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TABLE OF CONTENTS 1
2
General Information
1-1
1.1
1-2
Setup and Timing Issues
2-1
2.1 2.2
2-1 2-2 2-2 2-2 2-2 2-3 2-3 2-4 2-4 2-4 2-4 2-5 2-5 2-5 2-6 2-6 2-6
2.3 2.4 2.5
2.6
2.7 2.8 2.9 3
Introduction Setup Issues 2.2.1 Print Anvil 2.2.2 Printhead Gap 2.2.3 Ribbons Important Printer Settings Print Darkness 2.4.1 Print Speed Print Signal Issues 2.5.1 Debounce Time 2.5.2 Print Delay Moving the Printed Image 2.6.1 Registration 2.6.2 Offset Timing issues Distance between prints on the ribbon Distance between prints on the substrate
Maintenance 3.1 3.2
3.3 3.4 3.5
3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14
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Uptime™ Total Services
Introduction Cleaning and Care 3.2.1 Quick/Regular Checks 3.2.2 Monthly Checks Care of the Printhead Cleaning the Printhead Replacing the Printhead 3.5.1 Removing the damaged printhead 3.5.2 Setting the correct Printhead Resistance Replacing the Peel Roller Replacing the Ribbon Guide Rollers Replacing the Ribbon Movement Roller 3.8.1 Replacing the Ribbon Movement Sensor Replacing the Ribbon Tension Roller Replacing the Ribbon Tension Sensor Sensor Calibration 3.11.1 Calibration procedure Replacing the Solenoid Replacing the Drive Belt - Intermittent Replacing the Printer PCBs
3-1 3-1 3-2 3-2 3-2 3-3 3-3 3-4 3-4 3-5 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-15 3-17 3-18 3-19
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TABLE OF CONTENTS 4
Technical Information 4.1 4.2 4.3
4.4
4.5 4.6 4.7
4.8
4.9 4.10
8018
Introduction The 8018 Thermal Transfer Printer Printer Components 4.3.1 Intermittent Drive System - Model 8018i Printer 4.3.2 Continuous Drive System - Model 8018c Printer 4.3.3 Ribbon Drive System The Printhead Module 4.4.1 The Print Mechanism Components 4.4.2 Printhead Mechanism Operation Printhead Assembly 4.5.1 Printhead Voltage Control Printer Orientation Printer Calibration 4.7.1 Ribbon Movement Calibration 4.7.2 Ribbon Movement Roller 4.7.3 Ribbon Tension Roller Printer Electrical Components 4.8.1 Stepper Motors 4.8.2 Encoder Power Configuration 4.9.1 Mains Power Switch Printer Connection Points 4.10.1 Power Connections 4.10.2 Local User Interface Connection 4.10.3 Substrate Encoder Connection 4.10.4 External I/O Connection 4.10.5 Printer PCB 4.10.6 Printer PCB Components 4.10.7 Printer PCB Fuse 4.10.8 Printer PCB Connectors
4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-11 4-11 4-12 4-14 4-15 4-16 4-16 4-17 4-18 4-18 4-19 4-19 4-19 4-20 4-20 4-21 4-21 4-22 4-22 4-22 4-23
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TABLE OF CONTENTS 5
Troubleshooting 5.1 5.2
5.3
5.4 5.5 5.6
5.7 5.8
5.9
5.10
5.11
6
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Introduction Fault and Warning Messages 5.2.1 Fault Messages 5.2.2 Warning Messages Common Issues 5.3.1 No Power to the Printer 5.3.2 Printhead Cables 5.3.3 Encoder No Information Is Printed The Printhead Does Not Move Out Drive System Issues 5.6.1 Ribbon is not driving 5.6.2 Ribbon Drive Problems 5.6.3 Ribbon Creasing 5.6.4 Ribbon Breaking or Scuffing Prints 5.6.5 Ribbon Coning (Continuous Printers) 5.6.6 Peel Roller Problems 5.6.7 Head not returning to home position Printhead Module Carriage Drive Problems Display Issues 5.8.1 Back light only lit 5.8.2 LCD only, no Back light 5.8.3 Display is totally blank Print Quality Problems 5.9.1 Faded print 5.9.2 Faded on one side 5.9.3 Blurred edges 5.9.4 Missing lines perpendicular to printhead 5.9.5 Print rubs off 5.9.6 Elongated or compressed print 5.9.7 Double printing 5.9.8 Prints occur on every other product (or less) Image Selection Problems 5.10.1 Selecting an Image 5.10.2 Image corruption problems Checking Database Information 5.11.1 Local
5-1 5-1 5-2 5-2 5-7 5-11 5-11 5-11 5-11 5-11 5-11 5-12 5-12 5-12 5-12 5-12 5-13 5-13 5-13 5-14 5-14 5-14 5-14 5-14 5-15 5-15 5-16 5-16 5-16 5-16 5-17 5-17 5-17 5-18 5-18 5-18 5-18 5-18
Spares and Replacement Parts
6-1
6.1 6.2
6-1 6-1
Consumables Replacement Parts
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TABLE OF CONTENTS
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SECTION 1 GENERAL INFORMATION
8018 Thermal Transfer Printer Maintenance Manual
SECTION 1 - GENERAL INFORMATION 1
General Information This manual is designed to assist with keeping your 8018 Thermal Transfer Printer in good working order. Topics covered in the following sections include: • • • • •
General maintenance and cleaning. Technical information about the 8018. Information about using barcode laser scanners. Fault finding and troubleshooting problems. Replacement parts and recommended spares.
Additional information regarding mechanical drawings or electrical schematics can be found on the CD in the relevant folders.
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SECTION 1 - GENERAL INFORMATION 1.1
Uptime™ Total Services • Application Specialists • Installation • myMARKEM • Repair Centre • Training As part of the Markem.Imaje continuous commitment to helping customers succeed, Markem.Imaje has introduced the Uptime Total Solutions Program, a comprehensive array of services to maximize uptime, productivity and customer satisfaction. These value-added services focus in the following critical areas: Maximizing the reliability of your coding systems. The Markem.Imaje Reliability Program supports our customers with resources committed to the "science of reliability." Our Reliability Engineering team works integrally with the product development process to deliver best-in-class performance for all Markem.Imaje products. For real life simulation, the program also incorporates laboratory application testing as well as ongoing customer field reliability monitoring and testing. Markem.Imaje customers can register at myMarkem.com and view real-time reliability data, including MTB's on our most popular machine products. Ensuring a dependable supply chain. Markem.Imaje utilizes a fully Integrated Logistic Management System supported by strategic partnerships with other world-class companies like UPS Worldwide Logistics. Our regional repair centers offer a cost-effective solution for modular exchange or repairs of Markem.Imaje machines to keep your line running. Combining these capabilities with a strong local presence around the globe and consistent product availability and delivery performance all help keep you up and running. Strengthening your relationship with us. Markem.Imaje representatives are the industry-leading experts in marking and coding solutions. We work with the vast majority of packaging equipment manufacturers (OEMs) to provide a seamless integration and deliver you the right solution. Comprehensive support programs include print samples on your actual packaging materials, on-line trials or extended long-term trials to reinforce the high level of quality and reliability that Markem.Imaje can bring to your application. The program includes, but is not limited to, the following services: sample printing, training, technical support, logistics support, financing, on-line support, contracts, and project management. At the core of Uptime is our corporate reliability program, unrivaled in our industry and the reason products such as the 8018 Thermal Transfer Printer, SmartDate® and 5000 Series case coders are the undisputed industry leaders.
