Datamax I-Class Mark II, Maintenance Manual

Page 1: ...Maintenance Manual...

Page 2: ...uding direct incidental economic special or consequential damages arising out of the use or inability to use the Firmware Software WARNING Lithium Battery There is a danger of explosion or fire if the...

Page 3: ...2 3 Ribbon Path Alignment 18 2 4 Maintenance 20 2 4 1 Cleaning the Printhead 21 2 4 2 Cleaning the Platen 24 2 4 3 Cleaning the Media Path Media Sensor and Interior 25 2 4 4 Cleaning the Ribbon Path...

Page 4: ...Printhead 50 4 7 Printhead Assembly 52 4 7 1 Printhead Assembly Breakdown 54 4 8 Media Sensor 57 4 9 Main Logic PCB 58 4 10 Fuses 59 4 11 Power Supply PCB 60 4 12 Drive Motor Assembly 62 4 13 Media S...

Page 5: ...ation refer to the following documents available at http www datamax oneil com For operating information reference the Operator s Manual For software information reference the DPL Programmer s Manual...

Page 6: ...mponents of the printer Cover Assembly Media Hub Internal Rewind Ribbon Supply Hub Ribbon Take up Hub Front Panel Printhead Assembly Filler Block Platen Block Printhead Media Sensor Platen Leveling Ca...

Page 7: ...l at least one full label has been output then release the button and wait for the printer to process the data There are two possible outcomes CALIBRATION COMPLETE will be displayed and the media will...

Page 8: ...ess SENSOR CALIBRATION Then using the DOWN button scroll to PERFORM CALIBRATION Press ENTER again and then press YES to proceed PERFORM CALIBRATION Press NO to abort this procedure D With no media ins...

Page 9: ...ets the paper value where yyy represents the current sensor reading 1 If using preprinted media ensure that the area placed over the sensor is free of text graphics or borders 2 See the Operator s Man...

Page 10: ...complete B Press MENU button Make sure MEDIA SETTINGS is highlighted and press ENTER Then using the DOWN button scroll to SENSOR CALIBRATION Printer Menu C Using the DOWN button highlight ADVANCED EN...

Page 11: ...own below TRAN SENSOR GAIN 00 0 31 This is the Label Value for a gain setting of 00 Sample Calibration Table Gain Number Label Value TOF Value Difference Value 00 252 01 02 31 Step Action Displayed Me...

Page 12: ...er the black mark TRAN SENSOR GAIN 31 0 31 1 Do not position the Media Sensor under a perforation and if using preprinted media ensure the label area placed over the sensor is free of text graphics li...

Page 13: ...Action Displayed Message Comment K In your sample calibration table where both the Label Value and TOF Value are at least 20 subtract the amounts and record the result as a Difference Value see below...

Page 14: ...lower and latch the Printhead Assembly Record the sensor reading as P B Raise the Printhead Assembly Place the liner notch or mark over the Media Sensor then lower and latch the Printhead Assembly Rec...

Page 15: ...s is the Paper value O Press the ESC button Scroll to GAP SENSOR LEVEL or if using reflective media MARK SENSOR LEVEL and then press ENTER Set the Gap or Mark value determined in Step M and then press...

Page 16: ...ATION COMPLETE Followed by READY The printer is ready for use If the calibration attempt fails try desensitizing the sensor as follows Re enter the ADVANCED MENU Go to MEDIA SETTINGS SENSOR CALIBRATIO...

Page 17: ...the printer with media Download a label format or choose a Quick Test Label and begin printing 2 While observing the right side of the label rotate the Leveling Cam clockwise or counter clockwise unt...

Page 18: ...e steps below 1 Load 4 inch 102mm wide media and ribbon if needed Then disengage the Leveling Cam and latch the Printhead Assembly 2 Enter the Quick Test Mode then select 100 Print Quality Labels and...

Page 19: ...turn 3 Turn the Adjustment Screws counter clockwise until the Burn Line is past the platen vertex Print a Validation Label from the Quick Test Menu The label should look light and uneven 4 Tighten the...

