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Videojet 6210 Service Manual.book

1. 5 17 Setting the Printhead Resistance 5 18 Maintaining the Cassette 5 19 RevAA ICE Pegasus Service M anual Updating the CLAR TY Operating Softvvare 5 23 Chapter 6 System Events Chapter 7 Troubleshooting Chapter 8 Illustrated Parts List How to Read the IPL 8 1 He EIS eg da sea anos sie aaa shes anew WEN ans ake awe aad 8 1 Alphabets EE 8 2 M mbers cu usss ba dama a adlaya baa wea bad Faralar R 8 2 TableS 8 3 Controller Assembly Aaa aaz aaa cues deers 8 4 qo 4000000000 8 5 Printhead Assembly 8 5 Cassette A ssembi y Ae a aka yaaa arxa sag aa 8 7 Aloe osol n r n 8 8 Printer RIDDONS EE 8 9 Chapter 9 Drawings Printer DIMENSIONS 9 1 Electrical Wiring Schematics 9 4 ReAA iii Safety This chapter contains the following topics e Safety conventions used throughout this manual e Important safety guidelines to follow while operating the equipment N VVarning EQUIPMENT MAINTENANCE Read this chapter thoroughly before attempting to install operate service or maintain this product Introduction The policy of ICE is to manufacture printing coding systems
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4. es o LO N gt M6 Tapped Holes 20 73 mm 2 PLCS Thread Depth 6 00 0 82 inches 3 Places pri 70 73 mm 2 78 inches 185 30 mm 7 29 inches 159 60 167 15 mm 6 28 inches 6 58 inches 157 80 mm 164 00 mm 6 4 6 inches 6 21 inches _ u o no E Q EOS ES 252 Sx Bat sa SL Zog a 29 0 mm 26 20 mm 32 00 mm 1 14 inches 1 03 inches 1 26 inches Printable Area lt gt 132 50 mm 1 28 inches Printhead Stroke Figure 9 2 V ideolet 6210 30 mm LH Printer Dimensions 9 2 Printer Dimensions RevAA 208 35 mm 8 2 inches 191 25 mm 7 53 inches Videojet 6210 Service M anual Figure 9 3 shows the dimensions of the CLA RiTY controller 118 90 mm 4 68 inches a Rev AA Figure 9 3 CLARITY Controller Dimensions 41 00 mm 1 61 inches M6 Female Thread Both Sides Thread Depth 6 00 d 96 90 mm 3 81 inches 69 20 mm 2 72 inches Printer Dimensions 9 3 t SOLD unim 221 22213 S9 VO dd uondo 1914 sn YOUMS S ululo02 q mod epeq uondo S WWOD 4005 suren suren 1 MOd SUW ZEZ S4 FAW d l lid uag Z Z SH Mowe kd y x ex 9X 91 SIX ux ind IS L Y Tel 1191 y q N6 G M6 92 ame 89 A0SZHVSL A
5. gt MATERIAL FEED 1 Ribbon Transfer Carbon Print 2 Platten Roller 3 Substrate 4 Thermal Printhead Figure 2 3 Continuous Print M otion Theory of Printing 2 5 Technical Description This chapter contains the following topics e Unpacking the Printer Installing the Printer Mounting Considerations Installing the Ribbon in the Cassette Adjusting the Air Pressure Working with Printer Connections Switching the Power On Understanding Printhead LEDs Configuring the Printer Working with the Configurable Inputs and Outputs Unpacking the Printer Inspect the kit for any damage carefully Refer the list of parts in Table 3 1 and Figure 3 1 on page 3 2 If any item is damaged or missing call ICE Customer Service Department at 01159 640144 Printer Part Printer Cassette CLARITY Controller Air Regulator Power Cable I O Low Profile Cable Assembly Table 3 1 Printer Configuration Parts List RevAA Unpacking the Printer 3 1 ICE Pegasus Service M anual Printer Part CLARITY Configuration Manager CD 4mm Air Tubing CLARITY Controller Bracket QA Documentation and CE Certificate Table 3 1 Printer Configuration Parts List Continued 7 6 1 Air Regulator 6 Printer 2 4mm Air Tubing 7 O Low Profile Cable 3 CLARITY Controller Assembly 4 CLARITY Controller Bracket 8 Cassette 5 Power Cord 9 CLARITY Configuration Manager CD ROM
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7. Printhead Resistance Not Set Flash memory is lost Setthe resistance value from the user interface Webbing Error Supply ribbon reel eccentric 1mm Replace the reel End of Reel Less than 20 meters of ribbon remaining on reel Replace the reel Incorrect Reel Size Ribbon cores not fitted Try using a different reel Incorrect roll width fitted Make sure that the software reel width setting matches the width of the reel that you are using Table 7 1 Error M essages and R emedies Continued Re AA Error Message Printer is not powered up Possible Causes Power plug not fully seated in the socket ICE Pegasus Service M anual Remedies Check and correct Power not turned on at the source or at the power supply Check and correct Power cable not properly connected to the printer and power supply Check and correct Power supply voltage set incorrectly Check and correct Check the 5 A fuse on the Check and correct Refer CLARITY unit Replacing the Mains Fuse on page 5 2 Blown Fuse Replace Fuse CLARITY controller is not powered up Cable not properly connected to the printer and controller Check and correct Incorrect cable between the printer and controller Check and correct Faulty controller unit Check unit and replace the components as required Printhead does not move in and out Air
8. 1376 Figure 4 20 Printhead Consumables Diagnostics Page The following parameters can be accessed in the consumables diagnostics page Spool 1 2 Diameters 0 1mm are the measured diameters of the ribbon and can be compared to the actual ribbon diameters after calibration to determine the accurate functioning of the calibration system e Tension demand and measurement parameters are for debugging only and are not described here Ribbon Tension Statistics This is for software debugging only and is not described here 4 20 Using the Tools Page RevAA ICE Pegasus Service M anual Working with Control Diagnostics Touch Control button on the Diagnostics page to access the system Control page Communications Image Update Queue Ill Figure 4 21 Control P arameters Thefollovving parameters can be accessed in this page e Versions Displays the software versions of the various software components installed in the printer The most important number displayed when this button is touched is the Software Part Number This is the master version number and all the other data displayed is of secondary importance Notez If there is any inconsistency among the softuvare components that are installed in the printer the Software P art N umber displays the message Incompatible Software V ersions If this is seen a CLARITY software update must be performed otherwise the coder may perfor
9. Encoder Scaling A parameter set to run the printing ribbon at a slightly lower speed to the packaging film This can improve printing quality at very high packaging film speeds External Inputs 1 2 3 Shows the real time status of each of the two inputs and the unused spare input Printhead Position Indicates whether the printhead home sensor is detecting the head as parked or not Cassette Open Indicates whether the cassette home sensor is recognising the cassette as being open or closed Motor Volts Shows the voltage supply to the stepper motors must be 36V Printhead Volts Shows the drive voltage to the printhead This varies depending on the printhead resistance but should bein the range of 22V 27V depending on printhead resistance 24 Volt Supply Shows the voltage supply for the printers 1 O must be 24V Printhead Temperature Shows the real time reading of the thermistor on the thermal printhead Printer Ambient Temperature Shows the real time temperature of the hottest component inside the printer unit Using the Tools Page 4 11 ICE Pegasus Service M anual Touch Outputs on the Printhead Diagnostics page to access the output parameters Figure 4 12 A P rinthesd Outputs Printhead Position arked Printhead ls Open Wamings Contact 9 amp Li Fault Coniact 7 amp 8 a SeA EA Toggle Figure 4 12 AENEAN Outputs Diagnostics Page Each button shows the s
10. interactive coding equipment PegasusHS Service Manual DIN 361854 21 Revision AA November 2006 Copyright 2006 Clearmark solutions LLP herein referred to as ICE All rights reserved This document is the property of Clearmark solutions and contains confidential and proprietary information owned by ICE Any unauthorized copying use or disclosure of it without the prior written permission of ICE is strictly prohibited ICE interactive coding equpiment Olympic House Willow Drive Sherwood Park Nottingham Phone NG15 0DP Fax 01159 640144 01159 639317 www interactivecoding com Compliance Information For Customers in U S A This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation AN Warning Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide responsible protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and
11. ICE Pegasus Service M anual Replacing the Printhead To replace the printhead proceed as follows 1 Remove the printhead retaining screvv as shovvn in Figure 5 21 Printhead Screw Figure 5 21 Printhead Screw Removal 2 Movethe printhead from the parked position 3 Disconnect the printhead and remove Figure 5 22 Printhead R emoval Rev AA M aintaining the Printer 5 17 ICE Pegasus Service M anual 4 Reconnectthe printhead connector to the new printhead 5 Place the printhead in the parked position and secure it with the printhead screw 6 Set the printhead resistance Setting the Printhead Resistance Printheads are manufactured vvith variations in their resistance The printhead resistance is pre set in the factory The printer must be set up vvith the correct printhead resistance N Caution PRINTHEAD RESISTANCE If the printhead is changed the new printhead resistance must be set If not set correctly damage could occur to the printhead or poor quality images could result Such damage is not covered by your printer vvarranty To set the printhead resistance proceed as follovvs 1 Find and note the printhead resistance value from the label on the printhead e g R 1113 O as shown in Figure 5 23 Printhead Label 188 20 6 266 SABE iN p Figure 5 23 Printhead Resistance V alue 2 Touch the Tools button on the Home page 3 Touch the Setup button on the Tools
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13. Versions If this is seen a CLARITY update must be performed immediately to correct the situation otherwise unpredictable printer behavior may result The printer should be used only when a valid part number is displayed in the part number window There are two ways of performing a CLARITY Update 1 Connecting the printer to a PC that runs CLARITY Configuration manager 2 Inserting a USB memory stick containing the update file into the printer Before performing a CLARITY Update it is strongly recommended that a parameter archive is saved using CLARITY Configuration M anager Refer Archiving the Current Parameters on page 3 24 CLARITY Update Via a PC It is recommended that when updating via a PC the PC Printer connection is done via Ethernet This makes the process a lot quicker You must have the CLARITY Update CAB file stored on the PC disk Contact your local service representative to obtain the correct file for your printer To update the CLARITY proceed as follows Updating the CLARITY Operating Software 5 23 ICE Pegasus Service M anual 1 Connect the printer to the PC and when the coder icon is green right click on the icon les ET Figure 5 29 CLARITY Update Window 2 Click on CLAR TY Update and navigate to the CAB file stored on the PC disc 3 Clidc on thefile name and the update process commences 4 Theupdatefile is initially dovvnloaded and the progress of the download ca
14. functions of CLARITY Protection may be globally enabled or disabled through the CLARITY Configuration Manager The password protection is disabled in the default factory settings CLARITY has five different functions that may be optionally password protected Job Select Registration Working with Passwords 4 25 ICE Pegasus Service M anual Set up e Diagnostics e Databases This is can be easily explained by means of an example Table 4 1 Job Registration Set up Diagnostics Databases Level 1 X Operator Level 2 X X X X Line Super visor Level 3 X X X Mainte nance Table 4 1 Password Protection Example In this example registration is not selected for any of the three user access levels therefore available to all the users to use without any password protection If there is at least one X in a column then that function is only available to a user level against which a X appears Example Set up column in the Table 4 1 is accessible via a password only to Level 2 and Level 3 personnel Each user level has a different numeric password that can be between 4 and 10 digits Password Protection Set up Set up of password protection for CLARITY is done using the CLARITY Configuration Manager Run CLARITY Configuration Manager on the PC and upload the printer parameters 4 26 Working with Passwords RevAA Re AA ICE Pegasus Service M anual The menu tree t
15. us sss p u bia baa Pika Capua ah 3 23 Saving the Changes in the Printer 3 24 Archiving the Current Parameters 3 24 Loading a Saved Archive 3 25 Working with the Inputs and Outputs 3 25 Bas das EE 3 25 THE Q tp lS ir u Si usa 9200 333593060030930 0501 3 25 Default Options Configuration 3 26 Chapter 4 CLARITY Operating System Getting started with the CLARiTY 4 1 Using the Tools Page dss e 4 2 Working with Setup Page 4 3 Working with Diagnostics 4 8 Working with Passwords 4 25 Password Protection Set Up 4 26 Chapter 5 Maintenance Maintaining the Power Supp Y 5 2 ReplacingtheMainsFuse 5 2 Maintaining the CLARITY Controller 5 3 Replacing the Power Supply Unit 5 3 Replacing the CLA RiTY Processor PCB and LCD Touchscreen darc KEE 5 5 Maintaining the 5 11 Replacing the Compact Flash Card 5 11 Replacing the Main PCB 5 12 Replacing the Peel Roller 5 15 Replacing the Printhead
