Videojet 6210 Service-Manual

8/17/2019 Videojet 6210 Service-Manual

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PegasusHS

Service Manual

P/N 361854-21

Revision: AA, November 2006


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Copyright 2006, Clearmark solutions LLP. (herein referred to as ICE). All rights reserved.

This document is the property of Clearmark solutions.and contains confidential andproprietary information owned by ICE Any unauthorized copying, use or disclosure of it

without the prior written permission of ICE is strictly prohibited.

ICE (interactive coding equpiment)

Phone: 01159 640144

Fax: 01159 639317

Olympic House,Willow Drive

Sherwood Park,Nottingham

NG15 0DP

www.interactivecoding.com


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Rev AA i

Compliance Information

For Customers in U.S.A.

This device complies with Part 15 of the FCC Rules. Operation is

subject to the following two conditions: 1) this device may not causeharmful interference, and 2) this device must accept any interferencereceived, including interference that may cause undesired operation.

Warning

Changes or modifications to this unit not expressly approved bythe party responsible for compliance could void the user’sauthority to operate the equipment.

This equipment has been tested and found to comply with the limitsfor a Class A digital device, pursuant to Part 15 of the FCC Rules.

These limits are designed to provide responsible protection againstharmful interference when the equipment is operated in a commercialenvironment. This equipment generates, uses, and can radiate radio

frequency energy and, if not installed and used in accordance with theinstruction manual, may cause harmful interference to radiocommunications. Operation of this equipment in a residential area is

likely to cause harmful interference. In such cases, the users will berequired to correct the interference at their own expense.

Shielded cables must be used with this unit to ensure compliance withClass A FCC limits.

The user may find the following booklet prepared by the FederalCommunications Commission helpful: How to Identify and ResolveRadio-TV Interference Problems. This booklet is available from theU.S. Government Printing Office, Washington, DC 20402, Stock No.004-00-00345-4. This equipment has been tested and certified forcompliance with U.S. regulations regarding safety and electricalemissions by TUV Rheinland of North America, Inc.

For Customers in Canada

This digital apparatus does not exceed the Class A limits for radionoise emissions from digital apparatus set out in the RadioInterference Regulations of the Canadian Department ofCommunications.

This equipment has been tested and certified for compliance withCanadian regulations regarding safety and electrical emissions byTUV Rheinland of North America, Inc.


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ICE Pegasus Service Manual

ii Rev AA

Pour la Clientèle du Canada

Le present appareil numerique n’emet pas de bruits radioelectriquesdepassant les limites applicales aux appareils numerique de las class Aprescrites dans le Reglement sur le brouillage radioelectrique edictepar le ministere des Communications du Canada.

Cet équipement est certifié CSA.

For Customers in the European Union

This equipment displays the CE mark to indicate conformance to thefollowing legislation.

• EN55022:1998

• EN55024:1998

• EN61000-6-2:2001

• FCC CFR 47 parts 15.107 and 15.109


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Rev AA iii

Support and Training

Contact Information

If you have any questions or need assistance, please contact ICE

Technologies Inc. at 01159 640144

Interactive Coding Equipment (ICE)

Olympic House

Willow Drive

Sherwood Park

Nottingham

NG15 0DP

T: 01159 640144

F: 01159 639317

Service Program

About Total Source Commitment

Total Source® TOTAL SERVICE PLUS RELIABILITY, is the ICE.

commitment to provide you - our customer - the complete service

you deserve.

The Total Source Commitment

The ICE Service Program is an integral part of our business inproviding marks, codes, and images where, when, and how often

customers specify for packages, products, or printed materials. Our

commitment includes:

• Applications support

• Installation services

• Maintenance training

• Customer response center

• Technical support

• Field service

• Extended hours phone assistance

• Parts and supplies

• Repair service


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Customer Training

If you wish to perform your own service and maintenance onthe printer, ICE. highly recommends that you complete aCustomer Training Course on the printer.

Not e: The manuals are intended to be supplements to (and not replacements for) ICE. Customer Training.

For more information on ICE. Customer Training Courses, call 01159640144.



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Rev AA i

Table of Contents

Compliance Information

For Customers in U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iFor Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iPour la Clientèle du Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiFor Customers in the European Union. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Support and Training

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiService Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiCustomer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Chapter 1 — SafetyIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

Safety Conventions Used in the Manual. . . . . . . . . . . . . . . . . . . . . . . . 1–2

General Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

General Caution Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Comply with Electrical Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Do Not Remove Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

Placement of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

Using Printer Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

Chapter 2 — Introduct ion

Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Theory of Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Intermittent Motion Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Continuous Motion Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

Chapter 3 — Technical Descript ion

Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

Installing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

CLARiTY Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

Installing the Ribbon in the Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8

Adjusting the Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12


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Working with Printer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .3–12

Product Sensors/Print Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–12

Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14

Interlocks and Annunciation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15Data Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–16

Switching the Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–18

Configuring the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–19

CLARiTYTM Configuration Manager. . . . . . . . . . . . . . . . . . . . . .3–19

Installing the CLARiTY Configuration Manager . . . . . . . . . . . .3–21

Connecting the CLARiTY Configuration Manager to the Printer3–21

Editing Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23

Saving the Changes in the Printer . . . . . . . . . . . . . . . . . . . . . . . . .3–24

Archiving the Current Parameters. . . . . . . . . . . . . . . . . . . . . . . . . 3–24

