Adjustments and Maintenance

Transcription

1 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 Alignment Linear Scanner Alignment Maintenance Cleaning the Printhead Cotton Swab Procedure Cleaning Card Procedure Cleaning Film Procedure Cleaning the Platen Roller Cleaning the Media Sensor & Media Path i

2 2.5.4 Cleaning the Exterior Surfaces Cleaning the Cutter Cleaning the Light-Duty Cutter Cleaning the Standard Cutter Cleaning the Linear Scanner Cleaning the Peel and Present Mechanism 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

3 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 Operators 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

4 2.1.2 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. VODBMJCSBUFE Wait for the printer to initialize (about six seconds) before proceeding. 2 Press the Key. Raise the printhead assembly. 3 Press the Key to enter the Media Settings menu. NFOVNPEF NFEJBTFUUJOHT NFEJBTFUUJOHT NFEJBUZQF You are entering Menu Mode. See the Operator s Manual for the menu layout. 4 Press the Key and scroll to SENSOR CALIBRATION. NFEJBTFUUJOHT TFOTPSDBMJCSBUJPO Press the procedure. Key to abort this 5 Press the Key. 6 Press the Key. Remove the media from the Media Sensor then press any key. TFOTPSDBMJCSBUJPO QFSGPSNDBMJCSBUJPO SFNPWFMBCFMTUPDL QSFTTBOZLFZ=zzz? You are beginning the standard calibration procedure. This sets the parameter for the empty value. Where yyy is a numerical value representing the current sensor reading. Note: On later firmware versions, the key is specified. 2-2

5 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. TDBOCBDLJOH QSFTTBOZLFZ=zzz? Or, for reflective media: TDBONBSL QSFTTBOZLFZ=zzz? 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. TDBOQBQFS QSFTTBOZLFZ=zzz? This sets the parameter for the paper value. Where yyy is a numerical value representing the current sensor reading. 2-3

6 Standard Calibration (continued) Step Action Displayed Message Comment 9 Observe the message on the display. HBQNPEF DBMJCSBUJPODPNQMFUF Or, for reflective media: SFGMFDUJWFNPEF DBMJCSBUJPODPNQMFUF Or, for continuous media: DPOUJOVPVTNPEF DBMJCSBUJPODPNQMFUF The calibration was successful. If another message was displayed, see the note below. 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. SFBEZ The printer is now ready to begin printing. If this calibration was not successful, go to Section Note: When calibrating notched media, or media on a transparent liner, a WARNING LOW BACKING message is normal. For a list of all possible messages, see Section

7 2.1.3 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. 2 Press the Key. Raise the printhead assembly. VODBMJCSBUFE NFOVNPEF NFEJBTFUUJOHT Wait until the printer initializes (about six seconds). You are entering Menu Mode. 3 Press the Key to enter the Media Settings menu. NFEJBTFUUJOHT NFEJBUZQF See the Operator s Manual for the menu layout. 4 Press the Key and scroll to SENSOR CALIBRATION. NFEJBTFUUJOHT TFOTPSDBMJCSBUJPO Press the this procedure. Key to abort 5 Press the Key. 6 Press the Key to scroll to ADVANCED ENTRY. TFOTPSDBMJCSBUJPO QFSGPSNDBMJCSBUJPO TFOTPSDBMJCSBUJPO BEWBODFEFOUSZ You are entering the calibration submenu. You are entering Advanced Entry Calibration. 7 Press the Key. BEWBODFEFOUSZ TFOTPSMFWFMT Press the this procedure. Key to abort 2-5

8 Advanced Entry Calibration (continued) Step Action Displayed Message Comment 8 Press the Key. 9 Press the Key. Place the label under the Sensor Eye Mark and lower the printhead assembly. BEWBODFEFOUSZ TFOTPSHBJO HBJOUSBO=zzz? +11=1.42? -Or- HBJOSFGM=zzz? +11)1.42* You are beginning the Advanced Entry Calibration. If using preprinted media, ensure the label area under the sensor is free of preprinted text, graphics, borders or perforations. Note: 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). Do NOT move the position of the Media Sensor after it has been adjusted. HBJOUSBO=zzz? +11=1.42? -OR- HBJOSFGM=zzz? +11)1.42* 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