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17. Figure 3 1 Printer Configuration Parts 3 2 Unpacking the Printer RevAA ICE Pegasus Service M anual Installing the Printer Ensure that the following services are available while the printer is being installed e Power 90 264 VAC 320 VA 47 63Hz e Compressed Air 87 psi 6 bar max dry uncontaminated with a 6 mm pipe fitting e Print signal This is the signal that triggers the printing operation and can either be a PLC signal 24V DC PNP registration photocell 24V DC PNP proximity switch detecting acam timing point e An encoder kit DIN 403358 is required to monitor the speed of the packaging film on continuous motion packaging machines Mounting Considerations Rev AA Printer The thermal printhead must act against a flat print platen in an intermittent mode or a print roller in a continuous mode in order to print The platen or roller is a part of the mounting bracketry The printer can be mounted in any orientation However it is important to ensure that adequate operator access is available to renove and replace the cassette easily The exact position of the printer relative to the packaging machine needs to account for The physical constraints of the available space and operator access e The required position of the print on the substrate Figure 3 2 on page 3 4 shows the relevant dimensions of the printer relative to the mounting holes and the printhead It also shows the additional spa
18. M anual 1 Ribbon Roller x2 2 Ribbon Spool x2 Figure 3 7 Cassette Removed Pull the tvvo ribbon spools one containing the entire used ribbon from the cassette firmly as shown in Figure 3 8 The discs that are situated under each spool can be used to lever the spool off the cassette Figure 3 8 Ribbon Spools Removal Discard the used ribbon and the spools Open anew shrink wrapped roll of ribbon and unwind about 12 inches 30 cm of ribbon The spool holders on the cassette have different color discs Installing the Ribbon in the Cassette 3 9 ICE Pegasus Service M anual e The black disc for the new roll of ribbon Thesilver disk for the empty roll When the printer is running the new ribbon unwinds from the black holder and winds onto the silver spool holder 6 Slidethefull spool onto the spool holder that has a black disc The roll should be located such that the ribbon unwinds in the direction as shown in Figure 3 9 Note Ensure that the spool is pushed completely down onto the holder Figure 3 9 Ribbon Spool Installation 7 Routetheribbon so that it Unvvinds from the outside of the full roll Goes around the outside of the white roller that is nearest to the full roll e Runs along the bottom of the cassette e Goes around the outside of the second white roller e Passes around the outside of the empty spool 3 10 Installing the Ribbon in the Cassette RevAA ICE Pegasus Service M
19. Service M anual CLARITY panel It may be more convenient to make final adjustments at the panel rather than using the CLA R TY Configuration Manager Saving the Changes in the Printer To makethe changes effective proceed as follows 1 Click the printer icon in theleft hand paneto open the printer controls at the bottom pane of the window 2 Click thedownload button to updatethe printer with the changes that you have made to the parameters A dialog box opens with the message The parameters to be downloaded have not been saved to an archive 3 Touch OK to continue with the download 4 Thenew parameters are active when the download is complete Note U nless steps 1 to 4 are performed none of the parameter changes become effectivein the printer Archiving the Current Parameters The set of parameters can be saved as an archive and are stored on the PC The archive can be loaded into the Configuration Manager and downloaded to the printer again at a later dateto revert to the archived set of parameters Oncethe printer has been configured it is recommended that all the parameters be uploaded into the PC and saved as an archive To archive the current parameters proceed as follows 1 Rightclick the Archives folder in the left hand panel 2 Select the New Save option from the pop up menu A file for the new save appears under the archives folder with a name containing the current time and date 3 Change the name of
20. anual 8 Slidethe empty spool completely down onto the holder that has a silver disc Figure 3 10 Figure 3 10 Ribbon Spool Complete 9 Turn the empty spool by hand to take up any excess ribbon Stop turning the empty spool vvhen thefull spool starts to rotate Figure 3 11 Note If the supplied ribbon has a transparent section or printed leader at the start rotate the empty spool to take up all the transparent ribbon Figure 3 11 Ribbon Spool Routing 10 Insert the cassette into the printer body Rev AA Installing the Ribbon in the Cassette 3 11 ICE Pegasus Service M anual Note Ensure the following e Theribbon runs in between the printhead and the printer s print roller or print pad e Theribbon is not twisted or caught e Theribbon has not become loose while replacing the cassette Adjusting the Air Pressure A Warning PERSONAL INJURY Before connecting the compressed air supply to the printer ensure that the air regulator adjustment knob is turned fully counterclockwise Use the regulator to set the air pressure to 3 0 bar 43 5 psi Setting the pressure too high can shorten the lifetime of the printhead Setting the pressure too lovv can cause poor print quality VVorking vvith Printer Connections Product Sensors Print Signals One 15 pin D Type male connector located on the side of the printer is dedicated for input and output connections The printer can be triggered to print either by a me
21. called N jobs on the USB memory device 2 Insertthe USB memory device into the USB port Figure 4 23 3 Touch the Tools button on the home page and touch Database button to access the database page UsingtheToolsPage 4 23 ICE Pegasus Service M anual The database page displays the External Database Figure 4 24 Tools Databases Figure 4 24 External D atabase 4 Touch External Database button to view all the jobs in the USB device Figure 4 25 Tools Databases External a Job List Figure 4 25 Jobs List on USB Device 4 24 Using the Tools Page RevAA ICE Pegasus Service M anual Using the buttons in the bottom of the page Figure 4 25 on page 4 24 you can either view the job or send a file to the local database or deletethe job from the USB device 5 Touch on the send afileto the local database button A confirmation appears Figure 4 26 Touch ok to confirm External Restore Job Are you sure you want to restore the job Left Figure 4 26 Confirmation Screen Working with Passwords Rev AA Password protection on the CLARITY user interface allows different protected access levels for the various operational features of CLARITY for up to three different user groups For example the three user groups may be classified as Operators Production Supervisors and Maintenance Personnel each group requiring access to either all or a subset of the total
22. if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference In such cases the users will be required to correct the interference at their own expense Shielded cables must be used with this unit to ensure compliance with Class A FCC limits The user may find the following booklet prepared by the Federal Communications Commission helpful H ow to Identify and Resolve Radio TV Interference Problems This booklet is available from the U S Government Printing Office Washington DC 20402 Stock N o 004 00 00345 4 This equipment has been tested and certified for compliance with U S regulations regarding safety and electrical emissions by TUV Rheinland of N orth America Inc For Customers in Canada This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications This equipment has been tested and certified for compliance with Canadian regulations regarding safety and electrical emissions by TUV Rheinland of N orth A merica Inc Rev AA i ICE Pegasus Service M anual Pour la Clientele du Canada Le present appareil numerique n emet pas de bruits radioelectriques depassant les limites applicales aux appareils numerique de las class A prescrites d
23. its possible causes and the remedies Error Possible Causes Remedies Message Cassette not fully seated Push the cassette in until you hear it click into place Cassette latch out of Adjust the cassette latch adjustment Cassette Open Faulty cassette sensor Replace the printhead sensor Home switch magnet Replace the magnet missing from the cassette base plate Table 7 1 Error M essages and Remedies RevAA 7 1 ICE Pegasus Service M anual 7 2 Error Message Ribbon Break Possible Causes Broken ribbon Remedies Reinstall the ribbon Excess of slack in ribbon when the cassette is loaded Reinstall the ribbon Damaged cassette Check for the damaged cassette base plate giving misaligned drive or ribbon tracking problems usually this results when a cassette is dropped from a height onto its ribbon guide rollers Note The cassette base plate is usually the part that gets damaged as the ribbon guide rollers is made of stainless steel and therefore unlikely to bend End of reel Replace the ribbon reel Ribbon gets the vvrong side of the peel roller while loading the cassette Reinstall the ribbon Host machine is holding the ribbon firmly Review and correct the application Calibration Failed Ribbon installed incorrectly Reinstall the ribbon Ribbon reel diameter is out of range Use correct ribbon reel Damaged cassette Check for t
24. numbers less than 10 are read when there is an obstruction between the LED and the receiver Test the optics by toggling each one on in turn Gain Setting is the gain applied by the electronics to keep the LED signals within the correct limits As the LED s become old more gain needs to be applied to the circuit which is represented by a lovver number in the diagnostic New LED s must have a gain of around 50 and old LED s must have a gain significantly less than this number indicating that the LED needs to be replacement Rev AA U sing the Tools Page 4 13 ICE Pegasus Service M anual Touch the General button on the Printhead Diagnostics page access to the general diagnostic parameters Printhead General Printer Mode Printer Hand Print Sinnal Logic Positive Edge Trigger Print Test mage Figure 4 14 Printhead General Diagnostics Page The printhead general diagnostics page allows you access the following parameters e Printer Mode Indicates if the printer is configured as intermittent or continuous motion e Printer Hand Indicates what handing the printer is configured as e Print Signal Logic Indicates whether the print signal is Positive or Negative Edge Triggering e Print Test Image Triggers the printing of a test image Encoder Profiling Encoder profiling is designed for continuous motion applications where there may be doubt over suitability of the application for the VJ 62
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26. starting CLAR TY message appears Following this the CLAR TY home page Figure 3 17 on page 3 19 is displayed An initialization process of 15 seconds begins during vvhich the printer calibrates the ribbon drive The status bar flashes the vvords STARTING UP and the amber LED flashes on and off VVhen the process is complete the home page changes as follovvs e The CLARITY status panel changes from STARTING UP to OFFLINE e The Consumables area displays the percentage of ribbon remaining e In the Control Frame the Start and Stop buttons are enabled e The blue Povver LED on the printer is illuminated Figure 3 17 on page 3 19 displays the CLARITY home pagein the OFFLINE state 3 18 Switching the Power On RevAA ICE Pegasus Service M anual 11 35 25 07 2006 4 Line JoB qa E Batch Count Total Count Mi Consumables Ribbon Figure 3 17 CLARITY HomePagein the Offline State Configuring the Printer CLARiTY Configuration Manager As coding and labelling equipment have become increasingly versatile and flexible with a wide range of applications the number of variables that can be configured within a printer has become very large Although printers are pre programmed with default values as the extent of the application increases it becomes less likely that the default configuration is ideal This can lead to a large and cumbersome Menu Tree on the printer s contr
