CG Triumvirate is a trademark of Agfa Corporation.
CG Times based upon Times New Roman under license from the Monotype Corporation.
Windows is a registered trademark of the Microsoft Corporation.
All other brand and product names are trademarks, service marks, registered trademarks, or registered
service marks of their respective companies.
Firmware (Software) Agreement:
The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and is
licensed for used only on a single printer in the user’s Trade or Business. The User agrees not to, and
not to authorize or permit any other person or party to, duplicate or copy the Firmware or the
information contained in the non-volatile or programmable memory. The firmware (Software) is
protected by applicable copyright laws and Licensor retains all rights not expressly granted. In no event
will Licensor or its suppliers be liable for any damages or loss, including direct, incident al, economic,
special, or consequential damages, arising out of the use or inabilit y to use the Firmware (Software).
CAUTION
Lithium Battery: There is a danger of explosion or fire if the battery is incorrectly
replaced. Replace only with the same or equivalent type recommended by the
manufacturer. Discard used batteries according to the manufacturer’s instructions.
Information in this document is subject to change without notice and does not represent a commitment on
the part of Datamax-O’Neil. No part of this manual may be reproduced or transmitted in any form or by
any means, for any purpose other than the purchaser's personal use, without the expressed written
permission of Datamax-O’Neil.
1.1 About this Printer ................................................................................. 2
i
ii
1.0 Introduction
Overview
This manual, which primarily includes technical information relating to the electrical and
mechanical components, is intended for use by qualified serv ice personnel in the
maintenance and repair of M-Class Mark II printers. For related information, refer to the
following documents, available for download at http://www.datamax-oneil.com/
For operating information, reference the Operator’s Manual (part number 88-2340-01).
For software information, reference the Class Series 2 Programmer’s Manual (part
number 88-2341-01).
Important Information:
In this manual, the exclamation point inside an equilateral triangle is intended
to alert the technician to the presence of important operating, maintenance or
servicing information. Always, as with all electrical equipment, follow basic
safety precautions to avoid personal injury or printer damage.
1-1
Overview
1.1 About this Printer
The following drawing illustrates the basic exterior components an d controls of the printer.
The model number can be found on the Serial Tag affixed to the rear of the unit. Use this
model number when referencing specific information within this manual. (Because optional
items are not present on all models, certain printer configurations may not appear in some
of the illustrations in this manual.)
2.10Printhead Voltage Adjustment.............................................................. 28
ii
Adjustments and Maintenance
2.0 Introduction
This section covers maintenance and alignment procedures.
2.1 Maintenance
Recommended items, techniques, and schedules to help you safely and effectively maintain
the printer are detailed below. Keep the following items on hand to clean the printer:
• Isopropyl alcohol• Soapy water/mild detergent
• Cotton swabs• Compressed air
• Soft-bristle brush• Printhead Cleaning Cards or Printhead Cleaning Film
For your safety and to avoid damaging the printer, turn OFF and unplug the
printer before cleaning. Always take proper precautions when using isopropyl
CAUTION
Area / ItemCleaning Interval *Method / Supplies
Printhead
Platen and
Assist Rollers
Peel Assembly
Media & Ribbon
Path, & Media
Sensor
alcohol, a flammable liquid.
Recommended Maintenance Schedule
After each roll of ribbon if using
thermal transfer media, or after
each roll of media (or as needed)
if using direct thermal media.
After each roll of labels, after each
roll of ribbon, or as needed.
After each roll of labels, after each
roll of ribbon, or as needed.
As needed, based on a weekly
visual inspection.
Cotton swab dampened with
isopropyl alcohol; and, if necessary,
use Printhead Cleaning Cards or
Cleaning Film (see Section 2.1.1).
Cotton swab or cloth dampened with
isopropyl alcohol wiped across the
entire roller (see Section 2.1.3).
Cotton swab dampened with
isopropyl alcohol; wipe until clean.
Compressed air or a soft brush.