9 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). HBJOUSBO=zzz? +11)1.42* Or, for reflective media: HBJOSFGM=zzz? +11)1.42* 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. HBJOUSBO=zzz? +11)1.42* Or, for reflective media: HBJOSFGM=zzz? +11)1.42* Both sensor readings must be above

10 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. HBJOUSBO=zzz? +19)1.42* Or, for reflective media: HBJOSFGM=zzz? +19)1.42* 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. HBJOUSBO=zzz? +19)1.42* Or, for reflective media: HBJOSFGM=zzz? +19)1.42* BEWBODFEFOUSZ TFOTPSMFWFMT Where yyy is a numerical value representing the current sensor reading. The sensor readings must be manually entered into the printer now. 2-8

11 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. QBQFSTFOTPSMFWFM Q+2:9H+195F+125 HBQTFOTPSMFWFM Q+2:9H+195F+125 FNQUZTFOTPSMFWFM Q+2:9H+195F+125 Or, for reflective media: QBQFSTFOTPSMFWFM Q+126N+292F+324 NBSLTFOTPSMFWFM Q+126N+292F+324 FNQUZTFOTPSMFWFM Q+126N+292F+324 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. TBWFDIBOHFT@ FOUFSLFZ>ZFT 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

12 2.2 Printhead Adjustments To ensure even and consistent print quality across a wide range of media types and sizes, the printhead is equipped with three adjustments: the Leveling Cam, the Burn Line, and Pressure Leveling Cam Adjustment The Leveling Cam ensures that even pressure is maintained across the label. Whenever using media that is less than the full width of the platen roller, proceed as follows: Load the printer with media. Download a label format or choose a Quick Test Label and begin printing. While observing the right side of the label, rotate the Leveling Cam clockwise, or counter-clockwise, until even print is achieved across the width of the label (see examples below). Example 1 Over adjustment: 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: 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, TOF faults, position faults, and excessive wear on the printhead and platen roller. 2-10

13 2.2.2 Pressure Adjustment To accommodate a variety of media types, the pressure applied by the printhead assembly is adjustable. This pressure is factory-adjusted for most media types, so this adjustment should only be performed after attempting to improve print quality through the use of the (1) heat and/or (2) print speed. Use only the minimum pressure necessary. Adjust the Printhead Pressure Screws as follows: Load at least 4 (102mm) wide media and ribbon. Ensure the Leveling Cam is disengaged (fully clockwise); see Section Enter the Quick Test Mode then select 100 Print Quality Labels. Press the Key to begin printing. Turn the Printhead Pressure Adjustment Screws counterclockwise to increase the applied pressure or clockwise to decrease it. Make equal adjustments (as indicated by the Arrow) to each Printhead Pressure Adjustment Screw to achieve even print contrast across the label. Minimum Arrow Maximum Printhead Pressure Adjustment Screws 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. 2-11

14 2.2.3 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. 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 the Operator s 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: Load media (and ribbon, if needed). Rotate the Printhead Latch into the locked position. Disengage (fully clockwise) the Leveling Cam. Loosen the two Locking Screws no more than ½ to ¾ of a turn. Enter the Quick Test Mode then select 100 Print Quality Labels. Turn the Adjustment Screws counter-clockwise until the Burn Line is past the Platen Roller Vertex. Print a Validation Label from the Quick Test Menu. The label should look light and uneven. Tighten the Locking Screws just until they are snug tight enough to remove any play in the printhead assembly, yet loose enough to allow the Adjustment Screws to move the printhead. 2-12