27. the archive in the bottom panel and click the Apply button 3 24 ConfiguringthePrinter Rev AA ICE Pegasus Service M anual Loading a Saved Archive To load an archive that was saved previously proceed as follows 1 Locatethe archive in the left panel and right click on it 2 Choose Load from the pop up menu The archived parameters are displayed on the right hand pane Click the printer icon from the left hand panel and dick the Dovvnload button to load the archive of parameters to the printer Working with the Inputs and Outputs The printer has a number of input outputs for interfacing the printer to the packaging equipment or the packaging line The Inputs The inputs are pre configured as e Print Sensor Using a 24V PNP input to trigger the printer to start printing e Inhibit Print Using a 24V PNP input to inform the printer that the host packaging machine or line has an error and the printer should not print e Spare Input 1 Not A vailable for Use Repeat the steps 1 to 5for all the three inputs and then dovvnload the parameters to the printer to apply these new settings The Outputs The Outputs are pre configured as follows e Output 1 Printer enters fault A fault condition has occurred e Output 2 Printer enters warning A warning condition has occurred e Output 3 Printer is busy The printhead is out in its printing position e Spare Output Not Available for Use Rev AA Working with thelnputs and Output
28. with the Fault thermistor or the thermistor is disconnected E3011 Printhead Over Temperature Coder operating over Fault 65 degrees Celsius E3012 Low Ribbon Less than 50 metres of ribbon left on Warning the reel E3013 Printhead Absent Communications between Fault CLARITY and the printer have been lost check the cabling E3014 Webbing Error The ribbon has been incorrectly Fault loaded onto the cassette E3015 Motor Volts Error Fault E3016 Printhead Volts Error Fault E3017 Check the Set Up Substrate speed and the encoder Fault speed do not match Ribbon speed is not matched to substrate speed E3018 Ribbon Pull Through Ribbon is stuck to the sub Fault strate and has been pulled from the cassette Table 6 1 List of Faults and Warnings RevAA ICE Pegasus Service M anual Error Report on CLARITY Operator Interface Status No E3019 Unprinted Pack Substrate speed fell below 40mm s Fault for too long to print last pack E3020 Incorrect Reel Size Fault E3021 Print Cycle Error Note the values in Tools gt diagnos Fault tics gt printhead gt states gt captured states and report Possible printer PCB or motor fault E3024 24 Volt Error The 24 volts supply is not in the work Fault ing range Power the printer OFF and ON to try and clear the fault If the problem persists call your main tenance engineer or local service r
29. 10 printer due to excessive linear speed or acceleration problems Encoder profiling allows the VJ6210 printer to capture the behavior of the packaging film from the encoder and plot the information onto a useful CLARITY screen which also shows an on line oscilloscope of the machine inputs and outputs at the same time 4 14 Using the Tools Page RevAA Re AA ICE Pegasus Service M anual Figure 4 15 shows a typical screen display of an encoder profile Encoder Profile Speed mm s 0 0 1365 2730 4095 Ti me mz o T si Figure 4 15 Encoder Profiles Graph The graph displayed on the CLARITY Operator Interface takes into account settings for Maximum Print Speed current Registration settings and the image size printed Using these values the graph shows where the print signal was received and wherethe print would occur within the profile as shown in Figure 4 15 This feature can be used to solve problems such as drifting print registration caused by the packaging film travelling above the maximum print speed of the printer during the registration phase UsingtheToolsPage 4 15 ICE Pegasus Service M anual To capturethe Encoder profiling on the CLA RiTY screen proceed as follows 1 Touch the Encoder Profiles button on the Printhead Diagnostics page access to the Encoder Profiles parameters Figure 4 16 Ac Profiles Capture Encoder Prof
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31. Operating System This chapter contains the following topics e Getting started the CLARITY Operating System e Using the Tools page Working with Passwords Getting started with the CLARITY CLARITY is an icon based operator control system It has an easy to use touch screen and most areas of the display are active that is touching an area on the screen is like pressing a button on a traditional control panel The basics of the CLAR TY operator system are explained in the Videojet 6210 Operator Manual P N 361853 All technical aspects of the printer setup and control are accessed through the Tools button Figure 4 1 shows the home screen of the CLARITY operator sytem 1 2 11 38 25 07 2006 Default 4 Line j Text m3 Performance 4 I OK Batch Ribbon m m mn 1 Machine Status Bar 4 Control Frame Buttons 2 Tools Button 5 Home Button 3 Current Job Status Details Button Figure 4 1 CLARiTY Home Screen Rev AA Getting started withtheCLARiTY 4 1 ICE Pegasus Service M anual Using the Tools Page Touch the Tools button on the home screen to access the Tools page Figure 4 2 Figure 4 2 Tools P age Thetools page allows you to access the following pages e Setup page Permits you to modify a small subset of the printer setup parameters e Diagnostics page Provides on line fault finding routines and diagnostic functions
32. SE pe ululid y Bulounog Aue ww JO esu dwo9 0 p sn poul lu lluu lul l zud w 1 p10g H8S o pe ululid y Aq panow eo2ue1siq oz Uu 0 UON JUS IWI9 U WIL SY UHA yoe uo0d pp ululid luiod Sunieis v Wo 1 uoneuns S kyi uud y BulAoui lu uu Aouu pep ululid uonens S kyi qd UONEWOJU Vspud y JO UONOSJIP y ul Aejap 0116151 zud v 0 ww 21 020 1lu llluuj u uld s n d uud lu niuu lui Ue BuioS2u uuuuo2 Aey q 1414 yeubis 4114 y BulA19591 Joye Pem O U 1 00S Su uoN US Dunuud zu ue Sul l ul ped Jud y m 1981002 o uollisod zud UAOQ O S WO O pe ululid y 10 W oul oz Su uoN lu lliuuj lu A euon un ynejoq owen ALIYV19 UIEN JaieugIged uono s qns uon s enue snsvsag JO VV Zog uoneunByuoD suondo nepa 62 6 g nunuoo eue IN UOReINBYUOD Ud 0129 P P A LCE uud snonunuo JO Wee u Buluuni S v Lola S S lu niuu lu UON apo J lulid adh Joe uoleinBijuod HY JO HJ Sum s s snb l HREl D ON UON puEH Jeu puEH Jeu Bunuud poul 1lu llluu lul u p sn aq o p ds zud y 00c 2958 Jed ww p ds uud p ds 1014 UONEWJOJU WU Vspud Sou LUS OpP uu
33. To open and replacethe Power Supply Unit proceed as follows 1 Remove the top cover from the base of the CLAR TY Unit by unscrewing the 5 screws shown in Figure 5 3 1 1 Screvvs x5 2 Top Cover Figure 5 3 Controller O pening Rev AA M aintaining the CLARITY Controller 5 3 ICE Pegasus Service M anual 2 Disconnect the white power connectors from the front and back of the PSU and from the main PCB as shown in Figure 5 4 Connectors Figure 5 4 Power Connections Removal 5 4 Maintaining theCLARiTY Controller RevAA ICE Pegasus Service M anual 3 Nextturn the base over and undo the four screws from the base plate The PSU can now be separated from the base plate Figure 5 5 Base Screw Removal 4 Tore assemble reversethe above procedureensuring that all electrical connectors are securely pushed into place Replacing the CLARiTY Processor PCB and LCD Touchscreen Assembly In order to replace the CLARITY Processor PCB or the LCD Touchscreen Assembly remove the top cover as described in the section Replacing the Power Supply Unit on page 5 3 Then follovv the additional procedure belovv 1 Removethe povver connector from the main PCB Rev AA M aintaining the CLA R TY Controller 5 5 ICE Pegasus Service M anual 2 Remove the six securing screws from the D type connectors on the bottom of the CLAR TY unit Figure 5 6 D Type Securing Screvvs Figure 5 6 Top Case D etail 3 Carefully remove th
34. and suppliesthat meet high standards of performance and reliability Therefore we employ strict quality control measures to eliminate the potential for defects and hazards in our products The intended use of this printer is to print information directly onto the product Use of this equipment for any other purposes may lead to serious personal injury The safety guidelines provided in this chapter are intended to educate the operator on all safety issues so that the operator can operate the printer Safely Rev Introduction 1 1 ICE Pegasus Service M anual Safety Conventions Used in the Manual Specific safety information is listed throughout this manual in the form of Warning statements Pay close attention to these statements as they contain important information that help in avoiding potential hazards to yourself or to the equipment General Warning Notices Thefollowing warnings supplement the specific warnings that appear elsewhere in the manual These are general warnings which must be read completely understood and applied by all the personnel involved in the operation and or the maintenance of the machine AN Warning PERSONAL INJURY Only trained service or maintenance personnel should perform these installation procedures Qualified personnel have successfully completed the training courses have sufficient experience with this printer and are aware of the potential hazards to which they may be exposed AN Wa
35. angle is not suitable the resulting print may appear faded Note Other parameters are same as intermittent mode UsingtheToolsPage 4 5 ICE Pegasus Service M anual Working with the Consumables Setup Page Touch Consumables button on the setup page to access the consumables parameters Figure 4 6 Figure 4 6 Consumables P age The consumables page allows you to set the following parameters e Ribbon Width Sets the ribbon tension to the optimum value depending on the ribbon width narrow ribbons stretch morethan wide ones and should run at lower tension e Ribbon Color Allows the printer to accurately predict the end of reel condition when using the predictive end of reel detection systems 4 6 UsingtheTools Page Rev AA ICE Pegasus Service M anual Working with the Control Setup Page Touch the control button on the setup page to access the control page Figure 4 7 ols Setup Control ET Internationalisation Recalibrate Touchscreen 2 Kc Set Screen Contrast Gei Screen Orientation Ahk UA y as 7 Figure 4 7 Control P age The control page allows you to set the following parameters e Internationalisation Sets the language of the CLARITY screen and the international region which control date time formats displayed within CLARITY e Recalibrate Touchscreen Allows the user to recalibrate the touchscreen if touching the screen do
36. ans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada Cet quipement est certifi CSA For Customers in the European Union This equipment displays the CE mark to indicate conformance to the following legislation EN 55022 1998 e EN 55024 1998 e EN 61000 6 2 2001 e FCC CFR 47 parts 15 107 and 15 109 ii Ber AA Support and Training Contact Information If you have any questions or need assistance please contact ICE Technologies Inc at 01159 640144 Interactive Coding Equipment ICE Olympic House Willow Drive Sherwood Park Nottingham NG15 0DP T 01159 640144 F 01159 639317 Service Program About Total Source Commitment Total Source TOTAL SERVICE PLUS RELIABILITY isthelCE commitment to provide you our customer the complete service you deserve The Total Source Commitment The ICE Service Program is an integral part of our business in providing marks codes and images where when and how often customers specify for packages products or printed materials Our commitment includes e Applications support e Installation services e Maintenance training e Customer response center Technical support Field service e Extended hours phone assistance e Parts and supplies Repair service Rev AA ili ICE Pegasus Service M anual Customer Training If you wish to perform your own service and maintenance on the printer ICE highly
37. be set at the CLARITY panel For further information refer Configuring the Printer on page 3 19 Phase B Signa 1 Encoder 2 15 pin Male D type Connector Figure 3 14 Encoder Wiring 3 14 Working with Printer Connections RevAA Re AA Interlocks and Annunciation The 15 pin D type male connector located on the side of the printer unit is available for connecting with a variety of useful interlock and annunciation signals Videojet 6210 Service M anual Table 3 2 summarizes the input and output connections Pin Purpose 424V External input 1 PNP 24 V OV External input 2 PNP 24 V Not Used Relay output 1 N C Relay output 1 common Relay output 1 N O OI O I O oa B wy TO Relay output 2 common Relay output 2 N O ok PNP 24 V Output 1 12 OV 13 Not Used 14 Encoder Phase B input 15 Encoder Phase A input Table 3 2 Input and Output Connections Note For more information on configuring the inputs and outputs refer Working with the Inputs and Outputs on page 3 25 Working with Printer Connections 3 15 Videojet 6210 Service M anual Data Communication All external data communication to the printer are connected through the CLARITY controller It contains the following communication ports e RS232 Serial Communications Port 9 pin Male D type Connector Tabl
38. ce required to give adequate clearance to cables and air pipes that connect to the unit Installing the Printer 3 3 ICE Pegasus Service M anual o Ec G 28 O D Hi al o 20 Ec E o st st on M6 Tapped Holes Thread Depth 6 00 20 73 mm 2 PLCS 3 Places 0 82 inches 70 73 mm 2 78 inches 185 30 mm 159 60 mm 7 3 inches 6 23 inches 167 15 mm 6 58 inches 157 80 mm 6 21 inches 164 00 mm 6 46 inches o o oS lt Eco 5g ESE oto oN Og 9 ON aq zz H oo 5 E A 1 26 inches Printable Area 26 20 mm 25 70 mm 32 50 mm 1 28 inches 1 03 inches 1 01 inches Printhead Stroke Figure 3 2 Videojet 6210 30 mm RH Printer Dimensions Mount the printer using four M6 screvvs Consider the direction of travel of the target material relative to the printer when you mount the printer on a continuous motion packaging machine This determines whether the printer in use is left handed or right handed Figure 3 3 o Right handed Printer Left handed Printer Figure 3 3 Right handed and Left handed Printer 3 4 Mounting Considerations RevAA ICE Pegasus Service M anual Theprint platen rubber for printers in intermittent mode or the roller for printers in continuous mode should be positioned such that it is at a distance between 6 45 inch