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SECTION 2 SETUP AND TIMING ISSUES
8018 Thermal Transfer Printer Operation Manual
SECTION 2 - SETUP AND TIMING ISSUES 2
Setup and Timing Issues 2.1
Introduction The following section provides general advice for ensuring that your 8018 Thermal Transfer Printer is working at its most efficient. Topics covered in this section include: • • • • • • • •
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Printhead Gap Print Platen Ribbons Printer Settings Print Signals Print Quality Issues Moving the printed image Timing Issues
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SECTION 2 - SETUP AND TIMING ISSUES 2.2
Setup Issues 2.2.1
Print Anvil The print roller for Model 8018c and print anvil for Model 8018i are wear parts, and should be checked regularly for damage. If the print roller has become damaged this will cause print quality problems. For example a flat spot on the Model 8018c roller rubber will appear as a repeated blank area on the Test pattern. A worn area on the Model 8018i print platen rubber may cause the print to be faded on one side.
2.2.2
Printhead Gap This is the distance between the printhead in its home position and the contact point on the substrate. Do not use metal objects to test the gap distance, use only wood, plastic or other non conductive non abrasive materials. Adjustment to the print gap can be made by using the adjustment screw provided with the mounting bracket. The gap between the printhead and the print platen or print roller is critical to the performance of the printer. The following settings are recommended: Model 8018i - 1.00 mm - 3.00 mm Model 8018c - 1.00 mm - 3.00 mm Note:
2.2.3
The printhead pressure setting is associated with the amount of printhead gap. The smaller the printhead gap, the more printhead pressure required.
Ribbons The 8018 uses inside or outside wound ribbon; If this is webbed incorrectly (wound the wrong way around) no printing can occur. Ensure that the ribbon is webbed correctly around the print roller. (See webbing diagram on the rear of the User Interface) The correct substrate/paper to ribbon match is also important for print quality. Different conditions will require different types of ribbon. Some examples follow: Wax/Resin, Wax/High Resin and Resin For full details on ribbon please contact you local Markem.Imaje representative or visit the Markem.Imaje Web site.
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SECTION 2 - SETUP AND TIMING ISSUES 2.3
Important Printer Settings Various Printer Settings will affect the performance of the 8018 printers. The initial setup of the machine would normally be performed by a qualified Markem.Imaje trained technician, but if not the following information should prove helpful.
2.4
Print Darkness The print darkness is adjusted by varying the amount of time heat is applied for each row of dots printed and altering the amount of cooling time allowed between rows. Generally, increasing the Darkness darkens the printing but can increase smudging. Conversely, decreasing the Darkness reduces smudging. Some ribbon/substrate combinations may require a Darkness other than the standard 100. The 8018 automatically limits the amount of energy transferred to the Printhead. This prevents the head being damaged by incorrect use of the darkness value. If the print quality is not good refer to the Troubleshooting Section for diagnosis. Print darkness levels should be set in relation to the print speed. • • •
• • •
For example, if the print speed is high, the print darkness may have to be raised to achieve good print quality. If the print speed is lowered the print darkness should be reduced accordingly. As a general rule darkness levels should be kept as low as the line speed and print quality requirements will allow This will ensure that the print-head life will be used to its optimum. Darkness levels that are too high may also contribute to poor print quality or ribbon breakage (especially when printing bar-codes or horizontal lines.) The maximum darkness level for any print speed is 150%. The 8018 automatically compensates for this if the print speed is raised or lowered. If a printhead dot has become damaged and no replacement printhead is readily available, raising the darkness level may be enough to spread the heat to effectively close the gap. This would allow the printer to be used until a new printhead has arrived.
Note:
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The darkness level should be reduced when the new printhead is fitted.
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SECTION 2 - SETUP AND TIMING ISSUES 2.4.1
Print Speed The speed that Printhead moves along the linear slide (Model 8018i). The speed the ribbon moves on the print part of the cycle. (Model 8018c) With Intermittent printers the speed is determined by the dwell time when the substrate has stopped moving. • • • •
2.5
If the print speed is set too low the substrate may start to move before printing has finished. If the print speed is too fast the print quality may not be as good as it could be. With Continuous printers the speed is automatic as an encoder is used to match the speed of the substrate. The ribbon speed has to match the substrate speed before printing can occur. If the substrate speed is too high or too low this will affect the print quality.
Print Signal Issues 2.5.1
Debounce Time This is the time that the PRINT GO signal must be present before it is actioned. This avoids double triggering of the print signal if the signal is particularly noisy (e.g ringing on a relay contact) If the signal used is arriving as a double pulse, set the Debounce time just high enough to stop the printer double printing. The print signal is sampled every 5 milliseconds, so if the Debounce Time is set to 10 milliseconds, the Print Signal must be at least 15 milliseconds.
2.5.2
Print Delay With the Model 8018i Intermittent printers, this sets a delay between a valid PRINT GO signal and when the Printhead is moved out into position. If the PRINT GO signal is received before the substrate is stationary, this allows time for the substrate to settle before printing commences. Set the print delay setting as low as possible as it increases the overall cycle time of the printer. Default - 0 ms
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SECTION 2 - SETUP AND TIMING ISSUES 2.6
Moving the Printed Image The position of print within the printing area can be changed. Altering the Registration and Offset values moves the printed information in the head feeding direction and up and down the Printhead. On intermittent printers, when the Registration is altered the printhead will move to its new datum position immediately and will use this new datum until the Registration is altered again. 2.6.1
Registration It is possible to move the print image down the print area. This ability is useful if small movements are required. CAUTION:
If larger position changes are required this method may not be suitable.
For example, on a Model 8018i, if you have an image length of 30 mm and you move the image down the printhead by 15 mm, then that gives you a total length of 45 mm. The maximum print height is only 40 mm, so you will miss the last 5 mm of the image. When selecting the Image, if the amount of registration plus the image is too long, you will get a warning message. You can press “Hide” to clear this warning, but you should reduce the value or the image height before proceeding. 2.6.2
Offset This allows fine adjustment of the print position across the printhead. This ability is useful if small movements are required. CAUTION:
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If larger position changes are required this method may not be suitable.
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SECTION 2 - SETUP AND TIMING ISSUES 2.7
Timing issues Many timing issues (speeding up the line/host machine) can arise when setting up a new application, or when changing the way an existing application works. Timing issues can be common to the Model 8018i and Model 8018c. Since the machines work differently, it is likely that timing issues will vary with the machine type.
2.8
Distance between prints on the ribbon Two things can affect the distance between each print on the ribbon. • •
2.9
If the substrate accelerates or decelerates between the end of the registration and the start of print, the gap will be affected. When the printer adjusts the ribbon tension the gap will be affected.
Distance between prints on the substrate With Intermittent printers the distance between the prints is set by the stopping position of the substrate or labels. With Continuous printers several things can affect the “minimum” distance between the prints on the substrate: • •
The amount of registration set after the Print Go signal. The Debounce distance.
The Model 8018c printers always allows the substrate to move a set distance after receiving a Print go signal. This distance is the same no matter the speed of the substrate. After this distance the printhead has been lowered ready to print. This ensures the printed image does not drift from the required position on the substrate.
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SECTION 3 MAINTENANCE
8018 Thermal Transfer Printer Operation Manual
SECTION 3 - MAINTENANCE 3
Maintenance 3.1
Introduction The 8018 series of Thermal Transfer Printers are extremely successful, however as with any machine, if it is not set up and maintained correctly, problems can occur. This section is designed to provide information about how to keep your 8018 Thermal Transfer Printer in good working order. Topics covered in this section include: • • • • • • • • • • • • • •
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General cleaning and care. Maintenance schemes. Care of the printhead. Replacing the printhead. Replacing the peel roller. Replacing the ribbon guide rollers. Replacing the ribbon movement roller. Replacing the ribbon movement sensor. Replacing the ribbon tension roller. Calibrating the ribbon tension sensor. Replacing the ribbon tension sensor. Replacing the Solenoid Replacing the drive belt. Changing the printer hand.
