Copyright by Carl Valentin GmbH / 7988025A09.16
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
All named brands or trademarks are registered brands or registered
trademarks of their respective owners and may not be separately
labelled. It must not be concluded from the missing labelling that it is
not a registered brand or a registered trademark.
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
+49 (0)7720 9712-0
+49 (0)7720 9712-9901
E-Mail
Internet
info@carl-valentin.de
www.carl-valentin.de
Spectra II
Table of Contents
09.16
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 Cleaning the Transfer Ribbon Drawing Roller ....................... 14
4.2 General Cleaning................................................................... 14
4.3 Cleaning the Pressure Roller ................................................ 15
4.4 Cleaning the Printhead .......................................................... 16
4.5 Cleaning the Label Photocell ................................................. 17
5 Replacing Components ...................................................... 19
5.1 Tools List ............................................................................... 19
5.2 Replacing the Printhead (General) ........................................ 20
5.3 Replacing the Printhead (Flat Type)...................................... 21
5.4 Replacing the Printhead (Corner Type) ................................ 22
5.5 Adjusting the Print Position ................................................... 23
5.6 Replacing the Pressure Roller ............................................... 24
5.7 Replacing Label Photocell ..................................................... 25
5.8 Replacing the CPU PCB ....................................................... 26
5.9 Replacing the Power Supply ................................................. 28
5.10 Replacing the WLAN Module ................................................ 29
5.11 Replacing the I/O FPGA ........................................................ 30
5.12 Replacing the Battery ............................................................ 30
6 Adjustments, settings and alignments ............................. 31
6.1 Adjusting the print mechanism .............................................. 31
6.2 Adjusting the Printhead Position (Flat Type) ......................... 32
6.3 Adjusting the Printhead Position (Corner Type) .................... 34
6.4 Adjusting the Transfer Ribbon Feed Path ............................. 36
6.5 Adjusting the ribbon rewinder/unwinder ................................ 37
6.6 Adjusting the Head Photocell ................................................ 38
6.7 Adjusting the Cutter Ledge .................................................... 39
6.8 Adjusting the Angle of Aperture (Cutter Unit) ........................ 41
6.9 Adjusting the Pressure Curve (Ribbon Save) ....................... 42
6.10 Adjusting the Supporting Bar (Ribbon Save) ........................ 44
6.11 Oil and Lubricate ................................................................... 45
7 Refitting options .................................................................. 47
7.1 Internal rewinder .................................................................... 47
7.2 I/O Plate ................................................................................. 48
7.3 Dispensing unit ...................................................................... 49
7.4 Cutting unit ............................................................................ 50
7.5 Guiding for Leporello fold material ........................................ 51
8 Error correction ................................................................... 53
9 Control inputs and outputs ................................................ 63
Table of Contents
Spectra II
4
Service Instructions
09.16
10 Wiring Plan ........................................................................... 67
10.1 CPU Component Placement Specification ............................ 69
10.2 Power Electronics .................................................................. 70
11 Index ..................................................................................... 71
Vario III Series
Notes on this Document
09.16
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, 104/8, 106/12, 106/24, 107/12, 108/12,
160/12, 162/12 und 216/12.
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
09.16
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
Spectra II
Safety Instructions
09.16
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
Spectra II
8
Service Instructions
09.16
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
Spectra II
Safety Instructions
09.16
Serviceanleitung
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
Spectra II
10
Service Instructions
09.16
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.
Spectra II
Connector Pin Assignment (Printer Rear)
09.16
Service Instructions
11
3 Connector Pin Assignment (Printer Rear)
C
B
A
D
E
F
G
H
I
J
1
2
Figure 1
A
External output/input (option)
B
Winder connection
C
Switch On/Off
D
Power supply
E
Parallel interface
F
USB host for USB keyboard and USB memory stick
G
Ethernet 10/100 interface
H
Serial interface RS-232
I
USB interface
J
Plug-in for CF card
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
Spectra II
Cleaning
09.16
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.
Maintenance task
Frequency
General cleaning (see chapter
4.2, page 14).
As necessary.
Cleaning transfer ribbon
drawing roller (see section 4.1,
page 14).
Each time the transfer ribbon is
changed or when the printout is
adversely affected.
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
4.4, page 16).
Each time the transfer ribbon is
changed or when the printout is
adversely affected.
Cleaning label photocell (see
chapter 4.5, page 17).
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.
Maintenance schedule
Cleaning
Spectra II
14
Service Instructions
09.16
WARNING!
Risk of fire by easily inflammable label soluble!
When using label soluble, dust must be completely
removed from the label printer and cleaned.
4.1 Cleaning the Transfer Ribbon Drawing Roller
A soiled print roll can lead to reduced print quality and can affect
transport of material.
1. Open printer cover.
2. Remove transfer ribbon from the label printer.
3. Remove deposits with roller cleaner and a soft cloth.
4. If the roller appears damaged, replace it.
4.2 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.
Spectra II
Cleaning
09.16
Serviceanleitung
15
4.3 Cleaning the Pressure Roller
A soiled pressure roller can lead to reduced print quality and can
affect transport of material.
CAUTION!
Print roller can be damaged!
Do not use sharp or hard objects to clean the print
roller.
A
B
C
Figure 2
1. Open printer cover.
2. Turn lever (A) 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 (C) 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).
Cleaning
Spectra II
16
Service Instructions
09.16
4.4 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, in 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.
Spectra II
Cleaning
09.16
Serviceanleitung
17
4.5 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.
A
B
Figure 4
1. Open printer cover.
2. Turn lever 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.
Spectra II
Replacing Components
09.16
Service Instructions
19
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 2
Screwdriver, size 5
Allen wrench 1,5 mm / 2 mm / 2,5 mm
Hexagonal wrench 3 mm
Spring scale 50 N
Replacing Components
Spectra II
20
Service Instructions
09.16
5.2 Replacing the Printhead (General)
NOTICE!
The printhead (D) is preinstalled on a head plate (A) and
aligned at the factory.
B
F
E
C
A
DG
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 (D) with hard objects or your
hands.
Spectra II
Replacing Components
09.16
Serviceanleitung
21
5.3 Replacing the Printhead (Flat Type)
B
D
E
C
F
A
A
G
I
I
H
H
G
Figure 6
1. Remove labels and transfer ribbon from the label printer.
2. When printhead is closed, loosen the screws (G).
3. Turn lever (F) counter clockwise to lift up the printhead (E).
4. If the printhead (E) is not disengaged on the pressure roller,
continue loosen the screws (G).
5. Remove the printhead carefully to the front until you can reach the
plug connections.
6. Remove plug connections and then remove printhead (E).
1. Attach plug connections.
2. Position printhead (E) 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 (G).
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
Spectra II
22
Service Instructions
09.16
5.4 Replacing the Printhead (Corner Type)
B
D
E
C
F
A
A
J
I
G
H
H
G
I
J
Figure 7
1. Remove labels and transfer ribbon from the label printer.
2. When printhead is closed, loosen the hex (Allen) screws (H).
3. Turn lever (E) counter clockwise to lift up the printhead (F).
4. If the printhead (F) is not disengaged on the pressure roller,
continue loosen the hex (Allen) screws (H).
5. Remove the printhead carefully to the front until you can reach the
plug connections.
6. Remove plug connections and then remove printhead (F).
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 (H).
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
Spectra II
Replacing Components
09.16
Serviceanleitung
23
5.5 Adjusting the Print Position
Press key to access the function menu.
Press key as long as you arrive the Service Functions menu.
Press key to select the menu.
Press key as long as you arrive the menu item Zero point
adjustment.
