Carl Valentin FLEXICODE Service Instructions Manual
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Carl Valentin FLEXICODE Service Instructions Manual

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  • Page 1 FLEXICODE Service Instructions...
  • Page 2 It must not be concluded from the missing labelling that it is not a registered brand or a registered trademark. Carl Valentin direct print modules comply with the following safety guidelines: EG Machinery Directive (2006/42/EG)

  • Page 3: Table Of Contents

    Flexicode Table of Contents Table of Contents Notes on this Document ............5 User Notes ................5 Instructions ................5 Cross References ..............6 Safety Instructions ..............7 General Safety Instructions ............. 7 Safety Handling when Working with Electricity ....... 9 Environmentally-Friendly Disposal ........
  • Page 4 Inhaltsverzeichnis Flexicode Service Instructions 05.17...

  • Page 5: Notes On This Document

    Flexicode Notes on this Document 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 direct print module. Information about operation of the direct print module can be taken from our operating manual.

  • Page 6: Cross References

    Notes on this Document Flexicode 1.3 Cross References References to specific items in a figure are marked with letters. They Drawings 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.

  • Page 7: Safety Instructions

    Flexicode Safety Instructions Safety Instructions 2.1 General Safety Instructions  Workplace and Keep the area around the device clean during and after method of working maintenance.  Work in a safety-conscious manner.  Store dismantled device parts in a safe place while maintenance is being performed.
  • Page 8 Safety Instructions Flexicode Protective equipment 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.

  • Page 9: Safety Handling When Working With Electricity

    Safety Instructions Flexicode 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 direct print modules 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.

  • Page 10: Environmentally-Friendly Disposal

    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.

  • Page 11: General Notes

    Flexicode General Notes General Notes 3.1 Continuous Mode Material Speed Please note that the material has sufficient adhesion at the pressure transducer roll or encoder roll to permit the exact speed by the encoder. It is only possible to print when respecting the operating conditions, i.e.

  • Page 12: Intermittent Mode

    General Notes Flexicode 3.2 Intermittent Mode Print Principle Printhead Feed Packaging material Print surface Figure 3 After starting a print order the printhead moves against the print medium. Afterwards the printing carriage moves corresponding to the set or transferred layout length linear over the material which is to be printed.

  • Page 13: Changing The Module Type

    General Notes Flexicode 3.3 Changing the Module Type Switch on the control unit and the display shows the main menu. Press the key to access the function menu. Press the key until the menu Service functions is displayed. Press the key to select the menu.
  • Page 14 General Notes Flexicode Service Instructions 05.17...

  • Page 15: Electronics

    Flexicode Electronics Electronics 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. 4.1 Replace the Primary Fuses...

  • Page 16: Replace The Cpu Pcb

    Electronics Flexicode 4.2 Replace the CPU PCB Figure 6 Remove the HNOTICE! CPU PCB Save direct print module configuration onto a CF card. 1. Unplug the module from the electrical outlet. 2. Remove the screws (B) and remove the cover of control unit.

  • Page 17: Replace The Battery

    Flexicode Electronics 4.3 Replace the Battery Figure 7 DANGER! Danger of explosion due to improper replacement of the battery!  Use non-conductive tools.  Pay attention to polarity. 1. Lift up the fixing bracket by means of a non-metallic device (e.g.

  • Page 18: Replace The Input/Output Board

    Electronics Flexicode 4.4 Replace the Input/Output Board NOTICE! The inputs/outputs can be tested in the 'Service Functions'. If an input is activated then the position corresponding to this input changes to 1. To activate an output, move the cursor to the corresponding position and press the keys to set value 1.

  • Page 19: Replace The Distributor Plate

    Flexicode Electronics 4.5 Replace the Distributor Plate Figure 9 Remove the 1. Unplug the module from the electrical outlet. distributor plate 2. Remove the screws (A) and remove the control unit cover. 3. Unscrew the fixing screws (D) at the SUB-D socket.