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SECTION 3 - MAINTENANCE 3.2
Cleaning and Care To ensure that your 8018 Thermal Transfer Printer operates correctly, the entire unit should be cleaned on a regular basis. Particular attention should be given to the printer, especially if food products are able to fall into the unit. • •
• 3.2.1
Quick/Regular Checks • •
• •
•
• 3.2.2
Check and clean printhead (daily check). Check that the ribbon is tracking through the rollers correctly. Pull the ribbon through by hand, and visually check to see if the ribbon is creasing across the width of the ribbon. (See Troubleshooting 10.7.3) Check the Peel Roller for any ink build up and clean if necessary. Check that Darkness / Speed settings are site standard. This will ensure that the print remains a good quality, and it may also highlight any potential problems. For example, if the darkness is unusually high, the printhead may need cleaning. The darkness has probably been set high to compensate. Check condition of Platen rubber (Model 8018i). Clean or replace it if necessary. The platen rubber needs to be smooth, flat and free from debris. To change the platen rubber, first take the old platen rubber off. All the adhesive should be removed from the metal platen base. Replace with a Markem.Imaje platen rubber for best results. Check for wear or internal debris.
Monthly Checks • • • • • •
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Turn off the power to the printer. Clean inside the printer body. Since there are electronic components inside this casing, DO NOT use water to clean the unit. Isopropanol cleaning wipes can be used for this purpose. To clean debris from the inside of the printer body, Markem.Imaje recommend the use of a soft bristle brush.
Check condition of peel roller: Remove roller and inspect internally for wear. Replace if necessary. Check condition of the ribbon guide rollers: Check that bearings are smooth. Check condition of ribbon sensor roller. Inspect the roller coating for wear and damage. If worn or damaged, replace the roller. Ensure all rollers are square to the Printer. Print a test image to check printhead quality and alignment. See Section 6 Menus. Check condition of printhead carriage drive belt and associated components: pulleys, bearings, retainers and shafts.
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SECTION 3 - MAINTENANCE 3.3
Care of the Printhead Although purpose-built for its application, the printhead is still subject to wear and tear. Careful consideration at the time of installation and regular preventative maintenance can significantly help to maximise printhead life. The most frequent cause of printhead damage is abrasion - either from ingress of airborne particles or from an abrasive substrate surface. Consequently, printhead life varies considerably among substrate materials and among applications. The thermal ribbon protects the printhead against wear. With use of various ribbon widths and an abrasive substrate, it is possible that the unused, unprotected, section of the printhead is subjected to wear and damage. Usually, abrasive substrates have pre-printed inks. Particularly, some red inks may be more abrasive than other colours. Procedures for all thermal transfer printers follow: • •
3.4
Regularly clean the printhead. The frequency of cleaning is entirely application and environment specific. To minimise printhead wear, always use the minimum pressure that delivers an acceptable print quality.
Cleaning the Printhead The printhead should be cleaned at regular intervals. These depend on machine use, operating environment, and choice of thermal ribbon. 1.
Turn off the power to the controller and remove the ribbon.
2.
Allow the printhead to cool to normal room temperature before proceeding in order to prevent the possibility of thermal shock damage.
3.
Use a cotton swab or a soft cloth soaked in Isopropanol solvent to remove any residue from the printhead. Take care not to use excessive amounts of solvent.
The print line is located on the bevelled edge of the printhead.
Use great care not to damage the printhead during cleaning. UNDER NO CIRCUMSTANCES should abrasive materials, or tools such as screwdrivers, be used for cleaning the printhead. Replace the ribbon and check the print quality. If the overall quality is poor, or some of the dots are not printing, the printhead may need to be adjusted or changed.
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SECTION 3 - MAINTENANCE 3.5
Replacing the Printhead Turn off the power to the printer. Always ensure anti static precautions are used when handling new printheads. 3.5.1
Removing the damaged printhead
1. Remove the four retaining screws from the Printhead cable clamp.
3. Loosen the printhead ribbon securing connector by pushing the black section forward.
2. Lift the clamp off and place to one side.
4. Remove the printhead ribbon from the PCB.
6. Push the printhead backwards and 5. Undo the printhead quick release remove from the Module. screw. Note: When fitting a new printhead ribbon cable ensure that the black connector is fully extended before pushing in the ribbon. Secure fully after fitting.
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SECTION 3 - MAINTENANCE 3.5.2
Setting the correct Printhead Resistance Note the resistance value printed on the PCB side of the new Printhead. This value must be entered into the User Interface menu structure. The processor will then adjust the voltage level to suit the particular printhead resistance level. Each Printhead has an individual Resistance level, and the voltage level setting required for each is different. A label on the printhead displays the rating for that particular one. In this case, R = 1094
The Printhead resistance option can be accessed from the Print Settings menu. To access the Print Settings Menu: 1.
From the Menu screen select Print Settings. 4. Test Print 5. Print Settings 6. Darkness Back
2.
Select
The Print Settings Menu screen is displayed. 1. Registration 2. Offset 3. Pressure Back
3.
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Select
Use the bottom Quad button to scroll to the TPH Resistance menu or enter the item number at the numeric keypad.
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SECTION 3 - MAINTENANCE 4.
Press the right button to Select the menu. 3. Pressure 4. TPH Resistance 5. Print Speed Back
5.
Select
The TPH Resistance menu screen is displayed.
TPH Resistance Current:
1125
New:
1085
Cancel
3-6
Accept
6.
Enter the new value by using the numeric keypad or use the top and bottom Quad buttons to change the value.
7.
When finished press the right button to Accept the changes.
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SECTION 3 - MAINTENANCE 3.6
Replacing the Peel Roller The Peel Roller body is a wear part and should be checked for damage and changed if necessary.
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1. Remove the retaining screw from the end of peel roller.
2. Carefully remove the peel roller ensuring not to drop any components.
3. Fit a new peel roller assembly and secure.
4. After securing, rotate the roller to ensure it is moving freely.
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SECTION 3 - MAINTENANCE 3.7
Replacing the Ribbon Guide Rollers The ribbon guide rollers are vulnerable to damage through misuse and may have to be changed if they become bent or damaged. The procedure is as follows:
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1. Remove the retaining screw from the end of the guide roller.
2. Carefully remove the ribbon guide roller ensuring not to drop any components.
3. Fit a new guide roller assembly and secure.
4. After securing, rotate the roller to ensure it is moving freely.
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SECTION 3 - MAINTENANCE 3.8
Replacing the Ribbon Movement Roller If any parts of the movement roller has been damaged, the assembly will have to be replaced. The procedure is as follows: Switch off and disconnect the power to the machine.
1.Release the ribbon supply reel securing clasp by applying pressure with a screwdriver or Allen key.
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2. Pull the reel upwards to remove it.
3. Remove the securing screws from the roller housing.
4.Lift out the roller and housing from the printer body.
4.Fit a new assembly and secure.
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SECTION 3 - MAINTENANCE 3.8.1
Replacing the Ribbon Movement Sensor If the sensor has to be replaced, the procedure should be as follows: Switch off and disconnect the power to the machine. Remove the Ribbon Movement roller as previously described.
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1. Undo the six retaining screws and remove the cover from the printer body.
2. Disconnect the Sensor from the Printer PCB.
3. Undo the retaining screw and remove the sensor from the printer body.
4. When fitting a replacement sensor, ensure that the retaining screw is secured.
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SECTION 3 - MAINTENANCE 3.9
Replacing the Ribbon Tension Roller If the tension roller becomes damaged the whole assembly may require changing. The procedure is as follows: Switch off and disconnect the power to the machine.
1. Remove the retaining screw from the ribbon tension roller assembly.
2. Lift the assembly off the shaft. Ensure that the spring does not get lost.
3. Remove the retaining screw from the roller.
4. Fit a new assembly and secure.
When fitting a replacement assembly ensure that the spring is positioned towards the outside edge of the printer body. Due to the proximity of the magnets it may be necessary to use a small tool to retain the spring in position while fitting the new assembly.