Loading a Saved Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25

Working with the Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . .3–25

The Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25

The Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25

Default Options Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26

Chapter 4 — CLARiTY Operating System

Getting started with the CLARiTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1

Using the Tools Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–2Working with Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3

Working with Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8

Working with Passwords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–25

Password Protection Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–26

Chapter 5 — Maintenance

Maintaining the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

Replacing the Mains Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–2

Maintaining the CLARiTY Controller . . . . . . . . . . . . . . . . . . . . . . . . . .5–3Replacing the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . .5–3

Replacing the CLARiTY Processor PCB and LCD TouchscreenAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–5

Maintaining the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–11

Replacing the Compact Flash Card . . . . . . . . . . . . . . . . . . . . . . . .5–11

Replacing the Main PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12

Replacing the Peel Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–15

Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–17

Setting the Printhead Resistance . . . . . . . . . . . . . . . . . . . . . . . . . .5–18

Maintaining the Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–19



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Updating the CLARiTY Operating Software . . . . . . . . . . . . . . . . . . . 5–23

Chapter 6 — System Events

Chapter 7 — Troubleshooting

Chapter 8 — Illustrated Parts List

How to Read the IPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

Alphabets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4

Printer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5

Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5

Cassette Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8

Printer Ribbons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

Chapter 9 — Drawings

Printer Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

Electrical Wiring Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4



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Rev AA Introduction 1-1

1Safety

This chapter contains the following topics:

• Safety conventions used throughout this manual

• Important safety guidelines to follow while operating the equipment

Warning

EQUIPMENT MAINTENANCE. Read this chapter thoroughlybefore attempting to install, operate, service, or maintain thisproduct.

IntroductionThe policy of ICE. is to manufacture printing/coding systems andsupplies that meet high standards of performance and reliability.Therefore, we employ strict quality control measures to eliminate thepotential for defects and hazards in our products.

The intended use of this printer is to print information directly onto theproduct. Use of this equipment for any other purposes may lead to seriouspersonal injury.

The safety guidelines provided in this chapter are intended to educate theoperator on all safety issues, so that the operator can operate the printer

safely.


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1-2 Safety Conventions Used in the Manual Rev AA

Safety Conventions Used in the ManualSpecific safety information is listed throughout this manual in the form of

Warning statements. Pay close attention to these statements as theycontain important information that help in avoiding potential hazards toyourself or to the equipment.

General Warning Notices

The following warnings supplement the specific warnings that appearelsewhere in the manual. These are general warnings which must be read,completely understood, and applied by all the personnel involved in theoperation, and/or the maintenance of the machine.

Warning

PERSONAL INJURY. Only trained service or maintenance

personnel should perform these installation procedures. Qualifiedpersonnel have successfully completed the training courses, havesufficient experience with this printer, and are aware of the potentialhazards to which they may be exposed.

Warning

PERSONAL INJURY. Before attempting any maintenance or repairon any part of the product, disconnect the printer from the mainpower supply and isolate the printer from any external energysources including other connected equipment.

Warning

PERSONAL INJURY. Before connecting the compressed air supply

to printer, ensure that the air supply has been isolated. Turn theregulator adjustment knob counter-clockwise.

Warning

PERSONAL INJURY. The printer uses an operator control console.Ensure that this panel is mounted at an appropriate working heightand orientation for comfortable operation.



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Rev AA Safety Conventions Used in the Manual 1-3

Warning

PERSONAL INJURY. Keep hands and clothing clear of the printerwhile it is on.

Warning

PERSONAL INJURY. To ensure that the connecting cables and pipesdo not become a trip hazard or become entangled in any machinery,all connecting cables and pipes must be secured safely duringinstallation.

Warning

ELECTRICAL HAZARD. Voltages used to connect the printer to

other equipment must be limited to no greater than 50 V DC or peakAC.

Warning

ELECTRICAL HAZARD. Always wear a properly ground wrist-ground strap when handling printed circuit boards. Failure to do socan result in damage to the board components due to staticelectricity.

General Caution Notices

The following caution statements supplement the specific cautions that

appear elsewhere in the manual. These are general cautions, which mustbe read, completely understood and applied by all the personnel involved

with the operation, and/or the maintenance of the machine.



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1-4 Safety Guidelines Rev AA

Caution

EQUIPMENT MAINTENANCE. Before and after performing anymaintenance or repair on the product, check that the two safetylabels are clearly visible. One is on the power supply cover and theother by the potential nip point next to the pulley in the printerbody.

Caution

EQUIPMENT DAMAGE. The use of incompatible ribbon can

seriously damage your printer and such damage is not covered byyour printer warranty. Use only ribbon approved by your dealer.

Safety GuidelinesThis section contains important safety guidelines pertaining to theoperation and handling of the printer and associated equipment.

Warning

SAFETY GUIDELINES. Always observe the following safetyguidelines when operating and handling the printer and associatedequipment.

Comply with Electrical Codes

All the electrical wiring and connections must comply

with applicable local codes. Consult the appropriateregulatory agency for further information.



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Rev AA Placement of the Printer 1-5

Do Not Remove Warning Labels

Do not, under any circumstances, remove or obstruct anywarning or instruction labels on the printer.

Placement of the Printer

Warning

PERSONAL INJURY. Do not place the printer in a hazardous

location. Hazardous locations might create an explosion, leading topersonal injury.

Hazardous locations, as defined in the United States, are those areas thatmay contain hazardous materials in a quantity sufficient to create an

explosion. These are defined in Article 500 of the National Electrical CodeANSI/NFPA 70–1993.

