Copyright Information: Firmware (Software) Agreement:

Transcription

1 Maintenance Manual

2 Copyright Information: CG Triumvirate is a trademark of Agfa Corporation. CG Times, based upon Times New Roman under license from The Monotype Corporation. Firmware (Software) Agreement: The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and is licensed for use only on a single printer in the user s Trade or Business. The User agrees not to, and not to authorize or permit any other person or party to, duplicate or copy the Firmware or the information contained in the non-volatile or programmable memory. The firmware (Software) is protected by applicable copyright laws and Licensor retains all rights not expressly granted. In no event will Licensor or its suppliers be liable for any damages or loss, including direct, incidental, economic, special, or consequential damages, arising out of the use or inability to use the Firmware (Software). WARNING Lithium Battery: There is a danger of explosion or fire if the battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Discard used batteries according to the manufacturer s instructions. Information in this document is subject to change without notice and does not represent a commitment on the part of Datamax-O Neil. No part of this manual may be reproduced or transmitted in any form or by any means, for any purpose other than the purchaser's personal use, without the expressed written permission of Datamax-O Neil. All rights reserved. Printed in the United States of America Part Number Rev. G COPYRIGHT 2010, DATAMAX-O NEIL

3 Contents 1 Overview 2 Adjustments and Maintenance 3 Troubleshooting 4 5 Removal and Replacement Printer Assemblies i

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5 1 Overview 1.0 Introduction About the Printer... 2 i

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7 Overview 1.0 Introduction This manual is intended for use by qualified service personnel in the maintenance and repair of W-Class printers (hereafter referred to as the printer ). It primarily includes technical information relating to the printer s electrical and mechanical components. If necessary, refer to the following documents for additional printer information (available for download at For operating information, reference the Operator s Manual, part number For software language documentation, reference the Class Series Programmer s Manual, part number Important Information: The exclamation point inside an equilateral triangle is intended to alert the technician to the presence of important operating, maintenance or servicing information. Always, as with all electrical equipment, follow basic safety precautions to avoid personal injury or printer damage. 1-1

8 Overview 1.1 About the Printer The following drawing highlights the user-assessable components of the printer. 1-2

9 2 Adjustments and Maintenance 2.0 Introduction Media Sensor Calibration Quick Calibration Standard Calibration Advanced Entry Calibration Printhead Adjustments Leveling Cam Adjustment Pressure Adjustment Burn Line Adjustment Voltage Adjustment Ribbon Shield Adjustment Maintenance Cleaning the Printhead Cotton Swab Procedure Cleaning Card Procedure Cleaning Film Procedure Cleaning the Platen Roller Cleaning the Media Sensor & the Media Path Cleaning the Exterior Surfaces i

10 2.4.5 Cleaning the Cutter Light-Duty Cutter Standard Cutter Cleaning the Fan Filter Application Version Updates Updating from Ready Mode Updating from Download Mode Possible Problems during an Update Boot Loader Program Updates Resetting the Printer Soft Reset Level One Reset Level Two Reset ii

11 Adjustments and Maintenance 2.0 Introduction This section covers the necessary maintenance and alignment procedures for the printer. 2.1 Media Sensor Calibration This printer can use many different media compositions, configurations and colors. In addition to adjusting the Media Sensor and selecting the SENSOR TYPE, to ensure that each label is detected correctly and reliably, calibration is required. There are three different calibration methods Quick Calibration This is the easiest calibration method and should work for most die-cut and reflective media types. This procedure is not required for continuous media. If Uncalibrated is displayed, follow the Standard Calibration procedure in Section Perform a Quick Calibration as follows: Ensure that media is loaded, that the Media Sensor is adjusted, and that the printer is idle. Press and hold the Key. The printer will begin advancing media; allow at least one label gap or mark to pass through the sensor. Upon successful completion, CALIBRATION COMPLETE will be displayed, the printer will feed to the next label TOF and READY will be displayed. (A WARNING LOW BACKING message may appear if using notched media or media on a transparent liner; however, the calibration was successful). Note: Die-cut media containing large gaps may require a change in the PAPER OUT DISTANCE setting; see the Operator s Manual for details. Calibration Hints: In certain cases, the printer may have trouble differentiating between the label and liner. If CANNOT CALIBRATE is displayed, or if the printer stops feeding mid-label then try the following: Press and hold the Key to allow two gaps (or marks) to pass through under the sensor. If CANNOT CALIBRATE is displayed again, or if the printer stops feeding mid-label then try the following: Press and hold the Key to allow three or more gaps (or marks) to pass through the sensor. If this method fails, use the Standard Calibration method described in Section

12 Adjustments and Maintenance Standard Calibration During the Standard Calibration process, the printhead assembly can be raised for visual access to the media and media sensor. In addition, displayed sensor readings can be used to indicate the best position over the media. These features are helpful when using small, position-critical TOF notches or marks. Three readings are required: Empty: No media in the sensor. Gap (or Mark): Only the backing, notch, or reflective mark in the sensor. Paper: The label (with the liner attached) in the sensor. Make sure media is loaded and that the appropriate Sensor Type has been selected, then perform the Standard Calibration as follows: Step Action Displayed Message Comment 1 Turn On the printer. Wait for the printer to initialize (about six seconds) before proceeding. 2 Press the Key. Raise the printhead assembly. You are entering Menu Mode. 3 Press the Key to enter the Media Settings menu. See the Operator s Manual for menu layout details. 4 Press the Key and scroll to SENSOR CALIBRATION. Press the procedure. Key to abort this 5 Press the Key. You are beginning the standard calibration procedure. 6 Press the Key. Remove the media from the Media Sensor then press any key. This sets the parameter for the empty value. Where yyy is a numerical value representing the current sensor reading. 2-2

