Ice PegasusHS Service Manual

PegasusHS

Service Manual

P/N 361854-21

Revision: AA, November 2006

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

This document is the property of Clearmark solutions.and contains confidential and

proprietary 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: [phone]
Fax: [phone]

Olympic House,Willow Drive
Sherwood Park,Nottingham
NG15 0DP

www.interactivecoding.com

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 cause
harmful interference, and 2) this device must accept any interference
received, including interference that may cause undesired operation.

Warning

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

This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide responsible protection against
harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is
likely to cause harmful interference. In such cases, the users will be
required to correct the interference at their own expense.

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

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

For Customers in Canada

This digital apparatus does not exceed the Class A limits for radio
noise emissions from digital apparatus set out in the Radio
Interference Regulations of the Canadian Department of
Communications.

This equipment has been tested and certified for compliance with
Canadian regulations regarding safety and electrical emissions by
TUV Rheinland of North America, Inc.

ICE Pegasus Service Manual

ii

Rev AA

Pour la Clientèle du Canada

Le present appareil numerique n’emet pas de bruits radioelectriques
depassant les limites applicales aux appareils numerique de las class A
prescrites dans le Reglement sur le brouillage radioelectrique edicte
par 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 the
following legislation.

• EN55022:1998

• EN55024:1998

• EN61000-6-2:2001

• FCC CFR 47 parts 15.107 and 15.109

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

S

ervice 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 p

art of our business in
providing 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

iv

Rev AA

Customer Training

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

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

For more information on ICE. Customer Training Courses, call 01159

640144.

ICE Pegasus Service Manual

Rev AA i

Table of Contents

Compliance Information

For Customers in U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

For Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Pour la Clientèle du Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

For Customers in the European Union. . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Support and Training

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Chapter 1 — Safety

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 — Introduction

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 Description

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

ii

Rev AA

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

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

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

Interlocks and Annunciation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–15

Data 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–2

Working 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 . . . . . . . . . . . . . . . . . . . . . . . . . .5–3

Replacing the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . .5–3

Replacing the CLARiTY Processor PCB and LCD Touchscreen

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

ICE Pegasus Service Manual

Rev AA iii

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

Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

ICE Pegasus Service Manual

Rev AA Introduction 1-1

1

Safety

This chapter contains the following topics:

• Safety conventions used throug

hout this manual

• Important safety guidelines to follow while operating the equipment

Warning

EQUIPMENT MAINTENANCE. Read this chapter thoroughly
before attempting to install, operate, service, or maintain this
product.

Introduction

The policy of ICE. is to manufacture printing/coding systems and
supplies that meet high standards of performance and reliability.
There

fore, we employ strict quality control measures to eliminate the

potential for defects and hazards in our products.

The intended use of this printer is to print information directly onto the
product. Use of this equipment for any other purposes may lead to serious
personal injury.

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

1-2 Safety Conventions Used in the Manual

Rev AA

Safety Conventions Used in the Manual

Specific safety information is listed throughout this manual in the form of
Warning statements. Pay close attention to these statements as they
contain important information that help in avoiding potential hazards to
yourself or to the equipment.

General Warning Notices

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

Warning

PERSONAL INJURY. Only trained service or maintenance
personnel should perform these installation procedures. Qualified
personnel have successfully completed the training courses, have
sufficient experience with this printer, and are aware of the potential
hazards to which they may be exposed.

Warning

PERSONAL INJURY. Before attempting any maintenance or repair
on any part of the product, disconnect the printer from the main
power supply and isolate the printer from any external energy
sources including other connected equipment.

Warning

PERSONAL INJURY. Before connecting the compressed air supply
to printer, ensure that the air supply has been isolated. Turn the
regulator adjustment knob counter-clockwise.

Warning

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

ICE Pegasus Service Manual

Rev AA Safety Conventions Used in the Manual 1-3

Warning

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

Warning

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

Warning

ELECTRICAL HAZARD. Voltages used to connect the printer to
other equipment must be limited to no greater than 50 V DC or peak
AC.

Warning

ELECTRICAL HAZARD. Always wear a properly ground wrist­ground strap when handling printed circuit boards. Failure to do so
can result in damage to the board components due to static
electricity.

