Service Manual Label Printer A+ The Premium Class.
Service Manual for the following products Family Type A+ A2+ 2 A4+ A4.3+ A6+ A8+ A4+M Edition: 04/2014 - Part No. 9008508 Copyright This documentation as well as translation hereof are property of cab Produkttechnik GmbH & Co. KG. The replication, conversion, duplication or divulgement of the whole manual or parts of it for other intentions than its original intended purpose - in particular the procurement of spare parts for products sold by cab – demand the previous written authorisation by cab.
Table of Contents 1 1.1 1.2 1.3 1.4 Important Information............................................................................................................................. 4 General Safety Instructions....................................................................................................................... 4 Protective Devices.................................................................................................................................... 4 Handling Electricity ...
1 Important Information 1.1 General Safety Instructions This service manual is intended for use by qualified service and maintenance personnel. For more operation and configuration information, refer to the user or configuration manual. Follow the general safety rules below: • Keep the area around the device clean at all times! • Work with safety in mind. • Parts of device that are removed during the maintenance work must be put in a safe place. • Avoid risks of tripping over.
1 Important Information 1.3 Handling Electricity The following work may only be done by trained and qualified electricians: • Work on electrical components. • Work on an open device still connected to the mains supply. General precautions before starting maintenance work: • Find out where the emergency and power switches are so that they can be quickly thrown in an emergency. • Disconnect the current supply before carrying out the following work: -- Installing or removing power units.
2 Cleaning 2.1 Cleaning by the Operator 6 The following cleaning work is described in the “Operator's Manual“: 2.2 • cleaning the device • cleaning the printhead • cleaning the print roller • cleaning the label sensor A2+ A4+ Cleaning the Label Sensor A6+, A8+ 4 6 7 2 Fig.
2 Cleaning 2.3 Cleaning the Label Sensor A4+M 7 5 1 Fig. 2 3 2 2 4 Cleaning the label sensor A4+M Danger! Risk of death via electric shock! XX Before opening the housing cover, disconnect the device from the mains supply and wait at lease one minute until the power supply unit has discharged. 1. Remove media from the printer. 2. Remove the Allen key (5) from its retainer. 3. Remove the rear cover of the printer. 4. Unscrew knurled thumb screw (1). 5.
3 Replacing Assembly Units 3.1 Tools XX Do not use any worn of damaged tools. XX Only use tools and testing devices that are suitable for the task at hand. cab special tools: • Test collar for transfer ribbon winder (cab item number: 5534199) Standard tools: 3.
3 Replacing Assembly Units 3.3 Replacing the Printhead 3.3.1 Replacing the Printhead A2+, A4+, A4.3+, A4+M 9 The printhead of the label printer can be replaced without the need for fine adjustment. The printhead must be replaced if worn or when switching to a printhead with higher or lower resolution. For better differentiation, the print heads have a label stating the printer type and resolution.
3 Replacing Assembly Units 10 Removing the printhead 1. Turn lever (10) counterclockwise to lift the printhead. 2. Remove labels and transfer ribbon from the printer. 3. Remove Allen key (11) from its retainer. 4. Lightly keep printhead mounting bracket (9) on the print roller with one finger and screw out screw (8) with the Allen key and remove it and the washer. 5. Swivel printhead mounting bracket (9) upward. 6. Remove printhead from the printhead mounting bracket (9) if necessary. 7.
3 Replacing Assembly Units 11 6 7 6 8 2 1 4 9 4 5 Fig. 7 3 Removing and installing the printhead A6+, A8+ Removing the printhead 1. Turn lever (8) counterclockwise to lift the printhead. 2. Remove labels and transfer ribbon from the printer. 3. Remove Allen key (9) from its retainer. 4. Lightly keep printhead mounting bracket (7) on the print roller with one finger and loosen screws (6) with the Allen key. 5. Swivel printhead mounting bracket (7) upward. 6.