13 Adjustments and Maintenance Standard Calibration (continued) Step Action Displayed Message Comment 7 Proceed according to media type: Die-cut media: Peel media from the backing and then reinsert the backing into the sensor; adjust the Sensor Eye Mark near the center of the backing material. Press any key to continue. Notched media: Adjust the Sensor Eye Mark over the center of the notch. Press any key to continue. Reflective media: Adjust the Sensor Eye Mark over the center of the facedown black mark. Press any key to continue. Continuous media: Go to Step 8. Or, for reflective media: This sets the parameter for the gap or mark value. Where yyy is a numerical value representing the current sensor reading: useful in locating the best sensor position. Note: Never position the sensor over a perforation when recording a sensor reading. Note: Do not move the position of the Media Sensor after it has been adjusted. 8 Position a label (and backing, if any) under the Sensor Eye Mark. Press any key to continue. Note: If using preprinted media, ensure the label area under the sensor is free of preprinted text, graphics or borders. This sets the parameter for the paper value. Where yyy is a numerical value representing the current sensor reading. 2-3

14 Adjustments and Maintenance Standard Calibration (continued) Step Action Displayed Message Comment 9 Observe the message on the display. Or, for reflective media: The calibration was successful. If another message was displayed, see the note below. Or, for continuous media: 10 Exit the menu tree by repeatedly pressing the Key. If using gap or reflective media, press and hold the Key and allow at least one label gap (or mark) to advance under the sensor. The printer is now ready to begin printing. If this calibration was not successful, go to Section Note: A WARNING LOW BACKING message indicates that the calibration was successful with notched media or media on a transparent liner; for all possible messages, see Section

15 Adjustments and Maintenance Advanced Entry Calibration Advanced Entry Calibration is an alternate calibration method for special-case media types only. This procedure has two parts: (1) recording sensor readings using differing algorithms and, (2) selecting, resampling, and manually entering calibration values. Advanced Entry Calibration will override all previous calibration settings; use this method only when Standard Calibration has failed. Make sure media is loaded and that the appropriate Sensor Type has been selected, then perform the Advanced Entry Calibration as follows: Step Action Displayed Message Comment 1 Turn On the printer. Wait until the printer initializes (about six seconds). 2 Press the Key. Raise the printhead assembly. You are entering Menu Mode. 3 Press the Key to enter the Media Settings menu. See the Operator s Manual for menu layout details. 4 Press the Key and scroll to SENSOR CALIBRATION. Press the this procedure. Key to abort 5 Press the Key. You are entering the calibration submenu. 6 Press the Key to scroll to ADVANCED ENTRY. You are entering Advanced Entry Calibration. 7 Press the Key. Press the this procedure. Key to abort 2-5

16 Adjustments and Maintenance Advanced Entry Calibration (continued) Step Action Displayed Message Comment 8 Press the Key. You are beginning the Advanced Entry Calibration. 9 Press the Key. Place the label under the Sensor Eye Mark and lower the printhead assembly. -Or- If using preprinted media, ensure the label area under the sensor is free of preprinted text, graphics, borders or perforations. Note: Do NOT move the position of the Media Sensor after it has been adjusted. 10 Press the Key to select the setting (denoted by an * ). Record this sensor reading (the yyy value) as a Label Value in a table similar to the one shown below. Next, press the Key to increment the Gain Number. Repeat this step for each of the Gain Numbers (00-32). -OR- Where yyy is a numerical value representing the current sensor reading: useful in locating the best sensor position. Note: Never position the sensor over a perforation when recording a sensor reading. Sample table: Use a list similar to the one shown right, with enough rows to record the data for each of the 33 Gain Numbers. Gain Label Number Value TOF Value Difference Value 2-6

17 Adjustments and Maintenance Advanced Entry Calibration (continued) Step Action Displayed Message Comment 11 Proceed according to your media type: Die-cut stock: strip the media from the backing and then reinsert it into the sensor; adjust the Sensor Eye Mark over the center of the backing. Notched stock: adjust the Sensor Eye Mark over the center of the notch. Reflective stock: Adjust the Sensor Eye Mark over the center of the facedown black mark. Press the Key to select the setting and then record the sensor reading in your table as a TOF Value. Next, press the Key to increment the Gain Number. Repeat for each of the Gain Numbers (00-32). Or, for reflective media: Where yyy is a numerical value representing the current sensor reading. 12 From the data collected in Steps 10 and 11, where both the sensor readings are above 20, subtract each Label Value from the corresponding TOF Value. Record these as Difference Values. From the resulting list, find the largest Difference Value (see example below). Its associated Gain Number is the best algorithm for your media. Or, for reflective media: Both sensor readings must be above