Indication of value in 1/100 mm.
After replacing the printhead - the print cannot be continued at the
same position on the label, the difference can be corrected in printing
direction.
NOTICE!
The value for zero point adjustment is set ex works. After
replacing the printhead, only service personnel are allowed to
set this value anew.
Press key to arrive the next menu item.
Indication of value in 1/100 mm.
After replacing the printhead - the print cannot be continued at the
same position on the label, the difference can be corrected across the
printing direction.
NOTICE!
The value for zero point adjustment is set ex works. After
replacing the printhead, only service personnel are allowed to
set this value anew.
Zero point adjustment
in Y direction
Zero point adjustment
in X direction
Replacing Components
Spectra II
24
Service Instructions
09.16
5.6 Replacing the Pressure Roller
B
C
A
D
D
E
G
F
Figure 8
1. Turn lever (A) counter clockwise to lift up the printhead.
2. Remove labels and transfer ribbon from the printer.
3. Unscrew screws (D) and then remove tear-off edge (F) if
mounted.
4. Unscrew 2 screws (C) at the bearing cover (B) and then remove
the bearing cover (B).
5. Remove pressure roller (E) from the striker arm (G).
1. Press the pressure roller (E) into the striker arm (G).
Pay attention to the correct position of striker arm pins of the
pressure roller (E).
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 (E).
4. Remove the possible axial play of the pressure roller by
interlocking the striker arm (G) and the mounted pressure roll (F).
Removing the
pressure roller
Installing the
pressure roller
Spectra II
Replacing Components
09.16
Serviceanleitung
25
5.7 Replacing Label Photocell
NOTICE!
Soiling of the label photocell can also cause malfunctions.
Before replacing the label photocell, check whether it is soiled
and clean it if necessary (see chapter 4.5, page 17).
C
A
B
Figure 9
1. Remove media from the printer.
2. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
3. Remove the protective conductor at the inside of the printer cover.
4. Turn knurled knob (C) counter clockwise, until the photocell (A)
can be removed from the adjusting axis (B).
5. Unplug the cable from the plug on the rear end of the label
photocell (A).
1. Connect the cable to the label photocell (A).
2. Place photocell (A) on the adjusting axis (B) and turn knurled knob
(C) in clockwise direction until the photocell arrives at the desired
position.
3. Connect the protective conductor to the inside of printer cover.
4. Install the left printer cover.
5. Adjust the label photocell.
NOTICE!
When reinstalling the photocell take care that the photocell runs
centrically in the plate aperture. One-sided tilting can entail a
worse signal level or label accumulation.
Removing label
photocell
Installing the label
photocell
Replacing Components
Spectra II
26
Service Instructions
09.16
5.8 Replacing the CPU PCB
B
B
B
B
A
A
A
Figure 10
1. If possible, save the printer configuration to a Compact Flash
card.
2. Unplug the printer from the electrical outlet.
3. Remove left printer cover.
Loosen two screws at the lower left printer edge and two screws
at the chassis upper edge.
4. Remove the protective conductor at the inside of the printer cover.
5. Detach all interface cables from the back of the printer.
6. Remove the memory card from the slot.
7. Unplug all side plug connections from the CPU PCB.
8. Remove the 4 screw bolts (B) at the parallel interface and 3 fixing
bolts (A) from the CPU PCB.
9. Carefully remove the CPU PCB.
Removing the
CPU PCB
Spectra II
Replacing Components
09.16
Serviceanleitung
27
1. Place CPU PCB into the printer.
2. Secure PCB to the chassis with the 4 screw bolts (B) and 3 fixing
screws (B).
3. Insert all plug connections on the PCB.
4. Restore all interface connections on the back of the printer.
5. Connect the protective conductor to the inside of cover.
6. Mount again the left printer cover.
7. Connect the power cable at the rear of the printer.
8. Update the firmware if necessary.
9. Adjust the label photocell.
10. Load the printer configuration from the memory card if possible.
Otherwise, set the printer configuration via the operating panel.
Installing the
CPU PCB
Replacing Components
Spectra II
28
Service Instructions
09.16
5.9 Replacing the Power Supply
AA BC
Figure 11
1. Unplug the printer from the electrical outlet.
2. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
3. Remove the protective conductor at the inside of the printer cover.
4. Remove 4 fixing screws (A) onto the printer bottom side.
5. Pivot the power supply (B) and the intermediate plate (C) from the
printer.
6. Disconnect the cable connections at the power supply (B) and
remove the power supply.
1. Establish the cable connections to the power supply.
2. Insert the power supply and intermediate plate (C) into the printer
and fix it with the fixing screws (A).
CAUTION!
Jamming of lines can cause short-circuits.
Do not jam lines under the power supply.
3. Connect the protective conductor to the inside of cover.
4. Mount again the left printer cover.
Removing the
power supply
Installing the
power supply
Spectra II
Replacing Components
09.16
Serviceanleitung
29
5.10 Replacing the WLAN Module
M
F
H
G
G
H
J
K
F
I
E
L
D C B A
Figure 12
1. Unplug the printer from the electrical outlet.
2. Screw off the left printer cover.
3. Remove hot melt glue from WLAN module (K) and then remove
antenna cable (A) from WLAN module (K).
4. Remove connecting cable (E) from WLAN adapter (I).
5. Loosen screws (G) and washers (H) and dismount the WLAN
adapter (I).
6. Dismount screws (L), spacer rings (J) and hex nuts (F) and
remove WLAN module (K) from WLAN adapter (I).
1. Insert the new WLAN module (K) to the WLAN adapter (I) and fix
it with screws (L), spacer rings (J) and hex nuts (F) at the WLAN
adapter (I).
2. Mount the WLAN adapter (I) with screws (G) and washers (H) at
support bracket (B).
3. Insert connection cable (E) in the WLAN adapter (K).
4. Connect antenna cable (A) with WLAN module (K) and fix the plug
connectors with a drop of hot melt glue.
5. Install the left printer cover.
Removing the
WLAN module
Installing the
WLAN module
Replacing Components
Spectra II
30
Service Instructions
09.16
5.11 Replacing the I/O FPGA
1. Separate the I/O plate (if available) from the CPU.
The I/O FPGA is now visible.
2. Remove defective FPGA from PLCC support base with a suitable
displacement pincer.
3. Pay attention to polarity and press the new FPGA into the support
base.
5.12 Replacing the Battery
DANGER!
Danger of explosion when exchanging the battery
improper.
Pay attention to polarity.
A
Figure 13
1. Lift up the fixing bracket by means of a non-metallic device (e.g.
plastic ruler).
2. Remove the battery (A).
3. Insert a new battery (CR 2032) into the support and pay attention
to position of polarity.
NOTICE!
The battery is responsible for the current supply of the real-time
clock. After changing the battery the clock is to be set anew in
menu Date/Time.
Spectra II
Adjustments, settings and alignments
09.16
Service Instructions
31
6 Adjustments, settings and alignments
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.
6.1 Adjusting the print mechanism
Major adjustment of the printing mechanism beyond format-based
settings is only required if the printhead assembly has been removed
or parts in this area have been replaced. Excluded from this is the
replacement of the printhead, after which readjustment is generally
not required.
The following print quality imperfections may indicate maladjustment
of the printing mechanism:
Print image too light
Print image is spotty
Print image lighter on one side
Horizontal lines not parallel to the horizontal label edges
Clear lateral drift of the transfer ribbon
NOTICE!
Print image errors can also arise from wrinkling of the transfer
ribbon. This is why the transfer ribbon feed path and the head
locking system should be checked before making adjustments
to the printing mechanism (see 'operating manual').