Isopropyl alcohol, as needed (see
Section 2.1.2 and 2.1.4).
Exterior
Surfaces
*Whichever interval comes first.
As needed, based on a weekly
visual inspection.
Mild detergent applied with a
dampened cloth; wipe until clean.
2-1
Adjustments and Maintenance
2.1.1 Cleaning the Printhead
NEVER use a sharp object to clean the Printhead; damage can result.
CAUTION
If print quality declines (symptoms can include non-compliant bar codes, print dropouts,
streaks on the label), the typical cause is debris build-up on the printhead. Furthermore, if
the build-up is not removed it may lead to element failure, greatly reducing the life of the
printhead.
Faulty Label:Instead of consistent patterns, streaks in the print
indicate a dirty or faulty printhead.
According to the media, ribbon, and printing parameters used, different methods are
recommended for cleaning the printhead. In all cases, perform the f ollowing preliminary
operations:
Preliminary Cleaning Steps:
1. Stop printing. Raise the cover, unlock the Printhead Latch then raise the Printhead
Assembly and allow the printhead to cool.
2. Remove media and ribbon from the printer then proceed according to your cleaning
requirements.
2-2
Adjustments and Maintenance
2.1.1.1Cotton Swab Procedure
This procedure is recommended if using direct thermal media, or thermal transfer media
with a wax ribbon.
1. Perform the Preliminary Cleaning Steps, as described in Section 2.1.1.
2. Turn OFF and unplug the printer. Using a Cotton Swab moistened (not soaked) with
isopropyl alcohol, gently clean the entire Printhead surface, paying special attention to
the Burn Line, until all build-up is removed.
3. Allow the printhead to dry. Reinstall media (and ribbon, if needed). Lower and latch
the Printhead Assembly. (If necessary, perform a Media Width Adjustment; see Section
2.3.) Close the cover. Plug in and turn ON the prin ter. Run several sample labels and
examine the print quality. If streaks are still present, see Section 2.1.1.2; otherwise,
this completes the procedure.
2-3
Adjustments and Maintenance
2.1.1.2Cleaning Card Procedure
This procedure is recommended for printers using direct thermal media, or thermal transfer
media and a wax-based ribbon. Also use this procedure if symptoms continue after the
Cotton Swab Procedure (Section 2.1.1.1) has been tried.
1. Perform the Preliminary Cleaning Steps, as described in Section 2.1.1.
2. Place a Cleaning Card (part number 70-2013-01) under the printhead.
3. Lower and latch the Printhead Assembly. Disengage the Media Width Adjustment; see
Section 2.3.
4. Close the cover. Proceed according to printer type:
• Display-Equipped Models –
Press and hold TEST for approximately four seconds. (As an alternate, CLEAN HEAD
NOW can be selected in the menu system.)
• Non-Display Models –
Repeatedly press FEED until the Cleaning Card exits the printer.
5. Reinstall media (and ribbon, if necessary). Lock the Printhead Latch. If necessary,
perform a Media Width Adjustment, see Section 2.3. Close the cover. Run a few sample
labels and examine them. If streaking is still present, go to Section 2.1. 1.3; otherwise,
this completes the procedure.
2-4
Adjustments and Maintenance
2.1.1.3Cleaning Film Procedure
This procedure is recommended for printers using a resin ribbon with thermal transfer
media, or for printers that typically use a Heat Value of 22 or higher. Also use this
procedure if symptoms continue after the previous cleaning methods have been tried.
1. Perform the Preliminary Cleaning Steps, as described in Section 2.1.1.
2. Place a sheet of Cleaning Film (part number 70-2087-01) under the printhead.
3. Lower and latch the Printhead Assembly. Disengage the Media Width Adjustment; see
Section 2.3.
4. Close the cover. Proceed according to printer type:
• Display-Equipped Models –
Press and hold TEST for approximately four seconds. (As an alternate, CLEAN HEAD
NOW can be selected in the menu system.)