Outside the United States, you must ensure compliance with all localregulations regarding equipment placement in potentially hazardous

locations.

Using Printer Accessories

To maintain regulatory approval for the printer, use only Videojetapproved accessories when attaching any device to the equipment.



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Rev AA Equipment Description 2-1

2Introduction


• A description about the intended use of the product

• Information about the audience for whom this manual is intended

• A description of how the manual is organized

• Information about other manuals that are associated with this printer

• A description of the theory of printing

Warning

PERSONAL INJURY. Read Chapter 1, “Safety” before attempting tooperate the equipment.

Equipment DescriptionThe Videojet 6210 printer uses high-resolution thermal transfertechnology with a unique electronic ribbon drive system. The printeroffers greater reliability and ease of operation compared to earliersystems. It can print barcodes, dates, text, and graphics onto flexiblepackaging films and labels.

The printer is a suitable replacement for either hot stamp or rotaryprinters. It can print in either of the following modes:

• Intermittent Mode (i.e., while the substrate is stationary)

• Continuous Mode (i.e., while the substrate is moving)

It is suitable for use on most horizontal form/fill/seal, vertical form/fill/seal, and self-adhesive labeling machines.

The product is available in either left-handed or right-handed versions tosuit different configurations of the packaging machine.


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2-2 About this Manual Rev AA

About this ManualThis service manual includes information about installing, maintaining,

troubleshooting, and servicing the printer. It also contains sections aboutthe theory of operation and component identification, including anillustrated parts breakdown.

This document is intended to be used only by trained service personnel. Itis intended to be a supplement to (and not a replacement for) formal

training. Keep this manual in a safe location where it can be easilyaccessed for reference.

Related documents

The Videojet 6210 Operator Manual (P/N 361853) is intended for theoperator and contains information on routine operation of the printer.Unless specified, all procedures in this manual can be performed by theoperator of the printer. It is mandatory that the personnel read theOperator Manual before reading the Service Manual.

This manual is a supplement to (and not a replacement for) formaltraining.

Warning

PERSONAL INJURY. Customers who intend to service andmaintain the printer themselves must use only qualified personnel

to perform these procedures. Qualified personnel have successfullycompleted the training courses, have sufficient experience with thisprinter, and are aware of the potential hazards to which they may be

exposed.



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Rev AA Theory of Printing 2-3

Theory of PrintingThe information on how the thermal transfer printer works is as follows

(Figure 2-1):• The printhead contains miniature heating elements under a glass

coating (300 dpi - 12 dots/min)

• A carrier ribbon, with ink bonded to one side is used as the printingmedia

• The printhead presses against the thermal transfer ribbon with the inkside of ribbon in contact with the substrate, creating an image.

• Print elements heat small areas of the ribbon and this transfers the inkto the target substrate

• The printhead and the substrate move relative to each other

• The print elements are programmable and controlled to create animage

Intermittent Motion Printing

Intermittent motion printing (Figure 2-2 on page 2-4) is the concept usedfor printing on stationary packaging films in packaging equipment thathas a start/stop action each time a product is packed. Such applicationscan be found in intermittent Vertical Form Fill Seal (VFFS) or baggingmachines, and self adhesive label applicators.

Intermittent motion printing has the following features:

• The substrate is stationary

1

2

3

4

5 6

1. Ribbon Transferred Carbon

2. Substrate

3. Platten Rubber

4. Ink

5. Base Film

6. Thermal Printhead

Figure 2-1: Printing Process



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2-4 Theory of Printing Rev AA

• The printhead traverses across the ribbon, causing print to transferonto substrate.

• The printhead presses against a flat platten pad.

Continuous Motion Printing

Continuous motion printing (Figure 2-3 on page 2-5) is the concept usedfor printing on moving packaging films in packaging equipment that has acontinuous moving action each time a product is packed. Suchapplications can be found in Continuous Vertical Form Fill Seal (VFFS)and Horizontal Form Fill Seal (HFFS) or flow-wrap machines.

Continuous motion printing has the following features:

• The substrate moves while the printhead is stationary

• Speed of the substrate is monitored by an encoder

• The ribbon and the substrate speeds are matched by the ribbon drive

• The printhead presses against a rotating print roller

1

2

3

4

1. Ribbon Transferred Carbon

2. Substrate

3. Platten Rubber


Figure 2-2: Intermittent Printing Motion

HEAD OUT

HEAD INPRINT



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Rev AA Theory of Printing 2-5

1

2

3

4

RIBBON FEED

MATERIAL FEED

1. Ribbon Transfer Carbon Print

2. Platten Roller

3. Substrate


Figure 2-3: Continuous Print Motion



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Rev AA Unpacking the Printer 3-1

3Technical Description


• Unpacking the Printer

• Installing the Printer

• Mounting Considerations

• Installing the Ribbon in the Cassette

• Adjusting the Air Pressure

• Working with Printer Connections

• Switching the Power On

• Understanding Printhead LEDs

• Configuring the Printer

• Working with the Configurable Inputs and Outputs

Unpacking the Printer Inspect the kit for any damage carefully. Refer the list of parts inTable 3-1 and Figure 3-1 on page 3-2. If any item is damaged ormissing, call ICE., Customer Service Department at 01159 640144.