Page 20: ...er Supply PCB 2 Using a multi meter set to measure DC voltage connect the positive lead to Power Supply Connector J2 pin 1 and the negative lead to J2 pin 6 3 Raise the Printhead Assembly Locate and n...

Page 21: ...el Printhead Resistance ohms Printhead Voltage 0 1 Volt DC 572 597 22 4 598 622 22 9 623 647 23 3 648 672 23 8 673 697 24 2 698 722 24 7 723 747 25 1 I4212e 748 772 25 5 947 989 22 4 990 1030 22 9 103...

Page 22: ...Load a matching Ribbon and allow it to feed with the Media from the printer Ribbon Supply Hub Printhead Assembly Ribbon Media Idler Cam Idler Screw 3 Disengage the Leveling Cam see Section 2 2 1 4 Pl...

Page 23: ...d labels show no evidence of ribbon wrinkling proceed to Step 8 otherwise slightly loosen the Ribbon Shield Adjustment Screws Move the Ribbon Shield forward or backward to smooth the ribbon Tighten th...

Page 24: ...Component Area Cleaning Interval Method Supplies Printhead Media type dependent Thermal transfer after each roll of ribbon Direct thermal after each roll of media or as needed Isopropyl alcohol and i...

Page 25: ...rint can indicate a dirty or faulty printhead 2 4 1 1 Cotton Swab Procedure This cleaning method is recommended when using direct thermal media or thermal transfer media with a wax ribbon 1 Turn OFF a...

Page 26: ...nd ribbon if installed 3 Place a Cleaning Card part number 70 2013 01 under the printhead 4 Lower and latch the Printhead Assembly 5 Disengage the Leveling Cam see Section 2 2 1 Printhead Assembly Cle...

Page 27: ...nstalled 3 Place a sheet of Cleaning Film part number 70 2087 01 under the printhead see illustration Section 2 4 1 2 4 Lower and latch the Printhead Assembly 5 Disengage the Leveling Cam see Section...

Page 28: ...Clean the Platen as follows 1 Turn OFF and unplug the printer 2 Open the cover Raise the Printhead Assembly and remove the media 3 Using a Cotton Swab or lint free cloth dampened with isopropyl alcoho...

Page 29: ...he printer Raise the cover 2 Raise the Printhead Assembly then remove the media and ribbon if installed Tear Bar or Rewind Arcplate Media Sensor Media Guide Media Idler Baseplate 3 Using compressed ai...

Page 30: ...Idler 3 Using a cotton swab dampened with isopropyl alcohol wipe the Ribbon Idler and the Ribbon Shield clean 4 Allow the components to dry then replace the ribbon Lower and latch the Printhead Assem...

Page 31: ...er see the Operator s Manual for more information on NETira CT It is recommended that the configuration be saved before downloading firmware and restored when finished Be sure to check the box labeled...

Page 32: ...configuration 3 Go to the Tools Upgrade Firmware Select the binary files BIN files for each of the Boot files 4 Check the Select and Download Boot 1 file Select and Download Boot 2 file and Erase Sys...

Page 33: ...nplug the printer 2 ensure that the unit has been placed on a level stable surface and 3 use extreme care if measuring voltages Perform the following actions before troubleshooting then proceed accord...

Page 34: ...then press TEST Was a Print Quality Label produced Go to Step 4 3 Was a fault message generated Go to Section 3 3 2 Go to Section 3 2 3 4 Examine the label Is the print quality satisfactory Go to Step...

Page 35: ...ise replace the Front Panel PCB see Section 4 3 2 Turn OFF and unplug the printer Check fuses F1 and F2 on the Power Supply PCB Is a fuse blown Replace the fuse s see Section 4 10 If the fuse s contin...

Page 36: ...then if necessary replace the PCB see Section 4 11 Possible defective Main Logic PCB replace it see Section 4 9 If using thermal transfer media examine the used ribbon and then proceed accordingly The...

Page 37: ...ign or replace it see Section 2 2 or 4 6 respectively Possible loose or defective printhead cable Possible ribbon wrinkle see Section 2 3 Possible defective Main Logic PCB replace it see Section 4 9 P...