Adjustment of the printing mechanism encompasses the following
procedures in the order specified:
1. Adjust position of printhead (see chapter 6.2, page 32).
2. Adjust the ribbon feed path (see chapter 6.4, page 36).
3. Adjust the ribbon rewinder/unwinder (see chapter 6.5, page 37).
4. Adjust the printhead photocell (see chapter 6.6, page 38).
Adjustments, settings and alignments
Spectra II
32
Service Instructions
09.16
6.2 Adjusting the Printhead Position (Flat Type)
Complete the following printhead settings to achieve the best possible
print image:
Align the heating line with the highest point of the print roller.
Density of the print image is the greatest at this point.
Set the parallelism of horizontal lines with the edge of the label.
CAUTION!
The printhead assembly can be damaged.
Attempting to adjust the printhead when the fixing screw (I) is
tight can lead to defects at the printhead assembly.
Always loosen the fixing screw (I) before adjusting the
printhead.
NOTICE!
Open and close the printhead locking device after each step of
the adjustment.
An important characteristic for a high quality print is the parallelism of
the focal line of the thermal printhead to the pressure roll. Because of
the fact that the position of focal line of the printhead depends on
fluctuations caused by production, it is necessary to adjust the
parallelism.
B
D
E
C
F
A
A
G
I
I
H
H
G
Figure 14
1. Loosen the screws (I) with a hexagon
key by approx. ¼ rotations.
2. Adjust the parallelism with the
adjusting screws (H).
Clockwise = printhead moves
backwards
Counter clockwise = printhead moves
forwards
3. Clockwise = printhead moves
backwards
Counter clockwise = printhead moves
forwards
4. Tighten again screws (I).
5. Start a print order with approx. 10
labels and control the correct passage
of transfer ribbon.
Parallelism
Spectra II
Adjustments, settings and alignments
09.16
Serviceanleitung
33
After adjusting parallelism and no even strong pressure exists over
the complete print width, by means of a plate (B) you can set the
balance as follows:
1. Loosen screw (C, Figure 14) with a screwdriver by approx. ¼
rotations.
2. In order to achieve a pressure balance, turn the excentric bolt (D,
Figure 14) as long as the printing result comes up to your full
expectation.
3. Tighten again screw (C, Figure 14).
4. Start a print order with approx. 10 labels and control the correct
passage of transfer ribbon.
Increasing the head contact pressure leads to an improvement of the
print image density on the corresponding side and to a shifting of the
ribbon feed path in the corresponding direction.
CAUTION!
Damage of printhead by unequal use!
Change factory settings only in exceptional cases.
The selection of the smallest value can optimise the life cycle of
printhead.
1. Turn pressure screws (A, Figure 14) to change the pressure of
printhead.
2. Turning the pressure screws (A, Figure 14) as far as they will go
in clockwise direction results in a pressure increase of 10N in
contrast to the factory setting.
3. Turning the pressure screws (A, Figure 14) from the limit stop
counter clockwise to the corresponding scale value (see table)
result in the factory settings.
Printhead
Scale value
Spectra II 107
12
Spectra II 108
6
NOTICE!
It is importantly that the knurled button which is coated with
protective lacquer is not removed from the pressure screw as
otherwise the above mentioned settings are faulty.
Pressure balance
right/left
Pressure
Adjustments, settings and alignments
Spectra II
34
Service Instructions
09.16
6.3 Adjusting the Printhead Position (Corner Type)
Complete the following printhead settings to achieve the best possible
print image:
Align the heating line with the highest point of the print roller.
Density of the print image is the greatest at this point.
Set the parallelism of horizontal lines with the edge of the label.
CAUTION!
The printhead assembly can be damaged.
Attempting to adjust the printhead when the fixing screw (J
and HI) is tight can lead to defects at the printhead assembly.
Always loosen the fixing screw (J or H) before adjusting
the printhead.
NOTICE!
Open and close the printhead locking device after each step of
the adjustment.
B
D
E
C
F
A
A
J
I
G
H
H
G
I
J
Figure 15
An important characteristic for a high quality print is the parallelism of
the focal line of the thermal printhead to the pressure roll. Because of
the fact that the position of focal line of the printhead depends on
fluctuations caused by production, it is necessary to adjust the
parallelism.
Parallelismt
Spectra II
Adjustments, settings and alignments
09.16
Serviceanleitung
35
The form of the CornerType printhead needs the setting of parallelism
in direction of the adjusting angle and in horizontal position. It needs a
little bit of experience to know in which direction you have to adjust the
printhead to receive a high quality printing.
1. Loosen the screws (H or J, Figure 15) with a hexagon key by
approx. ¼ rotations.
2. Adjust the parallelism with the adjusting screws
(G or I, Figure 15).
Clockwise = printhead moves backwards
Counter clockwise = printhead moves forwards
3. Adjust the parallelism as long as the printing result comes up to
your full expectation.
4. Tighten again screws (H or J, Figure 15).
5. Start a print order with approx. 10 labels and control the correct
passage of transfer ribbon.
After adjusting parallelism and no even strong pressure exists over
the complete print width, by means of a plate (B) you can set the
balance as follows:
1. Loosen screw (C, Figure 15) by approx. ¼ rotations.
2. In order to achieve a pressure balance, turn the excentric bolt (D,
Figure 15) as long as the printing result comes up to your full
expectation.
3. Tighten again screw (C, Figure 15).
4. Start a print order with approx. 10 labels and control the correct
passage of transfer ribbon.
Increasing the head contact pressure leads to an improvement of the
print image density on the corresponding side and to a shifting of the
ribbon feed path in the corresponding direction.
CAUTION!
Damage of printhead by unequal use!
Change factory settings only in exceptional cases.
The selection of the smallest value can optimise the life cycle of
printhead.
1. Turn pressure screws (A, Figure 15) to change the pressure of
printhead.
2. Turning the pressure screws (A, Figure 15) as far as they will go
in clockwise direction results in a pressure increase of 10N in
contrast to the factory setting.
3. Turning the pressure screws (A, Figure 15) exactly one rotation
from the right stop position counter clockwise results in the factory
settings.
NOTICE!
It is importantly that the knurled button which is coated with
protective lacquer is not removed from the pressure screw as
otherwise the above mentioned settings are faulty.
Pressure balance
right/left
Pressure
Adjustments, settings and alignments
Spectra II
36
Service Instructions
09.16
6.4 Adjusting the Transfer Ribbon Feed Path
Adjust the transfer ribbon feed path by changing the head contact
pressure. Increasing the head contact pressure with the screws (A)
shifts the ribbon feed path in the corresponding direction. Possibly
arising formation of wrinkles can be eliminated by bowing the
printhead.
CAUTION!
The printhead assembly can be damaged when bowing the
printhead.
Turning the adjustment screw (D) too hard can cause
damage to the printhead assembly.
As soon as a clear resistance is perceived when
turning the adjustment screw (D), only continue turning
the screw in very small increments, but no more than
one eighth of a turn.
Only turn the adjustment screw (D) as far as is
absolutely necessary.
A
A
C
B
C
B
D
Figure 16
1. Check the transfer ribbon feed path.
The wound up ribbon should be the
same distance from the disk of the
winder as the supply roller is from the
disk of the rewinder.
2. If the ribbon runs inward or outward, turn
the corresponding screw (B) after
loosening the screw (C) clockwise in
small increments.
3. Wait until the ribbon feed path has
stabilized after each step of the
adjustment.