General Caution Notices

The following caution statements supplement the specific cautions that
appear elsewhere in the manual. These are general cautions, which must
be read, completely understood and applied by all the personnel involved
with the operation, and/or the maintenance of the machine.

ICE Pegasus Service Manual

1-4

Safety Guidelines

Rev AA

Caution

EQUIPMENT MAINTENANCE. Before and after performing any
maintenance or repair on the product, check that the two safety
labels are clearly visible. One is on the power supply cover and the
other by the potential nip point next to the pulley in the printer
body.

Caution

EQUIPMENT DAMAGE. The use of incompatible ribbon can
seriously damage your printer and such damage is not covered by
your printer warranty. Use only ribbon approved by your dealer.

Safety Guidelines

This section contains important safety guidelines pertaining to the
operation and handling of the printer and associated equipment.

Warning

SAFETY GUIDELINES. Always observe the following safety
guidelines when operating and handling the printer and associated
equipment.

Comply with Electrical Codes

All the electrical wiring and connections must comply
with applicable local codes. Consult the appropriate
regulatory agency for further information.

ICE Pegasus Service Manual

Rev AA Placement of the Printer 1-5

Do Not Remove Warning Labels

Do not, under any circumstances, remove or obstruct any
warning 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 to
personal injury.

Hazardous locations, as defined in the United States, are those areas that
may contain hazardous materials in a quantity sufficient to create an
explosion. These are defined in Article 500 of the National Electrical Code
ANSI/NFPA 70–1993.

Outside the United States, you must ensure compliance with all local
regulations regarding equipment placement in potentially hazardous
locations.

Using Printer Accessories

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

ICE Pegasus Service Manual

Rev AA Equipment Description 2-1

2

Introduction

This chapter contains the following topics:

• 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 to
operate the equipment.

Equipment Description

The Videojet 6210 printer uses high-resolution thermal transfer
technology with a unique electronic ribbon drive system. The printer
offers greater reliability and ease of operation compared to earlier
systems. It can print barcodes, dates, text, and graphics onto flexible
packaging films and labels.

The printer is a suitable replacement for either hot stamp or rotary
printers. 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 to
suit different configurations of the packaging machine.

2-2

About this Manual

Rev AA

About this Manual

This service manual includes information about installing, maintaining,
troubleshooting, and servicing the printer. It also contains sections about
the theory of operation and component identification, including an
illustrated parts breakdown.

This document is intended to be used only by trained service personnel. It
is intended to be a supplement to (and not a replacement for) formal
training. Keep this manual in a safe location where it can be easily
accessed for reference.

Related documents

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

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

Warning

PERSONAL INJURY. Customers who intend to service and
maintain the printer themselves must use only qualified personnel
to perform these procedures. Qualified personnel have successfully
completed the training courses, have sufficient experience with this
printer, and are aware of the potential hazards to which they may be
exposed.

ICE Pegasus Service Manual

Rev AA Theory of Printing 2-3

Theory of Printing

The information on how the thermal transfer printer works is as follows
(Figure 2-1):

• The printhead contains miniature heating

elements under a glass

coat

ing (300 dpi - 12 dots/min)

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

the printing

media

•

The printhead presses against the thermal transfer ribbon with

the ink

side of ribbon

in contact with the substrate, creating an image.

• Print elements heat small areas of the ribbon and this transfers th

e ink

to

the target substrate

• The printhead and the substrate move relative to each other

• T

he print elements are programmable and controlled to create an

image

Intermittent Motion Printing

Intermittent motion printing (Figure 2-2 on page 2-4) is the concept used
for printing on stationary packaging films in packaging equipment that
has a start/stop action each time a product is packed. Such applications
can be found in intermittent Vertical Form Fill Seal (VFFS) or bagging
machines, 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. Substr

ate

3. Platten Rubber

4. In

k

5. B

ase Film

6. T

hermal Printhead

Figure 2-1: Printing Process

ICE Pegasus Service Manual

2-4

Theory of Printing

Rev AA

• The printhead traverses across the ribbon, causing print to transfer
onto 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 used
for printing on moving packaging films in packaging equipment that has a
continuous moving action each time a product is packed. Such
applications 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

