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Dover markem-imaje SmartDate 5, Maintenance Manual

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SmartDate 5

06/08

TABLE OF CONTENTS

5.12

Print Quality Problems

5-29

5.12.1

Poor Print Quality (when in DRS Mode)

5-30

5.12.2

Faded print

5-30

5.12.3

Faded on one side

5-31

5.12.4

Blurred edges

5-31

5.12.5

Missing lines perpendicular to printhead

5-31

5.12.6

Text missing at start of print

5-32

5.12.7

Text missing at end of print

5-32

5.12.8

Print rubs off

5-32

5.12.9

First Dots Missing or Ragged

5-33

5.12.10

Last Dots Missing or Ragged

5-33

5.12.11

Elongated or compressed print

5-33

5.12.12

Double printing

5-34

5.12.13

Prints occur on every other product (or less)

5-34

5.12.14

Overlapping prints

5-34

5.12.15

Cropped Prints

5-34

5.13

Job Selection Problems

5-35

5.13.1

Selecting a Job

5-35

5.13.2

Host PC

5-35

5.13.3

Image corruption problems

5-35

5.14

Checking Database Information

5-36

5.14.1

Local

5-36

5.14.2

Host

5-36

5.14.3

Database mode

5-36

5.15

Communication Problems

5-37

5.15.1

Communications Do Not Work

5-37

5.15.2

Selecting RS-232/RS-485 operation

5-38

5.15.3

RS-485 Node Numbers and Network ID

5-38

5.15.4

RS-232 (NGPCL) Communication

5-38

5.15.5

Networking Issues

5-39

5.15.6

Communication ports

5-39

5.15.7

Communications connection

5-39

5.15.8

Broken wires or shorts

5-39

5.16

Disaster Recovery

5-40

5.16.1

Recovery Using CoLOS Create Pro

5-41

5.16.2

Recovery Using CoLOS Control

5-42

5.16.3

Recovery Using SmartTouch

5-43

5.16.4

Recovery using the PC Tools Application

5-43

5.16.5

Recovery using Compact Flash

5-43

6

Recommended Spares

6-1

6.1

Consumables

6-1

6.2

Replacement Parts

6-1

6.3

Spares Kits

6-2

Summary of Contents for markem-imaje SmartDate 5

Page 1: ... ...

Page 2: ......

Page 3: ...2 6 2 Start Border 2 8 2 6 3 End Border 2 8 2 6 4 Head In Time 2 8 2 6 5 Ribbon Advance Distance 2 8 2 7 Moving the Printed Image 2 9 2 7 1 Registration 2 9 2 7 2 Offset 2 9 2 8 Timing issues 2 10 2 8 1 Print Timings 2 11 2 8 2 SmartDate 5 Intermittent Mode 2 13 2 8 3 Printing Time Intermittent Printers 2 14 2 8 4 Print Cycle Time Intermittent Printers 2 14 2 8 5 SmartDate 5 Continuous Mode and Sm...

Page 4: ...ement Roller 3 14 3 9 1 Replacing the Roller Magnet 3 14 3 9 2 Replacing the Movement Roller 3 15 3 9 3 Replacing the Ribbon Movement Sensor 3 16 3 10 Replacing the Ribbon Tension Roller 3 17 3 11 Replacing the Ribbon Tension Sensor 3 18 3 12 Replacing the Micro Switches 3 19 3 13 Replacing the Solenoid Valves 3 20 3 14 Replacing the Drive Belts 3 21 3 14 1 Replacing the Drive Belt Combined Printe...

Page 5: ...e 4 13 4 4 1 Print Module Components 4 14 4 4 2 Printhead Module Operation 4 15 4 5 Printhead Assembly 4 16 4 5 1 Printhead Type Detection 4 17 4 5 2 Printhead Temperature Control 4 17 4 5 3 Printhead Voltage Control 4 17 4 6 Printer Orientation 4 18 4 6 1 Orientation SmartDate 5 Printer 4 20 4 6 2 Orientation SmartDate 5s Shuttle Printer 4 23 4 7 Printer Calibration 4 25 4 7 1 Print Module Shuttl...

Page 6: ...1 4 9 The SmartDate 5 Controller 4 52 4 9 1 Controller Components 4 53 4 9 2 Mains Power Switch 4 54 4 9 3 Power Supply 4 55 4 9 4 Controller PCB 4 56 4 9 5 Controller PCB Micro processor 4 56 4 9 6 Controller PCB Components 4 57 4 9 7 Controller PCB Connectors 4 58 4 9 8 Controller PCB Test Points 4 59 4 9 9 Controller PCB LEDs 4 60 4 9 10 Controller PCB Links 4 62 4 9 11 Controller PCB Fuses 4 6...

Page 7: ...g 5 23 5 7 2 Ribbon Drive Problems 5 23 5 7 3 Ribbon Creasing 5 23 5 7 4 Ribbon Breaking or Scuffing Prints 5 24 5 7 5 Ribbon Coning Continuous Printers 5 24 5 7 6 Peel Roller Problems 5 24 5 7 7 Head not returning to home position 5 25 5 7 8 Shuttle not driving 5 25 5 7 9 Drive Belt Issues 5 25 5 8 Printhead Module Shuttle Carriage Drive Problems 5 26 5 9 Cassette Problems 5 27 5 9 1 Cassette Rel...

Page 8: ...35 5 13 1 Selecting a Job 5 35 5 13 2 Host PC 5 35 5 13 3 Image corruption problems 5 35 5 14 Checking Database Information 5 36 5 14 1 Local 5 36 5 14 2 Host 5 36 5 14 3 Database mode 5 36 5 15 Communication Problems 5 37 5 15 1 Communications Do Not Work 5 37 5 15 2 Selecting RS 232 RS 485 operation 5 38 5 15 3 RS 485 Node Numbers and Network ID 5 38 5 15 4 RS 232 NGPCL Communication 5 38 5 15 5...

Page 9: ...SmartDate 5 Maintenance Manual SECTION 1 GENERAL INFORMATION ...

Page 10: ......

Page 11: ...working order Topics covered in the following sections include General maintenance and cleaning Technical information about the SmartDate 5 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 ...

Page 12: ...ogistic Management System supported by strategic partnerships with other world class companies like UPS Worldwide Logistics Our regional repair centres 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 performan...

Page 13: ...SmartDate 5 Maintenance Manual SECTION 2 SETUP AND TIMING ISSUES ...

Page 14: ......

Page 15: ...owing section provides general advice for ensuring that your SmartDate 5 is working at its most efficient Topics covered in this section include Air pressure Printhead Gap Print Anvils Ribbons Printer Settings Print Signals Print Quality Issues Moving the printed image Timing Issues Speed Profiles DRS issues ...

Page 16: ...te is marked where the printhead has dug in Exceeding the stated pressure will over stress the printhead To get the optimum air pressure for the application it is recommended that the printhead to substrate gap is set between 1 0 and 2 0 mm See below for exact details The air pressure should then be set to 3 bar and gradually increased until a good quality print is apparent The operation of the so...

Page 17: ...er The following settings are recommended SmartDate 5 1 00 mm to 2 00 mm SmartDate 5s 1 00 mm to 2 00 mm SmartDate 5s 0 5 mm to 1 mm High throughput applications In situations where it is necessary to increase the printhead gap above 3 mm zipper bags the Tension adjust setting should be reduced See Section 6 Menus Ribbon Setup 2 2 4 Ribbons SmartDate 5 uses inside wound ribbon If this is webbed in...

Page 18: ... 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...

Page 19: ...pped moving 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 to...