4. Check the ribbon feed path for wrinkles.
5. If the wrinkles cannot be remedied (e.g.
wrinkles in the centre), turn the
adjustment screw (D) clockwise with
extreme care (see warnings) using a
hexagonal wrench (2 mm) and observe
the ribbon feed path.
When the adjustment screw (D) is
tightened, the printhead is bent
downward slightly in the centre. It is
possible that a slight lightening at the
edge areas of the print image could
occur here.
Spectra II
Adjustments, settings and alignments
09.16
Serviceanleitung
37
6.5 Adjusting the ribbon rewinder/unwinder
B
A
B
A
Figure 17
Due to the many different transfer ribbon variants regarding roller
width, length and qualities it is necessary to provide the possibility to
set transfer ribbon tension.
The transfer ribbon tension is to set in such way that no wrinkles in the
ribbon appear but it is transported in the same way as the labels.
When using a too high ribbon tension this results usually in an
excellent run of the transfer ribbon but this could lead to streaks onto
the label or to a rip of ribbon particularly with narrow roles.
Ex factory the role tension is set to a transfer ribbon 110 mm width
and standard quality. As approximate values for the factory setting the
following can be accepted:
Transfer ribbon unwinder:
Distance of screw head (B) to roller face (A) = 2 mm
Transfer ribbon rewinder:
Distance of screw head (B) to roller face (A) = 4 mm
Tighten hex. head screw (B) = Increasing transfer ribbon tension
Loosen hex. head screw (B) = Reducing transfer ribbon tension
Adjustments, settings and alignments
Spectra II
38
Service Instructions
09.16
6.6 Adjusting the Head Photocell
The head photocell prevents printing from occurring when the
printhead is open.
C
B
D
A
A
Figure 18
1. Unplug the printer from the electrical outlet.
2. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
3. Lock printhead.
4. Slightly loosen the fixing screws (A) of the photocell (B).
5. Shift the photocell (B) in the hole sideways in such way that the
plate (D) extends slightly into the centre of photocell (into the
fork).
6. Tighten again the screws (A).
7. If this measure should not be sufficient, the plate (D) can be also
shifted by loosening the screws (C).
8. Install again the left printer cover.
9. Control the function of head photocell.
Access the service functions and enter the photocell parameters
so control the level value of 'H'.
Spectra II
Adjustments, settings and alignments
09.16
Serviceanleitung
39
6.7 Adjusting the Cutter Ledge
A
B
B
B
C
D
C
E
F
G
H
Figure 19
CAUTION!
Risk of injury, particularly during maintenance, the cutter
blades are sharp!
Switch off the before attaching the cutter!
The cutter may only be used when it is mounted on the
printer!
Do not try to cut any materials which exceed the
maximum width or thickness specifications.
Do NOT touch the area of the moving blades!
1. Loosen screws (C) and remove front plate (D) of the cutter unit.
2. Loosen hex socket head screws (E) and remove cutter unit.
3. Place the cutter unit in front of the printer and make sure that the
connecting cable has to be connected.
4. Insert the power plug and switch on the printer.
5. Insert paper or labels from behind through the inserting angle of
cutter unit between cutter shaft (H) and cutter ledge (GT).
6. Start a single cut.
In the main menu of printer of if a print order has been stopped,
press key to start a single cut.
Adjustments, settings and alignments
Spectra II
40
Service Instructions
09.16
If the cut is incorrect, the pressure between cutter shaft (H) and cutter
ledge (G) is to be increased as described below:
1. Remove the right side cover of the cutter unit.
Remove the 3 screws of the hexagon head bolts (B).
2. Loosen the 2 screws (A) of the spacer pillar (F).
3. Turn the spacer pillar (F) slightly downwards with a flat spanner
(size 8).
4. Tighten again the 2 screws (A).
5. Start a single cut.
In the main menu of printer of if a print order has been stopped,
press key to start a single cut.
In case the quality of the cut is not sufficient then repeat the above
mentioned steps.
If the pressure is too strong this could result in an increased ware.
Therefore select the pressure only as high as it is necessary for the
used material.
Switch off the printer and mount again the cutter unit in reverse order.
Spectra II
Adjustments, settings and alignments
09.16
Serviceanleitung
41
6.8 Adjusting the Angle of Aperture (Cutter Unit)
CAUTION!
Risk of injury, particularly during maintenance, the cutter
blades are sharp!
Switch off the before attaching the cutter!
The cutter may only be used when it is mounted on the
printer!
Do not try to cut any materials which exceed the
maximum width or thickness specifications.
Do NOT touch the area of the moving blades!
F
A
B
C
E
D
Figure 20
If the labels show dog-ears after the cutting procedure or if a paper
jam occurred then the angle of aperture (F) is to be increased.
1. Remove the 3 countersink screws (D).
2. Remove the right cover of cutter unit.
The reflexion photocell (E) scans the screw head (B) onto the belt
drive (A).
3. If the angle of aperture is too small, the photocell has to be turned
slightly in clockwise direction.
Loosen the screw (C). Keep the distance of 5 mm between
photocell and screw head.
4. Place the cover onto the spacer pillar in order that the reflexion
photocell is not exposed to extraneous light.
5. Start a number of test cuts.
Verify if the cutter unit effects the cuttings over the complete
passage width.
6. If an uncut margin remains at the right side then the angle of
aperture is too big.
In this case turn back slightly the photocell.
7. Mount again the cover.
Adjustments, settings and alignments
Spectra II
42
Service Instructions
09.16
6.9 Adjusting the Pressure Curve (Ribbon Save)
If the ribbon save function is activated and the printhead is not enough
lifted up from the label material, then the pressure curve is to be
adjusted anew. The pressure curve is onto the shaft of the ribbon
save motor (A).
A
Figure 21
1. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
2. Remove the protective conductor at the inside of the printer cover.
B
G
H
C
D
E
F
A
Adjusting position Printing position
Printing notch
Adjusting notch
Adjusting notch
Printing notch
Figure 22
Spectra II
Adjustments, settings and alignments
09.16
Serviceanleitung
43
The sketch (see Figure 22) shows from behind the shaft of ribbon
save motor (H) with pressure curve (C) and disc (B). The bearing ring
(D) with the attached sole plate (E) is underneath.
3. Make sure that the printhead is closed.
4. Loosen the hex socket head screw (F) about 1 turn until the sole
plate (E) with the attached ball bearing is freely mobile.
5. Turn by hand the motor shaft with pressure curve and disk in the
adjusting position.
6. Press the sole plate (E) with the ball bearing (G) in the adjusting
notch of the pressure curve. Take care of not to have too much
play. Fasten the hex socket head screw (F).
7. Lift up the printhead.
8. Turn by hand the motor shaft with pressure curve and disc into the
adjusting position.
9. Move down the printhead.
10. Turn by hand the motor shaft with pressure curve and disk from
the lift to the right until a slight resistance can be noticed. If the
slot in the disk can be moved slightly to the right and to the left out
of the photocell (A), then the pressure curve is adjusted correctly.
11. If the gap should not be in the range of the photocell, the following
causes are possible:
The wrong notch on the pressure curve was used for the
adjustment.
The pressure curve is twisted to the disc on the motor shaft.
The slot of disc has to be placed exactly face to face with
the printer position notch!
12. Connect the protective conductor to the inside of printer cover.
13. Move the printer cover onto the chassis.
14. Switch on the printer.
15. Press the keys and to move the printhead down and up. If
very thick label material is used it could occur that the printhead is
not enough lifted up. In order to position the printhead correctly,
repeat the adjusting steps again. However, keep the material
during the adjustment between the printhead and the roller.