Printer Part

Printer

Cassette

CLARiTY Controller

Air Regulator

Power Cable

I/O Low Profile Cable Assembly

Table 3-1: Printer Configuration Parts List


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3-2 Unpacking the Printer Rev AA

CLARiTY Configuration Manager CD

4mm Air Tubing

CLARiTY Controller Bracket

QA Documentation and CE Certificate

Printer Part

Table 3-1: Printer Configuration Parts List (Continued)

1. Air Regulator

2. 4mm Air Tubing

3. CLARiTY Controller

4. CLARiTY Controller Bracket

5. Power Cord

6. Printer

7. I/O Low Profile Cable

Assembly

8. Cassette

9. CLARiTY Configuration

Manager CD-ROM

Figure 3-1: Printer Configuration Parts

1

2

3

4

5

67

8

9



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Rev AA Installing the Printer 3-3

Installing the Printer Ensure that the following services are available while the printer is being

installed:• Power: 90 - 264 VAC, 320 VA, 47 - 63 Hz

• Compressed Air: 87 psi (6 bar) max, dry, uncontaminated with a 6 mmpipe fitting

• Print signal: This is the signal that triggers the printing operation and

can either be a:

- PLC signal

- 24 V DC, PNP registration photocell

- 24 V DC, PNP proximity switch detecting a cam timing point• An encoder kit (P/N 403358) is required to monitor the speed of the

packaging film on continuous motion packaging machines.

Mounting ConsiderationsThe thermal printhead must act against a flat print platen (in anintermittent mode) or a print roller (in a continuous mode) in order toprint. The platen or roller is a part of the mounting bracketry.

Printer

The printer can be mounted in any orientation. However, it is important toensure that adequate operator access is available to remove and replacethe cassette easily.

The exact position of the printer relative to the packaging machine, needs

to account for:

• The physical constraints of the available space and operator access

• The required position of the print on the substrate

Figure 3-2 on page 3-4 shows the relevant dimensions of the printerrelative to the mounting holes and the printhead. It also shows theadditional space required to give adequate clearance to cables and airpipes that connect to the unit.



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3-4 Mounting Considerations Rev AA

Mount the printer using four M6 screws. Consider the direction of travel

of the target material relative to the printer, when you mount the printeron a continuous motion packaging machine. This determines whether theprinter in use is left-handed or right-handed (Figure 3-3).

6 4 . 5

0 m m ( 2 P L C S

)

1 4 . 5

0 m m

70.73 mm (2.78 inches)

M6 Tapped Holes

Thread Depth 6.00

3 Places20.73 mm (2 PLCS)

167.15 mm

185.30 mm

1 5

8 . 0

0 m m

P r i n t h e a

d R e t r a c t e d

1 6 2 . 5 0 m m

25.70 mm 32.50 mm (1.28 inches)

157.80 mm

159.60 mm

26.20 mm

32.00 mm

Printable Area

Figure 3-2: Videojet 6210 30 mm RH Printer Dimensions

(7.3 inches)

(6.58 inches)164.00 mm

(6.46 inches)

(1.01 inches) Printhead Stroke

( 6 . 4

i n c h e s )

( 6 . 2

2 i n c h e s )

(6.23 inches)

(6.21 inches)

(1.03 inches)

(1.26 inches)

( 2 . 5

4 i n c h e s ) 0

. 5 7 i n c h e s

(0.82 inches)

Figure 3-3: Right-handed and Left-handed Printer

Right-handed Printer Left-handed Printer



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Rev AA Mounting Considerations 3-5

The print platen rubber (for printers in intermittent mode) or the roller(for printers in continuous mode) should be positioned such that it is at adistance between 6.45 inches and 6.50 inches (164 mm and 165.5 mm) from

the back edge of the printer (Figure 3-4).

CLARiTY Controller

The CLARiTY operator interface can be mounted at a convenient locationso that the operator has adequate access to the panel. The CLARiTYcontroller has a built-in power supply unit.

The unit has two M6 mounting holes located at the sides of the unit, as

shown in Figure 3-5 on page 3-6.

Figure 3-4: Printer Pad or Roller Position

Printer Pad or Roller

1 5 8 m m

1 6 4 m m

1 6 5 . 5 m m

( 6 . 2

i n c h e s )

( 6 . 4

6 i n c h e s )

( 6 .

5 2 i n c h e s )



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3-6 Mounting Considerations Rev AA

The maximum distance of the CLARiTY controller from the printer bodyis 9.8 ft (3 m).

The CLARiTY controller can be mounted in any convenient location,provided that the maximum lead length of 9.8 ft (3 m) is not exceeded. Themounting brackets provided allow you to position the controller against a

convenient vertical flush surface.

Figure 3-5: CLARiTY Controller Dimensions

69.20 mm

2 0 8 . 3

5 m m

1 9 1 . 2

5 m m

4 1 . 0

0 m m

M6 Female ThreadBoth Sides.

Thread Depth 6.00

9 6 . 9

0 m m

118.90 mm

(4. 68 inches)

( 8 . 2

i n c h e s )

( 7 . 5

3 i n c h e s )

( 3 . 8

1 i n c h e s )

(2.72 inches)

( 1 . 6

1 i n c h e s )



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Rev AA Mounting Considerations 3-7

Air Regulator

The air regulator should be connected to a clean, dry factory air supplyusing a 6 mm pipe. The 4 mm diameter pipe should be used to connect the

air regulator to the printer.

The air regulator should be mounted close to the printer. The regulatorshould be accessible for adjusting and checking the correct pressure of 3bar.