  • Page 20: Replace The Power Supply Unit

    Electronics Flexicode 4.6 Replace the Power Supply Unit Figure 10 Remove the power 1. Unplug the module from the electrical outlet. supply unit 2. Remove the screws (B) and remove the control unit cover. 3. Remove the CPU PCB (see chapter 4.2, page 16).

  • Page 21: Mechanics

    Flexicode Mechanics Mechanics 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 direct print module, personal protective equipment such as safety goggles and gloves are recommended.

  • Page 22: Clean The Transfer Ribbon Drawing Roller

    Mechanics Flexicode 5.2 Clean the Transfer Ribbon Drawing Roller A soiled drawing roller can lead to reduced print quality and can affect transport of material. Figure 11 1. Remove the cover. 2. Remove transfer ribbon from the direct print module.

  • Page 23: Replace The Printhead

    Flexicode Mechanics 5.4 Replace the Printhead CAUTION! The printhead can be damaged by static electricity discharges and impacts!  Set up the device on a grounded, conductive surface.  Ground your body, e.g. by wearing a grounded wristband.  Do not touch the contacts on the plug connections.

  • Page 24: Angle Adjustment

    Mechanics Flexicode 5.5 Angle Adjustment Figure 13 The installation angle of the printhead is default 26° to the print surface. However, manufacturing tolerances of the printhead and mechanics can require another angle. CAUTION! Damage of printhead by unequal use! Higher wastage of ribbon by faster ripping.

  • Page 25: Replace Parts At The Printing Carriage

    Flexicode Mechanics 5.6 Replace Parts at the Printing Carriage Figure 14 Figure 15 NOTICE! 243™ to secure the screw ® Use screw locking adhesive Loctite (B) and spring pillar (F) against unintentional unscrewing. 05.17 Service Instructions...
  • Page 26 Mechanics Flexicode Replace the printhead support Figure 16 1. Remove the front cover of the print mechanics. 2. Push both tension springs (G) with a tweezers from the spring pillars (F, Figure 14). 3. Remove the printhead cable (E, Figure 14) from the printhead (A, Figure 14).
  • Page 27 Flexicode Mechanics Replace the guiding carriage Figure 17 1. Remove the hexagon socket screws (N) for removing the pneumatic cylinder (O). 2. Remove the hexagon head screws (M) for removing the linear guiding (K). 3. Push the guiding carriage (H) aside until the track carriage underneath appears.
  • Page 28 Mechanics Flexicode Replace the linear cogged belt Figure 18 1. Remove the step motor (S). 2. Remove the power electronics and distributor board (see chapter 5.7, page 29). 3. Unscrew 3 screws (R) and remove the intermediate plate (Q) and step motor (S).

  • Page 29: Replace The Power Electronics + Distributor Plate

    Flexicode Mechanics 5.7 Replace the Power Electronics + Distributor Plate Figure 19 Remove the power 1. Remove the connection cable (C) to the control unit. electronics and 2. Release the pressure and remove the compressed-air tube (D). distributor board 3. Remove the screws (A) and detach the rear cover (high).
  • Page 30 Mechanics Flexicode 5. Unscrew two hexagonal bolts (M) at the SUB-D male connector. 6. Remove two screws (J) and detach the distributor board (K). Remove all wires from the distributor board. 7. Remove the pneumatic tube (G) from bulkhead connector.

  • Page 31: Replace The Valve And Pressure Control Device

    Flexicode Mechanics 5.8 Replace the Valve and Pressure Control Device DANGER! Risk of injury via a short-circuit. Because of technical reasons, the adjusting screw (J) of pressure control device is on a voltage potential of 5V.  Use isolated tools.
  • Page 32 Mechanics Flexicode Install the valve and 1. Fix the valve support (B) with screws (E) at the valve (A). pressure control device 2. Preassemble the new pressure control device (I) with the L connection (F) including blocking at the holding angle (H).