Page 20: ...fter receiving a PRINT GO signal This is similar to the debounce time for Intermittent printers in that it ensures that the print signal is valid and not double triggering Note The Debounce Time and Debounce distance increase the overall cycle time of the printer and should be kept as low as possible On Continuous printers it is advisable where possible to set the debounce distance to zero Otherwi...

Page 21: ... to accelerate the ribbon SmartDate 5 takes into account the Head Out Time and determines when the head must be moved into position In this way the printhead is in position and ready to print at the same time as the ribbon and substrate speed match Note If there are problems with the start of the print e g the first part of the print is missing cut off it could be that the Head Out Time is set too...

Page 22: ...ng allows a number of blank lines steps 1 line 0 083mm or 0 0033 after printing This helps to compensate for certain printing applications where it is difficult to obtain good print quality at the end of the print The value should be set to the lowest value possible to ensure good print quality Setting this too high will increase the overall cycle time and limit the throughput This setting does no...

Page 23: ...rtDate 5 Intermittent if you have an image length of 40mm and you move the image down the printhead by 40mm then that gives you a total length of 80mm The maximum print length is only 74mm so you will miss the last 6mm 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...

Page 24: ...ing application works Timing issues can be common to the SmartDate 5 and SmartDate 5s Since the machines work differently it is likely that timing issues will vary with the machine type The following information address these differences Please note that the actual Timing settings are common for all types of machine The last recorded Print Cycle timings can be viewed from the Engineering Diagnosti...

Page 25: ... To access the Print Timings menu 1 From the Engineering screen menus select Diagnostics 2 The Diagnostics screen is displayed 2 Printer Configuration 3 Input Status Menu 1 All Select Back 3 From the Diagnostics screen menu select Print Timings 4 The Print Timings screen is displayed Printing Time 250 ms Diagnostics Back Print Timing Information ...

Page 26: ...g Time This is the time taken to print the image Print Cycle Time This is the time taken for the printhead to move out print and return to the Home position Imaging Time Time after selection to image the design in the printer memory Image Update Time Time taken to update any incremental fields in the design ...

Page 27: ... the SmartDate 5 3 Select the design 4 Set the required print speed 5 Do a print 6 Look at the timings in the Diagnostics menu On an Intermittent printer it is not the Cycle Time that is critical but the Print Time because the return stroke can be carried out when the host machine is moving the substrate onward It is therefore important when trying to decide whether or not the SmartDate 5 can be c...

Page 28: ...nt Print speed set in Controller End Border Head In time On a SmartDate 5 Intermittent this time MUST be less than the dwell time for the application to work 2 8 4 Print Cycle Time Intermittent Printers On receipt of a print signal the whole print cycle is as follows Debounce Time Print Delay Head Out time Start Border Print Print speed set in Controller End Border Head In time Return Speed ...

Page 29: ...the Repeat Time 2 8 6 Printing Time Continuous Printers The Printing Time in the Timing menu consists of the following Head Out time Start Border Print Print speed set by Encoder End Border Head In time 2 8 7 Print Cycle Time Continuous Printers On receipt of a print signal the whole print cycle is as follows Debounce Distance Print Delay Head Out time Start Border Print Print speed set by Encoder...

Page 30: ... during the machine cycle for the substrate speed to exceed the maximum printing speed for SmartDate 5 If the print occurs at this point in the cycle the print quality will be unacceptable or the print may be discarded completely To ensure that the print is occurring at the correct point in the machine cycle a speed profile can be recorded and uploaded to a SmartTouch unit or PC This data can then...

Page 31: ...ternal Quadrature or External Pulse Train The Controller must be connected to a SmartTouch unit or a PC running the PC Tools application Two other options must be set up The Resolution how often the substrate speed is recorded The Trigger The action that will initiate the Speed profile To access the first of these options 1 From the Engineering menu screen select Settings 6 Diagnostics Menu 4 Digi...

Page 32: ...screen is displayed 2 Image 3 Print Features Menu 1 Machine Select Back 3 Use the bottom Quad button to scroll to Encoder 4 Select Encoder by pressing the right button 5 The Encoder menu screen is displayed 2 Encoder Direction 3 Encoder Resolution Menu 1 Encoder Type Select Back ...

Page 33: ...hat the Encoder type is set to External Quadrature or External Pulse Train 8 Select Back by pressing the left button 9 Use the bottom Quad button to scroll to Speed Profile Recorder 10 Select Speed Profile Recorder by pressing the right button 11 The Speed Profile Recorder screen is displayed 2 Trigger Menu 1 Resolution Select Back 12 Configure the two options to the preferred requirements ...

Page 34: ...rigger option allows you to set what action initiates the start of the Speed Profile Manual Trigger This allows you to manually initiate the start of the speed profile With the SmartDate 5 set to producing mode access the speed profile menu Press Select to initiate the start of the speed profile Print Go Trigger will initiate the start of the Speed profile after the SmartDate 5 is set to producing...

Page 35: ...rate The amount of registration set after the Print Go signal The amount of Start and End border set The Debounce distance The Head down and Head up time The Return speed of the ribbon SmartDate 5 and SmartDate 5s continuous 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 distanc...

Page 36: ... maximum ribbon save ratio will be the ratio the printer uses at 1800mm s If the DRS ratio is set at less than 56 the maximum ribbon save ratio will be 2 25 1 If the DRS setting is set above 56 the maximum ribbon save ratio will be derived from the DRS setting Example With a DRS setting of 20 the distance from the Print Go signal to the start of print will be 10 91 start border x 2 25 29mm With a ...

Page 37: ...SmartDate 5 Maintenance Manual SECTION 3 MAINTENANCE ...

Page 38: ......

Page 39: ...keep your SmartDate 5 in good working order Topics covered in this section include General cleaning and care Maintenance schemes Care of the printhead Replacing the printhead Replacing the ribbon guide rollers Replacing the peel roller Replacing the ribbon movement roller Replacing the ribbon movement sensor Replacing the ribbon tension roller Replacing the ribbon tension sensor Replacing the Micr...

Page 40: ... food products are able to fall into the unit Turn off the power to the controller Turn off and isolate the air supply to the printer body Remove the printer cassette and 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...

Page 41: ... 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 Air is set to recommended pressure Check condition of Platen rubber SD5 Combined Intermittent mode Clean or replace it if necessary The platen rubber needs to be smooth flat ...

Page 42: ...dition 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 Cassette or Printer Check the magnet for any damage or non alignment This magnet is used for ribbon detection and ribbon calibration Print a test image to check printhead quality and alignment See Section 6 Menus Check condition of printhead shutt...

Page 43: ...als 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 print...

Page 44: ... 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 cleanin...

Page 45: ...ve the ribbon cassette Always ensure anti static precautions are used when handling new printheads 3 6 1 Removing the damaged printhead 1 Push the printhead forwards in the direction of the print line against the retaining spring 2 Swing the back of printhead outward this allows it to be removed from the print module 3 Disconnect the printhead cable from the printhead 4 Inspect the module componen...

Page 46: ...08 6 Push the printhead forwards in the direction of the print line against the retaining spring 7 Swing the back of printhead inwards this allows it to be secured into the print module 5 Connect the printhead cable to a replacement printhead ...

Page 47: ...ge 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 1272 The Printhead resistance option can be accessed from the Engineering menus To access the Engineering Menus 1 From the Menus screen select Eng...

Page 48: ... button to scroll to the Printhead Resistance menu 4 Press the right button to Select the menu 5 The Printhead Resistance menu screen is displayed Cancel Accept Printhead Resistance Currently New 1298 1270 6 Use the left and right Quad buttons to move the cursor 7 Use the top and bottom Quad buttons to change the date or time 8 When finished press the right button to Accept the changes ...