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SECTION 3 - MAINTENANCE 3.10
Replacing the Ribbon Tension Sensor If the tension sensor has to be replaced, the procedure should be as follows: Switch off and disconnect the power to the machine.
1. Undo the six retaining screws and remove the cover from the printer body.
2. Undo the eight retaining screws and remove the printer PCB. Remove the printhead ribbon cable to avoid damage.
3. Remove the two sensor retaining screws from the printer body.
4. Remove the sensor from the printer
1. Disconnect the sensor connector from the printer PCB and remove.
2.When fitting a replacement sensor, ensure that the retaining screw is secured.
The Tension sensor is fragile, be careful not to damage it when replacing the assembly.
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SECTION 3 - MAINTENANCE 3.11
Sensor Calibration The tension sensor will require re-calibrating once it has been fitted. When you replace the Main PCB, Tension Sensor PBC, or Tension Sensor Assembly, you will need to calibrate the tension sensor. This is achieved by standing the printer on it’s side, and using the Local User Interface menu… 7 (Engineering), 3 (Manual Control), 3 (Tension Control) to take three readings from the sensor whilst applying weights… 1st reading with 0 Newton load 2nd reading with 1.5 Newton load 3rd reading with 2.5 Newton load A calibration value is then calculated and stored in the printer. The Calibration weights are shown below:
Figure 3–1: Calibration Weights Part No. 10028386
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SECTION 3 - MAINTENANCE
1.
2.
3.
4.
5.
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6.
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SECTION 3 - MAINTENANCE 3.11.1
Calibration procedure 1.
Place the 8018 Thermal Transfer Printer on its side and power up. (1)
2.
Remove the ribbon after the initial calibration process has finished. (2)
3.
From the Local User Interface select 7 (Engineering), 3 (Manual Control), 3 (Tension Setup) Tension Setup Remove System Tension ADC Value 13 Back
4.
Confirm
The LUI displays “Remove System Tension” check that there is no weight on the tension roller and then press Confirm. Tension Setup Install 1.5N Weight ADC Value 9 Back
Confirm
5.
The LUI displays “Install 1.5N weight”
6.
Locate the 1.5N weight on the Tension Roller (4 & 5)
7.
Press “Confirm”
8.
The LUI displays “Install 2.5N weight” Tension Setup Install 2.5N Weight ADC Value 61 Back
9.
Confirm
Locate the 1N weight on the 1.5N weight (6 & 7)
10. Press “Confirm”
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SECTION 3 - MAINTENANCE 11. The LUI displays “Distance per ADC” Tension Setup Target Tension 68 Dist per ADC 0.37 Back
Confirm
12. Press “Confirm” Note:
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The figures shown are examples and will not necessarily reflect the figures displayed for individual printers.
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SECTION 3 - MAINTENANCE 3.12
Replacing the Solenoid If the solenoid has to be replaced, the procedure should be as follows: Switch off and disconnect the power to the machine.
1. Undo the six retaining screws and remove the cover from the printer body.
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2. Undo the eight retaining screws and remove the printer PCB.
3. Remove the solenoid connector from the printer PCB.
4. Undo the two retaining screws and remove the solenoid retaining clamp.
5. Unscrew the solenoid from the printer body and remove.
6. Replace with a new solenoid and refit into the printer body. When replacing the solenoid ensure the wiring is not trapped.
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SECTION 3 - MAINTENANCE 3.13
Replacing the Drive Belt - Intermittent The Model 8018i Intermittent printer drive belt can become worn or damaged after long periods of running. The belt should be checked at regular intervals for wear or damage. If the belt has to be replaced, the procedure is as follows:
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1. Remove the four retaining screws from the print module and remove it.
1. Remove the four retaining screws from the print module carriage and remove it.
3. Note the belt clamp under the carriage plate.
4. Loosen off the belt tensioner screw.
3. Use a screwdriver to relieve the spring tension on the belt pulley.
3. Remove the drive belt and fit a replacement. Ensure that the tensioner screw is secured after fitting.
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SECTION 3 - MAINTENANCE 3.14
Replacing the Printer PCBs If the printer PCB has to be replaced the procedure should be as follows: Switch off and disconnect the power to the printer.
1. Undo the six retaining screws and remove the cover from the printer body.
2. Disconnect the connectors from the printer PCB. Take note of the position of the connectors.
2. Undo the eight retaining screws and remove the printer PCB.
Note:
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When a Printer PCB is replaced, the Printhead resistance has to be reentered and the Tension Sensor has to be re-calibrated.
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SECTION 3 - MAINTENANCE
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SECTION 4 TECHNICAL INFORMATION
8018 Thermal Transfer Printer Operation Manual
SECTION 4 - TECHNICAL INFORMATION 4
Technical Information 4.1
Introduction This section is designed to provide quick access to Technical information about the 8018 Thermal Transfer Printer. Topics covered in this section include: • • • • •
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Printer Components Printhead Module Printer Orientation Printer Electrical Components Interfaces
4-1
SECTION 4 - TECHNICAL INFORMATION 4.2
The 8018 Thermal Transfer Printer The 8018 Thermal Transfer Printer is the unit that contains all the printer mechanics together with the control electronics. Two distinct versions of the printer are available: Model 8018i - Intermittent Printer Model 8018c - Continuous Printer The Continuous model is available in left or right hand versions. The Intermittent print module is mounted onto a linear slide and the Continuous printer module is mounted onto a fixed mounting plate.
Figure 4–1: Model 8018i - Intermittent Printer
Figure 4–2: Model 8018c - Continuous LH and RH Printers
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SECTION 4 - TECHNICAL INFORMATION 4.3
Printer Components The image below shows the main components of the printers: 1. 2. 3. 4. 5. 6. 7. 8. 9.
Ribbon supply reel Ribbon take up reel Printhead module Thermal Transfer Printhead Actuator mechanism Ribbon tension roller Ribbon movement roller Ribbon guide rollers Intermittent linear slide / Continuous print module mounting plate 7
1 3
6
2
5
4
9
8
8
Figure 4–3: Intermittent Printer Components
7
1 6
3
2
8
5
4
9
8
Figure 4–4: Continuous Printer Components 8018 06/08
4-3
SECTION 4 - TECHNICAL INFORMATION 4.3.1
Intermittent Drive System - Model 8018i Printer The intermittent version of this printer requires the printhead to move over the substrate while printing occurs. The printhead module (A) is driven backward and forward along a linear slide (C) by means of a printhead carriage (B) that is connected to the drive belt. The printhead module is mounted on this carriage and is secured by four screws. The linear slides are supplied with a linear ball bearing carriage which provides a smooth motion for the assemblies. A stepper motor is used to drive a toothed drive belt (D) around two geared pulley's, (E) one of which is used to tension the belt. Two other stepper motors are used to control the ribbon drive system. Printing occurs while the substrate is stationary. I
E
E A
D C
B
Figure 4–5: Model 8018i - Intermittent Printer
4-4
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SECTION 4 - TECHNICAL INFORMATION 4.3.2
Continuous Drive System - Model 8018c Printer The Continuous version of this printer does not require the printhead to move over the substrate while printing occurs. The print module (A) is mounted onto the print carriage (B) the same way as for the Intermittent version of this printer, but this is then fixed onto a rigid mounting block (C). The printhead module is held in a fixed position and has no linear motion. Printing occurs when the substrate is in motion.
A C
B
Figure 4–6: Model 8018c LH - Continuous Mode Two Stepper motors are used to control the ribbon drive system. These are responsible for accelerating the ribbon up to the same speed as the substrate so that printing can occur.
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4-5
SECTION 4 - TECHNICAL INFORMATION 4.3.3
Ribbon Drive System The ribbon drive system is responsible for control of the ribbon tension, ribbon movement and ribbon operating speed.