18 Adjustments and Maintenance Advanced Entry Calibration (continued) For example, if your compiled data had the values shown in this table, Gain Number 8 would be chosen because it has the highest Difference Value (146), where both the Label Value and the TOF Value are above 20. Gain Number Label Value TOF Value Difference Value N/A N/A N/A N/A Step Action Displayed Message Comment 13 Using the Key, select the Gain Number determined in Step 12. Press the Key to select the setting. Or, for reflective media: This example uses Gain Number 8. Selection is denoted with an *. 14 Place the media in the Media Sensor. Record the sensor reading and label it P (paper). Place the backing, mark, or notch in the sensor. Record the reading and label it G or M (Gap or Mark). Remove all media. Record the reading and label it E (Empty). 15 Press the Key. Then press the Key. Or, for reflective media: Where yyy is a numerical value representing the current sensor reading. The sensor readings must be manually entered into the printer now. 2-8

19 Adjustments and Maintenance Advanced Entry Calibration (continued) For example, at Gain Number 8, these were the sensor readings for each of the media conditions. (Actual readings will vary.) Paper Gap (or Mark) Empty Step Action Displayed Message Comment 16 Press the Key. Using the or the Key, set the Paper level to the value determined in the previous step. Press the Key to set the entry (indicated by the * ) and advance the menu. Repeat for the Gap (or Mark ) and Empty levels. Or, for reflective media: The selection will flash and the display heading will change to indicate the item for entry. 17 After all entries have been made, press the Key to back out of the menu and then press the Key to save the settings and return to the Ready Mode. From READY, press the Key to advance to the next label TOF. Note: If the Advanced Entry Calibration fails, try the following procedure: Re-enter the menu system. Go to Media Settings Calibration Advanced Entry Sensor Gain and lower the selected Gain Setting number by one (to make the sensor less sensitive). Select the new Gain Setting, save the changes, exit the menu, and then test your media. Repeat the procedure until a usable media setting is obtained. 2-9

20 Adjustments and Maintenance 2.2 Printhead Adjustments Leveling Cam Adjustment To maintain even print pressure across a wide range of media widths, the printer features a Printhead Leveling Cam. This cam offsets the right side of the Printhead Assembly. It is numbered for your reference. However, these numbers do not correspond to specific media widths: one is the highest setting, while nine is the lowest. Make this adjustment when using media that is less than the full width of the Platen Roller, as follows: With the printer On, and media loaded (including ribbon, if transfer printing), download a label format or use one of the resident formats Begin printing the batch of labels. Examine the right side of the printed labels. Rotate the Printhead Leveling Cam until even print is achieved (see examples next page). 2-10

21 Adjustments and Maintenance Example 1 Over adjustment of the cam: Too much adjustment produces an image that fades across the label. To correct this, decrease the setting of the Leveling Cam. Example 2 Correct adjustment of the cam: Proper adjustment produces a complete image, with even print contrast across the label (see note below). Note: Under-adjustment of the Leveling Cam can cause ribbon wrinkling, lateral label movement, and excessive wear on the printhead and platen roller. 2-11

22 Adjustments and Maintenance Pressure Adjustment To accommodate a wide variety of media types the Printhead Pressure Adjustment is factory set for most media types, so this adjustment should only be made after attempting to improve print quality through the use of the heat and/or print speed settings (see the Operator s Manual for details.). When adjusting, use only the minimum pressure necessary for imaging. To increase the pressure, turn the Adjustment Screws clockwise; to decrease the pressure, turn the screws counterclockwise. Adjustments should be made equally for even pressure across the media. Notes: (1) Excessive pressure can reduce the service life of the printhead and platen roller. (2) Unequal pressure may cause ribbon wrinkle and label tracking problems. 2-12

23 Adjustments and Maintenance Burn Line Adjustment This adjustment is NOT REQUIRED during a normal printhead replacement. The Printhead Burn Line is the row of thermal elements that creates the image on the label. At the factory, the Burn Line is adjusted to strict compliance using 6.5-mil (.0065 inch) media, enabling the printer to maintain print quality across a majority of media types. Depending upon the equipped printing option, the alignment is different. The position of the burn line on direct thermal models is over the platen roller vertex for maximum heat transfer. Conversely, the position of the burn line on thermal transfer models is slightly forward of the vertex to allow the wax/ink to separate easily from the ribbon base film and adhere to the label while hot. In extreme cases, when media with a different thickness or rigidity is used (heavy tag stock, for example), this relationship can change. To compensate for the change, first try the suggestions in Section 1.5 of the Operator s Manual, and in Sections 2.2.1, and of this manual. If the print quality remains unacceptable, then an adjustment may be required. In most cases, the burn line requires a slight forward adjustment for thicker media, while thinner media requires a slight backward adjustment. Adjust the Burn Line as follows: With media installed (and ribbon, if thermal transfer printing), lower the printhead assembly and rotate the Printhead Latch completely back, to the locked position. Disengage the Leveling Cam. Loosen the two Anchor Screws. Begin printing. Enter the Quick Test Mode then select 100 Print Quality Labels; see the Operator s Manual for details. Rotate the Burnpoint Adjustment Screws (making only small changes each time) adjusting for the best print quality across the label. Note: When unevenly adjusted, the print will tend to fade on toward one side of the label. Tighten the Anchor Screws. Retest, and repeat if necessary. 2-13