Encoders

An encoder is used to match the printing speed to the speed of the targetmaterial as it passes the printhead.

Use the Encoder Kit part number 403358 for these applications.

The encoder must ideally be mounted to run on the packaging film, closeto the printer, in order to accurately measure the film speed. Anydiscrepancy between measured and actual film speed can result in poor

print quality or ribbon breakage.

Note: Use the encoder only in the continuous mode.



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3-8 Installing the Ribbon in the Cassette Rev AA

Installing the Ribbon in the Cassette

Caution

EQUIPMENT DAMAGE. The use of incompatible ribbon canseriously damage your printer and such a damage is not covered byyour printer warranty. Use only the ribbon that is approved by yourdealer.

To install the ribbon, proceed as follows:

1 Remove the cassette (Figure 3-6).

2 Put the cassette down on a flat surface with the ribbon spools (Item 1,

Figure 3-7 on page 3-9) facing upwards and the ribbon rollers (Item 2)towards you.

Figure 3-6: Cassette Removal



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Rev AA Installing the Ribbon in the Cassette 3-9

3 Pull the two ribbon spools (one containing the entire used ribbon)from the cassette firmly, as shown in Figure 3-8. The discs that aresituated under each spool can be used to lever the spool off the

cassette.

4 Discard the used ribbon and the spools.

5 Open a new shrink-wrapped roll of ribbon, and unwind about 12inches (30 cm) of ribbon.

The spool holders on the cassette have different color discs:

Figure 3-7: Cassette Removed

1. Ribbon Roller (x2)

2. Ribbon Spool (x2)

1

2

Figure 3-8: Ribbon Spools Removal



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3-10 Installing the Ribbon in the Cassette Rev AA

• The black disc for the new roll of ribbon

• The silver disk for the empty roll

When the printer is running, the new ribbon unwinds from the blackholder and winds onto the silver spool holder.

6 Slide the full spool onto the spool holder that has a black disc. The rollshould be located such that the ribbon unwinds in the direction asshown in Figure 3-9.

Note: Ensure that the spool is pushed completely down onto the holder.

7 Route the ribbon, so that it:

• Unwinds from the outside of the full roll

• Goes around the outside of the white roller that is nearest to the fullroll

• Runs along the bottom of the cassette

• Goes around the outside of the second white roller

• Passes around the outside of the empty spool

Figure 3-9: Ribbon Spool Installation



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Rev AA Installing the Ribbon in the Cassette 3-11

8 Slide the empty spool completely down onto the holder that has asilver disc (Figure 3-10).

9 Turn the empty spool by hand to take up any excess ribbon. Stopturning the empty spool when the full spool starts to rotate (Figure 3-11).

Note: If the supplied ribbon has a transparent section or printed leader at the

start, rotate the empty spool to take up all the transparent ribbon.

10 Insert the cassette into the printer body.

Figure 3-10: Ribbon Spool Complete

Figure 3-11: Ribbon Spool Routing



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3-12 Adjusting the Air Pressure Rev AA

Note: Ensure the following:

• The ribbon runs in between the printhead and the printer's print roller or

print pad

• The ribbon is not twisted or caught

• The ribbon has not become loose while replacing the cassette

Adjusting the Air Pressure

Warning

PERSONAL INJURY. Before connecting the compressed air supplyto the printer, ensure that the air regulator adjustment knob isturned fully counterclockwise.

Use the regulator to set the air pressure to 3.0 bar (43.5 psi). Setting the

pressure too high can shorten the lifetime of the printhead. Setting thepressure too low can cause poor print quality.

Working with Printer Connections

Product Sensors/Print Signals

One 15-pin D-Type (male) connector, located on the side of the printer isdedicated for input and output connections.

The printer can be triggered to print either by a mechanical contact-printsignal or a 24 V DC PNP product sensor.

The printer can be configured to print either on a positive or a negativeedge signal.

Note: These settings are known as configuration settings and cannot be set on theCLARiTY panel. For further information, refer “Configuring the Printer” on

page 3-19.

Connect the wiring for the sensor or mechanical contact operation, asshown in Figure 3-12 on page 3-13 and Figure 3-13 on page 3-13.



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Rev AA Working with Printer Connections 3-13

Figure 3-12: PNP Sensor Wiring (Print Sensor)

1

1. PNP Sensor

2. 15-pin Male D-type Connector

2

1

9

SIG

8

24VDC

15

0V

Figure 3-13: Mechanical Contact Wiring (Print Sensor)

2

1

1. Print Signal Relay Contact


1

9

SIG

8

24VDC

15



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3-14 Working with Printer Connections Rev AA

Encoder

For the continuous motion operation of the printer, an encoder is used totrack the speed of the packaging material. The encoder is wired into the

printer's input/output connector.

The printer is configured to use a quadrature mode encoder by default, N.The use of a quadrature mode encoder enables the printer to react if thepackaging material is traveling backwards. This prevents the occurrenceof breaks in the ribbon and possible damage to the printer. The use of aquadrature mode encoder is obligatory.

Note: These settings are known as configuration settings and cannot be set at the

CLARiTY panel. For further information, refer “Configuring the Printer” on

page 3-19.

Figure 3-14: Encoder Wiring

1

2

1. Encoder


1

9

8

+24V

15

Phase - B Signal

Phase - A Signal

0V



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Videojet 6210 Service Manual


Interlocks and Annunciation

The 15-pin D-type (male) connector, located on the side of the printer unitis available for connecting with a variety of useful interlock and

annunciation signals.

