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. Windows is a registered trademark of the Microsoft Corporation. All other brand and product names are trademarks, service marks, registered trademarks, or registered service marks of their respective companies. Firmware (Software) Agreement: The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and is licensed for used 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). Information in this document is subject to change without notice and does not represent a commitment on the part of Datamax-O Neil Corporation. 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 Corporation. All rights reserved. Part Number , Rev. A Copyright 2009 by Datamax-O Neil Corporation

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

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

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7 1.0 Introduction This manual is intended for use by qualified service personnel in the maintenance and repair of Datamax E-Class model printers. It primarily includes technical information relating to the printer s electrical and mechanical components. For related information, refer to the following documents, available at For general user information, reference the Operator s Manual (part number ). For software documentation, reference the Class Series 2 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, servicing, or maintenance information. Always, as with all electrical equipment, follow basic safety precautions to avoid personal injury and/or printer damage. Overview 1-1

8 1.1 About this Printer The user-assessable components of the printer are shown below. Note that some items are optional equipment. Front Panel Thumbwheel Printhead Assembly Media Hub Media Flange Printhead Media Sensor (optional AMS shown) Printhead Latch Platen 1-2 Overview

9 2 Maintenance and Adjustments 2.0 Introduction Maintenance Cleaning the Printhead Cotton Swab Procedure Cleaning Card Procedure Cleaning Film Procedure Cleaning the Platen Cleaning the Media Sensor Media Width Adjustment Ribbon Width Adjustment Printhead Adjustment Resetting the Printer Downloading Firmware and Fonts Media Sensor Calibration Auto Calibration Manual Calibration i

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11 2.0 Introduction This section covers maintenance and alignment procedures. 2.1 Maintenance Recommended items, techniques, and schedules to keep the printer in top working order are detailed below. The following items will help you safely and effectively maintain the printer: Isopropyl alcohol Cotton swabs Clean, lint-free cloth Soft-bristle brush Soapy water/mild detergent Compressed air Printhead Cleaning Cards or Printhead Cleaning Film For your safety and to avoid damaging the unit, always turn OFF the power switch and unplug the AC power cord before servicing the printer. CAUTION Isopropyl alcohol is a flammable liquid -- take proper precautions when using this solvent. Recommended Maintenance Schedule Component / Area Cleaning Interval Method / Supplies Printhead After every roll of media. A cotton swab dampened with isopropyl alcohol then wiped across the surface and, if necessary, Printhead Cleaning Cards or Cleaning Film when needed; see Section Platen After every roll of media. A cotton swab or cloth dampened with isopropyl alcohol wiped across the roller, rotating as needed to clean the entire surface; see Section Peel-Off Roller After every roll of media. Rotate the peel-off roller and clean it thoroughly using isopropyl alcohol and a cotton swab. Media Path / Media Sensor / Peel Bar As needed. Compressed air or a soft brush to remove all debris, and isopropyl alcohol to remove adhesive buildup; see Section Interior As needed. Compressed air or a soft brush to remove all debris. Exterior Surfaces As needed. A cloth dampened with mild detergent wiped across the surface until clean. Maintenance and Adjustments 2-1

12 2.1.1 Cleaning the Printhead If print quality declines (symptoms can include non-compliant bar codes, print dropouts, streaks, etc.), the typical cause is debris buildup on the Printhead. If not removed, this buildup can lead to element failure, reducing the service life of the Printhead. Depending upon the media, ribbon, and printing parameters used, different methods and supplies are recommended to clean the Printhead. CAUTION NEVER use a sharp object on the Printhead; damage can result. Faulty Label: Streaks (e.g., white lines) in the direction of print can indicate a dirty or faulty Printhead Cotton Swab Procedure This procedure is recommended when using direct thermal media, or thermal transfer media with wax ribbon. 1. Stop printing. Allow the Printhead to cool. 2. Raise the Printhead Assembly then remove media and ribbon from the printer. 3. Turn OFF and unplug the printer. Using a Cotton Swab moistened (not soaked) with isopropyl alcohol, gently wipe the entire Printhead surface clean, while paying special attention to the Burn Line to ensure all buildup is removed. Allow the Printhead to dry. Burn Line Printhead buildup Printhead Latch Cotton Swab 2-2 Maintenance and Adjustments