Page 38: ...Dump Mode disable it cycle power 3 Press TEST Scroll to PRINT CONFIGURATION and then press TEST Compare the communications settings listed on the Configuration Label to the host s communication settin...

Page 39: ...eptable see Section 4 6 N A Gap Mode Warning Low Backing A small difference exists between the measured empty and gap media sensor readings This is typical of labels mounted on a transparent backing o...

Page 40: ...ny obstructions from the cutter 5 The Cutter Motor or Motor Controller PCB may be defective replace the option 6 The Main Logic PCB may be defective replace it see Section 4 9 RED ON GREEN OFF Gap Mod...

Page 41: ...2 The Media Sensor may be defective replace it see Section 4 8 3 The Main Logic PCB may be defective replace it see Section 4 9 N A Clean Print Head The programmed printhead cleaning distance has bee...

Page 42: ...based ink 2 Possible debris in the Media Sensor clean and retry calibration see Section 2 4 3 3 The Media Sensor may be defective replace it see Section 4 8 4 The Main Logic PCB may be defective repla...

Page 43: ...core that is within specification 3 The ribbon may be slipping over the media Possible causes include an incorrect media ribbon combination a worn Platen or a severely misaligned printhead assembly pr...

Page 44: ...SOR TYPE setting may be incorrect check the position and setting 3 The Media Sensor may need cleaning see Section 2 4 3 4 The Leveling Cam may be improperly set adjust it see Section 2 2 1 5 The label...

Page 45: ...e replace Flashing Yellow GREEN OFF GPIO Waiting for Signal The GPIO option card if equipped is awaiting a signal from the host or other remote equipment Refer to the GPIO Installation Instructions in...

Page 46: ...nt To debug DPL label formats reference the DPL Programmer s Manual After sending a label format to the printer the output will be immediate and in the form shown below As a final note many software p...

Page 47: ...es the configuration CAUTION Always disconnect AC power before performing service Wear a wrist strap and follow all ESD prevention measures and Use extreme care and never use sharp objects on the Prin...

Page 48: ...that secure it to the Centerplate and then lift the entire Cover Assembly off the printer Cover Assembly Centerplate Screws Replacement 1 Lower the Cover Assembly onto the printer 2 Reinstall the thr...

Page 49: ...mbly see Section 4 1 3 Slightly flex the Tabs that extend through notches in the Centerplate and then remove the Front Panel Fascia Front Panel Fascia Notches Tabs Replacement 1 Align the Tabs of the...

Page 50: ...t Panel Assembly to the Centerplate then disconnect the Front Panel Cable and remove the Front Panel Assembly from the printer Screws Front Panel Assembly Front Panel Cable Centerplate Replacement 1 C...

Page 51: ...he printer 2 Raise the cover and remove the Tearplate Fascia Thumbscrew and Tearplate 3 Remove the Gear Cover by pulling the far side out then away from the Centerplate Note If necessary loosen the Fr...

Page 52: ...from the printer If necessary loosen the Front Panel Fascia to facilitate removal see Section 4 2 Replacement Bearing Plate Screws Platen Assembly Platen Block 1 Place the Platen Assembly into the Pl...

Page 53: ...e Section 4 1 4 4 3 Remove the three Screws securing the Platen Block to the Centerplate Slide the Platen Block out of the printer Screws Platen Block Replacement 1 Position the Platen Block in the pr...

Page 54: ...g the printer 2 Raise the cover With the Printhead Assembly lowered loosen the Printhead Mounting Screw it will remain in the assembly Printhead Mounting Screw Printhead Assembly 3 While carefully sup...

Page 55: ...ure the Printhead to the Printhead Assembly with the Printhead Mounting Screw but do NOT over tighten 4 Clean the Printhead see Section 2 4 1 5 Lower and latch the Printhead Assembly 6 Adjust the Dark...

Page 56: ...ction 4 4 3 Remove the two Screws that secure the End Cap to the Extrusion 4 While supporting the Printhead Assembly remove the End Cap Wavy Washer and Bushings note Bushings may remain captive in the...