16. Install again the printer cover.
Adjustments, settings and alignments
Spectra II
44
Service Instructions
09.16
6.10 Adjusting the Supporting Bar (Ribbon Save)
B
A
A
Figure 23
If the transfer ribbon save function is active and a paper jam occurs or
if the print position onto the label is incorrect, this could be traced back
to an inadequate adjustment of the supporting bar (B).
The supporting bar (B) in connection with the beneath positioned
transport roller is responsible for the label feed (if printhead is lifted
up). The pressure of the supporting bar should be the same as the
value for the printhead. The factory setting corresponds to an average
for standard labels. For very narrow, extremely smooth or thick labels
a different setting is necessary.
Use the threaded pins (A) to change the pressure.
Pressure increase = screw threaded pins (A).
Pressure decrease = loosen threaded pins (A).
By means of test prints you can adjust the specific pressure you need
for your application.
Spectra II
Adjustments, settings and alignments
09.16
Serviceanleitung
45
6.11 Oil and Lubricate
NOTICE!
Make sure when oiling and greasing that no lubricants deposit
on photocells, electronic components, circuit boards, printhead
and rolls.
A = Low viscosity oil
B = Grease
A
A
A
Figure 24
A
A
B
Figure 25
In case that dust or other dirt is deposit you have
to clean the lubrication at first with alcohol.
Apply rather in regular intervals (1-2 per year) a
bit of lubricant, as only rarely too much.
Otherwise the surplus of lubricant could settle on
neighbouring components and disturb the
functions.
In case those components should have run it
because of lack of lubricant, exchange these as
soon as possible so the functions of the
components and the printer remain.
Install again all components which you have
dismantled for the lubrication in the correct
position.
Take care e.g. tensions of belt.
Spectra II
Refitting options
09.16
Service Instructions
47
7 Refitting options
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.
7.1 Internal rewinder
F
H
J
K
I
A
B
C
C
D
E
G
Figure 26
1. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
2. Remove the protective conductor at the inside of the printer cover.
3. At the print mechanics side, remove both of the label unwinding
disks (A + B).
4. Unscrew 4 screws (C) and remove cover sheet for the rewinder.
5. Push the supporting plate with motor (K) of the set-up kit from
behind through the chassis aperture and fix the rewinder with the
countersink screws (C).
6. Insert the motor cable (A) corresponding to the wiring plan (see
chapter 10, page 67) into the appropriate plug-in positions.
7. Push the rewinding roll (D) onto the tube (J) of the rewinding unit.
8. Push the brake disc (E) to the rewinding axe.
Refitting options
Spectra II
48
Service Instructions
09.16
9. Push the pressure spring (F) onto the rewinding axe and screw
the hex socket head screw (H) with disc (G) as far as it will go.
After this loosen the hex socket head screw (H) about 3 turns
counter clockwise.
10. Push the handle (I) onto the roll.
11. Connect the protective conductor to the inside of cover.
12. Mount again the printer cover and label unwinding disks.
7.2 I/O Plate
A
B
C
D
F
E
G
G
Figure 27
Insert the motor cable (A) with connector housings in the designated
slot (see wiring plan on page 63).
1. Remove left printer cover.
Loosen 3 screws at the lower left printer edge and 3 screws at the
chassis upper edge.
2. Remove the protective conductor at the inside of the printer cover.
3. Remove covers (C) at the interface disruptions from the chassis
rear.
4. Fix the support angle (F) with protective disks (E) and hexagon
nut (D) at the connecting plate.
5. Place the input/output plate (C) with fixing screws (G) at the
break-out.
6. Insert the connecting cables for input/output corresponding to the
wiring plan (see chapter 10, page 67) into the appropriate plug-in
positions of the I/O plate.
7. Connect the protective conductor to the inside of printer cover.
8. Mount again the printer cover.
Spectra II
Refitting options
09.16
Serviceanleitung
49
7.3 Dispensing unit
A
C
B
C
D
E
Figure 28
1. Remove tear off edge (if mounted) at the front of printer.
2. For an easier handling, remove front plate (if mounted) which is
fixed at the printer base.
3. Pull the knurled knob (A) to open the dispenser rocker.
4. Place the dispenser unit (B) before the pressure roller. Fix it with
Allen screws (C) at the aluminium profile below the pressure roller
5. Engage again the dispenser rocker.
1. Remove tear off edge (if mounted) at the front of printer.
2. For an easier handling, remove front plate (if mounted) which is
fixed at the printer base.
3. Pull the knurled knob (A) to open the dispenser rocker.
4. Place the dispensing unit (B) before the pressure roller. Introduce
the photocell cable (D) between the chassis and the left
supporting plate of the dispenser downwards.
5. Fix the dispensing unit with the hex. head screws (C) at the
aluminium profile beneath the pressure roller.
6. Engage again the dispenser rocker.
7. Insert the plug of photocell cable (D) into the female connector (E)
and fasten it.
Dispensing unit
without photocell
Dispensing unit
with photocell
Refitting options
Spectra II
50
Service Instructions
09.16
7.4 Cutting unit
CAUTION!
Risk of injury, particularly during maintenance, the cutter
blades are sharp!
Switch off the before attaching the cutter!
The cutter may only be used when it is mounted on
the printer!
Do not try to cut any materials which exceed the
maximum width or thickness specifications.
Do NOT touch the area of the moving blades!
D
A
B
D
B
E
C
F
Figure 29
1. Remove tear-off edge (if mounted) and the fixing screws at the
printer front.
2. Remove front plate (if mounted) which is fixed at the printer base.
3. If pre-assembled, remove front plate (C) of cutting unit (A).
4. Hold the cutting unit slightly inclined on the right side in front of the
pressure roller so that the threaded holes of the aluminium profile
have approximately the same height as the through holes at the
cutting unit.
5. Press the cutting unit backwards at the left side.
6. Fix the cutting unit with the screws (D) at the aluminium profile.
7. Insert the plug of cable (E) into the female connector (F) and
fasten it.
8. Fix the front plate (C) with the screws (D) at the side panels of the
cutting unit. Make sure that the front plate with the upper short
chamfer in the slot is placed between the cutter blade and the
square pillar.
Spectra II
Refitting options
09.16
Serviceanleitung
51
7.5 Guiding for Leporello fold material
B
A
A
C
C
D
Figure 30
At the printer rear you can find a breakout (B) for externally supplied
label material.
1. Place the setup-kit for Leporello guiding (D) as illustrated above in
front of the breakout.
2. Fix the Leporello guiding with the enclosed screws (A) and slot
nuts at the rear.
3. Adjust the label guiding (C) according to material width.
4. The supplied label material should be aligned as parallel as
possible to the centre panel of the printer.
Spectra II
Error correction
09.16
Service Instructions
53
8 Error correction
Error message
Cause
Remedy
1
Line too high
Line rises up completely or
partly over the upper edge of
label.
Move line down (increase Y
value).
Check rotation and font.
2
Line too low
Line rises up completely or
partly over the bottom edge of
label.
Move line up (reduce X value).
Check rotation and font.
3
Character set
One res. several characters of
the text is res. are not available
in the selected font.
Change text.
Change font.
4
Unknown code type
Selected code is not available.
Check code type.
5
Unvalid position
Selected position is not
available.
Check position.
6
CV font
Selected font is not available.
Check font.
7
Vector font
Selected font is not available.
Check font.
8
Measuring label
While measuring no label was
found.
Set label length is too large.
Check label length and if labels
are inserted correctly.
Restart measuring anew.
9
No label found
No label available.
Soiled label photocell.
Labels not inserted correctly.