13 4. Reinstall media (and ribbon, if needed). Lower and latch the Printhead Assembly. Adjust the Media Width Setting. Close the cover then plug in and turn ON the printer. Print then examine several sample labels. If symptoms persist, see Section ; otherwise, this completes the procedure Cleaning Card Procedure This procedure is recommended when using direct thermal media, thermal transfer media with wax ribbon, or if symptoms persist after performing the Cotton Swab Procedure (Section ). 1. Stop printing. Allow the Printhead to cool. 2. Raise the Printhead Assembly then remove media and ribbon from the printer. 3. Place a Cleaning Card under the Printhead. 4. Lower and latch the Printhead Assembly then zero the Media Width Setting; see Section Repeatedly press the FEED Key until the Cleaning Card exits the printer. 6. Reinstall media (and ribbon, if needed). Lower and latch the Printhead Assembly then adjust the Media Width Setting. Close the cover. Print then examine several sample labels. If symptoms persist, see Section ; otherwise, this completes the procedure Cleaning Film Procedure This procedure is recommended when using thermal transfer media with resin ribbon, a Heat setting above 21, or if symptoms persist after the other cleaning methods have been tried. 1. Stop printing. Allow the Printhead to cool. 2. Raise the Printhead Assembly then remove media and ribbon from the printer. 3. Place a sheet of Cleaning Film under the Printhead. 4. Lower and latch the Printhead Assembly then zero the Media Width Setting; see Section Repeatedly press the FEED Key until the Cleaning Film exits the printer. 6. Turn OFF and unplug the printer. Clean the Printhead using a Cotton Swab; see Section Allow the Printhead to dry. 7. Reinstall media and ribbon. Lower and latch the Printhead Assembly then adjust the Media Width Setting. Close the cover. Print then examine several sample labels. If symptoms persist, see Section 3.2. Maintenance and Adjustments 2-3

14 2.1.2 Cleaning the Platen The Platen, if contaminated with grit, label adhesive, or ink can cause a decline in print quality and, in extreme cases, cause labels to adhere to the roller. Clean the Platen as follows: CAUTION NEVER use a sharp object on the Platen. 1. Turn OFF and unplug the printer. Move media away from the Platen. 2. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, gently wipe the Platen clean, rotating it as needed to clean the entire surface. Allow the Platen to dry. 3. Reinstall media. Latch the Printhead Assembly and close the cover. Platen Cotton Swab Cleaning the Media Sensor The Media Sensor, if covered with paper dust or adhesive, can cause media sensing and positioning problems. Clean the Media Sensor as follows: 1. Turn OFF and unplug the printer. Remove media. 2. Using a brush or compressed air, remove all debris from the Media Sensor. Note: To remove adhesive buildup, wipe the Media Sensor clean using a Cotton Swab dampened with isopropyl alcohol; allow the sensor to dry before resuming operation. 2-4 Maintenance and Adjustments

15 Stationary Media Sensor Location: Printhead Assembly Stationary Media Sensor Cotton Swab Adjustable Media Sensor Location: Printhead Assembly Adjustable Media Sensor Cotton Swab Maintenance and Adjustments 2-5

16 2.2 Media Width Adjustment To prevent wear on the Printhead and Platen, adjust the printer when using media that is less than four inches (102 mm) wide, as follows: 1. Load media. Print a batch of labels. (Simultaneously press F2 and F3, or send a format from the host.) While facing the front of the printer Turning the Thumbwheel clockwise increases the effect. Turning the Thumbwheel counterclockwise decreases the effect. Note: The Thumbwheel is numbered for reference, where zero is the lowest setting and nine is the highest. 2. While the labels print, adjust the Thumbwheel until the image begins to fade. Over-adjustment produces an image that fades across the label. 3. Then turn the Thumbwheel in the opposite direction until the full image is produced. Correct adjustment produces a complete image, with even print contrast across the label. Note: Under-adjustment can cause ribbon wrinkling and excessive wear on the Printhead and Platen. If the media moves excessively rightward while printing, the Thumbwheel should be adjusted clockwise. 2-6 Maintenance and Adjustments

