8–21
The Slave LPAs ................................................................................................................. 8–25
Using Master/Slave Mode - Group Control Mode .......................................................... 8–25
The Master LPA................................................................................................................ 8–25
The Slave LPAs ................................................................................................................. 8–28
Disabling Master/Slave Mode ......................................................................................... 8–28
Disabling Auto-Changeover Mode................................................................................... 8–31

9
ICEVulcanServiceManual
Appendix A —Specifications
Technical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
CLARiTY Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Label Printer Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4
External Connectors and Interface Specifications . . . . . . . . . . . A–4
Appendix B —CLARiTY Configuration Manager
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B–1
CLARiTY Configuration Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B–2
Appendix C —Main Board Test Points
Main Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1
Appendix D —Theory Of Printing
Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–2
Appendix E —Availability
Overall Equipment Effectiveness - Availability Tools . . . . . . . . . . . . E–1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1
Equipment Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1
Operational Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–2
Availability Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3
Glossary

Equipment Description 1-1
ICEVulcanServiceManual
Introduction
This chapter contains the following topics:
• Equipment description
• About the manual
• Related publications
• Content presentation
• Abbreviations and acronyms
• Chapters in the manual
Equipment Description
The Vulcan is a smarter print and apply labeller that eliminates unscheduled downtime and
reduces costs and errors in case coding operations. The Label Printer Applicator is a simple,
reliable system with a minimum number of wear parts, and zero manual adjustments. Applying
Intelligent MotionTM technology ensures automatic and precise control of the entire system. In
addition, Direct Apply provides accurate placement of on-demand labels at high speed without
the need for an applicator (top or side applications only), enabling it to never miss a pack even
during build-back.
Vulcan maximizes uptime, increase productivity and remove the risk of mislabelled packages
by using the most intelligent and user friendly labelling system.
About the Manual
The Service Manual is intended for the use of technicians servicing the LPA. The Service Manual
contains the configuration, maintenance, and troubleshootingprocedures.

Equipment Description 1-1
ICEVulcanServiceManual
Related Publications
The following manuals are available for reference: Vulcan Operator
Manual, Part Number: 462469. Tamp Applicator Addendum, Part Number:
462475-01.
Language Codes
When you order this manual, make sure to add the 2-digit language code at the end of the
part number. For example, the English UK version of the service manual is part number
462470-21. Table 1-1 shows the list of language codes that you can use to identify the
translated versions of this manual.
Note: The availability of the Operator Manual is indicated by an asterisk (*). Availability of
the Service Manual is indicated by a plus sign (+). For more information, contact the ICE
distributor or subsidiary.
Code
Language
Availability
(see
note)
01
English (US)
*
+
02
French
*
03
German
*
04
Spanish
*
05
Portuguese Brazilian
*
06
Japanese
*
07
Russian
*
08
Italian
*
09
Dutch
*
10
Chinese (Simplified)
*
11
Arabic
*
12
Korean
*
13
Thai
*
15
Norwegian
*
16
Finnish
*
17
Swedish
*
Table 1-1: List of Language Codes

Content Presentation 1-3
ICEVulcanServiceManual
Code
Language
Availability
(see
note)
18
Danish
*
19
Greek
*
20
Hebrew
*
21
English (UK)
*
+
23
Polish
*
24
Turkish
*
25
Czech
*
26
Hungarian
*
33
Vietnamese
*
34
Bulgarian
*
36
Chinese (Traditional)
*
Table 1-1: List of Language Codes (Continued)
Content Presentation
This Service Manual contains different types of information like safety guidelines, additional
notes, CLARiTY configuration manager terminologies and so on. To help you identify the
different types of information, different writing styles are used in this manual.
Positional References
Positions and directions like left, right, front, rear, to the right and to the left are with respect
to the CLARiTY display when you see it from the front.
Units of Measurement
This manual uses metric units of measurement. The equivalent English measures are included in
parenthesis. For example, 240 mm (9.44 inches).

Content Presentation 1-3
ICEVulcanServiceManual
Safety Information
Specific safety information is listed throughout this manual in the form of Warning and
Caution statements. Pay close attention to these statements as they contain important
information that help in avoiding potential hazards to yourself or to the equipment.
Warning
• The warning statements indicate hazards or unsafe practices that can cause severe personal
injury or death.
• They have a triangular symbol with an exclamation mark to the immediate left of the
text
• They are always preceded by the word “Warning”
• They are always found before the step or information referring to the hazard
For example:
Warning
PERSONAL INJURY. All electrical wiring and connections must comply with applicable local
codes. Consult the appropriate regulatory agency for further information.
Caution
• The caution statements indicate hazards or unsafe practices that result in equipment or
property damage
• They have a triangular symbol with an exclamation mark to the immediate left of the
text
• They are always preceded by the word “Caution”
• They are always found before the step or information referring to the hazard
For example:
Caution
EQUIPMENT DAMAGE. Read this chapter thoroughly before attempting to install, operate,
service, or maintain this equipment.