Table 3-2 summarizes the input and output connections.

Note: For more information on configuring the inputs and outputs, refer“Working with the Inputs and Outputs” on page 3-25.

Pin Purpose

1 +24 V

2 External input #1 PNP 24 V

3 0 V

4 External input #2 PNP 24 V

5 Not Used

6 Relay output #1 N/C

7 Relay output #1 common

8 Relay output #1 N/O

9 Relay output #2 common

10 Relay output #2 N/O

11 PNP 24 V Output #1

12 0 V

13 Not Used

14 Encoder Phase B input

15 Encoder Phase A input

Table 3-2: Input and Output Connections


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Videojet 6210 Service Manual

3-16 Working with Printer Connections Rev AA

Data Communication

All external data communication to the printer are connected through theCLARiTY controller. It contains the following communication ports:

• RS232 Serial Communications Port (9-pin Male D-type Connector)

Table 3-3 lists the connections to the RS232 Serial Communications Port.

The printer is primarily designed to communicate with the CLARICOM™

Package Coding Management Software, such as the CLARiSOFT™ forVJ6210 Image Design Software (P/N 703490). CLARiTY is supplied withsome default images installed in its database memory.

CLARiTY can be configured to work in the following mode:

• Standalone Mode

Download images to CLARiTY using a standard PC null-modemcable (twisted 9-pin D-type, female to female) connected between PCCOM1 port and CLARiTY RS232 port (cable supplied separately),using CLARiSOFT.

Cable Connections

Figure 3-15 on page 3-17 displays the details of the printer cableconnections.

Pin Connection

1

2 Receive Data (Rx)

3 Transmit Data (Tx)

4

5 GROUND

6

7

8

9

Table 3-3: RS232 Serial Communications Port Connections


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Figure 3-15: Videojet 6210 Cable Connections

D25 - M

Low Profile Connector

Encoder

Mains Power

Air

PRINTER

RS232

D9 - F

15 Way I/O Cable Unterminated

USB



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3-18 Switching the Power On Rev AA

Switching the Power OnTo switch the printer on, turn the power switch on the CLARiTY

controller to the I (On) position (Figure 3-16).

The boot-up takes approximately 90 seconds. During this a "startingCLARiTY …" message appears. Following this, the CLARiTY home page(Figure 3-17 on page 3-19) is displayed.

An initialization process of 15 seconds begins, during which the printercalibrates the ribbon drive. The status bar flashes the words STARTING

UP and the amber LED flashes on and off. When the process is complete,the home page changes, as follows:

• The CLARiTY status panel changes from STARTING UP to OFFLINE.

• The Consumables area displays the percentage of ribbon remaining.

• In the Control Frame, the Start and Stop buttons are enabled.

• The blue Power LED on the printer is illuminated.

Figure 3-17 on page 3-19 displays the CLARiTY home page in theOFFLINE state.

Figure 3-16: Printer Power Switch

Power Switch



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Rev AA Configuring the Printer 3-19

Configuring the Printer

CLARiTYTM Configuration Manager

As coding and labelling equipment have become increasingly versatile

and flexible with a wide range of applications, the number of variablesthat can be configured within a printer, has become very large. Althoughprinters are pre-programmed with default values, as the extent of the

application increases, it becomes less likely that the default configurationis ideal. This can lead to a large and cumbersome Menu Tree on theprinter’s controller that users have to work with.

Most printer variables are set during the installation process. The

variables are set to values that tailor the printer to the application. Onceset, these variables only need to be changed when the application for theprinter changes. As such, there is no need to make these installationparameters available at the printer interface. They are set through aconfiguration programme called CLARiTY Configuration Manager.

Figure 3-17: CLARiTY Home Page in the Offline State



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3-20 Configuring the Printer Rev AA

The CLARiTY Configuration Manager (Figure 3-18) is a PC softwareprogram, that provides the following basic features:

• Setting all the printer variables

• Saving/retrieving a set of variable values to a PC file for later/repeated use

• Downloading a set of variables to the printer's CLARiTY controller for

non-volatile (permanent) memory storage in the printer

• Uploading a set of variables from the printer for review/comparison/modification

• Updating the system software

• Saving/retrieving language files

• Saving/retrieving job, font, and graphics files

• Configuring master/slave functionality

• Snapshot of CLARiTY screens

As a result, the CLARiTY Controller only retains the availability of a smallnumber of operating variables for the user to change. Apart from makingthe CLARiTY control system more simple and user-friendly, it alsoprovides an increased level of printer system integrity, because the

configuration variables cannot be accessed from the printer itself, but onlyfrom a connected PC.If the printer is installed to run in a standalone mode (i.e., the printer is not

networked), the PC is only linked briefly (via the RS232 serial or ethernetport) for the period of upload/download of the variables (a few seconds).The PC would then be removed.

In a networked environment, system administrators could have direct

Figure 3-18: CLARiTY Configuration Manager



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access to the printer, while line operators are limited to accessing only theoperating variables that are relevant to them.

Installing the CLARiTY Configuration Manager

To install the CLARiTY Configuration Manager on a PC, insert theCLARiTY Configuration Manager CD-ROM. The installation routine

commences automatically. Follow the on-screen instructions to install thesoftware.