A
B C D
(A) Ribbon Take up Reel (B) Ribbon Supply Reel (C) Ribbon Movement Roller (D) Ribbon Tension Roller The ribbon drive is a direct drive system and does not require the use of a clutch. This is achieved by the use of two stepper motors. The stepper motors are connected to the ribbon supply and waste take up spools. This gives the printer the ability to drive the ribbon accurately in both directions. The drive system requires no setting up and therefore alleviates the possibility of incorrect torque being used. The ribbon is routed around a movement roller and a tension roller. When operating these supply data to a microprocessor via hall effect sensors. The 8018 firmware uses an algorithm to calculate the amount of tension required for the ribbon and adjusts the stepper motors accordingly.
4-6
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SECTION 4 - TECHNICAL INFORMATION 4.4
The Printhead Module The 8018 print module is designed to be used on all versions of the 8018 printers. The modular design means that it can be used for both Intermittent and Continuous versions of the printer. The module can also be easily changed from a left hand to a right hand version. (L) and (R) The print module (A) houses the spring loaded quick release mechanism (B) for printhead movement. The printhead assembly (C) is connected via an adapter plate (D) to the this mechanism. .
A
A
B
L
C
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D
R
C
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SECTION 4 - TECHNICAL INFORMATION 4.4.1
The Print Mechanism Components The print mechanism consists of a 24V solenoid (A), an actuator mechanism (B), a print module housing (C) containing a gimballed printhead assembly (D) with thermal transfer printhead (E). The Peel Roller (F) is used to separate the Ink ribbon from the substrate after printing.
A B
C
C F
D
E
4-8
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SECTION 4 - TECHNICAL INFORMATION 4.4.2
Printhead Mechanism Operation When the Solenoid (A) is activated (1) the actuator mechanism (B) is rotated to its down position.(2) This in turn moves the printhead assembly (D) into contact with the substrate ready to print. (3)
A
1
2 B
D
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3
4-9
SECTION 4 - TECHNICAL INFORMATION The Model 8018i Intermittent printer also has a linear motion when printing. The distance travelled is dependant on the size of the print. The following example shows the start position (A) and end position (B) of the printhead during the printing process. After each print the printhead is raised and returned to the start position.
B
A
Figure 4–7: Printhead linear motion
A
B
Figure 4–8: Print Module start and end position 4 3
1 2 Figure 4–9: Intermittent printing sequence
4-10
1.
Head down.
2.
Print
3.
Head up
4.
Return
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SECTION 4 - TECHNICAL INFORMATION 4.5
Printhead Assembly The printhead assembly is designed for easy removal and replacement. The assembly plate is attached to the printhead by two 3 mm dowel pins and two 3 mm cap head screws. The complete assembly can be detached from the print module easily by undoing the quarter turn spring loaded screw mechanism behind the printhead. The printhead assembly can then be removed.
The printhead resistance level is shown on the label attached to the printhead.
4.5.1
Printhead Voltage Control The printhead voltage is electronically adjusted under processor control. The resistance level of the printhead is entered at the Local User Interface. Menu - Print Settings - TPH Resistance.
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4-11
SECTION 4 - TECHNICAL INFORMATION 4.6
Printer Orientation It is critical to the success of the printer that all parties understand the orientation of the printer. With Model 8018i printers, the substrate is stationary when being printed onto and the only issue here is access to the printer. Intermittent printers are therefore Left Hand only. The Model 8018c printers can be Left or Right hand orientated. The decision to select a right or left hand printer will depend on the direction of the substrate. With Continuous printers the print-head angle must always be in the direction of travel of the substrate. The rule for determining the printer hand is as follows:
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SECTION 4 - TECHNICAL INFORMATION
Left Hand Printer showing: Angle of the Printhead. Direction of the Substrate travel.
Right Hand Printer showing: Angle of the Printhead. Direction of the Substrate travel.
If the Model 8018c is to print from the underside of the substrate, and access to the printer is to face in the same direction, the opposite hand would be required. Alternatively the same hand could be used but access would have to be from the opposite side.
Right Hand Printer showing: Angle of the Printhead. Direction of the Substrate travel.
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Left Hand Printer showing: Angle of the Printhead. Direction of the Substrate travel.
4-13
SECTION 4 - TECHNICAL INFORMATION 4.7
Printer Calibration The Model 8018i printer calibrates on power up or if the ribbon has been removed and replaced. This is done to check the diameter of the ribbon and the ribbon tension. A
B
C
C
Figure 4–10: Model 8018iIntermittent Printer A
C
B
C
C
C
A
B
Figure 4–11: Model 8018c Continuous Printer (A) Ribbon movement roller (B) Ribbon tension roller (C) Ribbon guide rollers Note:
4-14
The mechanical mechanism for the Model 8018c ribbon tension is fitted as standard to both sides, but the tension sensor is in the same position for both.
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SECTION 4 - TECHNICAL INFORMATION 4.7.1
Ribbon Movement Calibration Both Intermittent and Continuous versions of the 8018 Thermal Transfer Printer require the ribbon drive to be calibrated. Ribbon calibration is performed by running the two ribbon drive stepper motors. This in turn drives the ribbon round a movement roller which has a 2 pole magnet on the end of it. The ribbon sensor input is connected to a Hall-effect sensor mounted in the printer base plate. The printer electronics detect the rotation of the magnet. This signal is then analysed by the firmware to establish the diameters of the ribbon supply and take up reels. Ribbon tension is then adjusted by stepping the two ribbon drive motors independently at the required ratio.
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4-15
SECTION 4 - TECHNICAL INFORMATION 4.7.2
Ribbon Movement Roller The ribbon movement roller (A) has a high friction coating and has a 2 pole magnet (B) on the end. The roller is fitted with bearings (C) and mounted into a housing unit (D). This unit is then fitted onto the base plate of the printer. With the roller in position it is located next to a Hall effect sensor (E). As the roller and magnet rotate, the magnetic field strength varies. Data is gathered by the Hall effect sensor and analysed by the processor. This used to control the ribbon drive.
AA
CC
DD
BB
4.7.3
E
Ribbon Tension Roller The ribbon tension roller is used to help maintain a constant tension on the ribbon. The roller is mounted onto a sprung and pivoting dancing arm mechanism (A). At the opposite end of the mechanism are two magnets(B).These are positioned either side of a Hall Effect sensor (C). The magnetic field strengths are measured between each print. The data from this sensor is then analysed by the processor and the stepper motors are adjusted accordingly. .
A C B B
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SECTION 4 - TECHNICAL INFORMATION 4.8
Printer Electrical Components The image below show the main electrical components of the printers:
5 4 1 8
6
2
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1.
Ribbon Tension Sensor.
2.
Ribbon Movement Sensor.
3.
USB Port.
4.
Printhead Power/Logic Ribbon.
5.
Carriage Stepper Motor.
6.
Ribbon Stepper Motor.
7.
Ribbon Stepper Motor.
8.
Solenoid.
7
3
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SECTION 4 - TECHNICAL INFORMATION 4.8.1
Stepper Motors The 8018 Thermal Transfer Printers use three stepper motors, one to drive the carriage for the printhead module and two for control of the ribbon. The 18i uses three stepper motors and the 18c two stepper motors. The position of the stepper motors is the same for all models of the 8018. The stepper motors are four wire motors connected in a unipolar configuration. The motors are connected to the printer board via 4-way 2.54 mm Molex KK connectors. Connection points: • • •
J7 - Ribbon motor 1 (Supply LH Printers) J8 - Ribbon motor 2 (Take up LH printers) J9 - Carriage Motor (Intermittent Printer)
When the printer is in Intermittent mode the printhead carriage motor steps are in direct relationship to the linear movement of the printhead. With Continuous versions of the printer the printhead carriage has no linear motion during printing. The ribbon motors steps are configured according to data from the Ribbon roller sensor, Ribbon tension sensor and Encoder if being used. 4.8.2
Encoder The Encoder is used in conjunction with Continuous printers. The Encoder is used to calculate the current Substrate speed and adjust the ribbon speed to match. The four wires from the Encoder connect into the printer through a removable screw terminal connector on the printer body.