  • Page 33: Replace The Transfer Ribbon Drawing Roller

    Flexicode Mechanics 5.9 Replace the Transfer Ribbon Drawing Roller Figure 22 Remove the transfer 1. Remove the connecting cable (E) to the control unit. ribbon drawing roller 2. Release the pressure and remove the compressed-air tube (F). 3. Remove the screws (A) and detach the rear cover (low) of the print mechanics.
  • Page 34 Mechanics Flexicode 5. If the eccentric bearing has become loosened, you must adjust the belt tension. Then tighten the screw (D) again. CAUTION! Too high belt tension leads to greater wear and premature failure of the slide bearings.  To protect the bearing points, do not set the belt tension too high.

  • Page 35: Replace The Transfer Ribbon Rewinder/Unwinder Unit

    Flexicode Mechanics 5.10 Replace the Transfer Ribbon Rewinder/Unwinder Unit Figure 23 1. Remove the connecting cable (E) to the control unit. Remove the transfer ribbon rewinder roll 2. Release the pressure and remove the compressed-air tube (F). 3. Remove the front cover of print mechanics.
  • Page 36 Mechanics Flexicode 1. If the eccentric bearing has become loose, you must adjust the belt tension. Then tighten the screw (C) again. CAUTION! Too high belt tension leads to greater wear and premature failure of the slide bearings.  To protect the bearing points, do not set the belt tension too high.

  • Page 37: Replace The Encoder

    Flexicode Mechanics 5.11 Replace the Encoder Figure 24 1. Remove the connecting cable to the control unit. Remove the encoder 2. Release the pressure and remove the compressed-air tube. 3. Remove the screws (A) and detach the rear cover (high).

  • Page 38: Replace The Cover Switch

    Mechanics Flexicode 5.12 Replace the Cover Switch Figure 25 1. Remove the connecting cable to the control unit. Remove the cover switch 2. Release the pressure and remove the compressed-air tube. 3. Remove the front cover of print mechanics. 4. Remove the screws (A) and detach the rear cover (high).

  • Page 39: Replace The Limit Switch

    Flexicode Mechanics 5.13 Replace the Limit Switch Figure 26 Remove the 1. Remove the connecting cable to the control unit. limit switch 2. Release the pressure and remove the compressed-air tube. 3. Remove the front cover of print mechanics. 4. Remove 11 screws (B) and dismount both rear covers of print mechanics.
  • Page 40 Mechanics Flexicode Install the 1. Insert the supply line (I) of the limit switch (D) into the nut (E). limit switch 2. Insert the insulating tube (F) into the bore underneath the nut (E). 3. Mount the limit switch (D) with screws (C).

  • Page 41: Error Correction

    Flexicode Error Correction Error Correction Error message Cause Remedy Line too high Line rises up completely or Move line down (increase Y partly over the upper edge of value). label. Check rotation and font. Line too low Line rises up completely or Move line up (reduce Y value).
  • Page 42 Error Correction Flexicode Error message Cause Remedy Field number Received line number is invalid. Check sent data. Check connection PC - printer. Length mask Invalid length of received mask Check sent data. statement. Check connection PC - printer. Unknown mask Transferred mask statement is Check sent data.
  • Page 43 Flexicode Error Correction Error message Cause Remedy Application Selected application identifier is Check code data. Identifier not available in GS1-128. HIBC definition Missing HIBC system sign. Check definition of HIBC code. Missing primary code. System clock Real Time Clock function is Change battery.
  • Page 44 Error Correction Flexicode Error message Cause Remedy Drive write- Memory card is write-protected. Deactivate write protection. protected Directory not file Attempt to indicate a directory Correct your entry. as file name. File already open Attempt to change a file during Select another file.
  • Page 45 Flexicode Error Correction Error message Cause Remedy Zero point Defective photocell. Change photocell. Compressed air Pressure air is not connected. Check pressure air. External release External print release signal is Check input signal. missing. Column too wide Wrong definition of column Reduce the column width res.
  • Page 46 Error Correction Flexicode Error message Cause Remedy Time generation Printing creation was still active Reduce print speed. at print start. Use printers' output signal for synchronization. Use bitmap fonts to reduce generating time. Transport protection Both DPM position sensors Displace zero point sensor (start/end) are active.
  • Page 47 Flexicode Error Correction Error message Cause Remedy Scanner layout Scanner data does not Check adjustment of scanner. difference correspond to bar code data. Check scanner settings / connection. COM break Serial interface error. Check settings for serial data transmission as well as cable (printer-PC).
  • Page 48 Error Correction Flexicode Error message Cause Remedy Housing open When starting the print order Close the housing cover and the housing cover is not closed. start the print order anew. EAN.UCC code Transferred EAN.UCC code is Verify bar code data (see invalid.
  • Page 49 Flexicode Error Correction Error message Cause Remedy Print asynchronous The label photocell do not work Check label size and gap size. in the order as it is expected according to print data. The settings of the photocell Check label photocell settings.
  • Page 50 Error Correction Flexicode Error message Cause Remedy Script failure LUA script is incorrect. Check the script. Script user error Error in LUA script user input. Correct the input value. No reprint available No label data for reprinting Send new label data to the available.