3 Replacing Assembly Units 3.4 Replacing the Print Roller and Rewind Assist Roller 12 Removing the side plate 1. Turn lever (1) counterclockwise to lift the printhead. 2. Lift the pinch roller (5) off the rewind assist roller. 3. Remove labels and transfer ribbon from the printer. 1 4. Loosen screws (4) on plate (6) with Allen key by several turns and remove plate (6). 4 3a 3b 2 6 5 Fig. 9 5. Unscrew screws (3abc) of the side plate (2) with Allen key.
3 Replacing Assembly Units 3.5 Replacing the Slipping Clutches 13 The rewinder for the transfer ribbon and the internal rewinder are coupled to slipping clutches in the main drive. The supply hub of the transfer ribbon is braked with a slipping clutch during printing. Change the slipping clutch when it can no longer be set 4.1 on page 19. Removal and installation of the slipping clutch is also required for replacement of a winder.
3 Replacing Assembly Units 14 Installing the slipping clutch on the rewinders 8 7 6 5 4 Fig. 12 4 5 6 7 8 Snap ring Slipping clutch Coupling disks Winder axis Collar of the belt wheel Slipping clutch on the rewinders 1. Slide coupling (5) onto the winder axis (7). 2. Align grooves in the coupling disks (6) with the guides in the collar of the belt wheel (8). 3. Slide coupling further until it stops. 4. Secure the snap ring (4). 5. Adjust the coupling 4.1 on page 19. 6.
3 Replacing Assembly Units 3.6 Replacing the Label Sensor i 15 Notice! Soiling of the label sensor can also cause malfunctions. Before replacing the label sensor, check whether it is soiled and clean it if necessary.. For A2+, A4+, A4.3+ Operator's Manual, for A6+, A8+ 2.2 on page 6. Danger! Risk of death via electric shock! XX Before opening the housing cover, disconnect the device from the mains supply and wait at lease one minute until the power supply unit has discharged. 3.6.
3 Replacing Assembly Units 3.6.2 Replacing Label Sensor A4+M 16 5 1 Fig. 15 3 2 2 4 Replacing the label sensor A4+M Danger! Risk of death via electric shock! XX Before opening the housing cover, disconnect the device from the mains supply and wait at lease one minute until the power supply unit has discharged. Removing the label sensor 1. Remove the Allen key (5) from its retainer. 2. Remove the rear cover of the printer. 3. Unscrew knurled thumb screw (1). 4.
3 Replacing Assembly Units 3.7 Replacing the PCB CPU 17 Danger! Risk of death via electric shock! XX Before opening the housing cover, disconnect the device from the mains supply and wait at lease one minute until the power supply unit has discharged. Removing the PCB CPU 1 1. If possible, save the printer configuration to a CompactFlash card Configuration Manual. 2. Unplug the printer from the electrical outlet. 3. Detach all interface cables from the back of the printer. 4.
3 Replacing Assembly Units 3.8 Replacing the Power Supply Unit 18 Danger! Risk of death via electric shock! XX Before opening the housing cover, disconnect the device from the mains supply and wait at lease one minute until the power supply unit has discharged. 2 Removing the power supply unit 1. Unplug the printer from the electrical outlet. 2. Remove the PCB CPU 3.7 on page 17. 3. Remove the two screws (6) of the cover plate (5). 4. Remove the cover plate (5). 5.
4 Adjustments 4.1 Measuring and Adjusting the Winding Torques The rewinder for the transfer ribbon and the internal rewinder are coupled to slipping clutches in the main drive. The supply hub of the transfer ribbon is braked with a slipping clutch during printing.
4 Adjustments 20 The set values for the winding torque and the resulting pulling force at the test collar are: Slipping clutch on Direction of rotation Printer Winding torque M Pulling force F Ribbon take up hub clockwise A2+ A4+, A4.3+, A6+ A8+ 10.2 - 10.8 Ncm 13.5 - 14.4 Ncm 17.7 - 18.1 Ncm 3.4 - 3.6 N 4.3 - 4.8 N 5.9 - 6.1 N counterclockwise all 2.1 - 3.0 Ncm 0.7 - 1.0 N any A2+, A4+, A4.3+, A6+ A8+ 3.6 - 4.5 Ncm 4.5 - 5.1 Ncm 1.2 - 1.5 N 1.5 - 1.