24 Adjustments and Maintenance NEVER force or over tighten the adjustment screws CAUTION 2-14

25 Adjustments and Maintenance Voltage Adjustment This procedure requires voltage measurement: Use extreme caution. CAUTION The following conditions will require the adjustment of the printhead supply voltage: (1) Replacement of the power supply; (2) An inadvertent adjustment of the power supply s factory setting; or, (3) Replacement of the printhead in a W-8306 model printer. Note: This adjustment is not required during routine printhead replacements in W-6208 and W-6308 model printers. To adjust the printhead supply voltage perform the following procedure: Turn Off and unplug the printer. Remove the Electronics Cover; see Section 4.1. Remove the Power Supply Cover; see Section Using a DVM set to measure DC voltage, connect the positive lead to Power Supply Connector J2 - pin 1 and the negative lead to J2 - pin

26 Adjustments and Maintenance Raise the Printhead Assembly. Locate and note the Printhead Resistance Value (this location differs slightly depending upon the printer model). W-6208 and W-6308 models: W-8306 models: After ensuring that media is loaded, latch the Printhead Assembly in the down position. Plug in and turn On the printer. 2-16

27 Adjustments and Maintenance Wait for the printer to initialize. After Ready is displayed, press the FEED button (this will enable the printhead voltage for approximately 30 seconds). While monitoring the DVM, adjust the voltage using RP1 on the Power Supply PCB according to the resistance range listed in the appropriate table below. WARNING An over-voltage condition can permanently damage or shorten the life of the printhead. Printhead Voltage Adjustment Table Model Printhead Resistance Range (in ohms) Printhead Supply Voltage (in VDC) W6208 W6308 W Turn Off and unplug the printer. Remove the DVM leads. Reinstall the Power Supply Cover. Reinstall the Electronics Cover. 2-17

28 Adjustments and Maintenance 2.3 Ribbon Shield Adjustment Adjustments for ribbon alignment ensure smooth, taut ribbon flow during the print process. Irregular voids that extend diagonally through the printed image may be due to ribbon overlap problems (i.e., wrinkling). When troubleshooting a wrinkling problem, always begin by checking the Leveling Cam (Section 2.2.1), the Pressure Adjustment (Section 2.2.2), and the Burn Line Adjustment (Section 2.2.3). In addition, examine the Platen Roller for signs of build-up or wear, correcting as necessary before continuing. If the problem persists, perform the following adjustment: Load full width media and ribbon. Ensure the Leveling Cam is disengaged; see Section Press the FEED Button several times to normalize the tracking of the ribbon and media. (If label tracking is a problem it must be corrected before proceeding, typical causes include uneven printhead pressure or a worn platen roller.) Enter the Quick Test Mode and select 100 Quick Ribbon Test Labels. 2-18

29 Adjustments and Maintenance Press the key to begin printing. Observe the ribbon for rippling or bagging as it travels from the Ribbon Shield to the Upper Ribbon Idlers. If the travel is smooth and the printed labels show no evidence of ribbon wrinkling, proceed to Step 6. If wrinkling is evident, loosen the Ribbon Shield Adjustment Screws and move the either side of the Ribbon Shield up or down until the ribbon is taken up smoothly (without any rippling or bagging) and the printed labels are free of voids due to ribbon wrinkle. Without moving the position of the Ribbon Shield, tighten the Ribbon Shield Adjustment Screws. Print several labels, repeat if necessary. Press the key to stop printing. Install your normal media and ribbon. Adjust the Printhead Leveling Cam as necessary for narrow media. Send your label format to the printer. Examine the printed labels; readjust the Ribbon Shield slightly if needed. 2-19

30 Adjustments and Maintenance 2.4 Maintenance The following list and table detail the recommended items, techniques and schedules to help you safely and effectively maintain the printer. No other regular maintenance is required. Isopropyl alcohol Cotton swabs A clean, lint-free cloth Soft-bristle brush Soapy water/mild detergent Compressed air Printhead Cleaning Cards and/or Printhead Cleaning Film CAUTION For your safety and to avoid damaging the printer, turn Off and unplug the printer before cleaning. Always take proper precautions when using isopropyl alcohol, a flammable liquid. Recommended Maintenance Schedule Component / Area Cleaning Interval * Method / Supplies Printhead Platen Roller Media Sensor / Media Path / Interior Exterior Surfaces Thermal transfer media after each roll of ribbon. Direct thermal media after each roll of media, or as needed. After each roll of labels, after each roll of ribbon, or as needed. Compressed air or a soft brush. Isopropyl alcohol, as needed. Remove all build-up. As needed, based on a weekly visual inspection. Isopropyl alcohol; and, if necessary, Printhead Cleaning Cards and / or Printhead Cleaning Film. See Section Cotton swab or cloth dampened with isopropyl alcohol. See Section Clean as needed, based on a weekly visual inspection. See Section Mild detergent. See Section Cutter Option Power Supply Fan Filter *Whichever occurs first. After each roll of labels, after each roll of ribbon, or as needed. Clean as needed, depending upon environmental conditions. Compressed air and isopropyl alcohol dampened cotton swabs. See Section Mild detergent. Remove all buildup. See Section