If your PC has the auto run facility disabled, the installation routine willnot start automatically. To enable the installation procedure, proceed as

follows:

1 Click the Start button.

2 Click the Run button to open a dialog box.

3 Type “D:\setup.exe” in the dialog box and press enter/return key.

Note: D: is the drive letter of the PC's CD-ROM drive. If it is different for

your PC, replace the letter D with the appropriate drive letter.

The software is installed in the PC and is ready for use.

Connecting the CLARiTY Configuration Manager to the Prin ter

Connecting CLARiTY Configuration Manager to the Printer using anRS 232 connection

To connect the CLARiTY Configuration Manager to the printer, proceedas follows:

1 Connect the PC serial port to the CLARiTY controller using the null-modem cable.

Ensure that all other programs (such as, Active sync and other PDA

applications) that use the serial port are disabled.



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2 Run the CLARiTY Configuration Manager on the PC (Figure 3-19).

3 Ensure that the printer status panel (at the bottom left of the window)reports the message "Connection Active" and the new printer iconturns green.

If the status displays "Not connected", as shown in Figure 3-19, disableor quit the other applications running on the PC that are using the

serial port. Check that the baud rate settings on the ConfigurationManager matches with the printer’s baud rate.

4 Click the Upload button. The progress of the operation is displayed inthe status pane. This uploads the printer parameters set to the PC.

The list of folders containing the configuration parameters appears in

the parameter listing (in the right hand frame of the ConfigurationManager).

Figure 3-19: CLARiTY Configuration Manager

Status Panel



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Editing Parameters

Figure 3-20 displays the list of parameters that are available in the printersettings.

Click the folder required to open or close it or to gain access to the

parameters it contains. You may have to click and open a number of

nested folders to get to the parameter that you want.

There are a number of different types of parameters. Click 'Help' on themenu at the top of the screen, and select 'Key To Legends' to get a

complete list of the different types of parameters.

To change the value of a parameter, proceed as follows:

1 Click the required parameter from the parameter list. The currentvalue is displayed in the ‘Value’ box at the bottom of the screen.

2 Change the value to the required value using the mouse and thekeyboard.

3 Click the Apply button. The value displayed in the parameters list isupdated to reflect the change.

Note: Event parameters do not have values that can be set. Touching the Triggerbutton that is available in the bottom pane causes the printer to perform the givenaction immediately.

For many parameters, it may be satisfactory to leave them with theirdefault values. Some of the parameters may need tuning after some initialprints have been made. Some of the listed parameters are available at the

Figure 3-20: Parameter Settings

Parameters

List



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CLARiTY panel. It may be more convenient to make final adjustments atthe panel rather than using the CLARiTY Configuration Manager.

Saving the Changes in the Printer

To make the changes effective, proceed as follows:

1 Click the printer icon in the left-hand pane to open the printer controlsat the bottom pane of the window.

2 Click the download button to update the printer with the changes that

you have made to the parameters.

A dialog box opens with the message “The parameters to bedownloaded have not been saved to an archive”.

3 Touch OK to continue with the download.

4 The new parameters are active when the download is complete.

Note: Unless steps 1 to 4 are performed, none of the parameter changes

become effective in the printer.

Archiv ing the Current Parameters

The set of parameters can be saved as an archive and are stored on the PC.

The archive can be loaded into the Configuration Manager anddownloaded to the printer again at a later date to revert to the archived set

of parameters.

Once the printer has been configured, it is recommended that all theparameters be uploaded into the PC, and saved as an archive.

To archive the current parameters, proceed as follows:

1 Right click the Archives folder in the left-hand panel.

2 Select the New Save option from the pop-up menu.

A file for the new save appears under the archives folder with a namecontaining the current time and date.

3 Change the name of the archive in the bottom panel, and click theApply button.



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Rev AA Working with the Inputs and Outputs 3-25

Loading a Saved Archive

To load an archive that was saved previously, proceed as follows:

1 Locate the archive in the left panel and right click on it.2 Choose Load from the pop-up menu.

The archived parameters are displayed on the right-hand pane.

Click the printer icon from the left-hand panel and click the Downloadbutton to load the archive of parameters to the printer.

Working with the Inputs and OutputsThe printer has a number of input/outputs for interfacing the printer tothe packaging equipment or the packaging line.

The Inputs

The inputs are pre-configured as:

• Print Sensor: Using a 24 V PNP input to trigger the printer to start

printing

• Inhibit Print: Using a 24 V PNP input to inform the printer that the

host packaging machine or line has an error and the printer shouldnot print.

• Spare Input 1: Not Available for Use

Repeat the steps 1 to 5 for all the three inputs and then download theparameters to the printer to apply these new settings.

The Outputs

The Outputs are pre-configured as follows:

• Output 1: Printer enters fault: A fault condition has occurred

• Output 2: Printer enters warning: A warning condition has occurred

• Output 3: Printer is busy: The printhead is out in its printing position

• Spare Output: Not Available for Use.



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R e v A A

D e f a u l t O p t i o n s C o n f i g u r a t i o n 3 - 2 6

D

e f a u l t O p t i o n s C o n f i g u r a t i o n

T a

b l e 3 - 1

l i s t s

t h e

d e

f a u

l t o p

t i o n s c o n

f i g u r a

t i o n

f o r

t h e p r i n

t e r .