Page 49: ...ould be checked for damage and changed if necessary 1 Remove the retaining screw from the end of Peel roller 4 Clean off any excess fluid and ensure the roller is free to rotate 3 Fit a new Peel roller body over the shaft and secure the screw with Loctite 222 2 Remove the screw and washer and lift off the roller body ...

Page 50: ...NANCE 3 12 SmartDate 5 06 08 5 If the peel roller shaft has been damaged undo the retaining nut at the base and remove the complete assembly 6 Fit a new peel roller assembly and ensure that the retaining nut is secure ...

Page 51: ...d if they become bent or damaged The procedure is as follows 1 Remove the damaged roller by applying a spanner to the two flat surfaces at the base of the roller 2 Before fitting a replacement roller apply Loctite to the screw thread at the base of the roller 3 Place the new roller in position and tighten 4 Clean off any excess fluid and ensure the roller is free to rotate ...

Page 52: ...ovement roller has been damaged it will have to be replaced The procedure is as follows 1 Remove the securing screw on the end of the roller 2 Remove the damaged components 3 Fit a new set of components to the end of the roller and secure the retaining screw with Loctite 222 4 Clean off any excess fluid and ensure the roller is free to rotate ...

Page 53: ...bon guide rollers The procedure is as follows 1 Remove the damaged roller by applying a spanner to the two flat surfaces at the base of the roller 2 Before fitting a replacement roller apply Loctite 222 to the screw thread at the base of the roller 3 Place the new roller in position and tighten 4 Clean off any excess fluid and ensure the roller is free to rotate ...

Page 54: ...uld be as follows Switch off and disconnect the power to the machine 2 Remove the retaining screw from the printer base plate 3 Remove the sensor from the printer body 4 When fitting a replacement sensor ensure that the retaining screw is secured with Loctite 222 1 Remove the cover from the printer body and disconnect the sensor connector ...

Page 55: ...ribbon supply flange red may have to be removed to gain access to the securing screws The procedure is as follows 1 Remove the four retaining screws from the tension roller carriage 2 Remove the damaged tension roller assembly Be careful not to loose the spring or damage the linear slide assembly 3 Note the spring 4 Replace with a new assembly and secure the screws with Loctite 222 Do not forget t...

Page 56: ...machine 2 Remove the sensor retaining screws from the printer base plate 3 Remove the sensor from the printer body 4 When fitting a replacement sensor ensure that the retaining screws are secured with Loctite 222 1 Remove the cover from the printer body and disconnect the sensor connector After fitting a new Ribbon Tension sensor the sensor will require calibrating Please contact Markem Imaje for ...

Page 57: ...itch off and disconnect the power to the machine 2 Remove the micro switch retaining screws from the printer base plate 3 Remove the micro switch from the printer body 4 When fitting a replacement sensor ensure that the retaining screws are secured with Loctite 222 1 Remove the cover from the printer body and disconnect the appropriate micro switch connector ...

Page 58: ...s Switch off and disconnect the power to the machine 2 Disconnect the air pipes from the appropriate valve 3 Remove the securing screws and lift off the solenoid valve 4 When fitting a replacement valve ensure that the retaining screws is secured with Loctite 222 1 Remove the cover from the printer body and disconnect the PCB connectors and remove the PCB ...

Page 59: ...should be checked at regular intervals for wear or damage If the belt has to be replaced the procedure is as follows 3 14 1 Replacing the Drive Belt Combined Printer 1 Remove the four retaining screws from the print module 2 Pull the module upwards off the key and move it out of the way 3 Remove the securing screws from the print module carriage belt clamp 4 Loosen off the belt tensioner screws ...

Page 60: ...damaged drive belt 6 Remove the belt clamp and re fit it to the new belt 9 Adjust the belt tensioner allowing approximately 4 mm of movement on the belt 7 Fit the new belt onto the printer 8 Refit the Drive belt clamp 10 Position and re secure the print module ...

Page 61: ...tle Printer 1 Remove the two retaining screws from the finger guard and place to the side 2 Remove the four retaining screws from the print module 3 Pull the module upwards off the key and move it out of the way 4 Remove the three retaining screws from the printhead adapter plate ...

Page 62: ...e adapter plate and place to the side 6 Loosen off the belt tensioner screws 7 Remove the securing screws from the shuttle carriage 8 Remove the shuttle carriage and damaged drive belt SECTION 3 MAINTENANCE 3 24 SmartDate 5 06 08 ...

Page 63: ...08 10 Fit a new belt to the printer and re connect the Shuttle carriage 9 Remove the belt clamp and re fit it to the new belt 12 Adjust the belt tensioner allowing approximately 4 mm of movement on the belt 11 Secure the Shuttle carriage screws ...

Page 64: ...SECTION 3 MAINTENANCE 3 26 SmartDate 5 06 08 14 Position and re secure the print module 13 Re fit and secure the print module adaptor plate 15 Re fit the finger guard and the printer covers ...

Page 65: ...ng from Markem Imaje Switch off and disconnect the power to the machine Disconnect the printer from the controller and remove the side covers New Images required without Micro switches 1 Remove the four retaining screws from the print module 2 Pull the module upwards off the key and move it out of the way 3 Remove the printhead cable cover plate and place to the side 4 Move the printhead cable and...

Page 66: ...e it to the opposite side 5 Reposition the air pipes to suit the opposite hand Ensure that the rubber ring is close to the edge of the support bracket 7 Re fit the printhead cable cover plate Note Ensure that the air pipes run in the channel in the adaptor plate and that they are not trapped Note When replacing the screws use Loctite 222 retaining fluid ...

Page 67: ...SECTION 3 MAINTENANCE 3 29 SmartDate 5 06 08 9 Position and re secure the print module 10 Re connect the printhead cable and printer side covers ...

Page 68: ...m Imaje Switch off and disconnect the power to the machine Disconnect the printer from the controller and remove the side covers New Images required without Micro switches 2 Remove the four retaining screws from the print module 3 Pull the module upwards off the key and move it out of the way 1 Remove the two retaining screws from the finger guard and place to the side 4 Remove the three retaining...

Page 69: ...from the Peel roller and move it to the opposite side 5 Move the printhead adaptor plate to the opposite side and secure it using Loctite 222 7 Secure the Peel roller in the new position 8 Remove the three retaining screws from the ribbon cable cover and place to the side ...

Page 70: ...ule to the adaptor plate and secure the screws 12 Re connect the printhead to the print module 13 Re fit the finger guard and the printer covers Note Ensure that the air pipes run in the channel in the adaptor plate and that they are not trapped When replacing the screws use Loctite 222 retaining fluid Note After re handing the print module it will also be necessary to re hand the printer cassette...

Page 71: ...ette must also be changed Below is an example of how to re hand the shuttle cassette the procedure for the combined cassette is the same 1 Use a 11 mm spanner to undo the ribbon take up reel from the cassette body 2 Repeat this operation for the ribbon supply reel 3 Re fit the take up and supply reels on the opposite sides of the cassete body ...

Page 72: ...r PCB has to be replaced the procedure should be as follows Switch off and disconnect the power to the printer Remove the printer base cover 2 Disconnect the connectors from the printer PCB 3 Remove the retaining screws from the printer PCB heatsink 1 Remove the covers from the printer body ...

Page 73: ...f the PCB 5 Remove the retaining nuts from the printer PCB 4 Remove the securing nuts from the printer power control connector 6 Pull back the connector plate and release the PCB After fitting a new printer PCB the Ribbon Tension sensor will require calibrating Please contact Markem Imaje for details ...