31 Adjustments and Maintenance Cleaning the Printhead CAUTION NEVER use a sharp object to clean the Printhead. If print quality declines (symptoms can include unreadable bar codes, or streaks through the text and graphics), the typical cause is debris build-up on the printhead. Furthermore, if not removed, this build-up may lead to premature dot failure. Clean the printhead every time a roll of ribbon has been used. If using direct thermal stock, clean the printhead every time a roll of labels has been used, or as needed. To help you remember this important maintenance procedure, the printer can be programmed to prompt you for cleaning; see the Operator s Manual for details. Faulty Label: Instead of consistent patterns, streaks in the direction of print indicate a dirty or faulty printhead. According to the media, ribbon, and printing parameters used, different methods are recommended for cleaning the printhead. In all cases, perform the following preliminary operations before cleaning the printhead: Preliminary Cleaning Steps: Stop printing. Raise the cover, unlock the Printhead Latch and raise the Printhead Assembly. Wait for the printhead to cool. Remove media and ribbon from the printer. Proceed according to your cleaning requirements. 2-21

32 Adjustments and Maintenance Cotton Swab Procedure This procedure is recommended for printers using direct thermal media, or thermal transfer media with a wax ribbon. Perform the Preliminary Cleaning Steps, as described in Section Turn Off and unplug the printer. Using a Cotton Swab moistened (not soaked) with isopropyl alcohol, gently clean the entire Printhead surface, paying special attention to the Burn Line, until all build-up is removed. Printhead Assembly Printhead Cotton Swab Debris Build-Up Burn Line Allow the printhead to dry. Reinstall media (and ribbon, if needed). Lower the Printhead Assembly and rotate the Printhead Latch to the locked position. (If necessary, adjust the Leveling Cam.) Close the cover. Plug in and turn On the printer. Run several sample labels and examine the print quality. If streaks are still present, go to Section ; otherwise, this completes the procedure. 2-22

33 Adjustments and Maintenance Cleaning Card Procedure This procedure is recommended for printers using direct thermal media, or thermal transfer media with a wax ribbon. Also use this procedure if symptoms continue after the Cotton Swab Procedure (see Section ) has been tried. Perform the Preliminary Cleaning Steps, as described in Section Place a Cleaning Card (use part number for 6-inch model printers; and, use part number for 8-inch models but insert the cleaning card sideways) under the printhead. Lower the Printhead Assembly and lock the Printhead Latch. Disengage the Leveling Cam; see Section Printhead Assembly Cleaning Card Printhead Latch Close the cover. Press and hold the Key for approximately four seconds. (As an alternate, CLEAN HEAD NOW can be selected in the menu system.) Reinstall media (and ribbon, if necessary). Lock the Printhead Latch. If necessary, adjust the Leveling Cam. Close the cover. Run a few sample labels and examine them. If streaking is still present, go to Section ; otherwise, this completes the procedure. 2-23

34 Adjustments and Maintenance Cleaning Film Procedure This procedure is recommended for printers using a resin ribbon with thermal transfer media, or for printers that typically use a Heat Value of 22 or higher. Also use this procedure if symptoms continue after the previous cleaning methods have been tried. Perform the Preliminary Cleaning Steps, as described in Section Place a sheet of Cleaning Film (part number for 6-inch model printers; and, use part number for 8-inch models) under the printhead. Lower the Printhead Assembly and lock the Printhead Latch. Disengage the Leveling Cam; see Section Printhead Assembly Cleaning Film Printhead Latch Close the cover. Press and hold the Key for approximately four seconds. (As an alternate, CLEAN HEAD NOW can be selected in the menu system.) 2-24

35 Adjustments and Maintenance Turn Off and unplug the printer. Open the cover, unlock the Printhead Latch, and raise the Printhead Assembly. Using a cotton swab moistened (not soaked) with isopropyl alcohol, gently clean the entire Printhead surface. Allow the printhead to dry. Printhead Assembly Printhead Cotton Swab Reinstall media and ribbon. Lower the Printhead Assembly and rotate the Printhead Latch to the locked position. If necessary, adjust the Leveling Cam. Close the cover. Plug in and turn On the printer. Run a few sample labels and examine them; if streaking is still present, see Section

36 Adjustments and Maintenance Cleaning the Platen Roller CAUTION NEVER use a sharp object to clean the Platen Roller. A platen roller contaminated with grit, label adhesive, or ink can cause a decline in print quality and, in extreme cases, can cause labels to stick and wrap around the roller. Clean the platen roller as follows: Turn Off and unplug the printer. Open the access cover. Remove the Tear-Bar, Arc Plate or peel mechanism, if attached. Unlock the Printhead Latch and raise the Printhead Assembly. Remove media and ribbon. Using a clean, lint-free cloth dampened with isopropyl alcohol wipe the Platen Roller clean. Manually rotate the roller to clean the entire surface. Allow the roller to dry. Replace the Tear-Bar, Arc Plate or peel mechanism. Replace ribbon and media. Lower the Printhead Assembly and lock the Printhead Latch. Close the access cover. Plug in and turn On the printer. Feed several labels to normalize tracking. 2-26