4 Adjustments 21 Internal rewinder Measurement of the winding torque at the internal rewinder occurs by determining the pulling forces with a cord wrapped around the rewinder.
4 Adjustments 4.1.2 Adjusting the Winding Torques 22 The winding torque of a winder can be changed at the knurled ring of the respective slipping clutch. The numbers on the knurled ring stand for the value of the winding torque: • 1: Lowest winding torque • 7: Highest winding torque The current value is indicated by the number located at the positions of the two locking tabs.
4 Adjustments 4.2 Adjusting the Printing Mechanism 23 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.
4 Adjustments 4.2.2 Adjusting the Printhead Position 24 In order to achieve the best possible print image the following printhead settings are necessary: ! • 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. Attention! The printhead assembly can be damaged.
4 Adjustments 4.2.3 Adjusting the Printhead Pressure 25 The printhead pressure can be changed with the screws (1a) and (1b) at the inside and outside of the printhead. 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. i Notice! XX At A8+ also use the screw on the middle plunger for the adjustment. 1a 1b Fig. 24 Adjusting the printhead pressure 1.
4 Adjustments 4.2.4 Adjusting the Transfer Ribbon Feed Path 26 You can adjust the transfer ribbon feed path by changing the head contact pressure and adjusting the transfer ribbon deflection. Increasing the head contact pressure with the screws (3a) and (3b) shifts the ribbon feed path in the corresponding direction. The skew of the transfer ribbon deflection is used to suppress wrinkles in the transfer ribbon feed path.
4 Adjustments 4.3 Adjusting the Belt Tension at the Main Drive Motor 27 Danger! Risk of death via electric shock! XX Before opening the housing cover, disconnect the device from the mains supply and wait at lease one minute until the power supply unit has discharged. ! Attention! The toothed belt could be damaged if adjustment is carried out improperly.
4 Adjustments 4.4 Adjusting the Head Switch 28 The head switch prevents printing from occurring when the printhead is open. Adjust the head switch if the error message Head open appears in the display even though the printhead is locked. Danger! Risk of death via electric shock! XX Before opening the housing cover, disconnect the device from the mains supply and wait at lease one minute until the power supply unit has discharged. 1. Unplug the printer from the electrical outlet. 2.
5 Troubleshooting and Error Treatment 5.
5 Troubleshooting and Error Treatment 5.2 Hardware Faults 30 Error message Cause Fault recovery ADC malfunction Fault on the PCB CPU Replace the PCB CPU Fault on the PCB CPU Replace the PCB CPU Fault on the PCB CPU Replace the PCB CPU VBAT Voltage of the battery on the PCB CPU is too low Replace the PCB CPU VMOT Motor voltage is too low Check motor voltage at the measurement point Vmot Fig. 30 on page 33: FPGA malfunction Invalid setup Voltage error 24 V 24 V too low 24 V ext.
6 Block Diagram Printer Type 31 Nr. 1 Nr. 2 Nr. 3 Nr. 4 Nr. 5 Nr. 6 A2+ all 5954105 5954293 5954292 5946203 5954098 5954090 A4+ 200, 200P 5954081 5954067 5954066 5946206 5954098 5954090 A4.
7 Layout Diagram PCB CPU Fig.
7 Layout Diagram PCB CPU Fig.
8 Index 34 A S Adjusting the belt tension..................27 Adjusting the printhead position........24 Slipping clutch replacing......................................13 winding torque.............................20 Adjusting the printhead pressure.......25 T Adjusting the printing mechanism.....23 Tools....................................................8 Adjusting the head switch..................28 Adjusting the ribbon feed path...........26 B Block diagram...............................