Insert new label roll.
Check if labels are inserted
correctly.
Clean the label photocell.
10
No ribbon
During the print order the
ribbon roll becomes empty
(front printhead).
Defect at the transfer ribbon
photocell (front photocell).
Change transfer ribbon.
Check transfer ribbon photocell
(service functions).
11
COM FRAMING
Stop bit error.
Check stop bits.
Check baud rate.
Check cable (printer and PC).
12
COM PARITY
Parity error.
Check parity.
Check baud rate.
Check cable (printer and PC).
13
COM OVERRUN
Loss of data at serial interface
(RS-232).
Check baud rate.
Check cable (printer and PC).
Error correction
Spectra II
54
Service Instructions
09.16
Error message
Cause
Remedy
14
Field numer
Received line number is invalid
at RS-232 and parallel
interface.
Check sent data.
Check connection PC - printer.
15
Length mask
Invalid length of received mask
statement.
Check sent data.
Check connection PC - printer.
16
Unknown mask
Transferred mask statement is
invalid.
Check sent data.
Check connection PC - printer.
17
Missing ETB
No end of data found.
Check sent data.
Check connection PC - printer.
18
Invalid character
One res. several characters of
the text is res. are not available
in the selected font.
Change text.
Change font.
19
Invalid statement
Unknown transferred data
record.
Check sent data.
Check connection PC - printer.
20
Invalid check digit
For check digit control the
entered res. received check
digit is wrong.
Calculate check digit anew.
Check code data.
21
Invalid SC number
Selected SC factor is invalid for
EAN res. UPC.
Check SC factor.
22
Invalid number of
digits
Entered digits for EAN res.
UPC are invalid
< 12; > 13.
Check number of digits.
23
Check digit
calculation
Selected check digit calculation
is not available in the bar code.
Check calculation of check
digit.
Check bar code type.
24
Invalid extension
Selected zoom factor is not
available.
Check zoom factor.
25
Offset sign
Entered sign is not available.
Check offset value.
26
Offset value
Entered offset value is invalid.
Check offset value.
27
Printhead
temperature
Printhead temperature is too
high.
Defective printhead sensing
device.
Reduce contrast.
Change printhead.
28
Cutter error
With cut an error occurred.
Paper jam.
Check label run.
Check cutter run.
29
Invalid parameter
Entered data do not correspond
to the characters allowed from
the application identifier.
Check code data.
Spectra II
Error correction
09.16
Serviceanleitung
55
Error message
Cause
Remedy
30
Application
Identifier
Selected application identifier is
not available in GS1-128.
Check code data.
31
HIBC definition
F Missing HIBC system sign.
Missing primary code.
Check definition of HIBC code.
32
System clock
Real Time Clock function is
selected but the battery is
empty.
Defective RTC.
Change battery.
Change RTC component.
33
No CF interface
Interrupted connection CPU CF card.
Defective CF card interface.
Check connection CPU - CF
card interface.
Check CF card interface.
34
No print memory
No print CF found.
Check CF assembly on CPU.
35
Cover open
At start of a print order the
printhead is open.
Close the printhead and start
print order anew.
36
BCD invalid format
BCD error
Invalid format for the
calculation of Euro variable.
Check entered format.
37
BCD overflow
BCD error
Invalid format for the
calculation of Euro variable.
Check entered format.
38
BCD division
BCD error
Invalid format for the
calculation of Euro variable.
Check entered format.
39
FLASH ERROR
Flash component error.
Run a software update.
Change CPU.
40
Length command
Invalid length of the received
command statement.
Check data sent.
Check connection PC - printer.
41
No drive
CF card not found / not
correctly inserted.
Insert CF card correctly.
42
Drive error
Impossible to read CF card
(faulty).
Check CF card, if necessary
change it.
43
Not formatted
CF Card not formatted.
Format CF card.
44
Delete current
directory
Attempt to delete the actual
directory.
Change directory.
45
Path too long
Too long indication of path.
Indicate a shorter path.
Error correction
Spectra II
56
Service Instructions
09.16
Error message
Cause
Remedy
46
Drive writeprotected
Memory card is write-protected.
Deactivate write protection.
47
Directory not file
Attempt to indicate a directory
as file name.
Correct your entry.
48
File already open
Attempt to change a file during
an access is active.
Select another file.
49
No file/directory
File does not exist on CF card.
Check file name.
50
Invalid file name
File name contains invalid
characters.
Correct entry of name, remove
special characters.
51
Internal file error
Internal file system error.
Please contact your distributor.
52
Root full
The max. number (64) of main
directory entries is reached.
Delete at least one main
directory entry and create
subdirectories.
53
Drive full
Maximum CF capacity is
reached.
Use new CF Card, delete no
longer required files.
54
File/directory
exists
The selected file/directory
already exists.
Check name, select a different
name.
55
File too large
During copying procedure not
enough memory space onto
target drive available.
Use a larger target card.
56
No update file
Errors in update file of
firmware.
Start update file anew.
57
Invalid graphic file
The selected file does not
contain graphic data.
Check file name.
58
Directory not empty
Attempt to delete a not empty
directory.
Delete all files and subdirectories in the desired
directory.
59
No interface
No CF card drive found.
Check connection of CF card
drive.
Contact your distributor
60
No CF card
No CF card is inserted.
Insert CF card in the slot.
61
Webserver error
Error at start of web server.
Please contact your distributor.
62
Wrong FPGA
The direct print module is
equipped with the wrong
FPGA.
Please contact your distributor.
63
End position
The label length is too long.
The number of labels per cycle
is too much.
Check label length res. the
number of labels per cycle.
Spectra II
Error correction
09.16
Serviceanleitung
57
Error message
Cause
Remedy
64
Zero point
Defective photocell.
Change photocell.
65
Compressed air
Pressure air is not connected.
Check pressure air.
66
External releaser
External print release signal is
missing.
Check input signal.
67
Row too long
Wrong definition of column
width res. number of columns.
Reduce the column width res.
correct the number of columns.
68
Scanner
The connected bar code
scanner signals a device error.
Check the connection
scanner/printer.
Check scanner (dirty).
69
Scanner NoRead
Bad print quality.
Printhead completely soiled or
defective.
Print speed too high.
Increase contrast.
Clean printhead or exchange (if
necessary).
Reduce print speed.
70
Scanner data
Scanned data does not
correspond to the data which is
to print.
Exchange printhead.
71
Invalid page
As page number either 0 or a
number > 9 is selected.
Select a number between 1
and 9.
72
Page selection
A page which is not available is
selected.
Check the defined pages.
73
Page not defined
The page is not defined.
Check the print definition.
74
Format user guiding
Wrong format for customised
entry.
Check the format string.
75
Format date/time
Wrong format for date/time.
Check the format string.
76
Hotstart CF
No CF card found.
If option hotstart was activated,
a CF card must be inserted.
Switch off the printer before
inserting the memory card.
77
Flip/Rotate
Selection of print of several
columns and also mirror/rotate.
It is only possible to select one
of both functions.
78
System file
Loading of temporary hotstart
files.
Not possible.
79
Shift variable
Faulty definition of shift times
(overlapping times).
Check definition of shift times.
80
GS1 Databar
General GS1 Databar error.
Check definition and parameter
of GS1 Databar code.
81
IGP error
Protocol error IGP.
Check sent data.
Error correction
Spectra II
58
Service Instructions
09.16
Error message
Cause
Remedy
82
Time generation
Printing creation was still active
at print start.
Reduce print speed.
Use printers' output signal for
synchronisation.
Use bitmap fonts to reduce
generating time.