4. Th

ermal Printhead

Figure 2-2: Intermittent Printing Motion

HEAD OUT

HEAD IN

PRINT

ICE Pegasus Service Manual

Rev AA Theory of Printing 2-5

1

2

3

4

RIBBON FEED

MATERIAL FEED

1. Ribbon Transfer Carbon Print

2. Platt

en Roller

3. Substrate

4. Th

ermal Printhead

Figure 2-3: Continuous Print Motion

ICE Pegasus Service Manual

Rev AA Unpacking the Printer 3-1

3

Technical Description

This chapter contains the following topics:

• 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 in
Table 3-1 and Figure 3-1 on page 3-2. If any item is damaged or
missing, 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

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 Co

rd

6. Printer

7.

I/O Low P

rofile Cable

Assembly

8. Cassette

9. CLARiTY Configuration
Manager CD-ROM

Figure 3-1: Printer Configuration Parts

1
2

3

4

5

6

7

8

9

ICE Pegasus Service Manual

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 mm
pipe 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 Considerations

The thermal printhead must act against a flat print platen (in an
intermittent mode) or a print roller (in a continuous mode) in order to
print. The platen or roller is a part of the mounting bracketry.

Printer

The printer can be mounted in any orientation. However, it is important to
ensure that adequate operator access is available to remove and replace
the 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 printer
relative to the mounting holes and the printhead. It also shows the
additional space required to give adequate clearance to cables and air
pipes 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 printer
on a continuous motion packaging machine. This determines whether the
printer in use is left-handed or right-handed (Figure 3-3).

64.50 mm (2 PLCS)

14.50 mm

70.73 mm (2.78 inches)

M6 Tapped Holes
Thread Depth 6.00
3 Places

20.73 mm (2 PLCS)

167.15 mm

185.30 mm

158.00 mm

Printhead Retracted

162.50 mm

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 inches)

(6.22 inches)

(6.23 inches)

(6.21 inches)

(1.03 inches)

(1.26 inches)

(2.54 inches)

0.57 inches

(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 a
distance 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 location
so that the operator has adequate access to the panel. The CLARiTY
controller 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

158 mm

164 mm

165.5 mm

(6.2 inches)

(6.46 inches)

(6. 52 inches)

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3-6

Mounting Considerations

Rev AA

The maximum distance of the CLARiTY controller from the printer body
is 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. The
mounting brackets provided allow you to position the controller against a
convenient vertical flush surface.

Figure 3-5: CLARiTY Controller Dimensions

69.20 mm

208.35 mm

191.25 mm

41.00 mm

M6 Female Thread
Both Sides.
Thread Depth 6.00

96.90 mm

118.90 mm

(4. 68 inches)

(8.2 inches)

(7.53 inches)

(3.81 inches)

(2.72 inches)

(1.61 inches)

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Rev AA Mounting Considerations 3-7

Air Regulator

The air regulator should be connected to a clean, dry factory air supply
using 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 regulator
should be accessible for adjusting and checking the correct pressure of 3
bar.

Encoders

An encoder is used to match the printing speed to the speed of the target
material 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, close

to the printer, in order to accurately measure the film speed. Any
discrepancy 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 can
seriously damage your printer and such a damage is not covered by
your printer warranty. Use only the ribbon that is approved by your
dealer.

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 are
situated 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 12

inches (30 cm) of ribbon.
The spool holders on the cassette have different color discs:

Figure 3-7: Cassette Removed

1. Ribbon Roller (x2)

2.

Ribb

on Spool (x2)

1

2

Figure 3-8: Ribbon Spools Removal

ICE Pegasus Service Manual

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 black

holder and winds onto the silver spool holder.

6 Slide the full spool onto the spool holder that has a black disc. The roll

should be located such that the ribbon unwinds in the direction as
shown 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 full
roll

•

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

ICE Pegasus Service Manual

Rev AA Installing the Ribbon in the Cassette 3-11

8 Slide the empty spool completely down onto the holder that has a

silver disc (Figure 3-10).