• Non-Display Models –
Repeatedly press FEED until the Cleaning Card exits the printer.
5. Turn OFF and unplug the printer. Open the cover, unlock and raise the Printhead
Assembly. Using a cotton swab moistened (not soaked) with isopropyl alcohol, gently
clean the entire Printhead surface.
6. Allow the printhead to dry. Reinstall media and ribbon. Lower and latch the Printhead
Assembly. If necessary, perform a Media Width Adjustment; see Section 2.3. Close the
cover. Plug in and turn ON the printer. Run a few sample labels and examine them; if
streaking is still present, see Section 3.1.
2-5
Adjustments and Maintenance
2.1.2 Cleaning the Media Sensor
If paper dust or debris accumulates in the Media Sensor, it can affect label detection. To
prevent problems, clean as follows:
1. Turn OFF and unplug the printer. Raise the cover.
2. Unlock and raise the Printhead Assembly. Remove any media.
3. Clean the Media Sensor using compressed air or a soft brush. Use a cotton swab
dampened with isopropyl alcohol as needed to remove adhesive accumulations.
4. Allow to dry. Reinstall media. If necessary, adjust the Media Sensor. Plug in and turn
on the printer.
2.1.3 Cleaning the Platen
The platen contaminated with grit, label adhesive, or ink can lead to a decline in print
quality and, in extreme cases, cause labels to adhere and wrap the roller. Clean the platen
as follows:
2-6
Adjustments and Maintenance
1. Turn OFF the Power Switch and unplug the power cord from the AC Receptacle.
2. Raise the Cover. Unlock and raise the Printhead Assembly.
3. Remove media and ribbon.
4. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, wipe the
Platen clean. Manually rotate the rollers as necessary, wiping, rotating, and repeating
until the surfaces of each are clean. Allow to dry.
2.1.4 Cleaning the Ribbon Path
Ribbon path components contaminated with ink buildup and grit can inhibit smooth flow and
result in wrinkling related problems. Clean the ribbon path compon ents as follows:
1. Turn OFF the Power Switch and unplug the power cord from the AC Receptacle.
2. Raise the Cover. Remove media and ribbon.
2-7
Adjustments and Maintenance
3. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, wipe the
Ribbon Idler and Ribbon Post clean.
4. Using a Cotton Swab (or lint-free cloth) dampened with isopropyl alcohol, wipe the
Ribbon Shield clean. Allow to dry.
2-8
Adjustments and Maintenance
2.2 Media Sensor Calibration
This printer can use many different media compositions, configurations and colors. In
addition to adjusting the Media Sensor and selecting the SENSOR TYPE, to ensure that each
label is detected correctly and reliably, calibration is required. Depending upon th e printer
type, there are different calibration methods.
2.2.1 Calibrating Non-Display Models
In Calibration Mode, button functions adjust the Media Sensor to the media being used.
Calibration can be performed either automatically or manually, as detailed below.
Notes: Printer faults remain disabled during calibration, but can still occur while printing
Test Labels. Also, if needed, factory defaults can be restored.
2.2.1.1Automatic Calibration
Automatic Calibration lets the printer establish the optimum media sensing values, as
follows:
Note:Before calibrating ensure that media is loaded, and that the Media Sensor
selected and positioned. Also, be sure that the printhead assembly is latched
and that the cover is closed.
1. Turn OFF the printer.
2. Depress and hold CANCEL while turning ON the printer. Continue to hold the button until
the STOP Light turns OFF.
3. Press PAUSE. About ten inches of media will be output during the process.
4. Upon completion, one of the following lights will flash fiv e t imes t o denote the result:
• STOP Light
= Successful calibration. Go to Step 5, below.
• ERROR Light
Note: To discard calibration changes and revert to the previous settings, turn OFF the
printer before performing Step 5.
= Unsuccessful calibration. Retry and if unsuccessful, see Section 2.2.1.2.