Page 57: ...lding the spring loaded Printhead Assembly in the Centerplate bushing place the Wavy Washer onto the opposite Printhead Assembly Boss Printhead Assembly Boss Wavy Washer 4 If removed insert the Ribbon...

Page 58: ...Printhead Assembly refer to the I Class Mark II Parts Catalog for available parts Removal 1 Remove the Printhead Assembly see Section 4 7 2 Carefully pry the Clip from the Printhead Assembly Also remo...

Page 59: ...embly compressing the spring loaded assembly as necessary to separate the parts and then remove the Alignment Springs Printhead Assembly Lower Carriage Alignment Springs 5 Separate the Middle Carriage...

Page 60: ...e Springs in the Cams then compress the Upper and Middle Carriage and attach the Lower Carriage to the assembly 3 Secure but do not tighten the Upper Middle and Lower Carriages with the Alignment Scre...

Page 61: ...er Assembly see Section 4 1 3 Disconnect the Media Sensor cable and remove the Screw that secures the Media Sensor Guide to the Post 4 Pull the Media Sensor Guide and then the Media Sensor from the pr...

Page 62: ...Logic PCB 4 Slide out the Main Logic PCB from the printer Screws Main Logic PCB Replacement 1 If necessary transfer any option cards to the new replacement Main Logic PCB 2 Insert the Main Logic PCB...

Page 63: ...ly blow during a failure in the primary switching circuit and may indicate a more serious electrical problem Removal 1 Turn OFF and unplug the printer 2 Remove the Cover Assembly see Section 4 1 3 Rem...

Page 64: ...e Section 4 1 3 Disconnect the cables from the Power Supply PCB 4 Remove the two Screws and Nut Plate that secure the AC Connector AC Connector Screws Nut Plate 5 Remove the Screw and Washer that secu...

Page 65: ...Screws 2 Place the Washer onto the Screw and then secure the Ground Wire Lug to the chassis with the Screw 3 Position the Nut Plate over the AC Connector and then secure the AC Connector and the Nut P...

Page 66: ...is the same for 300 600DPI Removal 1 Turn OFF and unplug the printer 2 Remove the Cover Assembly see Section 4 1 3 Disconnect the motor cable 4 Remove the two Screws that secure the Drive Motor to the...

Page 67: ...en secure it with the two Screws Centerplate Standoffs 203 DPI Centerplate Standoffs 300 600 DPI Screws Isolator Screws Isolator 2 Position the Drive Motor against the Isolator 3 Place the Ground Cabl...

Page 68: ...over Assembly see Section 4 1 3 Remove the Power Supply PCB see Section 4 11 4 Remove the Screw securing the Media Hub Assembly to the Printer Screw Media Hub Assembly Replacement 1 Install the Screw...

Page 69: ...printer Raise the cover 2 Remove the three Screws that secure the Thermal Transfer Assembly and then remove the assembly from the Centerplate Centerplate Thermal Transfer Assembly Screws Replacement...

Page 70: ...Metal Washer that secures the Ribbon Supply Hub to the Housing 3 Remove the Ribbon Supply Hub and Nylon Washer from the Housing Ribbon Supply Hub Nylon Washer Metal Washer Screw Housing Replacement 1...

Page 71: ...Rotate the Ribbon Supply Hub until the Pin engages the Notch in the Housing Housing Nylon Washer Pin Notch Ribbon Supply Hub 4 Secure the Ribbon Supply Hub to the Housing with the Metal Washer and Sc...

Page 72: ...g from the Thermal Transfer Housing 4 Slightly compress the Take Up Hub Clutch then remove it from the Thermal Transfer Housing Replacement 1 Reinstall the Outer Bearing in the Thermal Transfer Housin...

Page 73: ...nplug the printer Raise the cover 2 Remove the three Screws that secure the Rewind Assembly to the Centerplate then remove the Rewind Assembly Centerplate Rewind Assembly Screws Replacement 1 Reinstal...

Page 74: ...m the Housing and to remove the Spur Gear remove the Screw that secures the Idler Post to the Rewind Housing Replacement 1 Reinstall the Outer Bearing in the Rewind Housing 2 Position the Rewind Hub C...