9 Turn the empty spool by hand to take up any excess ribbon. Stop

turning 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 supply
to the printer, ensure that the air regulator adjustment knob is
turned 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 the
pressure 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 is
dedicated for input and output connections.

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

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

Note: These settings are known as configuration settings and cannot be set on the
CLARiTY panel. For further information, refer “Configuring the Printer” on
page 3-19.

Connect the wiring for the sensor or mechanical contact operation, as
shown 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

2.

15-p

in Male D-type Connector

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 to
track 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 the
packaging material is traveling backwards. This prevents the occurrence
of breaks in the ribbon and possible damage to the printer. The use of a
quadrature 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

2.

15-p

in Male D-type Connector

1

9

8

+24V

15

Phase - B Signal

Phase - A Signal

0V

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Videojet 6210 Service Manual

Rev AA Working with Printer Connections 3-15

Interlocks and Annunciation

The 15-pin D-type (male) connector, located on the side of the printer unit
is 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
30 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

Videojet 6210 Service Manual

3-16 Working with Printer Connections

Rev AA

Data Communication

All external data communication to the printer are connected through the
CLARiTY 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™ for
VJ6210 Image Design Software (P/N 703490). CLARiTY is supplied with
some 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-modem

cable (twisted 9-pin

D-type, female to female) connected between

PC

COM1 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 cable
connections.

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

Rev AA Working with Printer Connections 3-17

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 On

To 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 "starting
CLARiTY …" 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 printer
calibrates 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 the
OFFLINE state.

Figure 3-16: Printer Power Switch

Power Switch

I

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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 variables
that can be configured within a printer, has become very large. Although
printers are pre-programmed with default values, as the extent of the
application increases, it becomes less likely that the default configuration
is ideal. This can lead to a large and cumbersome Menu Tree on the
printer’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. Once
set, these variables only need to be changed when the application for the
printer changes. As such, there is no need to make these installation
parameters available at the printer interface. They are set through a
configuration 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 software
program, 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

• D

ownloading 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 small
number of operating variables for the user to change. Apart from making
the CLARiTY control system more simple and user-friendly, it also
provides an increased level of printer system integrity, because the
configuration variables cannot be accessed from the printer itself, but only
from 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 ethernet
port) 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

I

CE Pegasus Service Manual

Rev AA Configuring the Printer 3-21

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

Installing the CLARiTY Configuration Manager

To install the CLARiTY Configuration Manager on a PC, insert the
CLARiTY Configuration Manager CD-ROM. The installation routine
commences automatically. Follow the on-screen instructions to install the
software.

If your PC has the auto run facility disabled, the installation routine will
not 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 Printer

Connecting CLARiTY Configuration Manager to the Printer using an
RS 232 connection

To connect the CLARiTY Configuration Manager to the printer, proceed
as 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.

ICE Pegasus Service Manual

3-22

Configuring the Printer

Rev AA

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 icon
turns green.

If the status displays "Not connected", as shown in Figure 3-19, disable
or quit the other applications running on the PC that are using the
serial port. Check that the baud rate settings on the Configuration
Manager matches with the printer’s baud rate.

4 Click the Upload button. The progress of the operation is displayed in

the 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 Configuration
Manager).

Figure 3-19: CLARiTY Configuration Manager

Status Panel

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Rev AA Configuring the Printer 3-23

Editing Parameters

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

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 the
menu 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 current

value is displayed in the ‘Value’ box at the bottom of the screen.

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

keyboard.

3 Click the Apply button. The value displayed in the parameters list is

updated to reflect the change.

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

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

Figure 3-20: Parameter Settings

Parameters
List

IC

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3-24

Configuring the Printer

Rev AA

CLARiTY panel. It may be more convenient to make final adjustments at
the 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 controls

at 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 be

downloaded 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.

Archiving 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 and
downloaded 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 the
parameters 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 name
containing the current time and date.

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

Apply button.

ICE Pegasus Service Manual

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 Download
button to load the archive of parameters to the printer.

Working with the Inputs and Outputs

The printer has a number of input/outputs for interfacing the printer to
the 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

should

not print.