  • Page 51: Control Inputs And Outputs

    Flexicode Control Inputs and Outputs Control Inputs and Outputs By means of a maximum of 16 control inputs and outputs which, in the following, are also referred to as ports, different functions of the printer system can be triggered and operating states can be displayed.
  • Page 52 Control Inputs and Outputs Flexicode Configuration of D-Sub socket Figure 28 Cable identification Number Color white brown green yellow grey pink blue black violet grey-pink red-blue white-green brown-greed white-yellow yellow-brown white-grey grey-brown white-pink pink-brown white-blue brown-blue white-red brown-red white-black brown-black Service Instructions 05.17...
  • Page 53 Flexicode Control Inputs and Outputs Port 1 to Port 16 = Assignment for I/O Profile Std_Direct Port Description / Function 11 (Input) Print start 12 (Input) No function 13 (Input) Counter reset 14 (Input) No function 15 (Input) Error reset...
  • Page 54 Control Inputs and Outputs Flexicode Port Description / Function + 5 VDC 5 Volt DC output for external use. Max. 1 A. This voltage is provided from direct print module and can be used e.g. as control voltage. Never apply any external voltage to this output.
  • Page 55 Flexicode Control Inputs and Outputs Port 1 to Port 16 = Assignment for I/O Profile SP_Direct0 Port Description / Function 11 (Input) Print start 12 (Input) No function 13 (Input) Counter reset 14 (Input) No function 15 (Input) Error reset...
  • Page 56 Control Inputs and Outputs Flexicode Plug Connector Technical data Type D-Sub connector High Density 26-pin. / connector Manufacturer W+P-Products Reference number 110-26-2-1-20 Output Voltages (connected with GND-PE) + 24 V / 1 A Fuse: Polyswitch / 30 V / 1 A...
  • Page 57 Flexicode Control Inputs and Outputs Device connection to a machine with S7-300 SPS. Example 1 Figure 29 Example 2 Device connection to a operating panel. Figure 30 05.17 Service Instructions...
  • Page 58 Control Inputs and Outputs Flexicode Device connection version if 'Option: 2. LED'. Example 3 Figure 31 Precautions When connecting a reed contact with a control input, the contact must have a switching capacity of min. 1 A in order to prevent the contact from sticking due to the inrush current.

  • Page 59: Wiring Plans

    Flexicode Wiring Plans Wiring Plans 8.1 Control Unit Figure 32 05.17 Service Instructions...

  • Page 60: Print Mechanics

    Wiring Plans Flexicode 8.2 Print Mechanics Figure 33 Service Instructions 05.17...

  • Page 61: Layout Diagrams

    Flexicode Layout Diagrams Layout Diagrams 9.1 CPU Figure 34 Jumper plan JP1 (Debug) JP2 (Write-protection) Boot sector closed closed Programming Delivery closed open 05.17 Service Instructions...