39. chanical contact print signal or a 24V DC PNP product sensor The printer can be configured to print either on a positive or a negative edge signal Note T hese settings areknown as configuration settings and cannot be set on the CLARITY panel For further information refer Configuring the Printer on page 3 19 Connect the vviring for the sensor or mechanical contact operation as shovvn in Figure 3 12 on page 3 13 and Figure 3 13 on page 3 13 3 12 Adjusting theAir Pressure RevAA ICE Pegasus Service M anual ee 6 1 PNP Sensor 2 15 pin Male D type Connector Figure3 12 PNP Sensor Wiring Print Sensor 1 Print Signal Relay Contact 2 15 pin Male D type Connector Figure 3 13 M echanical Contact Wiring Print Sensor Rev AA Working with Printer Connections 3 13 ICE Pegasus Service M anual Encoder Phase A Signal For the continuous motion operation of the printer an encoder is used to track the speed of the packaging material The encoder is wired into the printer s input output connector The printer is configured to use a quadrature mode encoder by default N The use of a quadrature mode encoder enables the printer to react if the packaging material is traveling backwards This prevents the occurrence of breaks in the ribbon and possible damage to the printer The use of a quadrature mode encoder is obligatory Note T hese settings are known as configuration settings and cannot
40. d 1 10 403324 Peel Roller 5 off Table 8 4 P arts of Printer A ssembly Printer A ssembly Re AA Videojet 6210 Service M anual Cassette Assembly C Figure 8 5 Cassette A ssembly 7 NS Table 8 5 lists the parts of the cassette assembly Item Number P N Description Qty C Cassette Assembly Refer to Figure 8 5 11 403327 Silver Disc Pack 5 off 12 403323 53mm Cassette Roller Set of 6 13 Print Ribbon Refer to Table 8 7 on page 8 9 for details 14 403326 Black Disc Pack 5 off Table 8 5 P arts of Cassette A ssembly Rev AA Cassette Assembly 8 7 Videojet 6210 Service M anual Accessories 5 Yo mit Ha nf 4 gt o z 1 LS Cat Figure 8 6 A ccessories Table 8 6 lists the accessories of the printer Item Number P N Description Qty 1 403357 Spare 32T Bracket Platen Rubber 1 Pack of 10 Continuous 2 403357 Spare 32T Bracket Platen Rubber Pack of 10 Intermittent 3 401339 Spare Encoder O ring Pack of 10 4 403318 Intermittent Bracket Assembly 1 5 403317 Continuous Bracket Assembly 1 Table 8 6 Accessories List 8 8 Accessories RevAA Printe
41. e U Q Sey dn s su She UON UON AIU91V A LHVT S EM lU ynejeq o 1SEnu02 0129 3 O P A y uo pasn 10N UON UON 18S UBBJOSYONO y JO uollelqile 54 UON UON aleiqiueo aleiqueo A LIHV 19 SU Wo UOH B y SIE Ailenueul o sey Joen y pajqesip 51 gen 193 q 1lepdn y U YM HONS ul UO lli E SI J ayepdn AL HVTO ALIYV19 94 suni ileoneuroine A LVI p lqeu UO dwold SI GSN pue SI yos gsn E S A uoN uoN puiomssed AJUO Su uunu A 10 DAOMSSE oul UON UON UON s vepau ueloluyde B JASN e JO oul UON UON UON OWEN E 19497 Jon si sn I A 1 O lQEIIEAE q ag suol o9unj YOIUM UON UON UON YSEIN 19497 SpioASSEd puiomssed AJUO Su uunu Z A 10 Psomssed oul uoN uoN uoN Z 13497 1051 B a yasn zg E Jo OUL UON UON UON QWEN Z 3497 si sn 2 I A 1 O jqejene q o Bue suooun YOIUM UON UON UON YSEIN Z 19497 A euon un ynejoq spun weN UIEN Jo OwWeIeg uono s qns uon s enue AJ D A 5S snsvsag JO CLARiTY
42. e 3 3 lists the connections to the RS232 Serial Communications Port Pin Connection 1 2 Receive Data Rx 3 Transmit Data Tx 4 5 GROUND 6 7 8 9 Table 3 3 RS232 Serial Communications Port Connections The printer is primarily designed to communicate with the CLARICOM Package Coding Management Software such as the CLA R SOFT VJ6210 Image Design Software P N 703490 CLARITY is supplied with some default images installed in its database memory CLARITY can be configured to work in the following mode e Standalone Mode Dovvnload images to CLAR TY using a standard PC null modem cable tvvisted 9 pin D type female to female connected between PC COM 1 port and CLARITY RS232 port cable supplied separately using CLA R SOFT Cable Connections Figure 3 15 on page 3 17 displays the details of the printer cable connections 3 16 Working with Printer Connections RevAA ICE Pegasus Service M anual 15 Way I O Cable Unterminated C Encoder gt Low Profile Connector PRINTER Mains Power Figure 3 15 V ideojet 6210 Cable Connections Rev AA Working with Printer Connections 3 17 ICE Pegasus Service M anual Switching the Power On To switch the printer on turn the power switch on the CLARiTY controller to thel On position Figure 3 16 Figure 3 16 Printer Power Switch The boot up takes approximately 90 seconds During this a
43. e Databases page Provides control over the jobs database of the coder 4 2 Using theT ools Page RevAA ICE Pegasus Service M anual Working with Setup Page Touch Setup button on thetools page to access the setup page Figure 4 3 RH one EJ Consumables Figure 4 3 Setup P age The Setup page allovvs you to access the follovving parameters e Printhead and printing operations e Consumables ribbon e General Control eg time date language Options RevAA Using the Tools Page 4 3 ICE Pegasus Service M anual Printhead Setting in Intermittent Mode Touch the Printhead button on the setup page to access the printhead parameters T nls Setup Printhead acs AM A Vertical Registrafion mm Jj Print Orientation deg Print Delay ms A gt E Figure 4 4 Printhead P arameters in Intermittent M ode The Printhead page in intermittent mode allovvs you to access the follovving parameters Horizontal Registration The position of the print in the printers overall printing vvindovv measured in mm across the vvidth of the printhead It enables you to position the print along the vvidth of the printhead Vertical Registration The position of the print in the printers overall print window measured in mm in the direction perpendicular to the printhead Print Orientation Allows rotation of the whole image through 180 d
44. e maximum film speed during the previous printing cycle Minimum print speed mm s Indicates the actual minimum printing speed during the previous printing cycle Maximum print speed mm s Indicates the actual maximum printing speed during the last printing cycle Cycle Time ms Indicates the total time from the end of the print registration delay to the end of the printing operation Printing Time ms Indicates the actual time taken to print the image in the previous printing cycle Job Selection Time ms Indicates the time taken in selecting the last job from the moment the image was confirmed to being ready to print RevAA Using theTools Page 4 19 ICE Pegasus Service M anual Job Data Update Time ms Indicates thetotal timetaken to updateall the dynamic variables in the image time date counters e Counter Update Time ms Indicates the time taken to update all the counter fields in the image e Time Date Update Time ms Indicates the time taken to update all the time date fields in the image The States button in the printhead diagnostics screen is for softvvare debugging only and is not described in this manual Working with Consumables Diagnostics Touch Consumable button on the Diagnostics page to access to the Consumables diagnostics page Figure 4 20 Consumables lt 4 Spool 1 Diameter 1mm 2 7mm Spool 2 Diameter 1 mm Nominal Tension Demand Last Tension Measurement
45. e oes 2 2 Related documents 2 2 Theory Of Printing ee BEE E acha ada 004 2 3 Intermittent M otion Printing 2 3 Continuous Motion Printing 2 4 Chapter 3 Technical Description Un packi oth Printef ive tesgce cee cous kreta bir 3 1 Installing the Printer 1 3 3 Mounting CONSE BUGS 212504 yaaa yad Sus pa akad 3 3 Pur 233 3 3 CLARITY Controller 3 5 EE vee Mer e aywaq anu s 3 7 Encoders e 3 7 Installing the Ribbon in the Cassette 3 8 Adjusting the Air Pressure 3 12 Rev AA ICE Pegasus Service M anual Working with Printer Connections 3 12 Product Sensors Print Signals 3 12 seated sees 00 2 ASS 3 14 Interlocks and Annunciation 3 15 Data Comrnunicati n J anada uwa as bees as Bas 3 16 Cable Connections 3 16 Switching the Power On 3 18 Configuring the Printer r 3 19 CLAR TYTM Configuration Manager 3 19 Installing the CLARITY Configuration Manager 3 21 Connecting the CLARITY Configuration M anager to the Printer3 21 Editing Parameters u u u
46. ed Possible Causes Start border too short ICE Pegasus Service M anual Remedies Increase the start border Intermittent Mode Only Substrate is moving while attempting to print Print signal timing is incorrect If necessary delay the print until the film stops and settles Dwell Time by entering a Print Delay value Go to Tools Setup Printhead Intermittent Mode Only Incorrect Horizontal Registration setting Check and correct One or more dots missing cleaning does not help Faulty Printhead Replace the Printhead Ribbon is creasing Poor alignment of printer to platen or roller Correct the alignment with the shims between the printer and bracket or behind the platen Bent peel roller shaft or support Check and replace if necessary Table 7 1 Error M essages and Remedies Continued 7 9 lllustrated Parts List The Illustrated Part List IPL contains the illustrations and the parts lists for the different assemblies in the printer The parts lists give the part numbers description and quantity of all the items and the modules in the printer You can order the items and the modules for which the part numbers are given How to Read the IPL This section describes how the higher assemblies are broken down to their related subassemblies and other separate parts Illustrations Table 8 1 showsthe symbols used to indicate the different levels of mai
47. egrees Print Delay The delay betvveen the print signal and the commencing of the print Measured in milliseconds it allows time for the packaging film to come to a complete rest before the printhead comes in contact It should be set to the smallest possible value that gives a good quality print Print Speed The target printing speed of the head in mm sec It should be set to the lowest speed that allows completion of the print in the available dwell time of the packaging film 4 4 Using theTools Page RevAA Re AA ICE Pegasus Service M anual e Print Darkness The amount of energy being transferred into the printhead It should beset to the lovvest valuethat provides acceptable quality of print at the required throughput e Interleaved Images Enables a lower quality draft mode of printing with a 50 saving in ribbon consumption e Printhead Resistance M atches the drive electronics of the printer to the resistance characteristics of the printhead Printhead Setting in Continuous Mode Touch the Printhead button on the setup page to access the printhead parameters L al I nls S tup Printhead a Kai Horizontal Registration mm E Figure 4 5 Printhead Parameters in Continuous M ode The Printhead page in continuous mode allows you to access the following parameters e Print Position Changes the angle of the printhead against the target material This angle affects the print quality If the
48. eplace the compact flash card proceed as follows 1 Remove the cassette and place the printer face down on a flat surface Removetherear cover by unscrewing the 4screws one from each side of the printer Figure 5 12 and then lift the cover off 1 Screws Figure 5 12 Rear Cover Removal RevAA Maintaining the Printer 5 11 ICE Pegasus Service M anual 2 TheCompactFlash card is located on the side with the mounting plate the opposite side to the printhead Using a pair of long nosed pliers gently grip the Compact Flash Card and pull to extract Figure 5 13 Windows License Sticker Figure 5 13 Compact Flash Card Removal 3 Take the new card orientate such that the face with the Windows License sticker is facing away from the PCB and gently but firmly push home 4 Replace the rear cover Replacing the Main PCB To replace the main PCB proceed as follovvs 1 Before removing the rear cover place the printer on a flat surface cassette side up and remove the cassette if this hasn t already been removed 5 12 Maintaining the Printer RevAA ICE Pegasus Service M anual 2 Locate and remove the 2 screws Figure 5 14 Screws 3 Remove the rear cover as detailed above in the section Replacing the Compact Flash Card on page 5 11 4 Nextremovethenuts securing the D Type connectors to theside plate still secured to the unit Figure 5 15 Nuts RevAA Maintaining the Printer 5 13 ICE Pegasus Service M anua