2-9
Adjustments and Maintenance
5. Simultaneously press PAUSE and CANCEL briefly. Wait until the STOP Light goes OFF.
The printer is ready for operation.
2.2.1.2Manual Calibration
Manual Calibration should be used if Automatic Calibration f a ils, or in cases where sensing
problems continue to occur. Proceed as follows to manually calibrate th e Media Sensor:
Note:Before calibrating, be sure that the Media Sensor selected and positioned. Also,
be sure that the printhead assembly is latched and that the cover is closed.
1. Turn OFF the printer and remove the media.
2. Press and hold CANCEL while turning ON the printer. Continue to hold the button until
the STOP Light turns OFF.
3. Press and hold FEED until the STOP Light turns ON.
4. Press CANCEL. The ERROR Light will flash as “empty” is analyzed.
5. Position the backing material (or, if using reflective media, the black mark) in the Media
Sensor. Close the printhead assembly and press FEED. The ERROR Light will flash as
“Top of Form” is analyzed.
6. Place the media with the backing attached (or, if using reflective media, an area other
than the black mark) in the Media Sensor. Close the printhead assembly and press
PAUSE. The ERROR Light will flash as “label” is analyzed.
7. Simultaneously press PAUSE and CANCEL briefly, and then one of the following lights
will flash five times to denote the calibration result:
• STOP Light
= Successful calibration. Go to Step 8, below.
• ERROR Light
= Unsuccessful calibration. Retry.
2-10
Adjustments and Maintenance
8. Install media. Test the calibration by pressing FEED. A label should feed from theprinter. Press CANCEL. A Test Label should be produced.
Note: To discard calibration changes and revert to the previous settings, turn OFF the
printer before performing Step 9.
9. Simultaneously press PAUSE and CANCEL briefly. Wait until the STOP Light goes OFF.
The printer is ready for operation.
2.2.2 Calibrating Display-Equipped Models
Three different calibration methods are available.
2.2.2.1Quick Calibration
This is the easiest calibration method.
Note:Quick Calibration is not required for continuous media. If UNCALIBRATED is
displayed, use Standard Calibration (Section 2.2.2.2).
Perform a Quick Calibration as follows:
1. Ensure that media is loaded, that the Media Sensor is adjusted, and that the printer is
idle.
2. Press and hold FEED.
The printer will begin advancing media; allow at least one label gap or mark to pass
through the sensor. Upon successful completion, CALIBRATION COMPLETE will be
displayed, as the label is advanced to the next TOF and READY appears. (WARNING
LOW BACKING may appear if using notched media or media on a transparent liner;
however, the calibration was successful).
Note:Media with large TOF spaces may require a change in the PAPER EMPTY
DISTANCE.
2-11
Adjustments and Maintenance
Calibration Hints:
In certain cases, the printer may have trouble differentiating between the label and liner.
If CANNOT CALIBRATE is displayed, or if the printer stops feeding mid-label, try the
following:
Press and hold FEED to allow two gaps (or marks) to pass through under the sensor.
If CANNOT CALIBRATE is displayed again, or if the printer stops feeding mid-label, try the
following:
Press and hold FEED to allow three or more gaps (or marks) to pass through the
sensor. If this method fails, use Standard Calibration (see Section 2.2.2.2).
2.2.2.2Standard Calibration
During the Standard Calibration process, the printhead assembly can be raised for visual
access to the media and the sensor. In addition, displayed sensor readings can be used to
indicate the best position over the media. These features are helpful when using small,
position-critical TOF notches or marks. Three readings are required:
• Empty: No media in the sensor;
• Gap (or Mark): Only the backing, notch, or reflective mark in the sensor; and,
• Paper: The label (with the liner attached) in the sensor.
Make sure the SENSOR TYPE has been selected. Then, perform the Standard Calibration
steps:
Note:The procedure below assumes that the ADVANCED MENU is selected.