15 Turn each Adjustment Screws clockwise about ¼ a turn (or 1/8 a turn for finer adjustments). Print another Validation Label and examine the print quality. Repeat this step until labels with even print contrast (darkness) and acceptable print quality are produced. Note: When the Locking Screws are snug, turning the Adjustment Screws counter-clockwise will not move the printhead outward. If you have adjusted the printhead inward too far, restart the entire procedure. Tighten the Locking Screws. Print a final Quick Test Label to verify the adjustment Voltage Adjustment CAUTION This procedure requires voltage measurement: Use extreme caution. The printhead voltage adjustment is required (1) when replacing the power supply or (2) if the factory voltage setting of the power supply has been changed. No voltage adjustment is required during routine printhead replacements. Adjust the Printhead Voltage as follows: Turn Off and unplug the printer and remove the cover; see Section 4.1. 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

16 Raise the Printhead Assembly. Locate and note the Printhead Resistance. After ensuring that media is loaded, latch the Printhead Assembly in the down position. Plug in and turn On the printer. 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 observing the DVM, adjust the voltage using RP1 on the Power Supply PCB according to the corresponding printhead resistance listed in the appropriate table below. Turn Off and unplug the printer. Remove the DVM and replace the cover. WARNING When adjusting the printhead voltage, do not exceed the recommended voltage. Excessive voltage can cause permanent damage or shorten the service life of the printhead. Printhead Voltage Adjustment Table Printer Model Printhead Resistance Range (in ohms) Printhead Voltage (in Volts DC) I4206, I4208, I4210, & I4212 I

17 Printhead Voltage Adjustment Table (continued) Printer Model Printhead Resistance Range (in ohms) Printhead Voltage (in Volts DC) I4406 I Ribbon Alignment When equipped with the thermal transfer option, if irregular voids extend diagonally through a printed image the cause may be due to ribbon overlapping problems (wrinkling). Correct ribbon alignment ensures smooth, taut ribbon flow during the print process. Begin troubleshooting by checking the Leveling Cam (Section 2.2.1), Pressure Adjustment (Section 2.2.2), Burn Line Adjustment (Section 2.2.3), and examine the Platen Roller for signs of wear, debris build-up and excessive side-to-side play. Perform a Ribbon Alignment as follows: Load 4 inch (102mm) or wider media. Load a matching ribbon, but do not secure the leader to the Ribbon Take-up Hub. Instead, allow the media and ribbon to feed together out of the printer. 2-15

18 Ribbon Take-Up Hub Ribbon Supply Hub Printhead Assembly Support Cover Ribbon Idler Cam Ribbon Idler Screw Ensure the Leveling Cam is disengaged; see Section Plug in and turn On the printer. Press the FEED Button several times to normalize the tracking of the ribbon and media. (If label tracking is a problem, this must be corrected before proceeding. Typical causes include an unlatched printhead, uneven printhead pressure setting, a worn platen roller, or worn platen bearings.) Observe the ribbon for rippling and bagging as it travels down from the Ribbon Supply Hub and under to the Printhead Assembly. If the travel is smooth, proceed to Step 6; otherwise, loosen the Ribbon Idler Screw then, while repeatedly pressing the FEED Key, slowly turn the Ribbon Idler Cam until the ribbon is dispensed smoothly from the Ribbon Supply Hub to the Printhead Assembly. Carefully tighten the Ribbon Idler Screw and feed several more labels to verify the adjustment, repeat if necessary. 2-16

19 Attach the ribbon to the Ribbon Take-Up Hub. Enter the Quick Test Mode and select 100 Quick Ribbon Test Labels. Press the Key to begin printing. Observe the ribbon for rippling and bagging as it travels up from the Printhead Assembly to the Ribbon Take-Up Hub. If the travel is smooth and the printed labels show no evidence of ribbon wrinkling, proceed to Step 8; otherwise, slightly loosen the Ribbon Shield Adjustment Screws. Move either side of the Ribbon Shield in or out to smooth the ribbon and remove any wrinkle-related voids from the printed labels. Carefully tighten the Ribbon Shield Adjustment Screws. Print several labels. Verify the adjustment and repeat if necessary. Ribbon Supply Hub Ribbon Take-Up Hub Ribbon Shield Adjustment Screws Printhead Assembly Ribbon Shield Press the Key to stop printing. Install operating media and ribbon. Set the Printhead Leveling Cam, as needed. Send your label format to the printer from the host. Examine the printed labels; readjust the Ribbon Shield slightly, if needed. 2-17