49. epresentative E3025 Printer Ambient Temperature The internal ambient Warning temperature of the printer is outside its recommended operating range Touch the Clear button below to clear this warning E3026 External Error The operation of the printer has been 1 Fault suspended by the control system If the Clear button is available below you may touch it to clear this error and resume printing E1100 Invalid Job File Bad Field Reference Source field 1 Warning reference incorrect correct in CLARISOFT E1101 Invalid Job File Missing Data Source Field Job file Warning missing a data field correct in CLARISOFT E1102 Invalid Job File Duplicate Named Fields Field Warning names have been duplicated in Job File correct in CLARISOFT E1000 Image Update Failure CLARITY is unable to update Fault the image before receiving the next print signal since the products are too close to each other E1001 Count Limit Reached One or more fields in the Fault image design has reached the allocated end value E1002 Abort Operation Aborted The operation of the Fault printer has been stopped by the host control system Table 6 1 List of Faults and Warnings Rev AA 6 3 Troubleshooting This chapter contains the following topic Information on error messages its possible causes and the remedies Table 7 1 lists the error messages
50. es and 6 50inches 164 mm and 165 5 mm from the back edge of the printer Figure 3 4 Printer Pad or Roller 6 2 inches 6 52 inches 6 46 inches lt q 158 mm _ _pe lt lt 164 mm _ gt 165 5mm Figure 3 4 Printer Pad or Roller Position CLARITY Controller The CLARITY operator interface can be mounted at a convenient location so that the operator has adequate access to the panel The CLARITY controller has a built in power supply unit The unit has two M6 mounting holes located at the sides of the unit as shown in Figure 3 5 on page 3 6 RevAA Mounting Considerations 3 5 ICE Pegasus Service M anual 118 90 mm 4 68 inches eol EY EQ ES 00 2 ao ki Y Y M6 Female Thread Both Sides Thread Depth 6 00 oO 41 00 mm 1 61 inches Figure 3 5 CLARITY Controller Dimensions 69 20 mm 2 72 inches 96 90 mm 3 81 inches The maximum distance of the CLA R TY controller from the printer body is 9 8 ft 3 m The CLAR TY controller can be mounted in any convenient location provided that the maximum lead length of 9 8 ft 3 m is not exceeded The mounting brackets provided allovv you to position the controller against a convenient vertical flush surface 3 6 Mounting Considerations RevAA Re AA ICE Pegasus Service M anual Air Regulator The air regulat
51. es not accurately locate the correct CLARITY button or Icon The printer requests the user to touch several crosses vvhich are displayed on the screen one after the other The screen is recalibrated when the automated process is complete Note If the calibration of the machine has too many errors and does not allow a user to navigate to this screen via the CLA R TY panel the same functionality can be triggered from within CLARITY Configuration manager e Set Screen Orientation Rotates the entire display through 180 degrees in the event that the CLARITY panel is installed in an inverted orientation e Date and Time Sets the system date and time of the coder e Communications Enables resetting of all serial communication reports in the event that their setup has become corrupted RevAA Using theTools Page 4 7 ICE Pegasus Service M anual Working with the Options Setup Page There are no options available at this time it may be introduced in the next versions of the CLAR TY Working with Diagnostics Touch diagnostics button on the tools page to access the diagnostics page Figure 4 8 Tools Diagnostics F Figure 4 8 D iagnostics P age The diagnostics page allows you to access the following pages e Printhead and printing operations diagnostics e Consumables ribbon diagnostics e General control e g software versions communications port status diagnostics e Options 4 8 Using theTo
52. ethenew LCD touchscreen assembly face down on a clean soft surface and fit the support plate using the four screws removed earlier Ensure that the touchscreen signal ribbon cable is carefully routed through the slot in the base plate without damage Figure 5 10 GA L0G 24 VIL 5506 MADE IN CHINA ent ix THIS 11112 eke Figure 5 10 Touch Screen Ribbon Cable R outing Rev AA M aintaining the CLARITY Controller 5 9 ICE Pegasus Service M anual 11 12 13 14 15 16 Replace the white ribbon cable ensuring that the right angle is as shown Figure 5 11 Figure5 11 LCD Ribbon Cable D etail Slide lower this assembly back into the top case being careful not to damage the seal or to trap the backlight power cable and re fit the three securing screws and the anti vibration washers Refit the Processor PCB with its two securing screws again taking care not to trap the backlight power cable Refit the three connectors to the PCB and the securing screws for the D type connections Refit the power connector Replace the Top cover over the base and secure with the five screws on the sides 5 10 Maintaining theCLARiTY Controller RevAA ICE Pegasus Service M anual Maintaining the Printer This section contains the information on how to replace e The Compact Flash Card e The Main PCB of the printer e The Peel Roller e The Printhead e The Cassette Rollers Replacing the Compact Flash Card To r
53. ethree connectors from the PCB taking care not to bend or tvvist the cables Figure 5 6 5 6 Maintaining theCLARiTY Controller Rev AA ICE Pegasus Service M anual 4 Removeand retain the two screws securing the PCB Figure 5 7 Screws Figure5 7 PCB Connections 5 Gently slide and lift the PCB away from the LCD and touch screen assembly taking care not to damage the three cables coming from the LCD Touchscreen module If replacing the Processor PCB then refer to section 13 below If replacing the LCD Touchscreen A ssembly then continue below Replacing the LCD Touchscreen Assembly 6 Removeand retain the three screws and anti vibration washers holding the whole assembly and inverter module Remove this module from the case taking care not to remove the seal around the RevAA Maintaining the CLARITY Controller 5 7 ICE Pegasus Service M anual case aperture Figure 5 8 L A LS SM 2 d L t 641 WW 2 1 mo Gat POS SNS E m Figure 5 8 PCB Removal 7 Disconnect the backlight povver cable vvhite pink connection 8 Remove and retain the four screws holding the LCD touchscreen assembly to the metal support plate 5 8 Maintaining theCLARiTY Controller RevAA ICE Pegasus Service M anual 9 Removeand retain the white ribbon cable from the now separated LCD touchscreen assembly Figure 5 9 Figure 5 9 Separated LCD A ssembly 10 Plac
54. he damaged cassette base plate giving misaligned drive or ribbon tracking problems usually this results when a cassette is dropped from a height onto its ribbon guide rollers Head Crash Printhead microswitch is defective or out of adjustment Adjust or replace the printhead microswitch Printer hand incorrectly set Set the printer hand correctly Printhead motor stalling due to poorly positioned print platen Check and adjust the print platen Table 7 1 Error M essages and Remedies Continued Rev AA Error Message Optical Calibration Sensor Dirty Possible Causes Dirt or obstruction between the emitter and detector detector gently with a soft cloth ICE Pegasus Service M anual Remedies Clean the emitter and Faulty emitter assembly Replace the emitter assembly Faulty detector assembly Replace the detector assembly Faulty printhead cable Replace the printhead cable Optical Calibration Failed Ribbon reel diameters are out of the expected range Use the correct ribbon reel Ribbon reels and or cores incorrectly located on the mandrel Reinstall the ribbon reels and or cores correctly Large ribbon tag on the revvind reel concealing the calibration sensor Remove the tag Large ribbon tag on the revvind reel obscuring the calibration sensor Remove the tag Thermistor Fault Fauliy printhead Replace the
55. ile Profiling Staris Prufiila Type Profile X Axis Figure 4 16 Encoder Profiles P age 2 Tosetuptheoptions for the profile you are want to capture touch the following buttons e Profiling starts Has three options Automatically allows you to capture the profile after you touch the Capture Encoder Profile button On Print Underspeed allows you to only capture a profile if the film speed drops below the minimum limit of the printers specification On Print Signal allows you to only capture a profile after a print signal has been received e Profile Type Has three options vvhich present the information in slightly different graphical forms Choose the one which best suits your needs Profile X Axis Allows you to set the X Axis of the chart to be either time or distance 3 Once the options have been setup start the capture process by touching the Capture Encoder Profile button Note Encoder profiles are not captured during the ribbon calibration sequence 4 16 Using the Tools Page RevAA Re AA ICE Pegasus Service M anual In addition if CLARiTY Configuration M anager is communicating with the printer the encoder profile may be uploaded to a PC for analysis To upload encoder profile to a PC proceed as follows 1 Click on the new coder icon and navigate through devices and select Capture Encoder Profile from the list as shown in Figure 4 17 u ls Figure 4 17 Encoder P
56. l 5 Disconnect the 8 electrical connectors located around the edge of the PCB 6 Undothe2 screws securing the PCB to the supports and carefully withdraw the PCB including the 15vvay D Type connector for the l O connections Figure 5 16 I O Connection Cable Figure5 16 M ain PCB Removed 7 Remove and retain thel O connection ribbon cable 8 To replace the PCB firstly insert and securethel O D Type connector to the side plate Figure 5 17 UO D Type Connector Figure 5 17 M ain PCB Replacement 5 14 Maintaining the Printer RevAA Re AA ICE Pegasus Service M anual 9 Then connectthel O ribbon cable to the PCB and slide it into place Ensure that the connector X9 is threaded through the access hole in the heat sink Figure 5 18 Figure 5 18 X 9 Connector A ccess 10 Securethe PCB using the 2 screws and then reverse the procedure from 5 to 1 above Replacing the Peel Roller To replace the peel roller proceed as follovvs 1 Remove the cassette from the printer M aintaining the Printer 5 15 ICE Pegasus Service M anual 2 Removethe screw on the top of the peel roller as shown in Figure 5 19 2 1 Peel Roller 1 2 Screvv Figure 5 19 Peel Roller Screw Removal 3 Remove the peel roller Peel Roller Figure 5 20 P eel Roller Removal 4 Replace the peel roller and secure it using the screvv removed in step 2 5 Refit the cassette to the printer 5 16 Maintaining the Printer RevAA
57. ls s p seq w ay uolusiB i zud s luejen6 Surounoq p pou18ui souelsip y Buisn SUIM 1Idx O 151 OU UH unoq Qq JOSUaS luliq YUM uollo9un uo2 ul SYJO AA D UPADE SI BOURISIP ui y Aeme oB jeus 1414 y sneo q Y10M JOU a2unoq p Jo poul8ui p seq oue1sip y uolpniis SIU u p nssi s euBis 1414 y U UM 019Z JESU JO 018Z O dosp Aew p ds wji y UBYUM U91IAS e UL JOU s euBis JO 1OSU S P U UM S EU S Jud sno uo u dil nuu plore o passy uoO AUEOIDOL se indul euBis juud pijen e Buldasoe as0jaq Pem O SUI BU 519 01 ynejoq Su suun UON owen ALIYV19 sounogegq 10SU S 1414 UIEN JaieugIged uoneuuolul luud uono s qns Vspud Sou uon s enue AJ D A 5S snsvsag JO O E uonp inSnuo suondo nepa vv eu g nunuoo eue IN UOReINBYUOD 3iulid 0129 P P A LCE anyea 511 ud po d SUIT 52u 1 8J 1 yey S NOAR IS pue 1 u 10 um s 640 e s 1 CO eur uononpold y JO po jeioads nbiun e Jo Buas y SAO V uoN uoN d eur s poo JOU si Jud 2 qi 40198 E yey sino e Ile Bueu pue y o Dumes 840 e s 4 CO 40284 y JO po jeioads nbiun e Jo Buas y SAO V uoN uoN al 4024
58. m in an unpredictable manner Communications Touch this button to check thefunctions of the Communication Port on the printer The follovving parameters can be accessed in this page Communication Ports Displays the status of the serial ports induding the Baud rate the port is set to Image Queue Update Allows you to view all the print jobs that are in the allocation queue Rev AA UsingtheToolsPage 4 21 ICE Pegasus Service M anual Working with Options There are no diagnostics for the Options menu Working with Database Touch Database button on the Diagnostics page to access the Database BH ong internal Figure 4 22 D atabase P age The following parameters can be access in this page e Internal Shows the job stored in the printer e Capacity Shows the details like the space used in the internal database and space available VVhen an external USB memory device is connected to the printer itis accessed in the same page 4 22 Using the Tools Page RevAA Re AA ICE Pegasus Service M anual Connecting the USB Database Instead of connecting a PC laptop to theprinter via a null modem cablein order to download jobs the USB device can be connected directly into the USB port on the CLAR TY Operator Interface Figure 4 23 Figure 4 23 Printer U SB Port To download a job from the USB device proceed as follows 1 Copy thelmage CIFF file into a root directory