Page 74: ...rtDate 5 06 08 9 Remove the printer PCB from the printer body 10 Replace the printer PCB with a new one Note When a Printer PCB is replaced the Printhead resistance has to be re entered and the Tension Sensor has to be re calibrated ...

Page 75: ... be as follows Switch off and disconnect the power to the printer 2 Remove the four retaining screws from the Controller cover 1 Remove the six retaining screws from the D type connectors 3 Lift off the Controller cover 4 Disconnect the various connectors from the PCB Caution Anti static precautions should be adhered to when handling PCB s ...

Page 76: ...Carefully remove the PCB from the controller unit Fitting a new controller PCB is the reversal of this process 5 Remove the two PCB securing screws SECTION 3 MAINTENANCE 3 38 SmartDate 5 06 08 ...

Page 77: ...SmartDate 5 Maintenance Manual SECTION 4 TECHNICAL INFORMATION ...

Page 78: ......

Page 79: ... Introduction This section is designed to provide quick access to Technical information about the SmartDate 5 machines Topics covered in this section include Printer Components Printhead Module Printer Orientation Printer Cassette Printer Electrical Components Controller Interfaces ...

Page 80: ...lligent control board Two distinct versions of the printer are available SmartDate 5 Intermittent Continuous Printer SmartDate 5s Shuttle Continuous Printer The mechanical components vary between printer types within the SmartDate 5 family New Images required without Micro switches Figure 4 1 SmartDate 5 Combined Intermittent Continuous Figure 4 2 SmartDate 5s Shuttle Continuous ...

Page 81: ...hows the main components of the printers SmartDate 5 1 3 3 2 5 4 8 6 9 7 Figure 4 3 SmartDate 5 Printer Components 1 Ribbon Tension Sensor 2 Ribbon Movement Sensor 3 Ribbon Motor Drive Couplings 4 Cassette Lock 5 Carriage Drive Belt 6 Micro Switch 7 Linear Slide 8 Printhead Module 9 Peel Roller ...

Page 82: ... 1 3 3 2 5 4 9 6 10 8 7 Figure 4 4 SmartDate 5s Printer Components 1 Ribbon Tension Sensor 2 Ribbon Movement Sensor 3 Ribbon Motor Drive Couplings 4 Cassette Lock 5 Carriage Drive Belt 6 Micro Switch 7 Shuttle Carriage 8 Linear Slide 9 Printhead Module 10 Peel Roller ...

Page 83: ...r slide is used only to position the Print module if an offset is required Under normal circumstances the print module would be moved to the datum position and the Printer body position would be adjusted to align the printhead with the centre line of the print roller With the Shuttle version of the SmartDate 5s printer the print module position is fixed and no movement is possible In this case the...

Page 84: ...8 The SmartDate 5 printers have the print module carriage plate mounted onto the bearing carriage This slide is positioned near the edge of the printer plate 1 3 2 1 Print Module Carriage Plate 2 Linear Slide 3 Micro Switch 4 Linear Bearing Carriage 1 4 ...

Page 85: ...8 08 The SmartDate 5s printers have the shuttle carriage plate mounted onto the bearing carriage This slide is positioned in between the carriage drive belts 1 3 2 4 1 Print Module Mounting Plate 2 Linear Slide 3 Micro Switch 4 Shuttle Carriage 1 3 4 ...

Page 86: ...e by means of a printhead carriage that is connected to the drive belt A stepper motor is used to drive a toothed drive belt around two geared pulley s one of which is used to tension the belt Printing occurs while the substrate is stationary II 1 2 Figure 4 5 SmartDate 5 LH Intermittent Mode 1 Carriage Drive Belt 2 Clamp Plate The printhead module is mounted on this carriage and is secured by fou...

Page 87: ...has no motion on the linear slide The stepper drive is used for positioning the print module only and has no function during the print process Printing occurs when the substrate is in motion The Ribbon drive system is responsible for accelerating the ribbon up to the same speed as the substrate so that printing can occur I 1 2 Figure 4 6 SmartDate 5 LH Continuous Mode 1 Carriage Drive Belt 2 Clamp...

Page 88: ... printer does not require the printhead to move over the substrate while printing occurs With this model the printhead module is held in a fixed position and is independent of the linear slide The linear slide in this machine is used for the shuttle carriage 1 2 3 Figure 4 7 SmartDate 5s Shuttle LH 1 Carriage Drive Belt 2 Shuttle Carriage 3 Clamp Plate ...

Page 89: ... the drive shafts of the shuttle are engaged into the two bushed holes in the shuttle carriage The ribbon shuttle is then driven backward and forward along the linear slide During printing the ribbon is required to accelerate up to the same speed as the moving substrate before printing can take place Printing occurs when the substrate is in motion The unique Markem Imaje shuttle drive system allow...

Page 90: ... The stepper motors are connected to the ribbon supply and waste take up spools via dog clutches 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 which then supplies data to a microprocessor in the printer ...

Page 91: ...The modular design means that it can be used for both Combined and Shuttle versions of the printer The print module can also be easily changed from a right hand to a left hand module The module houses the mechanism for printhead movement and the printhead assembly Printhead Note Future developments may include larger printhead widths and a different size module will be required ...

Page 92: ...to an actuator block assembly The actuator block also provides connection points for the cylinder air supplies The actuator block and printhead mounting block are connected to a linear slide Two of the cylinders are used to move the actuator block to the Prime position ready to print The third cylinder is used to move the printhead mounting block and printhead to the printing position Housing unit...

Page 93: ...s are activated and the printhead is moved to its prime position ready print 1 This action is performed by the air cylinder pistons moving the actuator block assembly on the linear slide The third cylinder is activated when the printer receives a valid print signal This moves the printhead into contact with the substrate ready to print 2 Prime Position 1 Print Position 2 ...

Page 94: ...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 pushing against the retaining spring and pulling the assembly away from the print module ...

Page 95: ...d the temperature is constantly monitored The Strobe and Cont pulse widths are adjusted by the firmware to compensate ensuring a consistent print darkness at varying temperatures 4 5 3 Printhead Voltage Control The printhead voltage is electronically adjusted under processor control A lookup table based on an spreadsheet based off the electrical data sheets provides a means of determining the requ...

Page 96: ...SmartDate 5 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 and access to remove the ribbon cassette With Continuous printers the print head angle must always be in the direction of travel of the substrate With Intermittent printers the substrate is stationary when being printed onto and the only issue ...

Page 97: ... the SmartDate 5 is to print from the underside of the substrate and the Cassette is to face in the same direction the opposite hand would be required Alternatively the same hand could be used but access to the Cassette would have to be from the opposite side Right Hand Printer showing Angle of the Printhead Direction of the Substrate travel Left Hand Printer showing Angle of the Printhead Directi...

Page 98: ... handing switch Once the hand of the printer is established the print module will either remain in the left hand datum position or move to the right hand datum position The Datum positions for the Combined printers are shown below The actual print positions of the print module will depend upon any offset that may have been set in the printer settings This is particularly so with SmartDate 5 when u...

Page 99: ... TECHNICAL INFORMATION 4 21 SmartDate 5 08 08 Direction of Substrate Travel Figure 4 8 SmartDate 5 Combined LH Intermittent Mode Direction of Substrate Travel Figure 4 9 SmartDate 5 Combined RH Intermittent Mode ...

Page 100: ...martDate 5 08 08 Below are examples of the print module in offset positions Direction of Substrate Travel Figure 4 10 SmartDate 5 Combined LH Continuous Mode Direction of Substrate Travel Figure 4 11 SmartDate 5 Combined RH Continuous Mode ...