37 Adjustments and Maintenance Cleaning the Media Sensor & the Media Path When particles such as paper dust accumulate in the Media Sensor, it can affect the printer s ability to detect labels. If this dust accumulates along the media path, small voids in the text, graphics and bar codes can result. A build-up of debris on the Tear Bar or Rewind Plate can impair the movement of media. To prevent problems, clean these areas as follows: Turn Off and unplug the printer. Raise the cover. Unlock the Printhead Latch and raise the Printhead Assembly. Remove media and ribbon. Ribbon Sheild Tear Bar / Rewind Plate Media Path Media Sensor Media Guide Baseplate Using compressed air or a soft brush, clean the Media Path and Baseplate. Also clean the Media Sensor, and Tear Bar or Rewind Plate. Use a cotton swab dampened with isopropyl alcohol as needed to remove adhesive accumulations. If equipped with the thermal transfer option, clean the Ribbon Shield. After allowing all of the components to dry, replace ribbon and media. Lower the Printhead Assembly and lock the Printhead Latch and close the cover. 2-27

38 Adjustments and Maintenance Cleaning the Exterior Surfaces To clean the outside of the printer, never use abrasive cleansers or solvents. The outer surfaces of the printer should be cleaned using a general-purpose cleanser. Turn Off and unplug the printer. Then use a soft cloth or sponge dampened with a general-purpose cleanser to wipe the exterior surfaces clean. 2-28

39 Adjustments and Maintenance Cleaning the Cutter CAUTION Always turn off and unplug the printer when connecting or disconnecting the cutter. Use WD-40 sparingly. Never spray directly into the cutter or get this solvent in the printer; severe damage may result. The cutter blades are SHARP: to avoid injury, keep fingers and other body parts away from the cutting surfaces; and to avoid damage, never touch metal objects against the blade surfaces. The optional cutter should be cleaned every time a roll of labels has been used. In addition, if the performance of the cutter becomes sluggish, cleaning is recommended. Proceed according to the type of cutter being cleaned Light-Duty Cutter Complete the following steps to clean the Light-Duty Cutter: Turn Off and unplug the printer. If attached, remove the cutter tray. Raise the cover of the printer. Rotate the Latch and lower the cutter mechanism. Remove the Cover Screw and then carefully remove the Top Cover. Using compressed air, remove any debris from the interior cavity. Using a cotton swab soaked with WD-40 (or similar product), wipe the exposed blade until clean. 2-29

40 Adjustments and Maintenance Insert a 3mm Hex Key into the cutter, as shown. Using this Hex Key, rotate the mechanism to the next blade position and repeat Step 5 until all blade surfaces are clean. Clean all areas where the media enters and exits the cutter. Replace the Top Cover then replace the Cover Screw and tighten. Return the cutter mechanism to an upright position and rotate the Latch to secure it in place. Lower the cover of the printer. Reattach the cutter tray. Plug in and turn On the printer. 2-30

41 Adjustments and Maintenance Standard Cutter Complete the following steps to clean the Standard Cutter: Turn Off and unplug the printer. If attached, remove the cutter tray. Raise the cover of the printer. Disconnect the Cutter Cable from inside the printer. Swing the cutter open and lift it off the Mounting Pins. Remove the Cover of the cutter by removing the four screws, which also secure the Left and Right Shields to the cutter. Using compressed air, remove any debris from the interior cavity of the cutter. 2-31

42 Adjustments and Maintenance Press on the Lever to gain access to the Cutter Blades. Wipe the blade surfaces clean using a cotton swab dampened with WD-40 (or similar product). Close the blades. Replace the Cover and Left and Right Shields to the cutter using the previously removed screws. Mount the cutter onto the Mounting Pins and reconnect the Cutter Cable to the inside port. Close the cutter. Lower the cover of the printer. Reattach the cutter tray. Plug in and turn On the printer. 2-32

43 Adjustments and Maintenance Cleaning the Fan Filter The power supply fan filter should be cleaned as needed to prevent printer overheating. The cleaning interval will depend upon the environment the printer is in. Clean the fan filter as follows: Turn Off and unplug the printer. Loosen the Tabs and remove the Fan Guard and Filter from the printer. Fan Guard Tabs (4 places) Dust off the filter. Or, if needed, using a mild detergent, wash the filter If washed, allow the filter to dry thoroughly. (As an alternative, replace the filter, P/N ). 2-33

44 Adjustments and Maintenance Filter Fan Housing Fan Guard Install a clean dry Filter and Fan Guard onto the Fan Housing. Plug in and turn On the printer. 2-34

45 Adjustments and Maintenance 2.5 Application Version Updates The printer s application program is stored in Flash memory on the Main PCB. A feature is included that allows updates to this program. Updates can be found at ftp://ftp.datamax-oneil.com/. There are two modes in which the firmware of the printer can be updated: (1) the Ready Mode, or (2) the Download Mode. Before beginning an update, identify the current version of the printer s application program by printing a Configuration Label. Compare that version string to those filenames available from our FTP site and then download the desired file onto your computer s hard drive. Proceed with the printer update accordingly: If the current application version is or greater, refer to either Section or Section If the current application version is 2.08 or earlier, refer only to Section WARNING Should an error occur during the download (see Section 2.5.3), the update is aborted. If this process did not reach Erasing Flash or Updating Software, the previous program is left intact; otherwise, a successful download must be completed before the printer is operable. Note: Foreign language menu users: If updating from 2.xx to 3.xx firmware for the first time, you must also download the EFIGS menu language file. Go to the EFIGS ftp directory and copy C (or most current version) to lpt1: /b (the DOS Copy command requires the /b parameter because this file contains binary code) Updating from Ready Mode Update Procedure for Application Version or greater Step Displayed Message Operator Action Comment(s) Using the DOS copy command (where filename is the program to be loaded and lpt1 is the selected interface port), enter the following: copy filename lpt1: No action required. No action required. No action required. For example, this would be entered as: copy 6208tb ~ 1.zs lpt1 (Where lpt1 is the host computer s port; however, this selection can differ to include a serial or other port, as the printer is equipped.) The Ready Indicator will flash as data is received. The new application program is being stored and verified. The printer has reset automatically and is now displaying the new firmware version. The new application is now running. Note: If Uncalibrated or Position Fault is displayed see Section