17 2.3 Ribbon Width Adjustment If equipped with the thermal transfer option, the Ribbon Tension Adjustment Knob allows the optimum amount tension to be applied to the ribbon, as follows: 1. Turn OFF the printer. Remove ribbon, if installed. 2. While holding the Hub, rotate the Ribbon Tension Adjustment Knob to match the ribbon width, according on the table below. Ribbon Width Direction of Rotation 1-2 inches (25 51 mm) Clockwise 2-4 inches ( mm) Counterclockwise 3. Ensure that the Ribbon Tension Adjustment Knob is turned fully into position and will no longer rotate. Note: Never force or over-tighten the Ribbon Tension Adjustment Knob. 2.4 Printhead Adjustment If necessary, print quality can be mechanically adjusted. Although factory set for optimum print quality, some media types (for example, heavy card stock) may require a slight readjustment if quality changes. 1. Load media. Print a batch of labels. (Simultaneously press F2 and F3, or send a format from the host.) Maintenance and Adjustments 2-7

18 2. While the labels print, turn the Printhead Adjustment Screw until optimum print quality is obtained. Printhead Adjustment Screw Printhead Assembly Note: Never over-tighten the Printhead Adjustment Screw; damage can result. Also, if thermal transfer equipped, use the opening in the Ribbon Handler Assembly to access the screw. 2.5 Resetting the Printer To return the printer to factory default settings proceed as follows: Turn ON the printer, and then while all 3 lights are ON, press and hold the F1 + F2 + F3 Buttons until all lights turn OFF. 2.6 Downloading Firmware and Fonts The firmware application and fonts are stored in Flash memory. These files can be updated as newer version become available, as follows: 1. Identify the new version for the model of the printer at then download that file onto your computer s hard drive. 2. Connect the printer to the host and then, using the DOS copy command, enter: 2-8 Maintenance and Adjustments

19 copy filename.dlf lpt1/b Note: Other programs (e.g., hyper-terminal) can also be used to download this file. 3. The Paused Light will flash during the download. Then, following a successful download, the Paused Light will illuminate and then the printer will reset. (The previous printer setup will not be affected unless substantial firmware data structure changes have occurred.) 4. Print a Database Configuration Label to verify your new firmware version. Note: The Fault Light will illuminate if the download was unsuccessful. In this case, a reset will occur and the original firmware will remain operational. (If the reset does not occur, cycle power OFF and ON; and, if the printer fails to boot-up, turn OFF power then simultaneously press and hold F1 and F3 while turning ON the printer.) Try resending the file, and then if unsuccessful check the following possible causes: An invalid or corrupted file was downloaded - Ensure the file is correct and applicable for the printer model. Possible communications error - Check the interface connection between the host and printer, ensuring that a properly shielded cable has been used. Possible Flash memory problem Replace the Main PCB; see Section Media Sensor Calibration Calibration can be performed either automatically or manually. Notes: Before calibrating ensure that the Printhead Assembly is latched, that the Cover is closed, and that the appropriate Media Sensor has been selected for the media type. Enter Calibration Mode then select the method, as follows: Maintenance and Adjustments 2-9