20 2.4 Linear Scanner Alignment The optional Linear Scanner is factory-adjusted for optimum performance. If, however, the label exit angle changes (for example, due to the addition of an external rewinder) normally good bar codes may fail because of excessive specular reflection, which effectively blinds the scanner s optics. The diagram below illustrates the no read specular zone, between 0 to 10 degrees off perpendicular. CAUTION The use of controls, adjustments, or the performance of procedures other than those specified herein may result in hazardous LED light exposure. Class 1 LED power up to 15 mw in a 0.1 ms pulse at nm could be accessible in the interior. Align the Linear Scanner as follows: Ensure that the Tear Bar or Rewind Plate has been mounted to the printer. (If using an external rewinder, attach the media to the rewinder.) With four-inch wide label stock installed, use the enter QUICK TEST MODE and print a Print Quality Label, as shown below. Picket Fence Bar Code Unlock the Printhead Latch and raise the printhead assembly. Carefully position the Print Quality Label so that it comes straight out of the printer, and so that only the bottom ¼ inch of the Picket Fence Bar Code is showing from the Ribbon Shield (see the drawing below). Lower the printhead assembly and lock the Printhead Latch. 2-18

21 Adjustments and Maintenance Picket Fence Barcode Ribbon Shield Scanner Print Quality Label Printhead Latch Enter Menu Mode and go to DIAGNOSTICS ALIGNMENT TEST and then press the OPTIONS TESTING TEST SCANNER Key. Slightly loosen the Mounting Bracket Screws (see the drawing below) and tilt the Scanner away from the Ribbon Shield of the printer. Mounting Bracket Screws Ribbon Shield Scanner 2-19

22 While watching the SCAN COUNT in the Display Panel, slowly tilt the Scanner forward (toward the Ribbon Shield) until the numbers increment continuously and rapidly (also, a green Indicator Light will illuminate). This is the optimum reading position. Mounting Bracket Screws Indicator Light Ribbon Shield Display Panel Scanner Carefully tighten the Mounting Bracket Screws. Ensure that the SCAN COUNT continues to increment rapidly. Exit the ALIGNMENT TEST by repeatedly pressing the Key. Raise the printhead assembly, remove the Print Quality Label, and then install your operating media. Using your format, run a batch of labels to verify the alignment. If problems persist, see Section

23 2.5 Maintenance This section details the recommended items, techniques, and schedules to help you safely and effectively maintain the printer. Keep the following items on hand to clean the printer: 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 Lens tissue (for models equipped with the optional Linear Scanner) 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 Cutter Option Linear Scanner Option Peel and Present Option *Whichever occurs first. Thermal transfer media users after each roll of ribbon. Direct thermal media users 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. After each roll of labels, after each roll of ribbon, or as needed. As needed. After each roll of labels, after each roll of ribbon, or as needed. 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 applied with a dampened cloth. See Section Compressed air and isopropyl alcohol dampened cotton swabs. See Section Water-dampened lens tissue (or lint free cloth). See Section Cotton swab dampened with isopropyl alcohol. Remove all build-up. See Section

24 2.5.1 Cleaning the Printhead CAUTION NEVER use a sharp object on the Printhead; damage can result. 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 being 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. 2-22

25 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. Debris Build-up Cotton Swab Burn Line Printhead Assembly Printhead Printhead Latch 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. 2-23

26 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 (part number ) under the printhead. Lower the Printhead Assembly and lock the Printhead Latch. Disengage the Leveling Cam; see Section Cleaning Card Printhead Latch Printhead Assembly 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, see the Operator s Manual for details.) 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. 2-24

27 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 ) under the printhead. Lower the Printhead Assembly and lock the Printhead Latch. Disengage the Leveling Cam; see Section Cleaning Film Printhead Latch Printhead Assembly 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, see the Operator s Manual for details.) 2-25