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SECTION 4 - TECHNICAL INFORMATION 4.9
Power Configuration Connect the required power (90 - 260 V AC 50 - 60 Hz) to the power supply unit using the IEC lead provided. A 10 A fuse is used in the mains plug connector, or a 10 A MCB is recommended to protect the supply cable at source. The IEC inlet contains 20 mm T5AH250V ceramic fuses. The Power supply unit provides 24VDC for the Printer. 4.9.1
Mains Power Switch The power supply connector comprises of an On/Off switch, a IEC320 socket and a 250V Fuse holder. No voltage configuration is required as the unit uses a universal input power supply.
4.10
Printer Connection Points The main connection points for the Printer unit are shown below:
4
3 2
1
Figure 4–12: Printer Connection Points
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1.
Power Connector
2.
I/O Connector
3.
Local User Interface Connector
4.
Encoder Connector
4-19
SECTION 4 - TECHNICAL INFORMATION 4.10.1
Power Connections The Interface between the Power supply and Printer is a single multi-core cable. Connection is via a six way removable screw terminal (X14) on the rear of the printer. Table 4– 1: Power Connection (X14) Pin No.
4.10.2
Function
1
24 VDC - 36 VDC
2
24 VDC - 36 VDC
3
0V
4
0V
5
Earth
6
Earth
Local User Interface Connection The Interface between the printer and the Local User Interface is a single multi core cable. Connection is via an eight way removable screw terminal (X17) on the rear of the printer. Table 4– 2: User Interface Connection (X17) Pin No.
4-20
Function
1
24vdc - 36vdc
2
0v
3
Transmit Data +ve
4
Transmit Data -ve
5
Receive Data +ve
6
Receive Data -ve
7
Cable shield
8
Reserve
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SECTION 4 - TECHNICAL INFORMATION 4.10.3
Substrate Encoder Connection The Interface between the printer and the Substrate Encoder is a single multi core cable. Connection is via a five way removable screw terminal (X12) on the rear of the printer. Table 4– 3: Substrate Encoder Connection (X12) Pin No.
4.10.4
Function
1
5 VDC
2
Input 1 (Not used)
3
Input 2
4
0V
5
Reserve
External I/O Connection The Interface between the printer and the Host machine is a single multi core cable. Connection is via a seven way removable screw terminal (X4) on the rear of the printer. Table 4– 4: External I/O Connection (X4) Pin No.
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Function
1
+24 VDC - I/O
2
PRINT GO Input (PNP sensor or +24V Switched)
3
0V
4
Fault Output NC (Contacts Open for Fault)
5
Fault Common
6
Warning Output NC (Contacts Open on Warning)
7
Warning Common
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SECTION 4 - TECHNICAL INFORMATION 4.10.5
Printer PCB The 8018 Thermal Transfer Printer printer PCB is located in the printer unit. The printer PCB controls the printhead signals, motor movement and solenoid actuation inputs and outputs. The Continuous version of the printer interfaces with a speed encoder for matching of print speed.
4.10.6
Printer PCB Components The main components of the printer PCB are shown below:
4.10.7
Printer PCB Fuse The supply is protected by a 5 x 20mm anti surge fuse rated at 5A this is located under the PCB. Note:
4-22
The same PCB is used for both the 18i and 18c versions of the printer. The connections and Firmware required however are different.
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SECTION 4 - TECHNICAL INFORMATION 4.10.8
Printer PCB Connectors The printer PCB connectors are listed below: Table 4– 5: Printer PCB Connectors Number
Connector
J1
Function Programming Header (not fitted)
J2
24-way Ribbon
Printhead Power/Logic
J3
26-way IDC
BDM Header (not fitted)
J4
Removable screw terminal
I/O
J5
Expansion 1 (not fitted)
J6
Expansion 2 (not fitted)
J7
4-way 2.54 mm Molex KK
Ribbon Motor 1
J8
4-way 2.54 mm Molex KK
Ribbon Motor 2
J9
4-way 2.54 mm Molex KK
Carriage Motor
J11
2-way 2.54 mm Molex KK
Solenoid
J12
Removable screw terminal
Substrate Encoder
J13
9 way D socket
RS-232 Debug (not fitted)
J14
Removable screw terminal
Power
J15
3-way 2.54 mm Molex KK
Ribbon Tension Sensor
J16
3-way 2.54 mm Molex KK
Ribbon Movement Sensor (Encoder)
J17
Removable screw terminal
Local User Interface
J10
J18 J19
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Test Mode Link 4-way 2.54 mm Molex KK
USB
4-23
SECTION 4 - TECHNICAL INFORMATION
4-24
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SECTION 5 TROUBLESHOOTING
8018 Thermal Transfer Printer Operation Manual
SECTION 5 - TROUBLESHOOTING 5
Troubleshooting 5.1
Introduction This section is designed to provide information that will help you quickly solve problems which may stop your 8018 Thermal Transfer Printer working efficiently. Topics covered in this section include: • • • • • • • •
8018 06/08
Fault messages Warning messages Common Issues Drive System Issues Print Module Drive Problems Display Problems Print Quality Problems Image Selection Problems
5-1
SECTION 5 - TROUBLESHOOTING 5.2
Fault and Warning Messages The messages are listed below along with potential causes and remedial actions. 5.2.1
Fault Messages In the event of a fault, a message is displayed on the Home screen or Menu screen being accessed at the time. Some fault messages can be temporarily hidden by pressing the “Hide” option button. This allows the action being performed in a particular menu to be completed. Other faults will require immediate attention. Table 5– 1: Fault Messages Fault Message 1002 - Printer Hardware Fault Possible Causes
A problem has occurred with the printer hardware.
Remedial Action
Return the printer to the Markem.Imaje service centre. Fault Message 1004 - Printhead Detect Failure
Possible Causes
The printhead cable is loose. The printhead cable is damaged The printhead is damaged.
Remedial Action
Check the printhead and printhead cable for damage. Try a different printhead. Fault Message 1005 - Software Fault
5-2
Possible Causes
The software has experienced an error condition.
Remedial Action
Re-power the printer.
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SECTION 5 - TROUBLESHOOTING Table 5– 1: Fault Messages Fault Message 1006 - Software Assert Possible Causes
The software has experienced an error condition.
Remedial Action
Re-power the printer. Fault Message 1007 - Printhead Resistance Not Set
Possible Causes
A new printer PCB has been fitted.
Remedial Action
Set the printhead resistance level. Fault Message 1008 - Tension Not Calibrated
Possible Causes
A new printer PCB has been fitted.
Remedial Action
Calibrate the Tension sensor. Fault Message 1009 - Printer Orientation Not Set
Possible Causes
The printer orientation has not been set after a firmware upgrade.
Remedial Action
Set the printer Orientation. Left or Right Hand Fault Message 1011 - DC Power Supply Range Error
Possible Causes
PCB component failure.
Remedial Action
Repair or replace the PCB. Fault Message 1012 - 5v Logic Supply Range Error
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Possible Causes
PCB component failure.
Remedial Action
Repair or replace the PCB.
5-3
SECTION 5 - TROUBLESHOOTING Table 5– 1: Fault Messages Fault Message 1104 - Calibration Failed initial Tension
Possible Causes
No ribbon fitted. The ribbon is not webbed up correctly. Wrong ribbon width selected. The supply spool is slipping. The take up spool is slipping. The printer is set to the wrong printer type.
Remedial Action
Check the ribbon. Check the take up spool. Check the printer type in the Settings - Machine options Use the diagnostic screen to check the calibration values.
Fault Message 1105 - Calibration Ribbon Sensor Failed Possible Causes
The ribbon movement sensor is damaged. The ribbon movement roller magnet is damaged.