Page 101: ...tDate 5 printer does not move It is held in a fixed position on the printer plate A micro switch determines if the printer is a left hand or a right hand The switch is situated under the position for the left hand module and is only activated when the module is a left hand If the switch is not activated the printer is assumed to be a right hand machine ...

Page 102: ...SECTION 4 TECHNICAL INFORMATION 4 24 SmartDate 5 08 08 Direction of Substrate Travel Figure 4 12 SmartDate 5s Shuttle LH Direction of Substrate Travel Figure 4 13 SmartDate 5s Shuttle RH ...

Page 103: ...e style of the printer Intermittent or Continuous is determined by a printer parameter setting Power up On power up the printer establishes the following information The printer hand The diameter of the ribbon reels The tension of the ribbon Cassette Removal If the cassette is removed and replaced the printer establishes the following The datum position of the print module The diameter and tension...

Page 104: ... shuttle is moved to the appropriate position for a left or right hand machine Power up On power up the printer establishes the following information The printer hand The diameter of the ribbon reels The tension of the ribbon The required position for the shuttle Cassette Removal If the cassette is removed and replaced the printer establishes the following The datum position of the shuttle The dia...

Page 105: ...ft or right hand version A stepper motor is used to drive a toothed drive belt around two geared pulley s one of which is used to tension the belt Printhead Module The drive belt is connected to a print module carriage plate that is mounted on the Linear Slide carriage The Printhead module is mounted on the carriage plate and is secured by four screws Shuttle Carriage The drive belt is connected t...

Page 106: ... Figure 4 14 Combined Printer LH Continuous During calibration the print module is always moved towards the left hand limit switch Dependant on the print module hand these switches will be activated in a certain order This determines if the printer is a left or right hand version The print module is then held at the left hand datum position or driven to the right hand datum position The datum posi...

Page 107: ...e printer is a left hand or a right hand printer The switch is situated under the position for the left hand module and is only activated when the module is a left hand Once this is established the printer will move the shuttle carriage to the appropriate datum position Shuttle Printer LH Shuttle Printer RH Datum Micro Switches ...

Page 108: ...ves the ribbon round a movement roller which has a 16 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 sensor detects the rotation of the multi pole magnet and outputs an analogue signal through one of the control units ADC inputs This signal is then analysed by the firmware to establish the diameters of the ribbon supp...

Page 109: ...CAL INFORMATION 4 31 SmartDate 5 08 08 Movement Roller Hall Effect Sensor Combined Printer LH Intermittent Combined Printer LH Cassette Movement Roller Hall Effect Sensor Shuttle Printer LH Shuttle Printer LH Cassette ...

Page 110: ...are used to interlock the cassette with the printer body The ribbon supply and waste take up reels have dog clutches which are used to connect to the printer ribbon drive motors When the Cassette is inserted into the printer body the drive dogs are pushed backwards into the ribbon supply and take up spool shafts This action releases the brake mechanism on the shafts and allows the ribbon to rotate...

Page 111: ... 4 33 SmartDate 5 08 08 4 7 4 Cassette Components 1 2 3 4 5 5 Figure 4 15 SmartDate 5 Cassette 1 Ribbon Movement Roller 2 Ribbon Tension Roller 3 Ribbon Waste Take up 4 Ribbon Supply 5 Ribbon Guide Rollers and Cassette location Pins ...

Page 112: ...Date 5 08 08 1 2 3 4 5 5 6 6 7 Figure 4 16 SmartDate 5s Shuttle Cassette 1 Ribbon Movement Roller 2 Ribbon Tension Roller 3 Ribbon Waste Take up 4 Ribbon Supply 5 Ribbon Guide Rollers and Cassette location Pins 6 Ribbon Guide Rollers 7 Shuttle ...

Page 113: ...agnet which is located into a Hall effect sensor when the cassette is interlocked with the printer body 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 Information such as ribbon breaks or remaining length of ribbon are controlled from this data ...

Page 114: ...ear slide on the cassette the end of the shaft is dome shaped and does not rotate When the cassette is interlocked with the printer body the end of the shaft comes into contact with the tension sensor As the ribbon tension increases the pressure that is applied to the sensor also increases The data from this sensor is then analysed by the processor and the stepper motors are adjusted accordingly ...

Page 115: ...e 5 08 08 4 8 Printer Electrical Components The image below show the main electrical components of the printers Printer PCB Motor and Sensor Connectors Stepper Motors Printer Power and Signals Connector Encoder Connector Solenoid Valves Printhead ...

Page 116: ...r configuration The motors are connected to the printer board via 6 way 2 54 mm Molex KK connectors Connection points X2 Carriage Motor X4 Ribbon motor 1 X7 Ribbon motor 2 When the Combined 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...

Page 117: ...y and waste take up reel diameters and to enable ribbon break detection The ribbon sensor input is connected to a Hall effect sensor mounted on the printer base plate The sensor detects the magnetic field of a multi pole magnet mounted on the ribbon movement roller as it rotates This signal from the sensor is analysed by the Micro control unit ...

Page 118: ...en the cassette is interlocked with the printer body the end of the ribbon tension roller shaft comes into contact with the ribbon tension sensor As the ribbon is driven the amount of tension applied to the roller varies and therefore the amount of pressure applied to the sensor The Micro control unit will then determine how much ribbon tension is required and adjust the ribbon stepper motors acco...

Page 119: ...CAL INFORMATION 4 41 SmartDate 5 08 08 Cassette Printer Body Linear Slide Ribbon Tension Roller Ribbon Tension Sensor Roller moves as the ribbon tension increases Note The end of the ribbon roller shaft does not rotate ...

Page 120: ...printer uses three micro switches There is one Printer Hand switch used to determine the handing of the machine There is a Left Hand Home switch There is one Cassette Open Closed switch The position of these switches is different for the SmartDate 5 printer and the SmartDate 5s Shuttle printer ...

Page 121: ...ter is deemed to be a Left Hand printer If the printhead module is assembled as a Right Hand printer an additional component is attached to the print module This ensures that the Home switch is activated but not the Handing switch When this switch is detected the handing switch is checked In this case the printer is deemed to be a Right Hand printer SmartDate 5s Shuttle Continuous Printer The swit...

Page 122: ...me switch the motor must rotate clockwise Left and Right hand Home switches If after calibration the printer is deemed to be a Left hand printer the print module will remain in the left hand position If after calibration the printer is deemed to be a Right hand printer the print module will traverse to the other side until it activates the right hand position micro switch Cassette Open Closed Dete...

Page 123: ...e the printhead to the Ready position One is used to activate the Print position cylinder This moves the printhead to the printing position Prime Position Solenoid This solenoid is activated when the Cassette is closed and causes the first two cylinders to move the printhead to the prime position Print Position Solenoid This solenoid is activated by a Print go signal and causes the third cylinder ...

Page 124: ...d and adjust the ribbon speed to match The recommended Encoder used with SmartDate 5 is a Quadrature style encoder Bi directional The four wires from the Encoder connect into the printer through a 9 way D type connector on the printer body This connection also provides connection points for two customer configurable outputs These are options that can be set up at the controller interface ...

Page 125: ...nt and solenoid actuation inputs and outputs The Continuous shuttle version of the printer interfaces with a speed encoder for matching of print speed It is connected to receives power from and communicates with the Controller unit via a single multi core cable The printer board has its own Micro controller which communicates with the Main Controller unit and a PLD Programmable Logic Device ...