59. mage Fault message not cleared Clear the fault message Poor print quality Incorrect air pressure Check and set the air pressure to 3 bar Low Darkness level Goto Tools Setup Printhead and increase the Darkness setting Dirty Printhead Allow the printhead to cool and then clean Print speed and darkness levels have to be appropriate for the ribbon and substrate Check and correct Continuous Mode Only ncorrect Encoder signal Go to Tools Diagnostics Printhead Inputs and check for free encoder wheel rotation Continuous Mode Only Incorrect Print Position parameter Go to Tools Setup Printhead and check the print position to ensure optimum printhead position directly over roller centerline Parameter should be about 2100 for right hand units 2500 for left hand units Intermittent Mode Only Substrate is moving while attempting to print Print signal timing is incorrect If necessary delay the print until the film stops and settles Dwell Time by entering a Print Delay value Go to Tools Setup Printhead Intermittent Mode Only Incorrect Print Speed Go to Tools Setup Printhead Check and correct Dirty or worn print platen or roller Check clean reposition or replace if necessary Table 7 1 Error M essages and Remedies Continued 7 8 RevAA Re AA Error Message Top or bottom of print is missing or ragg
60. n assemblies in a printer and the subassemblies under the main assembly Assembly Symbol Main Assembly Subassembly 1 I Y Table 8 1 Symbols R epresentation A ssemblies The arrow indicates further explosion of the main assembly Rev AA How to Read thelPL 8 1 ICE Pegasus Service M anual Alphabets An alphabet is assigned to the main assemblies of a printer and each subassembly under the main assembly See Figure 8 1 For example If A B C and D identify the main assemblies of a printer then the alphabets E F and so on identify the subassemblies below each main assembly in a sequence e The alphabets assigned to main assemblies are used only for one ti me e The alphabets 1 and O are not used because you can read the alphabets incorrectly as the numbers 1 and 0 Numbers A natural number 1 2 3 is assigned to the standalone parts in the increasing order in the chapter See Figure 8 1 Note The numbers assigned to main assemblies are used only for one time Printer N 3 N G EF G 3 5 AN H 5 6 7 8 Figure 8 1 Graphical R epresentation of the different Subassemblies and parts 8 2 How to Read the P L Re AA ICE Pegasus Service M anual Tables Table 8 2 describes the styles used to show the explosion of the main assemblies in the parts lists Item Number P N Desc
61. n and set them as required When each parameter has been set select A pply Finally right click on the N ew icon and select Download to changethe set up of the printer Password protection is now be enabled Working with Passwords 4 27 Maintenance This chapter contains the following topics e Maintaining the Power Supply Maintaining the CLARiTY Controller Maintaining the Printer Maintaining the Cassette e Updating the CLARITY Operating Software N VVarning PERSONAL INJURY Before attempting any maintenance or repair on any part of the product disconnect the printer from the main power supply and isolate the printer from any external energy sources including other connected equipment RevAA 5 1 ICE Pegasus Service M anual Maintaining the Power Supply This section contains the information on how to replace the fuse Replacing the Mains Fuse The fuses are the only user serviceable parts in the power supply unit To replace the mains fuse proceed as follows 1 Using a small screwdriver press and turn the fuseholder anticlockvvise and remove the fuseholder Figure 5 1 Fuseholder Figure 5 1 Fuseholder 2 Replace the five ampere fuse if it is defective Figure 5 2 Fuse Figure 5 2 Fuse 5 2 Maintaining the Power Supply RevAA ICE Pegasus Service M anual 3 Refitthefuseholder in its original position Maintaining the CLARITY Controller Replacing the Power Supply Unit
62. n be followed in the Progress pane of the CLARITY Configuration Manager screen 5 Oncethe download is completed the CLARITY Update of the printer starts and the CLARITY screen indicates the progress of the update Note It is very Important to ensure that the power to the printer is not renoved during the update process or the flash card in the printer may get corrupted When the updateis finished CLARITY automatically re boots and the CLARITY Home Screen is finally displayed 6 Check the Software Part number in the Diagnostics screen to ensure that the update has been successful CLARITY Update via a USB Memory Stick Updating of printer software is possible from a USB memory stick as opposed to a PC Lap top and CLARITY Configuration Manager To update the CLARITY using an USB proceed as follows 5 24 Updating theCLARiTY Operating Software RevAA ICE Pegasus Service M anual 1 Copy the CLAR TY software onto an USB memory stick Note The software must be stored in a root directory called CLARITY update 2 Connect the stick to the CLARITY Operator Interface via the USB port as shovvn in Figure 5 30 USB Port Figure 5 30 U SB Location 3 IftheCLAR TY Configuration Manager parameter called Prompt On CLAR TY Update Detect is set to Yes vvhen the device is connected to the CLARITY Operator Interface a confirmation page is displayed Figure 5 31 The device that was just inserted contains software
63. n print barcodes dates text and graphics onto flexible packaging films and labels Theprinter is a suitable replacement for either hot stamp or rotary printers It can print in either of the following modes e Intermittent Mode i e while the substrate is stationary e Continuous Mode i e while the substrate is moving It is suitable for use on most horizontal formy fill seal vertical form fill seal and self adhesive labeling machines The product is available in either left handed or right handed versions to suit different configurations of the packaging machine Equipment Description 2 1 ICE Pegasus Service M anual About this Manual This service manual includes information about installing maintaining troubleshooting and servicing the printer It also contains sections about the theory of operation and component identification including an illustrated parts breakdown This document is intended to be used only by trained service personnel It is intended to be a supplement to and not a replacement for formal training Keep this manual in a safe location where it can be easily accessed for reference Related documents The Videojet 6210 Operator Manual P N 361853 is intended for the operator and contains information on routine operation of the printer Unless specified all procedures in this manual can be performed by the operator of the printer It is mandatory that the personnel read the Operator Manual befo
64. n the Diagnostics screen to check that the update has been successful Rev AA Updating the CLARITY Operating Software 5 27 System Events This chapter contains the following topic e List of faults and warnings Table 6 1 lists the faults and warnings Error Report on CLARITY Operator Interface Status No E1001 Count Limit Reached One or more of the counters Fault in the image has reached the end value set in the image design Please select a new job and touch the Clear button to restart the printer E1002 Operation Aborted The operation of the printer has 1 Fault been intentionally aborted by a host control system When ready to resume the operation the host control system cleared this abort condition and then this fault message clear automatically E1003 Real time Clock Fault There is a problem vvith the Fault real time clock which is required for the system to operate correctly E1004 Backup Battery is Flat The battery which powers Warning the printer s clock is flat This means that the date and time the currently selected job and some performance data is lost when the printer is switched off E1006 Image Update Failure CLARITY is unable to update Fault the image that is printed next This usually occurs because products are too close to each other Touch the Clear button to restart the printer E1007 Image Update Failure CLARITY is unable to update Faul
65. nager 3 22 Configuring the Printer RevAA ICE Pegasus Service M anual Editing Parameters Figure 3 20 displays the list of parameters that are available in the printer settings Parameters List Figure 3 20 Parameter Settings Click the folder required to open or close it or to gain access to the parameters it contains You may haveto click and open a number of nested folders to get to the parameter that you want There are a number of different types of parameters Click Help on the menu at the top of the screen and select Key To Legends to get a complete list of the different types of parameters To change the value of a parameter proceed as follows 1 Click the required parameter from the parameter list The current value is displayed in the Value box at the bottom of the screen 2 Change the value to the required value using the mouse and the keyboard 3 Click the Apply button The value displayed in the parameters list is updated to reflect the dhange Note Event parameters do not have values that can be set Touching the Trigger button that is availablein the bottom pane causes the printer to perform the given action immediately For many parameters it may be satisfactory to leave them with their default values Some of the parameters may need tuning after some initial prints have been made Some of the listed parameters are available at the Rev AA Configuring the Printer 3 23 ICE Pegasus
66. nary packaging films in packaging equipment that has a start stop action each time a product is packed Such applications can be found in intermittent Vertical Form Fill Seal VFFS or bagging machines and self adhesive label applicators Intermittent motion printing has the following features e The substrate is stationary Theory of Printing 2 3 ICE Pegasus Service M anual e The printhead traverses across the ribbon causing print to transfer onto substrate The printhead presses against a flat platten pad HEAD OUT 4 sb HEAD IN PRINT i 2 m 1 Ribbon Transferred Carbon 2 Substrate 3 Platten Rubber 4 Thermal Printhead Figure 2 2 Intermittent Printing M otion Continuous Motion Printing Continuous motion printing Figure 2 3 on page 2 5 is the concept used for printing on moving packaging filmsin packaging equipment that hasa continuous moving action each time a product is packed Such applications can be found in Continuous Vertical Form Fill Seal VFFS and Horizontal Form Fill Seal H FFS or flow wrap machines Continuous motion printing has the following features e The substrate moves while the printhead is stationary e Speed of the substrate is monitored by an encoder e Theribbon and the substrate speeds are matched by the ribbon drive The printhead presses against a rotating print roller 2 4 Theory of Printing RevAA Re AA ICE Pegasus Service M anual RIBBON FEED
67. o reach password protection set up is shown in the CLARITY screen in Figure 4 27 ET of E Name Value Mn Max l PrintSensorLope l 1 gt PinSpeed 580 200 l PimeHand 1 2 B PinteTipe 1 1 33 0 53 53 Z imaging 134 PiirtHeadM opng 2 Operations Lei System 123 Userinlerfaces S CLARITY D Language Engish 0 100 Passwords H EnablePasswods No 1 Level P Mask 0 n 3 t Name Operator D 40 M Password 4 10 Level2 P Mask H D Neng Supervisor D 40 Cos B 4 10 Level 3 P Mask 2 D 3 t Nome M nlenance a 40 At Password 4 10 CLARITYConfig y V Job Select T Registration Setup Figure 4 27 Password Set up In addition to the global enable disable of passvvords there are three parameters for each of the three user levels available e Mask This enables disables user access to each of the 5 CLARITY functions Job selection Image registration Set up Diagnostics and Databases Use the tick boxes at the bottom of the above CLARiTY Configuration Manager screen to select the required options and CLAR TY Configuration Manager generates the appropriate mask number Name A namethat may be optionally given to each user level as a reminder of the user group during set up of password protection e Password The password required for each user access level For each level select each of these parameters in turn as show
68. of the Printer AN Warning PERSONAL INJURY Do not place the printer in a hazardous location Hazardous locations might create an explosion leading to personal injury Hazardous locations as defined in the U nited States are those areas that may contain hazardous materials in a quantity sufficient to create an explosion These are defined in A rticle 500 of the N ational Electrical Code ANSI NFPA 70 1993 Outside the United States you must ensure compliance with all local regulations regarding equipment placement in potentially hazardous locations Using Printer Accessories To maintain regulatory approval for the printer use only Videojet approved accessories when attaching any device to the equipment Rev AA Placement of thePrinter 1 5 Introduction This chapter contains the following topics e A description about the intended use of the product e Information about the audience for whom this manual is intended e A description of how the manual is organized e Information about other manuals that are associated with this printer e A description of the theory of printing N VVarning PERSONAL IN URY Read Chapter 1 Safety before attempting to operate the equipment Equipment Description Re AA The Videojet 6210 printer uses high resolution thermal transfer technology with a unique electronic ribbon drive system The printer offers greater reliability and ease of operation compared to earlier systems It ca