28 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 Printhead Assembly Cotton Swab Printhead Latch 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

29 2.5.2 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, cause labels to stick and wrap around the roller. Clean the platen roller as follows: Turn Off and unplug the printer. Open the cover. Unlock the Printhead Latch and raise the Printhead Assembly. Remove media and ribbon. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, clean the Platen Roller; manually rotate the roller and repeat until the entire surface is clean. Allow the Platen Roller to dry. Replace ribbon and media. Lower the Printhead Assembly and lock the Printhead Latch. Close the cover. Plug in and turn On the printer. Feed several labels to normalize tracking. 2-27

30 2.5.3 Cleaning the Media Sensor & Media Path When particles such as paper dust accumulate along the paper path and in the bottom of the printer, small voids in the printed labels can result. If in the Media Sensor, these accumulations can affect the printer s ability to detect labels. 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 Media Path Tear Bar \ Rewind Plate Media Sensor Baseplate Media Idler Media Guide Using compressed air or a soft brush, clean the Media Path and Baseplate. Also clean the Media Sensor, Media Idler, 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, lock the Printhead Latch, and close the cover. 2-28

31 2.5.4 Cleaning the Exterior Surfaces Cleaning Exterior Surfaces: 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 generalpurpose cleanser to wipe the exterior surfaces clean. Never use abrasive cleansers or solvents 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 after each roll of labels (or box of tag stock) 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. 2-29

32 Cleaning the Light-Duty Cutter Turn Off and unplug the printer. Raise the cover. If attached, remove the Cutter Tray. Remove the Screw and Cutter Cover Plate from the Cutter Assembly. Use compressed air to remove any debris from the interior cavity. Using a Cotton Swab dampened with isopropyl alcohol or WD-40, wipe off all build-up from the cutter blade. Manually rotate the cutter blade and clean the entire cutting surface. Reinstall the previously removed Screw and Cutter Cover Plate. Reattach the Cutter Tray. Plug in and turn On the printer. Close the cover. 2-30

33 Cleaning the Standard Cutter Turn Off and unplug the printer. Raise the cover. If attached, remove the Cutter Tray. Remove the Cover Screw from the front of the Cutter Assembly and swing open the Cutter Cover Door. Use compressed air to remove any debris from the interior cavity. Using a Cotton Swab dampened with isopropyl alcohol or WD-40, wipe off all build-up from the cutter blade. Manually rotate the cutter blade and clean the entire cutting surface. Close the Cutter Cover Door and reinstall the previously removed screw. Reattach the Cutter Tray. Plug in and turn On the printer. Close the cover. 2-31

34 2.5.6 Cleaning the Linear Scanner CAUTION Avoid use of excessive moisture that could penetrate the housing and obscure the window. While the use of cleaning fluids other than water are not recommended, if necessary a neutral detergent or ethanol would be preferred. Never use bleach at any strength because damage to the painted case and/or window can result. No scheduled maintenance is required for the Scanner. Should it require cleaning proceed as follows: Turn Off and unplug the printer. Raise the cover. Using a water dampened lens tissue (or lint free cloth) carefully wipe the Window (see below) until clean. Allow the Window to dry. Scanner Window Plug in and turn On the printer. Close the cover. 2-32

35 2.5.7 Cleaning the Peel and Present Mechanism The Peel Mechanism needs to be disassembled and cleaned approximately every 100,000 inches to ensure trouble-free operation. This cleaning interval can vary depending on the type of adhesive on the back of the media. The use of media with heavy or gummy adhesives will require more frequent cleaning. The Upper Rollers: Turn Off and unplug the printer. Raise the cover. Remove any media from the Peel and Present Mechanism. Remove the Peel Mechanism from the printer. Press in on the Latch and allow the Front Cover to swing open. Remove the small C-Clip from the Upper Roller Shaft. C-Clip Latch Upper Roller Shaft Front Cover 2-33