20 F3 (Press and hold during power-up until the Paused Light turns off) Calibration Mode F1 Auto Media Calibration (See Section 4.6.1) F2 F2 ( ) Press and Feeds one label for test Release Press and hold until the ( Paused Light turns on ) F3 Prints the Test Label for test F1 + F3 Saves the current values and resumes Normal Mode Media Sensor Calibration (See Section 4.6.2) (The Fault Indicator flashes during analysis) F1 Analyze media F2 Analyze media backing material or reflective mark F3 F1 + F3 Analyze no media condition Accepts the current analysis for test Auto Calibration Auto Calibration automatically establishes the optimum sensing values for the media: 1. With media loaded and the sensor type enabled, hold the button while powering ON the printer and until the PAUSED Light turns OFF, then release the button. 2. Press the button. The printer will feed approximately ten inches of media as readings are taken. 3. Upon completion, one of the indicators will flash five times to denote the calibration result: PAUSED Light = Successful (proceed to Step 4); or, FAULT Light = Unsuccessful (see to Section 2.7.2). Note: To discard the changes and revert back to the previous calibration settings, turn OFF the printer before executing Step Press the + buttons simultaneously and briefly. Wait until the PAUSED Light goes OFF Maintenance and Adjustments

21 2.7.2 Manual Calibration If media sensing problems continue after Auto Calibration, use the procedure below. 1. Hold the button while powering ON the printer and until the PAUSED Light turns OFF, then release the button. 2. Press and hold the button until the PAUSED Light turns ON then release the button. 3. Place media (with backing material attached, if any) over the Media Sensor then close the Printhead Assembly and press the button. The FAULT Light will flash as the paper is analyzed. 4. Position only the backing material (or the black mark if using reflective media) over the Media Sensor then close the Printhead Assembly and press the button. The FAULT Light will flash as the TOF is analyzed. 5. Remove the media then close the Printhead Assembly and press the button. The FAULT Light will flash as the empty is analyzed. 6. Simultaneously and briefly press the + buttons to temporarily accept the settings and exit calibration. One of the following indicators will flash five times to denote the calibration result: PAUSED Light = Successful (proceed to Step 6); or, FAULT Light = Unsuccessful (return to Step 1 to retry the procedure). (Test the calibration: Use the button to feed labels and use the button to print test labels.) Note: To discard the changes and revert back to the previous calibration settings, turn OFF the printer before executing Step Press the + buttons simultaneously and briefly. Wait until the PAUSED Light goes OFF. Maintenance and Adjustments 2-11

22 2-12 Maintenance and Adjustments

23 3 Troubleshooting 3.0 Overview Initial Troubleshooting Steps Problem Resolution... 1 i

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25 3.0 Overview This section covers techniques for isolating and correcting printer problems. Use the following procedures to isolate and correct malfunctions. When problems are isolated to a Printed Circuit PCB (PCB), assembly replacement is suggested. Note: Unless otherwise noted, see the Operator s Manual for configuration, interfacing and setup information. 3.1 Initial Troubleshooting Steps CAUTION (1) Before servicing always unplug the printer; (2) ensure that the unit has been placed on a level, stable surface; and, (3) use extreme care if measuring voltages. Before troubleshooting, perform the following actions: Remove any dirt or dust from the printer (see Section 2); Confirm that AC outlet voltage is within the specification; Confirm that the printer is placed within an acceptable environmental; and, Confirm that media has been correctly loaded. 3.2 Problem Resolution In the table below, locate a description of the symptom in the Problem column to find the associated Possible Causes and solutions, which are arranged by probability. Troubleshooting Problem Possible Causes The power switch is not ON. Power LED is not ON The power supply is not properly connected to printer or the AC outlet. The Power Supply or the power cord is defective; replace. The Control Panel PCB is defective; see Section 4.7. The Main PCB is defective; see Section 4.3. (continued) Troubleshooting 3-1

26 Troubleshooting Problem No communications Possible Causes The interface cable is not properly connected to the host, is defective, or is an incorrect type. Printer / Host communication parameters are mismatched. The Main PCB is defective; see Section 4.3. Media loading is incorrect. The thermal transfer operation is enabled, but no ribbon is installed. Media does not feed from the printer The Printhead Assembly is not latched. The Platen is worn; see Section 4.6. The Drive Motor is defective or the cable is loose; see Section 4.5. The Main PCB is defective; see Section 4.3. Incorrect TOF setting. The Media Sensor is not calibrated; see Section 2.7. The enabled Media Sensor does not match the media type. Media feeds but stops at an incorrect location If using thermal transfer media, the ribbon is incorrectly loaded. If using an AMS-equipped model, the Media Sensor is not properly positioned. The Media Sensor is dirty or obstructed; see Section The Media Sensor is defective or its cable is loose; see Section 4.4. The Main PCB is defective; see Section 4.3. Incorrect HEAT and / or PRINT SPEED settings. Direct thermal is selected, but thermal transfer media is installed. If using thermal transfer media, an incorrect media and ribbon combination is being used. No printing occurs or the quality is poor The Media Width Adjustment is not correctly set; see Section 2.2. The Printhead is dirty; see Section The Platen is worn; see Section 4.6. The Printhead is defective or the cabling is loose; see Section 4.2. The Main PCB is defective; see Section Troubleshooting