Remedial Action
Check the sensor and magnet for damage.
Fault Message 1106 - Calibration Diameter Out of Range Possible Causes
Incorrect ribbon fitted. The ribbon is wound directly onto the take up spool without a ribbon core.
Remedial Action
Fit the correct ribbon Wind the ribbon onto a ribbon core. Fault Message 1107 - Calibration Unable to Tension
Possible Causes
The ribbon tension sensor is damaged. The ribbon tension roller is damaged. The ribbon tension sensor requires calibrating.
Remedial Action
Check the ribbon sensor and roller for damage. Use the diagnostic screen to check the tension sensor input signal. Re-calibrate the tension sensor. Fault Message 1108 - Tension Sensor Error
Possible Causes Remedial Action
5-4
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SECTION 5 - TROUBLESHOOTING Table 5– 1: Fault Messages Fault Message 1201- Ribbon Fault Possible Causes
The ribbon has broken during calibration. The ribbon has broken during printing. The ribbon tension sensor is faulty.
Remedial Action
Re- web the ribbon. Use the diagnostic screen to check the ribbon tension sensor input signal. Fault Message 1202 - Solenoid Fault
Possible Causes
The connector to the solenoid has become loose. The connector or wiring is damaged. The solenoid is damaged.
Remedial Action
Check the solenoid by using the Manual control function to operate it. Check the Diagnostics screen solenoid output to see if it toggles on/off Change the solenoid. Fault Message 1204 - Printhead Voltage Fault
Possible Causes
Faulty printhead. Faulty printhead ribbon cable. Faulty printer PCB
Remedial Action
Check the printhead and ribbon cable for damage. Try fitting a different printhead or ribbon cable. Replace the printer PCB Fault Message 1307 - RTC Fault
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Possible Causes
PCB component failure.
Remedial Action
Repair or replace the PCB.
5-5
SECTION 5 - TROUBLESHOOTING Table 5– 1: Fault Messages Fault Message 1400- Corrupt File system Possible Causes
The database has become corrupted.
Remedial Action
Use the “Restore to Factory” defaults function and redownload the Image. Fault Message 1401 - Failed to Restore Image
Possible Causes
Image / Font file missing
Remedial Action
Re- download the Image Select another Image Fault Message - 1500 Printer Overheat
Possible Causes
High ambient temperature The pack rate is too high.
Remedial Action
Switch off the printer and allow to cool down. Reduce the line speed. Fault Message 1502 - Printhead Over Temperature
5-6
Possible Causes
The print darkness level is too high. The printhead is damaged. The printhead thermistor is damaged.
Remedial Action
Reduce the darkness level. Replace the printhead.
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SECTION 5 - TROUBLESHOOTING 5.2.2
Warning Messages In the event of a warning, a message is displayed on the Home screen or Menu screen being accessed at the time. Home screen warnings can be hidden by pressing the “Hide” option button. If the same warning re-occurs the message will be displayed again. Menu screen warnings can also be hidden so that the action being performed in a particular menu can be completed. In this case if the warning re-occurs the message will not be displayed a second time, instead the Status symbol will change to the warning symbol. This allows manual operation of the printer without having to continually clear the warning message. e.g. missed print warnings. Table 5– 2: Warning Messages Warning Message 2001 Clock Problem Possible Causes
The system clock has been reset to the default value.
Remedial Action
Re-configure the system date and time. Warning Message 2100 - Image Not Ready
Possible Causes
The printer was unable to locate the image due to a timing issue
Remedial Action
Reduce the pack rate speed or reduce the number of updating fields on the image. Warning Message 2101 - Missed print
Possible Causes
The printer was unable to print the image due to a speed or timing issue. (Continuous printers)
Remedial Action
Reduce the pack rate speed or reduce the number of updating fields on the image.e. Warning Message 2102 - Truncated Print
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Possible Causes
The length of the image plus the amount of registration (Intermittent printer) exceeds the distance that the print module can travel.
Remedial Action
Reduce the amount of registration.
5-7
SECTION 5 - TROUBLESHOOTING Warning Message 2105 - Discarded Print Possible Causes
The printer has auto-aborted a print in Low speed reprint mode.
Remedial Action
Increase the substrate speed. Warning Message 2107 - Substrate Over speed
Possible Causes
The substrate is travelling faster than the maximum print speed of the 8018 Thermal Transfer Printer.
Remedial Action
Reduce the substrate speed. Warning Message 2108 - Substrate Under speed
Possible Causes
The substrate is travelling slower than the minimum print speed of the 8018 Thermal Transfer Printer.
Remedial Action
Increase the substrate speed. Warning Message 2109 - Low Ribbon
Possible Causes
The ribbon is nearing the end of the roll.
Remedial Action
Prepare a new roll of ribbon ready to replace the existing one.
Warning Message 2110 - Low Ribbon Tension Corrected During Print Possible Causes
The ribbon is nearing the end of the roll.
Remedial Action
Adjustments were made to correct the ribbon tension while printing. Warning Message 2116 - Reselect Offset
5-8
Possible Causes
The offset value is too large for the selected image.
Remedial Action
Reduce the offset value.
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SECTION 5 - TROUBLESHOOTING Warning Message 2201 - Settings Corrupt Possible Causes
The printer settings have become corrupted.
Remedial Action
By clearing this message the settings will be set to default values. Warning Message 2207 - File System Nearly Full
Possible Causes
The File system is almost full.
Remedial Action
Delete unwanted files from the database. Warning Message 2208 - File System Full
Possible Causes
The File system is full.
Remedial Action
Delete unwanted files from the database. Warning Message 2209 - Firmware Upgraded
Possible Causes
The Firmware upgrade has been successful.
Remedial Action
None. Warning Message 2210 - Firmware Upgrade Failed
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Possible Causes
USB stick removed before completion of the upgrade.
Remedial Action
Re-load Firmware.
5-9
SECTION 5 - TROUBLESHOOTING Warning Message 2300 - Printer High Temperature Possible Causes
The printer temperature is reaching an unacceptable level.
Remedial Action
Turn off the power to the 8018 Thermal Transfer Printer and allow the printer to cool down.
Warning Message 2302 - Printhead Under Temperature
5-10
Possible Causes
The printhead temperature has not yet reached an acceptable working level.
Remedial Action
The 8018 Thermal Transfer Printer will automatically initiate a pre-heat cycle before printing can commence.
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SECTION 5 - TROUBLESHOOTING 5.3
Common Issues Listed below are a number of possible faults and suggestions for possible corrective actions. 5.3.1
No Power to the Printer • • • •
5.3.2
Printhead Cables •
5.3.3
Connectors may vibrate loose under normal operation if not correctly installed. Loose connections may be the cause of many problems such as poor print, no print, or no power to the printhead.
Encoder • •
5.4
Power switch must be in the ON position. This switch is located at the rear of the power supply Check that the mains cable is correctly inserted into the mains connector below the switch. Check that the mains fuse on the fuse selector is OK and replace it if necessary. Check the mains supply to the 8018 Thermal Transfer Printer. There may be another fuse or MCB installed to protect the Mains Cable at source.
Check that the encoder is rotating freely. The Model 8018c in continuous mode will not print unless the encoder is moving. Check that the encoder is sending a signal back to the 8018 Thermal Transfer Printer. Use the diagnostics screen to check the encoder input signals.
No Information Is Printed If the printer appears to be operating correctly but no data is printed, check the following: • • • • • • •
5.5
Is a valid image selected? Check that the print speed and darkness values are at appropriate levels for the thermal ribbon and substrate. Is the printhead coming into full contact with the print platen / roller across its full width? Is the correct ribbon loaded with the inked surface away from the printhead. Is it driving correctly? Check that the ribbon is correctly webbed through the peel roller. On continuous printers, the encoder signal may not be providing the correct speed information. The printhead may be faulty.
