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.