27 4 Removal and Replacement 4.0 Introduction Cover Printhead Electronics Tray Print Mechanism Drive Motor Platen Control Panel Assembly Bottom Enclosure i

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29 4.0 Introduction This section details the removal and replacement of the printer parts. Wear a wrist strap and follow standard ESD prevention measures. CAUTION Use extreme care near the Printhead; never use a sharp object on the surface. Never use a sharp object on the Platen. Note: The procedures below assume a printer empty of media and ribbon. 4.1 Cover Removal: 1. Turn OFF and unplug the printer. 2. Open the cover then gently flex the side of the printer outward and remove the Cover from the hinge. Replacement: 1. Gently flex the side of the printer outward and then install the Cover onto the Hinge. Removal and Replacement 4-1

30 4.2 Printhead Removal: 1. Turn OFF and unplug the printer. 2. Completely loosen the Printhead Screw then carefully raise the Printhead Assembly and remove the Printhead. Note: If equipped with the Thermal Transfer option, it is not necessary to remove the Ribbon Handler Assembly, as an opening in the assembly is provided for access. Printhead Screw Printhead Assembly 3. Carefully disconnect the Printhead Cable from the Printhead. 4-2 Removal and Replacement

31 Replacement: 1. Carefully connect the Printhead Cable to the Printhead. 2. Position the Printhead onto the pins in the Printhead Assembly and, after ensuring that the Printhead Cable is not pinched, tighten (but not excessively) the Printhead Screw. 3. Clean the Printhead (see Section 2.1.1). 4. Adjust the Printhead; see Section Electronics Tray Removal: 1. Turn OFF and unplug the printer. 2. Remove the five Screws that secure the Electronics Tray to the Bottom Enclosure. Screws Electronics Tray Cover Bottom Enclosure 3. While holding the Electronics Tray, the Bottom Enclosure, and the Cover right the printer. Then gently lift the Bottom Enclosure and the Cover off and to the left of the Electronics Tray, as shown below. Removal and Replacement 4-3

32 Cables Main PCB Expansion Ports Electronics Tray 4. Remove any options from the Expansion Ports. 5. Remove all Cables connected to the Main PCB and then remove the Electronics Tray. Replacement: 1. Reconnect all Cables to the Main PCB in the Electronics Tray. 2. Reinstall any options to the Expansion Ports. 3. Position the Bottom Enclosure onto the Electronics Tray and reinstall the five Screws. 4. Plug in and turn ON the printer. Calibrate the Media Sensor (see Section 2.7) and verify the firmware version by printing a configuration label (press the + buttons simultaneously). 4.4 Print Mechanism Removal: 1. Turn OFF and unplug the printer. 2. Remove the Electronics Tray; see Section 4.3 (removal of the expansion option is not required). 3. Unlatch then raise the Printhead Assembly. Remove the four Screws that secure the mechanism to the Bottom Enclosure and the Cover (not shown). 4-4 Removal and Replacement

33 Screws Printhead Assembly Print Mechanism Bottom Enclosure 4. Latch the Printhead Assembly then lift the Print Mechanism out of the Bottom Enclosure, taking care to guide the Cables through the Cutout. Print Mechanism Cutout Cables Bottom Enclosure Removal and Replacement 4-5