  • Page 62: Distributor Plate (Control Unit)

    Layout Diagrams Flexicode 9.2 Distributor Plate (Control Unit) Figure 35 Service Instructions 05.17...

  • Page 63: Distributor Plate (Print Mechanics)

    Flexicode Layout Diagrams 9.3 Distributor Plate (Print Mechanics) Figure 36 Jumper plan Position Printing system left mechanics right mechanics 05.17 Service Instructions...

  • Page 64: Power Electronics

    Layout Diagrams Flexicode 9.4 Power Electronics Figure 37 Service Instructions 05.17...

  • Page 65: Operating Panel

    Flexicode Layout Diagrams 9.5 Operating Panel Figure 38 05.17 Service Instructions...
  • Page 66 Layout Diagrams Flexicode Service Instructions 05.17...

  • Page 67: Connection Plan Control Unit

    Flexicode Connection Plan Control Unit 10 Connection Plan Control Unit 12 - LED green 12 - Lighting = Speed 100 MBit 12 - Off = Speed 10 MBit 13 - LED orange 13 - Lighting = Connection active 13 -...

  • Page 68: Connection Cable Mechanics - Control Unit

    Connection Plan Control Unit Flexicode 10.1 Connection Cable Mechanics - Control Unit Figure 40 Signal Signal +48V Motor 3 Direction Motor 4 Direction TPH Temperature Brake TPH Clock Ribbon End position TPH Cont 1 Ribbon Photocell B TPH Cont 4...

  • Page 69: Encoder (Continuous Mode)

    Flexicode Connection Plan Control Unit 10.2 Encoder (Continuous Mode) 5-pin connecting bushing, contacts according to DIN 45322 Connector socket encoder Figure 41 PIN1 = 5 VDC PIN2 = Encoder signal (channel A) PIN3 = Encoder signal (channel B) PIN4 = GND...

  • Page 70: External Inputs/Outputs

    Connection Plan Control Unit Flexicode 10.3 External Inputs/Outputs Configuration of D-Sub socket Figure 43 Identification Description / Function Port 1 Print start Port 2 No function Port 3 Counter reset Port 4 No function Port 5 Error reset Port 6...

  • Page 71: Touch Panel

    Flexicode Connection Plan Control Unit 10.4 Touch Panel Power supply for touch panel: 12-pole DIN bushing Illustration: connector - soldering side Figure 44 Signal A, B, C, D, E, L F, G, H, J, K, M 05.17 Service Instructions...
  • Page 72 Connection Plan Control Unit Flexicode Service Instructions 05.17...

  • Page 73: Index

    Flexicode Index 11 Index angle adjustment ................24 battery, replacing ................17 changing, module type ............... 13 cleaning cleaning instructions ............... 21 printhead, cleaning ................. 22 transfer ribbon drawing roller ............22 connection plan control unit back side ..................67 connection cable mechanics-control unit ........
  • Page 74 Index Flexicode distributor plate (control unit), replacing ......... 19 I/O board, replacing ................ 18 power supply unit, replacing ............20 primary fuse, replacing ..............15 encoder, replacing ................37 environmentally-friendly disposal ............10 error messages/error corrections . 41, 42, 43, 44, 45, 46, 47, 48, 49, 50 guiding carriage, replacing ..............
  • Page 75 Flexicode Index transfer ribbon drawing roller, replacing ........33, 34 transfer ribbon rewinder roll, replacing ........... 35 transfer ribbon shaft, replacing ............35 transfer ribbon unwinder roll, replacing .......... 36 valve, replacing ................. 31, 32 module type, changing ............... 13 operating panel, layout diagram ............
  • Page 76 Carl Valentin GmbH Neckarstraße 78 86 u. 94 . 78056 Villingen-Schwenningen Phone +49 7720 9712-0 . Fax +49 7720 9712-9901 [email protected] . www.carl-valentin.de...

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