83
Transport protection
Both DPM position sensors
(start/end) are active.
Displace zero point sensor
Check sensors in service
functions menu
84
No font data
Font and web data is missing.
Run a software update.
85
No layout ID
Label ID definition is missing.
Define label ID onto the label.
86
Layout ID
Scanned data does not
correspond to defined ID.
Wrong label loaded from CF
card.
87
RFID no label
RFID unit cannot recognise a
label.
Displace RFID unit or use an
offset.
88
RFID verify
Error while checking
programmed data.
Faulty RFID label.
Check RFID definitions
89
RFID timeout
Error at programming the RFID
label.
Label positioning.
Faulty label.
90
RFID data
Faulty or incomplete definition
of RFID data.
Check RFID data definitions.
91
RFID tag type
Definition of label data does not
correspond with the used label.
Check storage partitioning of
used label type
92
RFID lock
Error at programming the RFID
label (locked fields).
Check RFID data definitions.
Label was already
programmed.
93
RFID programming
Error at programming the RFID
label.
Check RFID definitions.
94
Scanner timeout
The scanner could not read the
bar code within the set timeout
time.
Defective printhead.
Wrinkles in transfer ribbon.
Scanner wrong positioned.
Timeout time too short.
Check printhead.
Check transfer ribbon.
Position scanner correctly,
corresponding to the set
feeding.
Select longer timeout time.
Spectra II
Error correction
09.16
Serviceanleitung
59
Error message
Cause
Remedy
95
Scanner layout
difference
Scanner data does not
correspond to bar code data.
Check adjustment of scanner.
Check scanner settings /
connection.
96
COM break
Serial interface error.
Check settings for serial data
transmission as well as cable
(printer-PC).
97
COM general
Serial interface error.
Check settings for serial data
transmission as well as cable
(printer-PC).
98
No software
printhead FPGA
No printhead-FPGA data
available.
Please contact your
responsible distributor.
99
Load software
printhead FPGA
Error when programming
printhead-FPGA.
Please contact your
responsible distributor.
100
Upper position
Sensor signal up is missing
(option APL 100).
Check input signals /
compressed-air supply.
101
Lower position
Sensor signal down is missing
(option APL 100).
Check input signals /
compressed-air supply.
102
Vacuum plate empty
Sensor does not recognise a
label at vacuum plate
(option APL 100).
Check input signals /
compressed-air supply.
103
Start signal
Print order is active but device
not ready to process it.
Check start signal.
104
No print data
Print data outside the defined
label.
Selection of wrong module type
(design software).
Check selected module type.
Check selection of left/right
version.
105
Printhead
No original printhead is used.
Check the used printhead.
Contact your distributor.
106
Invalid Tag type
Wrong Tag type.
Tad data do not match the Tag
type in the printer.
Adapt data or use the correct
Tag type.
107
RFID invalid
RFID module is not activated.
No RFID data can be
processed.
Activate RFID module or
remove RFID data from label
data.
108
GS1-128 invalid
Transferred GS1-128 bar code
is invalid.
Verify bar code data (see GS1128 bar code specification).
109
EPC parameter
Error at EPC calculation.
Verify data (see EPC
specification).
Error correction
Spectra II
60
Service Instructions
09.16
Error message
Cause
Remedy
110
Housing open
When starting the print order
the housing cover is not closed.
Close the housing cover and
start the print order anew.
111
EAN.UCC code
Transferred EAN.UCC code is
invalid.
Verify bar code data (see
corresponding specification).
112
Print carriage
Printing carriage does not
move.
Check gear belt (possibly
broken).
113
Applicator error
Error while using applicator.
Check applicator.
114
Left position
Left final position switch is not
in correct position.
Check LEFT final position
switch for correct function and
position.
Check function of pneumatics
for cross traverse.
115
Right position
Right final position switch is not
in correct position.
Check RIGHT final position
switch for correct function and
position.
Check function of pneumatics
for cross traverse.
116
Print position
The print position is not correct.
Check TOP and RIGHT final
position switch for correct
function and position.
Check pneumatics for function
117
XML parameter
The parameters in the XML file
are not correct.
Please contact your
responsible distributor.
118
Invalid variable
Transferred variable is invalid
with customized entry.
Select correct variable without
customized entry and transfer
it.
119
No ribbon
During the print order the
ribbon roll becomes empty
(rear printhead).
Defect at the transfer ribbon
photocell (rear photocell).
Change transfer ribbon.
Check transfer ribbon photocell
(service functions).
120
Wrong directory
Invalid target directory when
copying.
Target directory must not be
within the source directory.
Check target directory.
121
No label found
No label found at the rear
printhead (DuoPrint).
Soiled label photocell.
Labels not inserted correctly.
Insert new label roll.
Clean the label photocell.
Check if labels are inserted
correctly.
122
IP occupied
The IP address was already
assigned.
Assign a new IP address.
Spectra II
Error correction
09.16
Serviceanleitung
61
Error message
Cause
Remedy
123
Print asynchronous
The label photocell do not work
in the order as it is expected
according to print data.
Check label size and gap size.
The settings of the photocell
are not correct.
Check label photocell settings.
Settings of label size and gap
size are not correct.
Check correct loading of label
material.
No label found at the rear
printhead.
Insert new label roll.
Soiled label photocell.
Clean the label photocell.
Labels not inserted correctly.
Check if labels are inserted
correctly.
124
Speed too slow
Print speed is too slow.
Increase the speed of
customers' machine.
Spectra II
Control inputs and outputs
09.16
Service Instructions
63
9 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.
The ports are provided by means of a D-Sub bushing (26pin HD) at
the rear panel of the printer system and are galvanically isolated from
protective earth (PE) by means of an optocoupler semi-conductor
route.
Each port can be configured as input and as output. This function
however, is predefined in the printer software and cannot be changed
by the user.
The following parameters can be changed and set by using the menu:
debounce times and high or low active.
Figure 31
Printer, internal
circuitry
Control inputs and outputs
Spectra II
64
Service Instructions
09.16
Figure 32
Port 1 to Port 16 = Assignment for I/O Profile 'Std_Label'
Identification
Pin
Description / Function
Port 1
10
Print start and cut (Input)
Port 2
1
Reprint last printed label (Input)
Port 3
11
Counter Reset (Input)
Port 4
2
No function
Port 5
12
Error reset (Input)
Port 6
3
No function
Port 7
13
No function
Port 8
4
No function
Port 9
15
Error (Output)
Port 10
6
Print order active (Output)
Port 11
16
Dispenser photocell:
Label exists at dispenser photocell (Output)
Port 12
7
Single print (Output)
Port 13
17
Ready (Output)
Port 14
8
No function
Port 15
18
Option scanner only
Bar code not readable (Output)
Port 16
9
Prior warning for transfer ribbon end (Output)
COM/VDC
for Inputs
19
Common reference potential of all control inputs. 'COM/VDC for
Inputs' is usually connected with the (-) terminal of the control voltage
and the control inputs are switched to active (+).
By means of the option '2nd LED', 'COM/VDC for Inputs' can
optionally be connected with the (+) terminal of the control voltage.
Then, the control inputs are switched to active (-).
VDC for
Outputs
20
Common supply connection of all control outputs. 'VDC for Outputs'
must be connected with the (+) terminal of the control voltage.
Never leave 'VDC for Outputs' open even if no output is used.
COM for
Outputs
5,14
21,22
Common reference potential of all control outputs. 'COM for Outputs'
must be connected with the (-) terminal of the control voltage.
Never leave 'COM for Outputs' open even if no output is used.