StepActionDisplayed MessageComment
1Turn ON the printer.UNCALIBRATED
(continued)
Wait briefly for initialization
before proceeding.
2-12
Adjustments and Maintenance
StepActionDisplayed MessageComment
Press MENU and then
2
raise the printhead
assembly.
3Press ENTER.
Scroll to SENSOR
4
CALIBRATION and
press ENTER.
Press ENTER, and then
5
to proceed press YES.
6
Remove the media
from the Media Sensor
and then press ESC.
Proceed according to
the media type, and
then press ESC:
• Die-cut: Peel labels
from the backing.
Insert the backing
under the Sensor Eye
Mark;
7
• Notched: Insert the
notch under the
Sensor Eye Mark; or,
• Reflective: Insert the
black mark facedown
under the Sensor Eye
Mark.
• Continuous: Go to
Step 8.
ADVANCED MENUMEDIA SETTINGS
MEDIA SETTINGS
MEDIA TYPE
SENSOR CALIBRATION
PERFORM CALIBRATION
PERFORM CALIBRATION
PERFORM CALIBRATION?
PERFORM CALIBRATION
REMOVE LABEL STOCK
PRESS ESC KEY
yyy
PERFORM CALIBRATION
SCAN BACKINGPRESS ESC KEY
yyy
You are in the ADVANCED
MENU.
You are entering MEDIA
SETTINGS.
Press EXIT to leave this
procedure.
Press NO to exit.
This sets the “empty”
parameter, where yyy is a
numeric value representing
the current sensor reading.
For reflective media, SCAN
MARK will be indicated.
This sets the TOF parameter,
where yyy is a numeric value
representing the current
sensor reading.
Never position a perforation
under the sensor when
sampling.
(continued)
2-13
Adjustments and Maintenance
StepActionDisplayed MessageComment
8
Position a label (with
backing, if any) under
the Sensor Eye Mark,
and then press ESC.
9
Observe the message.
10Press ESC and then
EXIT. Load media.
Adjust the Media
Sensor.
Press and hold FEED
until at least one label
has been output.
PERFORM CALIBRATION
SCAN PAPER
PRESS ESC KEY
yyy
PERFORM CALIBRATION
GAP MODE
CALIBRATION COMPLETE
yyy
READY
This sets the parameter for the
paper value, where yyy is a
numerical value representing
the current sensor reading.
If using preprinted media,
ensure the label area under
the sensor is free of preprinted
text, graphics or borders.
The calibration result is given.For reflective media,
REFLECTIVE MODE will be
indicated, and for continuous
media, CONTINUOUS MODE.
If other than Complete is
displayed, see the note below.
The printer is calibrated.
If another message is
displayed, see the note below.
Notes: (1) When calibrating notched media or media on a transparent liner, WARNING
LOW BACKING is normal message; and, (2) If CALIBRATION UNSUCCESSFUL
appears, see Section 2.2.2.3.
2-14
Adjustments and Maintenance
2.2.2.3Advanced Entry Calibration
Note:Advanced Entry Calibration should only be used if needed, after trying
Standard Calibration.
Advanced Entry is an alternate calibration method for special-case media. This procedure
consists of two parts: (1) compiling sensor readings using different algorithms; and, (2)
determining the best algorithm then sampling and entering the values. Make sure that the
SENSOR TYPE has been selected and then proceed with the steps below:
StepActionDisplayed MessageComment
1Turn ON the printer.UNCALIBRATED
Press MENU and then
2
raise the printhead
assembly.
3Press ENTER.
Scroll to SENSOR
4
CALIBRATION and
press ENTER.
Scroll to ADVANCED
5
ENTRY and press
ENTER.
Scroll to TRAN SENSOR
GAIN (for die-cut
media) or REFL
6
SENSOR GAIN (for
reflective media) then
press ENTER.