34 Replacement: 1. Route the Cables through the Cutout. 2. Position the Print Mechanism in the Bottom Enclosure and then open and it secure with the four Screws. 3. Reinstall the Electronics Tray; see Section Adjust the Printhead; see Section Drive Motor Removal: 1. Turn OFF and unplug the printer. 2. Remove the Print Mechanism; see Section Remove the two Motor Mounting Screws that secure the Drive Motor to the Print Mechanism. Drive Motor Motor Mounting Screws 4. Slightly pull the Drive Motor outward to disengage the gear, and then slide the motor down and out the Lower Hole in the Print Mechanism. 4-6 Removal and Replacement

35 Drive Motor Lower Hole Replacement: 1. Slide the Drive Motor gear into the Lower Hole then up into position, ensuring that the gears and mounting holes are aligned. 2. Reinstall the two Motor Mounting Screws. 3. Reinstall the Print Mechanism; see Section Platen Removal: 1. Turn OFF and unplug the printer. 2. Remove the Print Mechanism; see Section Remove the Drive Motor; see Section Remove the two screws that secure the Motor Mounting Bracket (also freeing the Ground Lug). Removal and Replacement 4-7

36 Motor Mounting Bracket Ground Lug 5. Remove the Motor Mounting Bracket from the Print Mechanism. Screws Printhead Assembly Motor Mounting Bracket Print Mechanism 6. Remove the Ribbon Drive Assembly and the Platen Gear from the shaft of the Platen. 4-8 Removal and Replacement

37 Platen Ribbon Gear Locator Platen Gear Ribbon Drive Assembly 7. Remove the C-Clips and Bushings from each end of the Platen. 8. Slide the Platen away from the Printhead Latch and out of the Print Mechanism. Replacement: 1. Slide the new Platen into the Print Mechanism then install Bushings and C-Clips at each end of the Platen. 2. Reinstall the Platen Gear and then the Ribbon Drive Assembly, ensuring that the center of the gear on the Ribbon Drive Assembly is placed over the Ribbon Gear Locator. 3. Position the Motor Mounting Bracket onto Print Mechanism. 4. Position the Ground Lug against the Motor Mounting Bracket. 5. Secure the Ground Lug, the Motor Mounting Bracket, and Print Mechanism with the two Screws. 6. Reinstall the Drive Motor; see Section Reinstall the Print Mechanism; see Section Control Panel Assembly Removal: 1. Turn OFF and unplug the printer. 2. If equipped with the Thermal Transfer or Present Sensor option, remove the connector from the Option Port. Removal and Replacement 4-9

38 3. Remove the Media Supply Hanger from the Bottom Enclosure. Option Port Control Panel Assembly Media Supply Hanger Bottom Enclosure 4. Using a screwdriver, gently push in the Locking Tab then lift the Control Panel Assembly off the Bottom Enclosure. Control Panel Assembly Locking Tab Bottom Enclosure 4-10 Removal and Replacement

39 5. Remove the Control Panel Cable from the Control Panel Assembly. Control Panel Assembly Cable Replacement: 1. Connect the Control Panel Cable to the Control Panel Assembly. 2. Insert the front of the Control Panel Assembly into the Bottom Enclosure and push down until the Locking Tab snaps into place. 3. Reconnect any removed option to the Option Port. 4. Reinstall the Media Supply Hanger into the Bottom Enclosure. 4.8 Bottom Enclosure Removal: 1. Turn OFF and unplug the printer. 2. Remove the Cover; see Section Remove the Control Panel Assembly; see Section Remove the Electronics Tray; see Section Remove the Print Mechanism; see Section 4.4. Removal and Replacement 4-11

40 6. Remove the Fascia, Cutter Option Slot Cover, and Memory Option Slot Cover. Fascia Bottom Enclosure Memory Option Slot Cover Cutter Option Slot Cover Replacement: 1. Reinstall the Print Mechanism; see Section Reinstall the Electronics Tray; see Section Reinstall the Control Panel Assembly; see Section Reinstall the Fascia, Cutter Option Slot Cover, and Memory Option Slot Cover. 5. Reinstall the Cover; see Section Removal and Replacement