GND-PE
23,24
'GND-PE' is the reference potential of the '+5 VDC EXT' and '+24
VDC EXT' voltages provided by the printer system.
'GND-PE' is printer internally connected with protective earth (PE).
Configuration of
D-Sub socket
Spectra II
Control inputs and outputs
09.16
Serviceanleitung
65
Identification
Pin
Description / Function
+ 5 VDC
EXT
25
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.
+ 24 VDC
EXT
26
24 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.
Plug Connector
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
+ 5 V / 1 A
Fuse: Polyswitch / 30 V / 1 A
Port 1 - 15
Input
Tension
5 VDC … 24 VDC
Impedance
47Ω + (100nF || 10 kΩ)
Output
Tension
5 VDC … 24 VDC
Impedance
47Ω + (100nF || 10 kΩ || 47Ω)
Current max.
High +15 mA
Low -15 mA
Port 16
Input
Tension
5 VDC … 24 VDC
Impedance
100nF || 10 kΩ
Output
Tension
5 VDC … 24 VDC
Impedance
100nF || 10 kΩ
Current max.
High +500 mA (Darlington BCP56-16)
Low - 500 mA (Darlington BCP56-16)
Optocoupler
Output
TCMT4106, CTR 100% - 300%, Vishay or
TLP281-4(GB), CTR 100% - 600%, Toshiba
Input
TCMT4106, CTR 100% - 300%, Vishay or
TLP281-4(GB), CTR 100% - 600%, Toshiba
Input
Option 2nd LED
TCMT4600, CTR 80% - 300%, Vishay or
TLP280-4, CTR 33% - 300%, Toshiba
Technical data
Control inputs and outputs
Spectra II
66
Service Instructions
09.16
Device connection to a machine with S7-300 SPS.
Figure 33
Device connection to a operating panel.
Figure 34
Example 1
Example 2
Spectra II
Control inputs and outputs
09.16
Serviceanleitung
67
Device connection version if 'Option: 2. LED'.
Figure 35
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. As an alternative, a suitable
resistor can be connected in series.
If one of the printer’s internal voltages '+5 VDC EXT' or '+24 VDC
EXT' is used, an external fuse e.g. 0.5 AF, should be additionally
installed to protect the printer electronics.
In the event of an inductive load, an antiparallel connected diode, for
instance, must be used to discharge the induction energy.
In order to minimise the influence of leakage currents at control
outputs, a resistor must, depending on what is connected, be installed
in parallel with the load.
In order to avoid any damages to the printing system, the max. output
currents must not be exceeded or outputs shorted.
Example 3
Precautions
Spectra II
Wiring Plan
09.16
Service Instructions
67
10 Wiring Plan
Figure 36
Wiring Plan
Spectra II
68
Service Instructions
09.16
Figure 37
Spectra II
Wiring Plan
09.16
Serviceanleitung
69
10.1 CPU Component Placement Specification
Figure 38
JP1 (Debug)
JP2 (write-protection)
Boot sector
Programming
closed
closed
Delivery
closed
open
Jumper plan
Wiring Plan
Spectra II
70
Service Instructions
09.16
10.2 Power Electronics
Figure 39
Spectra II
Index
09.16
Service Instructions
71
11 Index
A
Adjustments, settings, alignments
Cutter ledge ........................................................................ 39, 40, 41
Head photocell ................................................................................ 38
Oil and lubricate .............................................................................. 45
Pressure curve (ribbon save) ................................................... 42, 43
Print mechanism ............................................................................. 31
Printhead position (Corner Type) ............................................. 34, 35
Printhead position (Flat Type) .................................................. 32, 33
Rewinder ......................................................................................... 37
Supporting bar (ribbon save) .......................................................... 44
Transfer ribbon feed path ............................................................... 36
Unwinder ......................................................................................... 37
B
Battery, replacing ............................................................................... 30
C
Cleaning
General cleaning ............................................................................. 14
Label photocell cleaning ................................................................. 17
Maintenance schedule .................................................................... 13
Pressure roller cleaning .................................................................. 15
Printhead cleaning .......................................................................... 16
Component plan
Power electronics ........................................................................... 70
Component plan CPU ........................................................................ 69
Component replacing
Battery............................................................................................. 30
CPU PCB .................................................................................. 26, 27
I/O FPGA ........................................................................................ 30
Label photocell ................................................................................ 25
Power supply .................................................................................. 28
Pressure roller ................................................................................ 24
Printhead ........................................................................................ 20
Printhead (Corner Type) ................................................................. 22
Printhead (Flat Type) ...................................................................... 21
Tools list .......................................................................................... 19
WLAN module ................................................................................. 29
Connector pin assignment, printer rear .............................................. 11
Control inputs and outputs ................................................................. 64
CPU
Component plan ............................................................................. 69
CPU PCB, replacing ................................................................. 26, 27
Jumper plan .................................................................................... 69
Cutter ledge, adjusting ........................................................... 39, 40, 41
Cutting unit, refit ................................................................................. 50
D
Dispensing unit, refit ........................................................................... 49
E
Electricity, safety handling .................................................................... 9
Environmentally-friendly disposal ....................................................... 10
Error messages/Error corrections ...... 53, 54, 55, 56, 57, 58, 59, 60, 61
Index
Spectra II
72
Service Instructions
09.16
H
Head photocell, adjusting ................................................................... 38
I
I/O FPGA, replacing ........................................................................... 30
I/O plate, refit ...................................................................................... 48
Inputs/outputs ............................................................................... 63, 65
Instructions ........................................................................................... 5
J
Jumper plan CPU ............................................................................... 69
L
Label photocell
Replacing ........................................................................................ 25
Leporello guiding, refit ........................................................................ 51
M
Maintenance/cleaning
Ribbon drawing roller, cleaning ...................................................... 14
N
Notes
Document ......................................................................................... 5
User .................................................................................................. 5
O
Oil and lubricate ................................................................................. 45
P
Power electronics, component plan ................................................... 70
Power supply, replacing ..................................................................... 28
Pressure curve, adjusting ............................................................. 42, 43
Pressure roller
Replacing ........................................................................................ 24
Print mechanism, adjusting ................................................................ 31
Print position, adjusting ...................................................................... 23
Printhead
Corner Type, parallelism........................................................... 34, 35
Corner Type, pressure .................................................................... 35
Corner Type, pressure balance ...................................................... 35
Flat Type, parallelism ...................................................................... 32
Flat Type, pressure ......................................................................... 33
Flat Type, pressure balance ........................................................... 33
Replacing ........................................................................................ 20
Replacing (Corner Type) ................................................................ 22
Replacing (Flat Type) ..................................................................... 21
R
Refit options
Cutting unit ...................................................................................... 50
Dispensing unit ............................................................................... 49
I/O plate .......................................................................................... 48
Internal rewinder ............................................................................. 47
Leporello guiding ............................................................................ 51
Rewinder (internal), refit ..................................................................... 47
Rewinder, adjusting ............................................................................ 37
Spectra II
Index
09.16
Serviceanleitung
73
S
Safety handling when working with electricity ...................................... 9
Safety instructions ................................................................................ 8
Clothing ............................................................................................. 7
Protective clothing ............................................................................ 7
Protective equipment ........................................................................ 8
Workplace ......................................................................................... 7
Supporting bar, adjusting ................................................................... 44
T
Tools list ............................................................................................. 19
Transfer ribbon feed path, adjusting .................................................. 36
U
Unwinder, adjusting ............................................................................ 37
W
Wiring plan ................................................................................... 67, 68
WLAN module, replacing.................................................................... 29
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