Abbreviations and Acronyms 1-5
ICEVulcanServiceManual
Notes
Notes provide additional information about a particular topic. For example:
Note: You can set the password protection for some functions to prevent any access that is
not authorised.
Abbreviations and Acronyms
Abbreviation
Expansion
AC
Alternating Current
I/O
Input/Output
LCD
Liquid Crystal Display
LED
Light Emitting Diode
LPA
Label Printer Applicator
POE
Power Over Ethernet
UI
User Interface
USB
Universal Serial Bus
WYSIWYG
What You See Is What You Get
Table 1-2: Abbreviations and Acronyms

Abbreviations and Acronyms 1-5
ICEVulcanServiceManual
Chapters in the Manual
This manual is divided into thirteen chapters. An introduction to the topics that each chapter
covers is shown in Table 1-3.
Chapter
No.
Chapter Name
Description
1.
Introduction
Contains the information about this
manual, the related publications, and
writing styles used in this manual.
2.
Safety
Contains the safety and hazard information.
3.
Main Parts
Describes the main parts of the LPA.
4.
Installation
Contains the information about
installation of the main components of
LPA.
5.
CLARiTY Operating
System
Contains the information on CLARiTY configuration
manager.
6.
Maintenance and
Troubleshooting
Contains the information on replacement
instructions, service, maintenance, error
messages, its possible causes and the remedies.
7.
IPL
Contains the illustrated parts list of orderable parts.
8.
Master Slave Setup
Contains information about master/slave setup.
9.
Appendix A
Contains information about technical drawings,
technical and system specifications, and external
inputs and outputs.
10.
Appendix B
Contains the lists of all the configurable parameters
of LPA.
11.
Appendix C
Contains informations about Mains board test
points.
12.
Appendix D
Contains the theory of printing.
13.
Appendix E
Contains information about availability.
Table 1-3: List of Chapters

2-1
ICEVulcanServiceManual
Safety
This chapter contains the following topics:
• Introduction
• Equipment Safety Guidelines
• Print Ribbon Safety Guidelines
• Placement of Equipment
• Other Important Guidelines
Caution
EQUIPMENT DAMAGE. Read this chapter thoroughly before attempting to install, operate,
service, or maintain this equipment. All available safety information should be observed and
practised to operate the LPA safely and efficiently.
Warning
PERSONAL INJURY. Observe all safety and warning labels on the device for the safe operation of
the system.
Warning
PERSONAL INJURY. Follow the installation and operating instructions at all times. Only trained
personnel should carry out maintenance or repair. Adjustments should only be made as per
instructions and training given. Use of this equipment for any other purposes may lead to serious
personal injury.

2-2
ICEVulcanServiceManual
Introduction
The policy of ICE is to manufacture non-contact coding systems that meet high standards of
performance and reliability. Therefore, we employ strict quality control techniques to
eliminate the potential for defects and hazards in our products.
The safety guidelines provided in this chapter are intended to educate the operator on all
safety issues so that the operator can operate the equipment safely.
Equipment Safety Guidelines
This section contains important safety guidelines pertaining to the operation and handling
of the equipment.
Warning
PERSONAL INJURY. Only trained service or maintenance personnel should perform the
installation or replacement procedures. Qualified personnel are those who have successfully
completed the training courses, have sufficient experience with this equipment, and are
aware of the potential hazards to which they will be exposed.
Warning
PERSONAL INJURY. The LPA should be operated by an authorized personnel who can use the
machine independently and without causing damage to the equipment or a personal injury.
The operating personnel should be trained and informed regularly about safety and
environmental hazards.
Warning
PERSONAL INJURY. While performing maintenance or repair work, disconnect the mains
supply unless it is absolutely necessary to leave the supply on while carrying out adjustments.
The mains plug is the mains disconnect and must be accessible at all times.

Equipment Safety Guidelines 2-3
ICEVulcanServiceManual
Warning
PERSONAL INJURY. Before beginning any maintenance work or working close to the tamp
application module, ensure that the equipment is switched off and the air pressure is
exhausted.
Warning
PERSONAL INJURY. The LPA has exposed rotating parts. Keep hands, long hair, ties, loose
clothing and so on away from the machine at all times, when it is switched on. Do not wear
jewelry,
e.g. ear or finger rings, while working with the equipment.
Caution
EQUIPMENT DAMAGE. Operate the LPA in an area where the environmental conditions
outlined in Appendix A, “Specifications” of this manual are met. The LPA should be installed
and operated on a stable, solid base.
Caution
EQUIPMENT DAMAGE. The LPA should not be modified. Only add accessories that are
approved for the specific use by your supplier. Ensure that no fluids enter the LPA unit.
Comply with Electrical Codes
Warning
PERSONAL INJURY. All electrical wiring and connections must comply with applicable local
codes. Consult the appropriate regulatory agency for further information.

Equipment Safety Guidelines 2-4
ICEVulcanServiceManual
Electrical Power
Warning
PERSONAL INJURY. Ensure that all external energy sources, mains power leads are isolated
from equipment. This should be done before attempting any maintenance or repair on any
part of the product or before opening or removing any equipment covers.
Warning
PERSONAL INJURY. Ensure that any cables from the equipment and compressed air hoses (if
applicable) are secured to avoid chance of movement into walkways and becoming a trip
hazard. Route or protect all cables to prevent damage.
Warning
PERSONAL INJURY. There will be sections of the printer control board that will be permanently
powered via the on-board lithium battery - therefore it is essential that the board should
never be placed onto, nor stored in or on any conductive surface (including conductive, plastic
bags etc.) as this would flatten the battery and/or potentially result in battery overheating.
The battery is not to be replaced by the operator.
Caution
EQUIPMENT DAMAGE. Do not unplug any connector on the equipment when the mains
power is on (except USB and ethernet cables).
Caution
EQUIPMENT DAMAGE. Operate the LPA within the voltage range specified on the rating label
affixed to the unit. This information is also repeated in Appendix A, “Specifications” of this

Equipment Safety Guidelines 2-5
ICEVulcanServiceManual
manual.