Page 126: ...s The main components of the printer PCB are shown below X1 X2 X7 X4 X6 X16 X18 X17 X19 X12 X24 X5 X15 X14 X8 X20 X9 X3 X11 TP10 V44 TP3 TP29 F1 X45 V49 TP2 TP6 V50 V11 V6 TP1 V10 TP7 V33 V34 V35 TP9 TP8 TP4 TP5 4 8 9 Printer PCB Connectors The printer PCB connectors are listed below ...

Page 127: ...t Sensor X7 6W Molex Ribbon Wind Stepper Motor 2 X8 2W Molex Printer Hand Switch X9 4W Molex Left Head Home Switch X11 3W Molex Printhead Prime Position Solenoid X12 Header 7x2 Quadrature Encoder Input Status Output and Printer type ID X14 Header 5 x 2 Debug Port X15 Header 14 x 2 Debug Port X16 Header 8 x 2 Debug Port X17 Header 13 x 2 53 mm Printhead Power and Signals X18 Header 10 x 2 128 mm Pr...

Page 128: ...below Table 4 2 Printer PCB Test Points Test Point Function TP1 45VCP Controller to Printer TP2 5V Logic TP3 0VCP TP4 VPH Printhead Variable Voltage TP5 0VPH TP6 3 3V Logic TP7 2 5V Logic TP8 0V Logic TP9 0V Logic TP10 0V Logic TP29 24V Encoder 4 8 11 Printer PCB Fuse The printer PCB has two thermal resettable fuse F1 and F2 ...

Page 129: ...LD Yellow Flashes during PLD activity V44 Print Go Green On when Print Go signal is active V45 Status Front Panel Blue Power on This flashes off during the print cycle V46 Status Front Panel Tri Colour Green Producing Amber Warning Substrate over speed or under speed Red Ready Printing disabled Red Fault Flashes V47 Encoder Channel A Green On when Encoder channel A is active V48 Encoder Channel B ...

Page 130: ...e panel and various external connection points The User Interface panel uses a monochrome 1 bit 240 x 64 pixel screen with a six button membrane keypad The Controller is responsible for Power regulation and distribution Power and control for the printer Local User Interface control Serial communications Ethernet User configurable I O I O expansion Image data storage Image data transfer ...

Page 131: ...ponents of the Controller are shown below PCB Power Connector PCB Ethernet Connector Mains Power Connector Power Supply Unit User Interface LCD Connector Keypad Connector Power Supply Connectors Battery Main Power Switch Back Light Connector RS 232 RS 485 Comms External I O Printer Power Control ...

Page 132: ... 08 4 9 2 Mains Power Switch The power supply connector comprises of an On Off switch a IEC320 socket and a 250V Fuse holder Fuse Holder Power Connection On Off Switch No voltage configuration is required as the unit uses a universal input power supply ...

Page 133: ...ly The 45V for the stepper motors is routed via the Cassette closed switch for safety reasons 24V I O Supply The 24V supply powers the I O interfaces Logic Supplies The logic supply is split into four power rails 5V 3 3V 2 5V and 5VI 0VI Isolated Printhead Supply The printhead supply is based around an adjustable regulator that converts the 45V input to a software controlled voltage output The out...

Page 134: ...onnection points for Communication signals External I O and the SmartTouch user Interface The Controller PCB also provides power and control signals for the printer 4 9 5 Controller PCB Micro processor The Micro processor is responsible for the following Image manipulation Image data transfer to the Printer Communication signals Control of External Inputs and Outputs ...

Page 135: ...ON 4 TECHNICAL INFORMATION 4 57 SmartDate 5 08 08 4 9 6 Controller PCB Components X1 X14 X2 X3 X13 X15 X4 X8 X7 X6 X9 X21 X16 F1 F2 F5 F4 X11 12 F3 V26 V13 V16 V28 V4 V9 V12 V19 V21 V20 V3 V22 V2 V24 V35 PLD ...

Page 136: ...umber Connector Function X1 37W D Type SKT Printer Power and Signals X2 15W D Type PLG External I O X3 9W D Type PLG Auxiliary Communications X4 20W Molex Expansion I O X6 6W Molex Power Supply X7 Header 5 x 2 JTAG Port X8 Header 5 x 2 Power PC Debug Port X9 8W RJ45 SKT Ethernet 10 100 Base T X13 Header 8 Keypad X14 3W Molex LCD Back light X15 Header 10 x 2 Graphical LCD ...

Page 137: ...ntroller PCB Test points are listed below Table 4 5 Controller PCB Test Points Test Point Function TP10 5VI Isolated Comms Supply TP12 0VI Isolated TP14 45V Main PCB Supply TP15 5VL Logic TP16 3 3V Main PCB Logic Supply TP17 0VP Power TP20 0VL Logic TP21 2 5V PLD Logic Supply TP22 24V I O Supply ...

Page 138: ...when a Flash Device is being programmed V12 F2B Flash 1 Busy Illuminates only when a Flash Device is being programmed V13 PWR Power On Permanently Illuminated when 3 3V power supply is on V14 CPU Central Processor Unit Flashes during normal operation V15 SR Soft Reset Normally Off Flashes once on Power up or Software Reset V16 HR Hard Reset Normally Off Flashes once on Power up or Software Reset V...

Page 139: ...g Output Normally Open Relay Close on Warning V24 PG Print Go Input PNP Input V26 IN1 User Configurable Input PNP Input V28 TX RS 232 RS 485 Transmit Enable On when transmit is enabled V35 PLD Flashes when active Table 4 7 Controller PCB I O LEDs LED Description Function ...

Page 140: ...nput PNP Input Position A PNP X12 IN1 User Configurable Input PNP Input Position A PNP X16 Run Bootstrap Position A Default Position B Forced program refresh X21 Battery Position A Linked Position B Not Linked 4 9 11 Controller PCB Fuses The Controller PCB is fitted with thermal resettable fuses The Controller PCB fuses are listed below Table 4 9 Controller PCB Fuses Fuse Description F1 LCD Supply...

Page 141: ...Controller and Printer is a single multi core cable that carries the following Power supplies Serial channels for transferring printhead data Full Duplex serial data link to pass all control and monitoring information High speed control signals To ensure robust signal integrity the printer to controller link is via a twisted pair RS 422 interface The cable is terminated at each end with Male and F...

Page 142: ...4 on the Controller PCB The LCD connects via a 20 way IDC ribbon cable to X15 on the Controller PCB 4 9 15 Auxiliary Serial Comms Interface A 9 way D type connector provides RS 232 485 comms This enables the SmartDate 5 printers to be communicated with on a point to point basis RS 232 or Networked together RS 485 4 9 16 Ethernet Interface An Ethernet connection is provided as standard on the Smart...

Page 143: ...l customer inputs can be individually set to suit either PNP or NPN style devices Selection is made via jumper links X11 and X12 where position A is PNP default and B is NPN The green LED s on the Controller board indicate that the respective input is active Outputs All outputs are 24V PNP The yellow LED s indicate the status of each output Fault and Warning are volt free style outputs 30 V dc 1 a...

Page 144: ...lt configuration for the X2 pin numbers Table 4 10 X2 Default Configuration Pin Number Function 1 24V IO 2 Print Go 3 0V IO 4 User Configurable Input 1 5 X 6 X 7 Fault C 8 Fault N O 9 Warning C 10 Warning N O 11 User Configurable Output 1 12 0V IO 13 User Configurable Output 2 14 X 15 X ...

Page 145: ...SmartDate 5 Maintenance Manual SECTION 5 TROUBLESHOOTING ...

Page 146: ......