69. oller that users have to work with Most printer variables are set during the installation process The variables are set to values that tailor the printer to the application Once set these variables only need to be changed when the application for the printer changes As such thereis no need to make these installation parameters available at the printer interface They are set through a configuration programme called CLA RiTY Configuration Manager Rev AA Configuring the Printer 3 19 ICE Pegasus Service M anual 18 CLARITY Config Ele Help gi 22 Archives H E Coders SEN ev Printer Not connected Name Hew Pmter Upload Comfort fi DI Download Badate hiso 2 Figure3 18 CLARITY Configuration M anager The CLARITY Configuration Manager Figure 3 18 is a PC software program that provides the following basic features Setting all the printer variables Saving retrieving a set of variable values to a PC file for later repeated use Downloading a set of variables to the printer s CLARITY controller for non volatile permanent memory storage in the printer Uploading a set of variables from the printer for review comparison modification Updating the system software e Saving retrieving language files e Saving retrieving job font and graphics files e Configuring master slave functionality e Snapshot of CLARITY screens Asaresult the CLARITY Controller only retains the availability of a small numbe
70. ols Page RevAA ICE Pegasus Service M anual Working with Printhead Diagnostics Touch Printhead button on the Diagnostics page to access the printhead diagnostics page Figure 4 9 Diagnostics Printhead ee T Tol Figure 4 9 Printhead D iagnostics P age The printhead diagnostics page allovvs you to access the follovving parameters Inputs e Outputs Optics General Encoder Profiles Timings States Usethe Up and Down arrow keys to navigate through the options Rev AA U sing the Tools Page 4 9 ICE Pegasus Service M anual Touch Inputs on the Printhead diagnostics page to access the input parameters Figure 4 10 A P rinthead inputs q yllPrinter Present kli as Print Figure 4 10 P rinthead Inputs Diagnostics Page The input diagnostics page allows you access the following parameters e Encoder Touch the encoder button to access the encoder diagnostics page The encoder diagnostic page allows you to access the following encoder parameters Figure 4 11 npuls Encoder 06 2 Encoder Speed 5 Dmm s i A Lr Encoder Scaling sei 10096 4348 lt P V Figure 4 11 Encoder D iagnostics P age 4 10 Using the Tools Page RevAA Re AA ICE Pegasus Service M anual Encoder Speed Shows the actual real time speed of the film being measured by the encoder
71. or should be connected to a clean dry factory air supply using a 6 mm pipe The 4 mm diameter pipe should be used to connect the air regulator to the printer The air regulator should be mounted close to the printer The regulator should be accessible for adjusting and checking the correct pressure of 3 bar Encoders An encoder is used to match the printing speed to the speed of the target material as it passes the printhead Usethe Encoder Kit part number 403358 for these applications The encoder must ideally be mounted to run on the packaging film close to the printer in order to accurately measure the film speed Any discrepancy between measured and actual film speed can result in poor print quality or ribbon breakage Note U se the encoder only in the continuous mode Mounting Considerations 3 7 ICE Pegasus Service M anual Installing the Ribbon in the Cassette AN Caution EQUIPMENT DAMAGE Theuse of incompatible ribbon can seriously damage your printer and such a damage is not covered by your printer warranty U se only the ribbon that is approved by your dealer To install the ribbon proceed as follows 1 Removethe cassette Figure 3 6 Figure 3 6 Cassette R emoval 2 Putthe cassette down on a flat surface with the ribbon spools Item 1 Figure 3 7 on page 3 9 facing upwards and the ribbon rollers Item 2 towards you 3 8 Installing the Ribbon in the Cassette RevAA Re AA ICE Pegasus Service
72. page 5 18 Maintaining the Printer Re AA ICE Pegasus Service M anual 4 Touch the Printhead button to open the Printhead Setup Page 5 Select the Printhead Resistance parameter and enter the resistance value that was displayed on the printhead label Figure 5 24 OFFLINE 13 Printhead Resistance apnd e O fips Sevice1 gp 1476 Default 1300 A Figure 5 24 Printhead Resistance Setting 6 Usethe arrows or the keypad to set the settings and touch OK to save the settings 7 A confirmation message is displayed to ensure that this parameter is not changed inadvertently Choose Yes to proceed to set the new value Maintaining the Cassette Replacing the Cassette Rollers To replace the cassette rollers proceed as follovvs 1 Remove the cassette from the printer 2 Removetheribbon from the cassette Rev AA M aintaining the Printer 5 19 ICE Pegasus Service M anual 3 Loosen and remove the ribbon guide with a 12 mm spanner from the cassette as shown in Figure 5 25 Figure 5 25 Roller Guide Removal 4 Remove the roller from the ribbon guide as shown in Figure 5 26 Roller Figure 5 26 Roller Removal Place the nevv roller on the ribbon guide Install the ribbon guide on the cassette Replace the ribbon in the cassette D N o Oo Replace the cassette in the printer 5 20 Maintaining the Printer RevAA Re AA ICE Pegasus Service M anual Adjusting the Casse
73. ppear elsewhere in the manual These are general cautions which must be read completely understood and applied by all the personne involved with the operation and or the maintenance of the machine RevAA Safety Conventions U sed in the M anual 1 3 ICE Pegasus Service M anual A Caution EQUIPM ENT MAINTENANCE Before and after performing any maintenance or repair on the product check that the two safety labels are clearly visible One is on the power supply cover and the other by the potential nip point next to the pulley in the printer body N Caution EQUIPMENT DAMAGE Theuse of incompatible ribbon can seriously damage your printer and such damage is not covered by your printer warranty Use only ribbon approved by your dealer Safety Guidelines This section contains important safety guidelines pertaining to the operation and handling of the printer and associated equipment AN Warning SAFETY GUIDELINES Always observe the following safety guidelines when operating and handling the printer and associated equipment Comply with Electrical Codes All the electrical wiring and connections must comply 2 with applicable local codes Consult the appropriate regulatory agency for further information 1 4 Safety Guidelines Rev AA ICE Pegasus Service M anual Do Not Remove Warning Labels onotk under any circumstances remove or obstruct any warning or instruction labels on the printer Placement
74. printhead Ribbon cable has loosened place Push the ribbon back into Fauliy printhead ribbon cable cable Replace the printhead ribbon Printhead Over Printhead overheats Allovv the printhead to cool Temperature down Low Ribbon Ribbon has to be Replace the ribbon replaced Loss of communication Check the cable Printhead Absent between the CLARITY connections Try cycling controller and the printer between power on and off Ribbon Error Ribbon reel eccentricity is excessive Replace the ribbon Ribbon tags on the take up core fooling the optical calibration system the take up reel neatly Remove the tags and wind Replace the take up reel else replace the supply reel Table 7 1 Error M essages and Remedies Continued Rev AA 7 3 ICE Pegasus Service M anual 7 4 Error Message Motor Volts Error Possible Causes Power supply voltage varies too much Remedies Check the power supply output Faulty printer PCB Replace the main printer PCB Faulty Motor Check the motor and replace if necessary Printhead Volts Error Power supply voltage varies too much Check the power supply output Faulty printer PCB Replace the main printer PCB Printer Hand Not Set Flash memory is lost Use the CLARiTY configuration CD Motor Calibration Required Flash memory is lost Use the CLARiTY configuration CD
75. r No Encoder signal Go to Tools Diagnostics Printhead Inputs and check for free encoder wheel rotation Forward direction and incoming signal Continuous Mode Only ncorrect Print Position parameter Go to Tools Setup Printhead and check the print position to ensure optimum printhead position directly over the roller centerline Parameter should be about 2100 for righi hand units 2500 for left hand units Intermittent Mode Only Substrate is moving vvhile attempting to print Print signal timing is incorrect f necessary delay the print until the film stops and settles Dvvell Time by entering a Print Delay value Go to Tools Setup Printhead Intermittent Mode Only Incorrect Print Speed Go to Tools Setup Printhead Check and correct the print speed Printhead not contacting the print platen or roller Check and correct any obstructions No information is printed Incorrect Vertical Registration Set Vertical Registration to 0 Faulty Printhead Replace the printhead Production line speed fell below 40mm sec to Tools Diagnostics Confirm minimum speed Go Printhead Timings and increase the line speed Table 7 1 Error M essages and Remedies Continued Rev AA 7 1 ICE Pegasus Service M anual Error Message Printer will not go on line Possible Causes Invalid or no image selected Remedies Select a valid i
76. r Ribbons Table 8 7 lists the ribbons of the printer Re AA Videojet 6210 Service M anual Serial Number Part Number Description 1 702305 Standard Black 20mm x 600m 702304 Standard Black 35mm x 600m Standard White 20mm x 450m Standard White 35mm x 450m Premium Black 20mm x 550m Premium Black 35mm x 550m O ol wy N Premium White 20mm x 550m 8 Premium White 35mm x 550m Table 8 7 Printer Ribbons Printer Ribbons 8 9 Drawings Printer Dimensions Figure 9 1 shows the dimensions of the Videojet 6210 RH printer 14 50 mm 0 57 inches 64 50 mm 2 PLCS 2 54 inches M6 Tapped Holes Thread Depth 6 00 20 73 mm 2 PLCS 3 Places 0 82 inches 70 73 mm 2 78 inches 185 30mm 159 60 mm 7 3 inches 6 23 inches gt 167 15 mm 157 80 mm 6 58 inches 6 21 inches 6 4 inches Printhead Retracted 158 00 mm 6 22 inches 162 50 mm 1 26 inches 26 20 mm Printable Area 25 70 mm 32 50 mm 1 28 inches 1 03 inches 1 01 inches Printhead Stroke Figure 9 1 V ideolet 6210 30 mm RH Printer Dimensions Rev AA Printer Dimensions 9 1 Videojet 6210 Service M anual Figure 9 2 shows the dimensions of the Videojet 6210 LH printer 0 57 inches E o tO 00 o D I o tO 0
77. r of operating variables for the user to change A part from making the CLA R TY control system more simple and user friendly it also provides an increased level of printer system integrity because the configuration variables cannot be accessed from the printer itself but only from a connected PC If the printer is installed to run in a standalone mode i e the printer is not networked the PC is only linked briefly via the RS232 serial or ethernet port for the period of upload download of the variables a few seconds The PC would then be removed In a netvvorked environment system administrators could have direct 3 20 Configuring the Printer Rev AA ICE Pegasus Service M anual access to the printer while line operators are limited to accessing only the operating variables that are relevant to them Installing the CLARiTY Configuration Manager To install the CLARiTY Configuration M anager on a PC insert the CLARITY Configuration Manager CD ROM Theinstallation routine commences automatically Follow the on screen instructions to install the software If your PC has the auto run facility disabled the installation routine will not start automatically To enable the installation procedure proceed as follows 1 Click the Start button 2 Click the Run button to open a dialog box 3 Type DA setup exe in the dialog box and press enter return key Note is the drive letter of thePC s CD ROM drive If it is differen
78. re reading the Service Manual This manual is a supplement to and not a replacement for formal training N VVarning PERSONAL INJURY Customers who intend to service and maintain the printer themselves must use only qualified personnel to perform these procedures Qualified personnel have successfully completed the training courses have suffident experience vvith this printer and are aware of the potential hazards to which they may be exposed 2 2 About this M anual RevAA ICE Pegasus Service M anual Theory of Printing Re AA The information on how the thermal transfer printer works is as follows Figure 2 1 The printhead contains miniature heating elements under a glass coating 300 dpi 12 dots min A carrier ribbon with ink bonded to one side is used as the printing media The printhead presses against the thermal transfer ribbon with theink side of ribbon in contact with the substrate creating an image Print elements heat small areas of the ribbon and this transfers theink to the target substrate The printhead and the substrate move relative to each other The print elements are programmable and controlled to create an image 1 Ribbon Transferred Carbon 2 Substrate 3 Platten Rubber 4 Ink 5 Base Film 6 Thermal Printhead Figure 2 1 Printing Process Intermittent Motion Printing Intermittent motion printing Figure 2 2 on page 2 4 is the concept used for printing on statio