ADVANCED MENUMEDIA SETTINGS
MEDIA SETTINGS
MEDIA TYPE
SENSOR CALIBRATION
PERFORM CALIBRATION
ADVANCED ENTRY
PAPER SENSOR LEVEL
TRAN SENSOR GAIN
yyy (0 - 31)
25
Wait briefly for initialization
before proceeding.
You are in the ADVANCED
MENU.
You are entering MEDIA
SETTINGS.
Press EXIT to leave this
procedure.
You are entering the advanced
procedure.
Press ESC to abort this
procedure. (The following
examples detail die-cut media
calibration, and unless
otherwise noted the reflective
media procedure is the same.)
Install media. Position
the Sensor Eye Mark
7
over the label, then
lower and latch the
printhead assembly.
(continued)
TRAN SENSOR GAINyyy (0 - 31) 25
2-15
Do not position a perforation
in the Media Sensor; and if
using preprinted media,
ensure the label area placed in
the sensor is free of text,
graphics, lines, etc.
Adjustments and Maintenance
StepActionDisplayed MessageComment
Use the buttons to set
the Gain Number to 00
and then press ENTER.
Record the sensor
8
reading as a Label
Value for Gain Number
00 in a table (32 rows
TRAN SENSOR GAINyyy (0 - 31)
00
This is the Label Value for a
gain setting of 00, where
“yyy” represents the current
sensor reading.
by four columns, with
headings similar to
those shown below.)
Sample Calibration Table
Gain NumberLabel ValueTOF ValueDifference Value
00252
01
02
…
31
StepActionDisplayed MessageComment
Use the buttons to
increment the Gain
Number by one and
9
then press ENTER.
Record the Label Value.
Repeat this process for
TRAN SENSOR GAINyyy (0 - 31)
01
Remaining Label Values,
where “yyy” represents the
current sensor reading.
each Gain Number.
Sample Calibration Table
Gain NumberLabel ValueTOF ValueDifference Value
00252
01250
02248
……
3109
(continued)
2-16
Adjustments and Maintenance
StepActionDisplayed MessageComment
Raise the printhead
assembly then proceed
according to the media
type:
• Die-cut: Peel labels
from the backing
then insert the
backing under the
10
Sensor Eye Mark;
• Notched: Insert the
notch under the
Sensor Eye Mark; or,
TRAN SENSOR GAINyyy (0 - 31)
Do not position a perforation
in the Media Sensor; and if
using preprinted media,
ensure the label area placed
in the sensor is free of text,
31
graphics, lines, etc.
• Reflective: Insert the
black mark facedown
under the Sensor
Eye Mark.
Lower and latch the
printhead assembly.
Set the Gain Number to
00 and then press
11
ENTER.
Record the reading as a
TOF Value for Gain
Number 00 in the table.
Gain NumberLabel ValueTOF ValueDifference Value
00252248
01250
02248
……
3109
TRAN SENSOR GAINyyy (0 - 31)
00
Sample Calibration Table
This is the TOF Value for a
gain setting of 00, where
“yyy” represents the current
sensor reading.
(continued)
2-17
Adjustments and Maintenance
StepActionDisplayed MessageComment
Increment the Gain
Number by one and
then press ENTER.
12
Record the TOF Value.
Repeat this process for
each Gain Number.
Gain NumberLabel ValueTOF ValueDifference Value
00252248
01250245
02248234
………
310914
TRAN SENSOR GAINyyy (0 - 31)
01
Sample Calibration Table
Remaining TOF Values, where
“yyy” represents the current
sensor reading.
StepActionDisplayed MessageComment
Calculate the best Gain
Setting. In your sample
calibration table. Where
both the Label Value
and TOF Value are at
least 20, subtract the
amounts and record
the result as a
13
Difference Value (see
below).
TRAN SENSOR GAINyyy (0 - 31)
31
In this example, Gain Number
18 is chosen because, where
both values are at least
twenty, it has the highest
Difference Value.
Identify the largest
Difference Value and its
corresponding Gain
Number. This Gain
Number will be used to
resample the media.