Page 147: ...ckly solve problems which may stop your SmartDate 5 working efficiently Topics covered in this section include Status LEDs Fault messages Warning messages Common Issues Drive System Issues Print Module Shuttle Carriage Drive Problems Cassette Problems Display Problems Print Quality Problems Job Selection Problems Communication Problems Disaster Recovery ...

Page 148: ... in Producing mode or Ready mode LEDs will also indicate if the printer is in a Fault condition The SmartDate 5 user Interface will also display any Warning or Error messages Some basic guidelines for troubleshooting follow 5 3 Fault and Warning Messages The messages are listed below along with potential causes and remedial actions ...

Page 149: ...Printer cable loose Faulty printer cable Printer PCB Fault Controller PCB Fault Remedial Action Power off the SmartDate 5 check that the connecting cable is secure and then re power Try a different printer cable Try a different printer unit Try a different Controller unit Fault Message 1001 Printer Power Supply Fault Description Printer fails to function Possible Causes The power supply to the pri...

Page 150: ...ead cable is loose The printhead cable is damaged The printhead is damaged Remedial Action Remove the cassette check printhead and printhead cable for damage Try a different printhead Try a different printhead cable Fault Message 1005 Software Fault Description A system fault has occurred Possible Causes The software has experienced an error condition Remedial Action Re power the SmartDate 5 Fault...

Page 151: ...e requires setting Possible Causes A new printer PCB has been fitted Remedial Action Set the printhead resistance level Fault Message 1008 Tension Not Calibrated Description The Tension sensor requires calibration Possible Causes A new printer PCB has been fitted Remedial Action Calibrate the Tension sensor Table 5 1 Fault Messages ...

Page 152: ...s screen to check the limit switch input signals Fault Message 1104 Calibration Failed initial Tension Description The printer will not calibrate 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 Open the cassette and check the rib...

Page 153: ...on tension roller is damaged The ribbon tension sensor requires calibrating Remedial Action Remove the cassette and 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 Offset Out of Range Description Unable to obtain the correct ribbon tension Possible Causes The ribbon tension s...

Page 154: ...assette and re web the ribbon Use the diagnostic screen to check the ribbon tension sensor input signal Fault Message 1202 Solenoid Fault Description One of the print module solenoid valves is not activating 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 functio...

Page 155: ...sible Causes Ribbon not fitted correctly in the cassette Remedial Action Remove the cassette re fit the ribbon Re insert the cassette to clear the fault Fault Message 1206 Low Air Pressure Description Possible Causes The air pressure has dropped Remedial Action Check the air pressure and increase if required Fault Message 1207 Multiple Missed Prints Description Possible Causes Print trigger sensor...

Page 156: ...te has stopped moving Intermittent printer Remedial Action Check the sensor Fault Message 1210 Encoder Failed Description Possible Causes The Encoder signal is not being received when Print Go signals are active Remedial Action Check the Encoder Fault Message 1211 Printhead Prime Failure Description Possible Causes Printer hardware fault Remedial Action Notify Markem Imaje Table 5 1 Fault Messages...

Page 157: ...ics screen to check the cassette closed micro switch input Fault Message 1301 1305 User Defined Faults Description User Defined Faults Possible Causes These faults are raised via the Flex I O inputs Remedial Action Fault Message 1306 Prnt Go while Allocation Complete Description The printer has stopped printing Possible Causes The allocation limit for the number of prints has been reached The numb...

Page 158: ...scription Image field data will not update Possible Causes NGPCL communications fault Remedial Action Check the communications connection and configuration Fault Message 1403 Log File Full Description Printing may be stopped depending on the option set for logging Possible Causes The system Log file has become full up Remedial Action Retrieve the log file or disable the variable data logging to co...

Page 159: ...lt Message 1501 Controller Overheat Description The controller temperature has reached an unacceptable level Possible Causes High ambient temperature Remedial Action Switch off the SmartDate 5 and allow to cool down Fault Message 1502 Printhead Over Temperature Description The printhead temperature is too high Possible Causes The print darkness level is too high The printhead is damaged The printh...

Page 160: ...ng 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 2000 Printhead Clean Required Possible Causes The printhead has performed a specified number of prints and requires cleaning Remedial Action Remove the cassette clean the printhead then replace the cassette Warning Messag...

Page 161: ...urring at the correct point of the packaging machine cycle Warning Message 2102 Truncated Print 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 Warning Message 2103 Cropped Print Possible Causes The image has been designed with fields which are off th...

Page 162: ...Offset has been reduced to prevent cropping of the image Remedial Action Reduce the amount of Offset Warning Message 2107 Substrate Over speed Possible Causes The substrate is travelling faster than the maximum print speed of the SmartDate 5 Remedial Action Reduce the substrate speed Warning Message 2108 Substrate Under speed Possible Causes The substrate is travelling slower than the minimum prin...

Page 163: ... Ribbon sensor requires calibrating Remedial Action Warning message cleared by operator action Warning Message 2113 Relative Motion Missed Print Possible Causes The substrate was moving when the Print Go signal was received Remedial Action Warning message cleared by operator action Warning Message 2114 Relative Motion Spoiled Print Possible Causes The printer failed to complete the print The subst...

Page 164: ...age 2203 Log File Wrap Round Possible Causes The log file has reached full capacity and is re starting the log Remedial Action If this is unacceptable re configure the Logging options Warning Message 2204 Log File Nearly Full Possible Causes The system log file is almost at full capacity Remedial Action Retrieve the log file or disable image field update data logging Warning Message 2205 Calendar ...

Page 165: ...ll Possible Causes The file system is full Remedial Action Delete unnecessary files from the system Warning Message 2209 Firmware Upgraded Settings Lost Possible Causes The Firmware has been upgraded and the machine settings have been returned to the factory default values Remedial Action Warning Message 2210 Firmware Upgrade Failed Possible Causes The attempted Firmware upgrade failed Remedial Ac...

Page 166: ... 2301 Controller High Temperature Possible Causes The controller temperature is reaching an unacceptable level Remedial Action Turn off the power to the SmartDate 5 and allow the controller to cool down Warning Message 2302 Printhead Under Temperature Possible Causes The printhead temperature has not yet reached an acceptable working level Remedial Action The SmartDate 5 will automatically initiat...

Page 167: ...ose connections may be the cause of many problems such as poor print no print or no power to the printhead Check that there are no kinks in the printhead data flexible ribbon cable Check that the wires in the printhead power cable are securely fastened to the connectors 5 4 3 Encoder Check that the encoder is rotating freely The SmartDate 5 in continuous mode or SmartDate 5s will not print unless ...

Page 168: ...inthead Is it driving correctly Check that the air supply is at the appropriate pressure On continuous printers the encoder signal may not be providing the correct speed information The printhead may be faulty 5 6 The Printhead Does Not Move Out The Printhead in out motion is driven by a small pneumatic solenoid If the head does not move out use Manual mode to test the operation of the solenoid Ch...

Page 169: ...arkness 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 5 7 3 Ribbon Creasing Ribbon creasing is generally due to the ribbon attempting to track across the Printhead The most common cause...

Page 170: ...temperature is below 5deg C 5 7 5 Ribbon Coning Continuous Printers If there is a problem with the waste ribbon coning on the take up reel check the following 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 cassette rollers and is positioned correctly En...

Page 171: ... 0 5 7 8 Shuttle not driving SmartDate 5s only Check that the shuttle drive belt is not damaged or broken 5 7 9 Drive Belt Issues The drive belts are tensioned by adjusting the position of the idler pulley If any of the belts are slipping this will cause carriage feed or print quality problems The drive pulley on the stepper motor drive shaft should also be secure When the belt is tensioned correc...

Page 172: ...nder excessive load If the carriage does not drive check the following 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 ...