46 Adjustments and Maintenance Updating from Download Mode Required Update Procedure for Application Version 2.08 or earlier* Step Displayed Message Operator Action Comment(s) Press and hold the PAUSE and TEST Keys while turning On the printer to enter the Download Mode. Using the DOS copy command, (where filename is the program to be loaded and lpt1 is the parallel port), enter the following: copy filename lpt1: No action required. No action required. No action required. The Boot Loader version is displayed. Note: This information will vary with the printer model and Boot Loader version. The printer is ready to accept the new application version. Note: The parallel port must be used to write to the printer. For example, this would be entered as: copy 6208tb ~ 1.zs lpt1 The printer is receiving the new image (program). The program has been received and verified; now memory is being cleared of the previous application. The new program is being written into Flash memory. Upon completion, the printer will automatically reset, starting the new application; however, before continuing, the printer must be calibrated; see Section 2.1. *This can also be used as an alternate download method for all other version levels. 2-36

47 Adjustments and Maintenance Possible Problems during an Update If experiencing trouble when attempting to download the file to the printer, try the following alternate methods: Use Download Mode (see Section 2.5.2). Windows users try restarting the computer in MS-DOS mode. Use the Datamax-O Neil Printer Driver to send the file. The following is a list of possible error messages when downloading: Application Update Error Messages Displayed Message Descriptions / Causes / Solutions The printer detected an error during the decompression and transfer of file data from cache storage into the Flash memory. Confirm the version and retry in Download Mode; however, if the problem continues call for service. The printer could not successfully erase Flash memory. The possible cause is defective Flash memory. Try the download again; however, if the problem continues call for service. The printer could not successfully write the program into Flash memory. A possible cause is defective Flash memory. Try the download again; however, if the problem continues call for service. Application Firmware downloaded was not compatible with the printer s Main PCB. The firmware used was for a different class model and not supported by this boot loader version. See System Settings / Configuration Level in the Operator s Manual details. The printer detected an error in the download. The possible causes include: An invalid or corrupted file was downloading. Try saving the file to the host and then download again. A communications error. Recheck cabling and port setting. Software level not authorized for this printer (See System Settings / Configuration Level / Printer Key in the Operator s Manual details.). 2-37

48 Adjustments and Maintenance 2.6 Boot Loader Program Updates The Boot Loader is stored in Flash memory on the Main Logic Card. Updates to this program can be made through any of the printer s communication interfaces. Updates can be found at ftp://ftp.datamaxoneil.com/ Note: Only printers with an Application Version of 2.09 or greater can update the Boot Loader Program. WARNING If power is lost while Upgrading Software is displayed, the printer will become non-functional; in this case the main logic board must be replaced with a programmed board or returned to the factory for programming. Before beginning the Boot Loader update, identify the printer s current version by printing a Configuration Label and comparing its version string to those available from our FTP site. Download the desired version onto your computer s hard drive. To update the Boot Loader Program: Boot Loader Update Procedure Step Displayed Message Operator Action Comment(s) 1 2 Using the DOS copy command (where filename is the program to be loaded and lpt1 is the selected interface port), enter the following: copy filename lpt1: No action required. For example, this would be entered as: copy boottb ~ 1.bs lpt1 (Where lpt1 is the host computer s output port; however, your selection can differ to include a serial or other port, as the printer is equipped). The Ready Indicator will flash as data is received. The new program is being stored and verified. 3 No action required. The printer has reset automatically. 4 No action required. The new application is now running. Note: If Uncalibrated or Position Fault is displayed see Section

49 Adjustments and Maintenance 2.7 Resetting the Printer Depending upon the method used, there are three reset levels possible: Soft Reset To reset the printer and clear any temporary host settings: With the printer On, press and hold the CANCEL Key for approximately four seconds Level One Reset To return the printer to the factory default settings or, if saved, to restore the Factory Setting File: Turn Off the printer. Press and hold the PAUSE and CANCEL Keys while turning On the printer; continue to depress the keys until the SYSTEM RESET message flashes. Note: This reset has the same effect as the System Settings / Set Factory Defaults selection in the menu system. (See the Operators Manual for details.) Level Two Reset To return the printer to the factory default settings, and clear all the calibration and adjustment parameters: Turn Off the printer. Press and hold the PAUSE, FEED, and CANCEL Keys while turning On the printer; continue to depress the keys until the SYSTEM RESET message flashes. Note: After executing a Level 2 Reset, media calibration must be performed; see Section 2.1. A listing of the factory default settings can be found in the Operators Manual. 2-39