79. recommends that you complete a Customer Training Course on the printer Note T he manuals are intended to be supplements to and not replacements for ICE Customer Training For more information on ICE Customer Training Courses call 01159 640144 Re AA Table of Contents Compliance Information For C stomersin U S A u as rdar daa dram Cas asya aspas aa i For Customers in Canada i Pour la Client le du Canada il For Customers in the European Union il Support and Training Contact Information sad ve xx eee oe ax ili Service Progra NEE EA ET EE DE Ae ili Customer ESA s aaa a a aaa ay dad wanqa Aa Oe lz Qa was 4 iv Chapter 1 Safety Introductions cane toss edu waked as s b retest 1 1 Safety Conventions Used in the Manual 1 2 General Warning Notices 1 2 General Caution Notices 1 3 Safety Guidelines 1 4 Comply with Electrical Codes 1 4 Do Not Remove Warning Labels 1 5 Placement of the Printer 1 5 Using Printer A ccessories 1 5 Chapter 2 Introduction Equipment Description EE 2 1 Aboutthis Manual ya NEE Ye umaq ee
80. ription Qty Main Assembly wA 1 2 3 4 5 6 Main Assembly B 7 8 Subassembly 1 q D 9 10 Main Assembly j gt C 11 12 13 14 Table 8 2 R epresentation of the different Subassemblies and parts in the T able Rev AA How to Read thelPL 8 3 Controller Assembly A 4 Figure 8 2 Controller A ssembly Table 8 3 lists the parts of the controller assembly Item Number P N Description Qty A Controller Assembly Refer to Figure 8 2 1 400885 Thermal Coder Fuse Kit Set of 10 2 403348 Power Supply Unit 1 3 403345 Processor PCB 1 4 403344 LCD Touchscreen 1 5 403183 Controller Mounting Yoke Kit 1 6 402793 Thermal Printer Mains Lead 1 Assembly Table 8 3 Controller Assembly Parts List 8 4 Controller Assembly RevAA Videojet 6210 Service M anual Printer Assembly Printer Assembly with PCB Printer Assembly without PCB Figure 8 3 Printer A ssembly Printhead Assembiy Figure 8 4 Printhead A ssembly Rev AA Printer Assembly 8 5 Videojet 6210 Service M anual 8 6 Table 8 4 lists the parts of the printer assembly Item Number P N Description Qty B Printer Assembly Refer to Figure 8 3 on page 8 5 7 403332 Videojet 6210 Thermal Printer PCB 1 8 403339 Thermal Printer 128mb Flash Card 1 D Printhead Assembly Refer to Figure 8 4 on page 8 5 9 403325 Thermal Printhea
81. rning PERSONAL INJURY Before attempting any maintenance or repair on any part of the product disconnect the printer from the main power supply and isolate the printer from any external energy sources including other connected equipment N VVarning PERSONAL INJURY Before connecting the compressed air supply to printer ensure that the air supply has been isolated Turn the regulator adjustment knob counter clockwise AN Warning PERSONAL INJURY The printer uses an operator control console Ensure that this panel is mounted at an appropriate working height and orientation for comfortable operation 1 2 Safety Conventions U sed in the M anual RevAA ICE Pegasus Service M anual A Warning PERSONAL INJURY Keep hands and dothing clear of the printer vvhile it is on N VVarning PERSONAL INJURY To ensurethat the connecting cables and pipes do not become a trip hazard or become entangled in any machinery all connecting cables and pipes must be secured safely during installation N VVarning ELECTRICAL HAZARD Voltages used to connect the printer to other equipment must be limited to no greater than 50V DC or peak AC A Warning ELECTRICAL HAZARD Always wear a properly ground wrist ground strap when handling printed circuit boards Failure to do so can result in damage to the board components due to static electricity General Caution Notices The following caution statements supplement the specific cautions that a
82. rofiles CLARITY Configuration Settings 2 Click on Trigger button the profile is captured in afilewhich isin a special encoder profile format enc Using the Tools Page 4 17 ICE Pegasus Service M anual 3 To access this file select Log Files folder from new coder as shown in Figure 4 18 5 Sg ar 9 LEES Ier Care 9 deet 17 p iwa sab Fae ee emoy renger e Figure 4 18 Profiles Log Files This file can be used for diagnostic purposes by the Development Team for advanced diagnostics purposes 4 18 UsingtheTools Page RevAA ICE Pegasus Service M anual Working with Printhead Timings Touch the Timings button on the Printhead Diagnostics page access to the timings page Figure 4 19 This diagnostic page provides information about the last print or print job selection that was made It is useful in high throughput applications to understand what the printer is trying to do especially in continuous motion applications _ Printhead Timings Minimum Speed mmis Minimum Print Speed mm 5 Maximum Print Speed mms Figure 4 19 Printhead Timings iagnostics P age The following parameters can be accessed in the printhead timings diagnostics page e Minimum speed mm s Indicates the minimum film speed during the previous printing cycle Maximum speed mm s Indicates th
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84. supply disconnected Check and set air pressure to 3 bar Solenoid wiring or air lines defective Check and correct Defective solenoid Check and correct Printhead is jammed Turn the power off and move the head out of its parked position See if the head is free to move in and out on its pivot assembly If not clear the obstruction Table 7 1 Error M essages and Remedies Continued Rev AA 7 5 ICE Pegasus Service M anual 7 6 Error Message Printhead does not drive Possible Causes Condition of the belt drive and pulleys Remedies Check and correct Printhead stepper motor not plugged in securely Check and correct Linear slide carriage jammed Turn the power off Try to move the linear slide If jammed clear the obstruction Incorrect tension on the timing belt Re tension the timing belt Faulty Motor Check the motor and replace it if necessary Table 7 1 Error M essages and Remedies Continued RevAA Error Message No information is printed Possible Causes Insufficient or no air pressure ICE Pegasus Service M anual Remedies Check and set the air pressure to 3 bar No Print Signal Go to Tools Diagnostics Printhead Inputs and check the presence of incoming print signal Low Darkness level Goto Tools Setup Printhead and increase the Darkness setting Continuous Mode Only Incorrect o
85. t the image that is printed next This usually occurs because products are too close to each other Touch the Clear button to restart the printer E3000 Printer Hand Not Set Set the Printer hand in CLAR Fault iTY Config Table 6 1 List of Faults and Warnings RevAA 6 1 ICE Pegasus Service M anual 6 2 Error Report on CLARITY Operator Interface Status No E3001 Perform Motor Calibration Motors have not been Fault calibrated Calibrate via CLARITY Config E3002 Printhead Resistance Not Set Set the printhead Fault resistance on CLARITY Tools gt Setup gt Print head gt Printhead resistance E3003 Cassette Open Re insert the ribbon cassette into Fault the printer E3004 Ribbon Break Print ribbon has broken or run out Fault E3005 End of Reel Print ribbon has run out Fault E3006 Calibration Failed Ensure that the correct ribbon is Fault being used and the ribbon core is not slipping on man drel bodies E3007 Printhead Crash Printhead carriage is jammed Fault Remove the cassette and check for any obstruction E3008 Optical Calibration Dirty Remove the cassette and Fault clean the optical sensors on the printhead carriage and the printer body E3009 Bad Optical Calibration Ribbon cores are of incor Fault rect size E3010 Thermistor Fault Printer has detected fault
86. t for your PC replace the letter D with the appropriate drive letter The softvvare is installed in the PC and is ready for use Connecting the CLARITY Configuration Manager to the Printer Connecting CLAR TY Configuration Manager to the Printer using an RS 232 connection To connect the CLARITY Configuration M anager to the printer proceed as follovvs 1 Connect the PC serial port to the CLARITY controller using the null modem cable Ensure that all other programs such as Active sync and other PDA applications that use the serial port are disabled Rev AA Configuring the Printer 3 21 ICE Pegasus Service M anual 2 Run the CLAR TY Configuration Manager on the PC Figure 3 19 Status Panel Figure 3 19 CLARITY Configuration M anager 3 Ensurethat the printer status panel at the bottom left of the window reports the message Connection Active and the nevv printer icon turns green If the status displays Not connected as shown in Figure 3 19 disable or quit the other applications running on the PC that are using the serial port Check that the baud rate settings on the Configuration Manager matches with the printer s baud rate 4 Click the Upload button The progress of the operation is displayed in the status pane This uploads the printer parameters set to the PC The list of folders containing the configuration parameters appears in the parameter listing in the right hand frame of the Configuration Ma
87. tatus of a physical output on the printer Touching the Toggle button allows you to force the state of an output high or low which is useful for diagnostic purposes e Printhead Position M oves the printhead from its parked to its printing position e Printhead In Out Drives the air solenoid that moves the printhead in and out towards the print platen or roller e External Relay and PNP Outputs The printer has 2 relay outputs and 2 PNP 24V outputs U sing the Tools Page Rev AA ICE Pegasus Service M anual Touch the Optics button on the Printhead Diagnostics page to access the ribbon calibration system page G orrlune 9 5 Figure 4 13 Printhead Ribbon Calibration P age Theribbon calibration systems works on a shadowgraph principle A pair or LED s are mounted inside the printer and a receiver is mounted onto the back of the printhead carriage When the ribbon cassette is placed in the printer the calibration process moves the printhead up and down its carriage such that the receiver can detect the edges of the shadow cast by the rolls of ribbon Using geometry the printer can then accurately calculate the diameter of both the supply and waste rolls Emitter 1 2 allows you to togglethe LED s Receiver gives a real time reading of the output High numbers of greater than 250 are read when one of the LED s are shining directly at the receiver Low
88. tte Latch The latch components on the printer are set at the factory and normally do not require adjustment If it is necessary to adjust the latch proceed as follows 1 Removethe cassette from the printer 2 Removeany ribbon from the cassette 3 Loosen the lock nut on the cassette latch 10 mm as shown in Figure 5 27 Figure 5 27 Latch Screw Locking N ut Loosening Maintaining the Printer 5 21 ICE Pegasus Service M anual 4 Adjust thelatch screw 4mm hex socket and hold it in place while tightening the lock nut as shown in Figure 5 28 Figure 5 28 Latch Screw Adjustment Note A correctly adjusted latch should not allow the movement of the cassette when in theprinter but should allow the cassette to be pulled from the printer under any circumstances when the release button is pressed 5 22 Maintaining the Printer RevAA ICE Pegasus Service M anual Updating the CLAR TY Operating Software Re AA The operating software of the printer can be upgraded by a process called a CLAR TY Update The current version of the software is displayed at the page TOOLS gt DIAGNOSTICS gt CONTROL gt VERSIONS where the software part number can be read The part number has the format Part Version Service Pack Eg 403034 R01 SP01 would be part number 403034 Revision 01 Service pack 1 In the event that the software has become corrupt or was incorrectly installed the software part number states Incompatible Software
89. updates that are suitable for this printer Would you like to install one of them Figure 5 31 Confirmation Page RevAA Updating the CLARITY Operating Software 5 25 ICE Pegasus Service M anual 4 Ifthe parameter is set to No navigateto TOOLS gt SETUP gt CONTROL and touch the CLAR TY Update button 5 Select Yes to proceed to the next stage of the update or No to return to the Home screen If Yes is selected the CLAR TY update screen is displayed Control CLARITY Update 403034 r01 B sri Available Updates 403034 r01 Beta 2 SES Figure5 32 CLAR TY U pdate Page Only updates applicable to the current model of printer are displayed 5 26 Updating theCLAR TY Operating Software RevAA ICE Pegasus Service M anual 6 Touch OK a confirmation page appears Figure 5 33 Control CLARITY Update carity geg Are you sure you want to install the CLARITY Update 403034 r01 Beta 2 VVhile he update is being installed the printer will not be able to print Figure 5 33 CLAR TY Confirmation Page 7 Touch Yes and the printer starts to update the softvvare Note t is very important to ensure that the power to the printer is not removed during the update process or theflash card in the printer may get corrupted When the update is finished CLARITY automatically re boots and the CLAR TY Home Screen isfinally displayed 8 Check the Softvvare Part number i
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