Page 173: ...urrent product will not be printed 5 10 Cassette Insertion Problems If the cassette will not insert into the printer body check the following SmartDate 5 Check that there is no mechanical interference Check that the cassette rollers are not bent SmartDate 5s Check that the Shuttle mechanism is set to the home position before insertion Check that the Shuttle rollers are not bent or damaged Replace ...

Page 174: ...e the Controller LCD module If necessary replace the Controller PCB 5 11 2 LCD only no Back light If the LCD text is visible but the back light is not on check the following Has the back light connector to the controller PCB become loose Is the wiring damaged If necessary replace the Controller LCD module If necessary replace the Controller PCB 5 11 3 Display is totally blank Check the status ligh...

Page 175: ...vibration of the packaging machine Improve the mounting of the SmartDate 5 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 Ma...

Page 176: ...ir 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...

Page 177: ... the printhead is misaligned loosen the screws on the mounting bracket and align the printhead along the roller Tighten the screws and try a test print 5 12 4 Blurred edges This is generally due to the darkness setting being too great however it could also be compromised if DRS is enabled Recommendations Reduce the darkness or increase the print speed 5 12 5 Missing lines perpendicular to printhea...

Page 178: ...s the background energy levels of the head can make a difference to the permeability Putting the SmartDate 5 in High Speed Mode will also make a difference 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...

Page 179: ...agged Increase the End Border if you experience print quality problems such as the last dots of the print are missing or ragged The printhead will move X lines Set in End Border on the ribbon when the print is complete 5 12 11 Elongated or compressed print Intermittent printers The printhead is printing on the substrate when it is still moving Modify the Print Delay Parameter Depending on whether ...

Page 180: ...inter this can be done by increasing the print speed or possibly the return speed depending on the particular application On a Continuous printer this can be done by increasing the return speed only Also check the Debounce and Delay Time Registration setting is too long Continuous only This can increase the Cycle time to be greater than the product to product time thus only printing every other pr...

Page 181: ...5 13 2 Host PC If a host PC is being used it is important that the communication parameters are set correctly both at the PC and the SmartDate 5 5 13 3 Image corruption problems Images can occasionally become corrupted This would be noticed in the form of missing text fields on the image or not being able to select a Job To ensure that the images are as they should be it is best to clear the probl...

Page 182: ...u must have the correct mode selected on the SmartDate 5 for Job selection to be possible If it is a stand alone SmartDate 5 you should be in Local mode If you are part of a network of SmartDates connected to a PC then you could be using Local mode or you could be in Host mode depending on the particular application To determine whether you are in Local mode or Host mode select a product using the...

Page 183: ...D on CoLOS Control Are the Ethernet cable or connectors faulty RS 485 Communications Is the SmartDate 5 serial Port 1configured correctly DCP RS 485 Is Serial Port 1 Baud Rate configured correctly This must be the same as the setting on CoLOS Control Is Serial Port 1 CimComms Node configured correctly This must be the same as the Device setting on CoLOS Control Is the DCP Actor name Device Network...

Page 184: ...ue actor name and node number This should be set to individual numbers for RS 485 operation When using DCP over a RS 485 network the Machine Network ID Actor name must also be the same on the SmartDate 5 as it is for the Device in CoLOS Control Node number Range 1 to 31 Device Network ID variable up to 16 characters The effects of having more than one machine with the same node number or Device Ne...

Page 185: ...00 57600 or 115000 Data bits 8 Parity None Stop Bits 1 RS485 You should make sure that the RS485 port selected in CoLOS Control is the actual Comm port connected on your PC Typically Com1 on the network card is Com3 on the PC Com2 on the network card is Com4 on the PC 5 15 7 Communications connection For details of the pin connections please refer to Section 3 Installation and Section 12 Electrica...

Page 186: ...b information There are two methods of backing up the contents of the SmartDate 5 memory depending on whether you have purchased certain options If you can say Yes to one of the questions below go to the SmartDate 5 General Operation section of the manual and follow the instructions given Questions Do you have CoLOS Create Pro Design Software Do you have CoLOS Control networking software Do you ha...

Page 187: ... your CoLOS Create Pro Help files for details on how to download Jobs Settings Files CoLOS Create Pro does not support the uploading downloading of printer settings files Settings files are created using Markem Imaje CoLOS Control software The Markem Imaje service engineer should if requested leave you with a copy of the settings file for the particular application This file can also be printed ou...

Page 188: ...ings to refresh the details Select Save Settings name the file and save the settings file to an appropriate place on your PC This file can then be attached to a Job file or used to re install your specific printer setting to your SmartDate 5 To download the settings file to the SmartDate 5 or a different SmartDate 5 select the Download Settings option for the appropriate Device 5 16 3 Recovery usi...

Page 189: ...SmartDate 5 Maintenance Manual SECTION 6 RECOMMENDED SPARES ...

Page 190: ......

Page 191: ...8mm 1 B03285AA Head cleaning kit 1 B03286AA Cleaning kit top up 1 5824648 Cleaning wipes Pack 100 1 6 2 Replacement Parts Table 6 2 Replacement Parts Part Number Description Quantity 10031959 Guide roller assembly 4 10029510 Locating guide roller assembly 2 10026546 Peel roller assembly 1 5825287 Shuttle assembly SD5s 1 5630381 Toothed drive belt 1 5825294 Drive belt tensioner pulley assembly 1 52...

Page 192: ...ummary of Spares Kits Available Part Number Description Quantity 5564972 Combined Basic Spares Kit 1 5564974 Shuttled Basic Spares Kit 1 5825371 Printer Hardware Kit 1 5825343 Controller Hardware Kit 1 5825286 Roller magnet replacement kit 1 5825358 Ribbon retention spring kit 1 ...

Page 193: ...nsion sensor roller spring 1 5825286 Roller magnet replacement kit 1 5943530 Peel roller body 1 5825548 Adaptor plate assembly 1 Table 6 5 Shuttled Basic Spares Kit 5564974 Part Number Description Quantity B04297AA T5AH250V Fuse 2 5825051 Ribbon cable assembly 1 5825334 Print solenoid valve assembly 1 5825396 Cassette latch switch assembly 1 5825050 Limit switch assembly 1 5630381 Toothed drive be...

Page 194: ... SmartDate 5s Shuttled printer Left Hand Table 6 8 Spare Cassette Part Number Description 10030245 SmartDate 5 Combined cassette Right Hand 10030243 SmartDate 5 Combined cassette Left Hand 10030249 SmartDate 5s Shuttled cassette Right Hand 10030247 SmartDate 5s Shuttled cassette Left Hand Table 6 9 Spare Printer Cassette Part Number Description 10031984 SmartDate 5 Combined printer Right Hand 1003...

Page 195: ...r power and signals cable 3 0 m 37 way D type connector UL approved 1 5686423 Low Profile Printer power and signals cable 10 0 m 37 way D type connector UL approved 5686441 Standard Profile Printer power and signals cable 1 0 m 37 way D type connector UL approved 1 5686443 Standard Profile Printer power and signals cable 3 0 m 37 way D type connector UL approved 1 5686445 Standard Profile Printer ...

Page 196: ...k cable LAN Ethernet RJ45 connector 1 5686406 PC cross over cable Ethernet RJ45 connector 1 5824644 Communication 232 Cable assembly 9 way D type connector UL approved 1 Table 6 12 Recommended Power Cable Spares Part Number Description Qty 5686230 IEC320 Mains Lead European Colour 5 0 m Euro 1 5686229 IEC320 Mains Lead N America Colour 5 0m UL approved 1 ...

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Page 198: ...User Documentation Department ...

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