36 Remove Upper Roller Shaft and the associated Rollers. Note the order of the Rollers as they are removed; they must be re-installed in the same order. Clean all surfaces of the Rollers and the Upper Roller Shaft with isopropyl alcohol. For heavy or stubborn deposits WD-40 or an adhesive remover can be used. Be sure all the ridges on the rollers are free of debris. Upper Roller Shaft Rollers Re-assemble the Upper Roller Shaft, Rollers, and C-Clip into the Peel Mechanism Assembly. 2-34

37 The Lower Rollers: Push in on the Tab as shown, then repeat for the other side and then remove the entire Lower Roller Assembly. Push in on Tab Lower Roller Assembly Remove Lower Roller Shaft and the associated Rollers. Note the order of the Rollers as they are removed, they must be re-installed in the same order. Lower Roller Shaft 2-35

38 Clean all surfaces of the Rollers and the Lower Roller Shaft. Isopropyl Alcohol can be used, for heavy or stubborn deposits WD-40 or an adhesive remover can be used. Be sure all the ridges on the rollers are free of debris. Re-assemble the Lower Roller Shaft and Rollers. Reinstall the Lower Roller Assembly into the Peel Mechanism Assembly. Attach the Peel and Present Mechanism to the printer. Reload Media. Plug in and turn On the printer. Close the cover. 2.6 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.datamaxcorp.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 (see the Operator s Manual for details). Note: If unable to print a Configuration Label, the firmware version can be obtained from the LCD upon printer power-up. 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 Note: Should an error occur during the download (see Section 2.6.3), 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. 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). 2-36

39 2.6.1 Updating from Ready Mode Update Procedure for Application Version or greater Step Displayed Message Operator Action Comment(s) 1 SFBEZ 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: For example, this would be entered as: copy 4212tb ~ 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. 2 VQHSBEJOH TPGUXBSF No action required. The new application program is being stored and verified / No action required. The printer has reset automatically and is now displaying the new firmware version. 4 SFBEZ No action required. The new application is now running. Note: If Uncalibrated or Position Fault is displayed, the printer will have to be calibrated (see Section 2.1). 2-37

40 2.6.2 Updating from Download Mode Required Update Procedure for Application Version 2.08 or earlier* Step Displayed Message Operator Action Comment(s) 1 CPPU.QB21 13/ Press and hold the PAUSE and TEST Keys while turning On the printer to enter the Download Mode. The Boot Loader version is displayed. Note: This information will vary with the printer model and Boot Loader version. 2 VQEBUFTPGUXBSF TFOETPGUXBSF 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: 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 4212tb ~ 1.zs lpt1 3 VQEBUFTPGUXBSF SFBEJOHJNBHF No action required. The printer is receiving the new image (program). 4 FSBTJOHGMBTI TPGUXBSFJNBHF No action required. The program has been received and verified; now memory is being cleared of the previous application. 5 XSJUJOHGMBTI TPGUXBSFJNBHF No action required. 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. 2-38

41 2.6.3 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 2.6.2). Windows users try restarting the computer in MS-DOS mode. Use the Datamax Printer Driver to send the file. The following is a list of possible error messages when downloading: Application Update Error Messages Displayed Message EFDPNQSFTTJPOFSSPS FSSPSFSBTJOHGMBTI FSSPSXSJUJOHGMBTI IBSEXBSFNJTNBUDI EBUBSFKFDUFE JOWBMJETPGUXBSF EBUBSFKFDUFE TPGUXBSFNJTNBUDI EBUBSFKFDUFE 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. 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 for details). 2-39

42 2.7 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 communications interfaces. Updates can be found at ftp://ftp.datamaxcorp.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 (see the Operator s Manual for details) 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 SFBEZ 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: 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. 2 VQHSBEJOH TPGUXBSF No action required. The new program is being stored and verified / No action required. The printer has reset automatically. 4 SFBEZ No action required. The new application is now running. Note: If Uncalibrated or Position Fault is displayed, the printer must be calibrated (see Section 2.1). 2-40

43 2.8 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. 2-41

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