The Printhead Does Not Move Out The Printhead in / out motion is driven by a small solenoid. If the head does not move out, use Manual mode to test the operation of the solenoid. Check the following: • • • •
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Check that the head is free to rotate in its mounting. Check the solenoid wiring. Replace the solenoid as required. If the fault persists, replace the Printer PCB.
5-11
SECTION 5 - TROUBLESHOOTING 5.6
Drive System Issues 5.6.1
Ribbon is not driving • •
5.6.2
Ribbon Drive Problems •
• •
5.6.3
Check that the ribbon cores on the supply and take up spools are not slipping. You can see this by taking the ribbon core off and looking on the inside. Check that the drive couplings for the ribbon drive have not come loose. This can easily be checked by trying the coupling by hand.
If the print darkness is too high or the print speed too low, the ribbon can be weakened and break. This can be eliminated by reducing the darkness or increasing the speed. The ribbon take up is not winding the waste ribbon correctly. Check that there is no interference between the accumulated wasted ribbon and any other part of the printer body. Ensure that the waste ribbon spool is gripping the core firmly.
Ribbon Creasing Ribbon creasing is generally due to the ribbon attempting to ‘track’ across the Printhead. The most common causes are: •
• • 5.6.4
Bent ribbon guide rollers. This may occur if the printer is dropped. It is not usually possible to bend a pin back into position. Remove and replace the guide roller. A bent peel roller. Remove and replace the peel bar. Poor print platen / roller alignment can in some cases cause ribbon creasing as the substrate tries to pull the ribbon across the printhead.
Ribbon Breaking or Scuffing Prints (Continuous printers) If there are problems with ribbon breaking or scuffing prints, it is possible that the printhead gap is set too small. The printhead will move out as the ribbon begins to accelerate.The printhead will then make contact with the ribbon before it is up to speed. •
Try increasing the printhead gap.
(Intermittent printers) The printhead may be starting to print before the substrate / labels have stopped moving. The target material must be stationary before printing occurs. •
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Try increasing the print delay.
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SECTION 5 - TROUBLESHOOTING 5.6.5
Ribbon Coning (Continuous Printers) If there is a problem with the waste ribbon coning on the take up reel, check the following: • • • •
5.6.6
Peel Roller Problems • •
5.6.7
Ensure that the printhead is aligned correctly with the print roller. (See Installation) If incorrectly aligned this will cause tracking problems. Ensure that the ribbon is tracking parallel on the printer rollers and is positioned correctly. Ensure that none of the rollers have been bent or damaged. Ensure that the Printhead and Peel roller are clean. Ink deposits can also contribute to ribbon coning.
If a peel roller is difficult to spin due to a build up of material debris between the inner roller body and shaft, change the roller. If the peel roller is very worn and running loose on the shaft, change the roller.
Head not returning to home position (Model 8018i) This problem only relates to the Intermittent printer. If the head feeds satisfactorily, but does not return to the correct home position, check the amount of registration that has been set. The printhead module will only return to the default start position if the registration is set to 0.
8018 06/08
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SECTION 5 - TROUBLESHOOTING 5.7
Printhead Module Carriage Drive Problems A stepper motor, drive belt and linear slide are used to move the Printhead module carriage. The carriage drive may stall when the 8018 Thermal Transfer Printer is under excessive load. If the carriage does not drive, check the following: • • • • • • •
5.8
Is the ribbon is loaded correctly? Is there any mechanical interference stopping the carriage moving? Check the condition of the drive belt and drive pulleys. Check the condition of the linear slide. With the power to the unit turned off, is the Printhead module free to move along the slide? Are the stepper motor connections correct and secure. If the fault persists, replace the Printer PCB.
Display Issues 5.8.1
Back light only lit If the User Interface LCD screen is lit, but the text or icons are just visible check the following: • • • •
5.8.2
Has the LCD contrast been set too high or low? Adjust the contrast by pressing the button left of the 0 on the numeric keypad. If no text or icons are visible check that the LCD connector to the printer PCB has not become loose. If necessary replace the Use Interface.
LCD only, no Back light If the LCD text is visible but the back light is not on check the following: • • • •
5.8.3
Display is totally blank • • • •
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Has the back light connector to the controller PCB become loose? Is the wiring damaged? If necessary replace the User Interface LCD module. If necessary replace the User Interface PCB.
Check the power to the 8018 Thermal Transfer Printer. Check the User interface cable for damage. Check that the LCD and Back light connectors to the User Interface PCB have not become loose. If necessary replace the User Interface module.
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SECTION 5 - TROUBLESHOOTING 5.9
Print Quality Problems The most common causes of poor print quality are: •
• • •
• • •
• 5.9.1
Dirty printhead: Clean the printhead with the Markem.Imaje Isopropanol wipes and try again. Take care not to damage the printhead during cleaning. Always allow the printhead to cool prior to cleaning. Dirty, worn or badly misaligned print platen / roller: Produce a full-size test print to establish the quality of the print. Ribbon is not driving correctly: Clean the ribbon rollers and check that the ribbon is loaded correctly. Excessive vibration of the packaging machine: Improve the mounting of the 8018 Thermal Transfer Printer. If possible, increase the print delay so that vibration has reduced by the time printing starts. On intermittent printers, the substrate is still moving when printing starts: Increase the print delay. On continuous printers, the speed encoder is not providing an accurate measurement of the speed of the substrate: Adjust encoder. Matching of the ribbon to the substrate is very important. An improper match will not produce good print quality: Contact your local Markem.Imaje Business Centre for further details. Lines of dots are not printing. If cleaning the printhead and platen / roller does not resolve the problem: Replace the printhead.
Faded print Print quality is dependent on the following: • Quality of the substrate and ribbon being used, • Print Darkness • Printhead pressure and print speed combination • Condition of the machine being used to print The age and storage conditions of the ribbon can also affect the print quality. The printhead should be kept clean by using Isopropanol wipes. It should never be touched with any abrasive material or metallic objects. The Test Pattern function is the best way of setting the machine print standards, such as evenness of the print; positioning of the image; and checking for damage to the dots. Recommendations: • • • •
8018 06/08
Clean the printhead and platen Increase the darkness or Reduce the print speed Review ribbon.
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SECTION 5 - TROUBLESHOOTING 5.9.2
Faded on one side This is generally due to a misalignment of the printer to the platen roller/ pad. The printhead will move down to print on the substrate, and will hit one side of the roller/ pad first. Recommendations: •
5.9.3
Check that the printer is not loose, especially if it has just been replaced.
Blurred edges This is generally due to the darkness setting being too great. Recommendations: •
5.9.4
Reduce the darkness or increase the print speed
Missing lines perpendicular to printhead This is generally due to either a dirty printhead or a damaged printhead. Dirt can build up on the printhead after a period of time causing dots to be missing. If a printhead becomes damaged by physical or element damage, it can cause missing dots, see section Printhead Care. Recommendations: • •
5.9.5
Clean the printhead. Use the Offset to move the image away from the damaged dots, or replace the printhead.
Print rubs off This can be for a number of reasons: •
•
•
5-16
There is not enough energy going to the printhead. This is more apparent in cold environments. Increasing the Darkness and in extreme conditions, the background energy levels of the head can make a difference to the permeability. In environments of high temperature and humidity, the applied ribbon may still be warm and could rub off. Trying a different ribbon grade could be the solution. Mismatch in ribbon/ substrate. Some substrates have coatings that make it very difficult to adhere to. The coatings may be, for example, a wax/ resin mix similar to the actual ribbon. If this is the case, then trying another ribbon grade is the best recommendation. If you are using a Markem.Imaje Grade 3810, then try a Grade 3510 or Grade 3910. This may resolve the problem, but remember this is a resin-based ribbon that needs more energy to print, so may be limited in speed (typically to