50 Adjustments and Maintenance 2-40

51 3 Troubleshooting 3.0 Overview Fault and Warning Messages Warning Messages Fault Messages Using the Troubleshooting Flowcharts Problem Isolation Checklist No Power No Print Parallel Communication Faults Serial Communication Faults Hex Dump Mode i

52 ii

53 Troubleshooting 3.0 Overview This chapter discusses troubleshooting the printer. Depending upon the malfunction, use a procedure(s) listed below to diagnose and correct the problem: When a displayed message is generated, use Fault and Warning Messages, Section 3.1. When no message is generated, use the Troubleshooting Flowchart, Section 3.2. When label formatting problems occur, use the Hex Dump mode, Section 3.3. If faults are localized to a Printed Circuit Board, replacement is recommended. Due to the complexity of the PCBs, it is not feasible to do component level repair in the field. A defective PCB can be returned to the factory for service. 3.1 Fault and Warning Messages All printer functions are monitored. During operation, when a potential problem (a Warning) or problem (a Fault) is detected, the printer will display a corresponding message. Message types, along with the possible solutions, are described below. Note: Warning and Fault Messages are not displayed when the printer is in Menu or Test Mode Warning Messages Warning Messages have a medium display priority and are shown for a period of five seconds. If multiple Warning conditions are detected, the display will reflect the highest priority message. Warning Messages Displayed Message Description Possible Solution(s) The printer has detected burned-out printhead elements. The printer measured only a small difference between the empty and gap sensor readings. Replace the printhead when the print quality becomes unacceptable; see Section 4.2. Transparent backing or notched media typically gives this indication. In this case, there may be a slight delay in the Out of Stock indication, after the media supply is emptied; no action is required. Power has been removed and shutdown is in progress. The printer power switch was turned Off, the line fuse has blown, or the AC line voltage has been lost. 3-1

54 Troubleshooting Warning Messages Displayed Message Description Possible Solution(s) The scheduled printhead cleaning distance has been reached. Press and hold the TEST Key, or select CLEAN HEAD NOW. See Section for details. The host has pending configuration changes that will not take effect until a host reset command is issued. To save the changes, send a host reset command (in DPL). To discard the changes, perform a soft reset; see Section 2.7 for details. The 24 VDC line has dipped below the threshold value. Possible low or fluctuating line voltage level. Verify this condition with a voltage measurement. If this condition persists, try moving the printer to another outlet circuit. Other possible causes include a faulty power supply, main logic board, or printhead. The printer was unable to save settings in permanent memory. If the condition persists, possible faulty main logic board; see Section A high printhead temperature has been detected. Allow the printhead time to cool. 3-2

55 Troubleshooting Fault Messages Fault Messages receive the highest display priority. If more than one fault is detected the display will cycle between messages. Note: To return to normal operation after the printer enters a fault condition, the fault must be corrected and then the FEED key pressed to clear the condition. Fault Messages Displayed Message Description Possible Solution(s) A drop in the 24 volt power supply has been detected. 1) Try cycling the printer power Off and On to clear the fault. 2) Possible defective power supply board. Verify the 24 VDC supply voltage. For replacement see Section WARNING! Use extreme caution when measuring printer voltages. An analog to digital converter failure has been detected. 1) Try cycling the printer power Off and On to clear the fault. 2) Replace the main logic board; see Section A blade-positioning fault has been detected. 1) Try cycling the printer power Off and On to clear the fault. 2) Ensure the thickness of the media being cut is within specification for the cutter; see the Operator s Manual for details. WARNING! Turn Off the printer and unplug the power cord before examining the cutter. 3) Ensure the cutter and cable are properly installed, and that the cutter cable is free of damage. 4) Examine and clear any obstructions from the cutter. See Section ) The cutter may be defective. Replace it. 6) The main logic board may be defective. Replace the board; see Section

56 Troubleshooting Fault Messages (continued) Displayed Message Description Possible Solution(s) The printer has detected a Direct Memory Access failure. Consistently low sensor readings were detected. Consistently high sensor readings were detected. 1) Try cycling the printer power Off and On to clear the fault. 2) Replace the main logic board; see Section Press any key to continue. 1) Ensure that media was inserted in the media sensor during the appropriate calibration step. 2) Ensure that the sensor is free of debris. Retry the calibration. If the problem persists, try Advanced Entry Calibration ; see Section Press any key to continue. 1) Ensure that the media was removed from the media sensor during the appropriate calibration step. 2) Ensure that no labels are stuck in the media sensor. Retry the calibration. If the problem persists: 1) Possible loose Media Sensor cable. 2) The media sensor may be defective. Replace the sensor; see Section ) The main logic board may be defective. Replace the board; see Section The scheduled printhead cleaning has been exceeded by an amount equal to three times the pre-programmed distance. Press and hold the TEST Key, or select CLEAN HEAD NOW. See Section for details. The optical sensor cannot detect the position of the printhead assembly. Press any key to continue. 1) Ensure that the printhead assembly is locked in the down position. 2) The Head-Up Sensor may be defective. Replace the sensor. 2) The main logic board may be defective. Replace the board; see Section