S e c t i o n

S u b - S e c t i o n

P

a r a m e t e r

N

a m e

C L A R i T Y

N a m e

U n i t s

D e f a u l t

F u n c t i o

n a l i t y

D e v i c e s ,

P h d s , 1

C o n s u m a b l e s

R

i b b o n C o l o r

R i b b o n C o l o r

N o n e

B l a c k

S e t s t h e

r i b b o n c o l o r t o B l a c k ,

W h i t e o r O t h e r .

R

i b b o n W i d t h

R i b b o n W i d t h

m m

3 5

T h e w i d t h o f t h e r i b b o n r u n n i n g o n t h e m a

c h i n e

( m m )

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I n f o r m a t i o n

M

i r r o r e d I m a g e

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C o n v e r t s t h e s e l e c t e d i m a g e t o p r i n t a s i f i t w e r e

v i e w e d i n a m i r r o r ( u s e d i f i t i s r e q u i r e d t o

p r i n t o n

t h e i n s i d

e o f a b a g ,

i n s t e a d o n t h e o u t s i d e

o f a

b a g ) .

D e v i c e s ,

P h d s , 1

I m a g e


P

r i n t O r i e n t a t i o n

N o n e

D e g r e

e s

0

R o t a t e s

a l l s e l e c t e d i m a g e s t h r o u g h 1 8 0 d

e g r e e s

R

e s e t I m a g e

S

e q u e n c e O n

O

f f l i n e

N o n e

N o n e

Y e s

W h e n u s i n g a s e q u e n c e o f p r i n t i m a g e s , t h i s

p a r a m e t e r f o r c e s t h e s e q u e n c e t o r e s e t b a

c k t o t h e

s t a r t w h e n t h e p r i n t e r g o e s o f f l i n e

D e v i c e s ,

P h d s , 1

P r i n t


C

o n t i n u o u s

A

u t o P r i n t

T

r i g g e r i n g

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A l l o w s i n d e f i n i t e c o n t i n u o u s m o t i o n p r i n t i n

g f r o m a

s i n g l e p r i n t t r i g g e r . E a c h p r i n t i s s e p a r a t e d b y a

d i s t a n c e

s e t i n t h e p a r a m e t e r C o n t i n u o u s

R e p e a t

D i s t a n c e

C

o n t i n u o u s

H

e a d D o w n

T

i m e

N o n e

m S

1 5

T i m e t a k e n f o r t h e p r i n t h e a d t o t r a v e l f r o m

t h e

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p r i n t p o s i t i o n ,

t o p r i n t i n g a g a i n s t t h e r o l l e r

i n c o n t i n

u o u s m o d e .

T a b l e 3 - 1 : V i d e o j e t 6 2 1 0 P r i n t e r C o n f i g u r a t i o n M

a n a g e r

I C E P e g a

s u s S e r v i c e M a n u a l


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3 - 2 7

D e f a u l t O p t i o n s C o n f i g u r a t i o n

R e v A A

D e v i c e s ,

P h d s , 1

P r i n t


C

o n t i n u o u s

M

u l t i P r i n t M o d e

N o n e

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E n a b l e s

M u l t i P r i n t m o d e i n c o n t i n u o u s m o t i o n

p r i n t i n g .

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b e r o f

p r i n t s , s e p a r a t e d b y a d e f i n e d d i s t a n c e . E n a b l i n g

t h i s m o d

e r e q u i r e s t h e u s e r t o a l s o s e t t h e

C o n t i n u o u s P r i n t s p e r S i g n a l , C o n t i n u o u s

R e p e a t

D i s t a n c e a n d C o n t i n u o u s R e g i s t r a t i o n D e l a y

p a r a m e t e r s c o r r e c t l y

C

o n t i n u o u s

P

r i n t P o s i t i o n

P r i n t P o s i t i o n

0 . 0

1 m

m

2 1 0 0

P o s i t i o n

o f t h e p r i n t h e a d f r o m i t s p a r k e d p

o s i t i o n ,

w h e n p r

i n t i n g i n c o n t i n u o u s m o t i o n .

D e f i n e s t h e

p o s i t i o n

o f t h e p r i n t h e a d r e l a t i v e t o t h e p r i n t r o l l e r

C

o n t i n u o u s

P

r i n t s p e r

S

i g n a l

N o n e

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1

T h e n u m

b e r o f p r i n t s p e r p r i n t s i g n a l w h e n u s i n g

C o n t i n u o u s M u l t i P r i n t M o d e

D e v i c e s ,

P h d s , 1

P r i n t


C

o n t i n u o u s

R

e g i s t r a t i o n

D

e l a y

H o r i z o n t a l

R e g i s t r a t i o n

m m

0

T h e d i s t a n c e t o d e l a y t h e p r i n t a f t e r r e c e i p

t o f t h e

p r i n t s i g n a l . I n C o n t i n o u s M u l t i P r i n t M o d e t h i s

d e f i n e s t h e d i s t a n c e t o t h e f i r s t p r i n t .

C

o n t i n u o u s

R

e p e a t

D

i s t a n c e

N o n e

m m

1 0 0

T h e d i s t a n c e b e t w e e n s u c c e s s i v e p r i n t s i n

C o n t i n u o u s M u l t i P r i n t M o d e

E

n c o d e r

S

c a l i n g P e r c e n t

E n c o d e r

S c a l i n g

%

1 0 0

P e r m i t s

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n p r i n t e d P a c k

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T h e r e a r e 3 o p t i o n s .

1 ) N o f a

u l t .

T h e c o d e r c a r r i e s o n w i t h o u t e

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