•

Spare Input 1: Not Available for Use

Repeat the steps 1 to 5 for all the three inputs and then download the
parameters 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.

ICE Pegasus Service Manual

Rev AA Default Options Configuration 3-26

Default Options Configuration

Table 3-1 lists the default options configuration for the printer.

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Devices,

Phds,1

Consumables Ribbon Color Ribbon Color None Black Sets the ribbon color to Black, White or Other.

Ribbon Width Ribbon Width mm 35 The width of the ribbon running on the machine

(mm)

Image

Information

Mirrored Image None None No Converts the selected image to print as if it were

viewed in a mirror (used if it is required to print on

the inside of a bag, instead on the outside of a

bag).

Devices,

Phds,1

Image

Information

Print Orientation None Degre

es

0 Rotates all selected images through 180 degrees

Reset Image

Sequence On

Offline

None None Yes When using a sequence of print images, this

parameter forces the sequence to reset back to the

start when the printer goes offline

Devices,

Phds,1

Print

Information

Continuous

Auto Print

Triggering

None None No Allows indefinite continuous motion printing from a

single print trigger. Each print is separated by a

distance set in the parameter Continuous Repeat

Distance

Continuous

Head Down

Time

None mS 15 Time taken for the printhead to travel from the

ready to print position, to printing against the roller

in continuous mode.

Table 3-1: Videojet 6210 Printer Configuration Manager

ICE Pegasus Service Manual

3-27

Default Options Configuration

Rev AA

Devices,

Phds,1

Print

Information

Continuous

Multi Print Mode

None None No Enables Multi Print mode in continuous motion

printing. One print signal generates a number of

prints, separated by a defined distance. Enabling

this mode requires the user to also set the

Continuous Prints per Signal, Continuous Repeat

Distance and Continuous Registration Delay

parameters correctly

Continuous

Print Position

Print Position 0.01m

m

2100 Position of the printhead from its parked position,

when printing in continuous motion. Defines the

position of the printhead relative to the print roller

Continuous

Prints per

Signal

None None 1 The number of prints per print signal when using

Continuous Multi Print Mode

Devices,

Phds,1

Print

Information

Continuous

Registration

Delay

Horizontal

Registration

mm 0 The distance to delay the print after receipt of the

print signal. In Con ti no us Multi Print Mode this

defines the distance to the first print.

Continuous

Repeat

Distance

None mm 100 The distance between successive prints in

Continuous Multi Print Mode

Encoder

Scaling Percent

Encoder

Scaling

% 100 Permits the machine to be run with a slightly

mismatched ribbon and substrate speed

Interleaved

Images

Interleaved

Images

None No Enables ribbon saving via interleaved images

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Table 3-1: Videojet 6210 Printer Configuration Manager (Continued)

ICE Pegasus Service Manual

Rev AA Default Options Configuration 3-28

Devices,

Phds,1

Print

Information

Intermittent

Head Down

Time

None mS 20 The time for the printhead to move from its ready to

print position to contact with the print pad in

intermittent printing mode.

Intermittent

Print Delay

None mS 500 The time to wait after receiving the print signal

before commencing an intermittent print.

Intermittent

Print

Registration

Horizontal

Registration

mm 0 A print registration delay in the direction of the

printhead movement, effectively moving the print

further from the starting point of printhead contact

with the film.

Intermittent

Start Border

Tmm

None 0.1m

m

20 Distance moved by the printhead before starting to

print in intermittent mode. Used to compensate for

any bouncing of the printhead as it hits the print

pad.

Devices,

Phds,1

Print

Information

Maximum Re

Print Gap

None mm 40 If the Low Speed Behavior is set to Resume on

Speedup, then if the bag moves a distance greater

than this parameter, whilst in 'low speed', the coder

prints a complete, whole code on the bag as soon

as the film speed exceeds 65mm/s

Print Darkness Print

Darkness

% 75 Sets the amount of energy being sent to the

printhead

Devices,

Phds,1

Print

Information

Print Sensor

Debounce

None mm 1 The distance of film that has to advance with the

print signal being 'on' before it is accepted.

Used to avoid multiple erroneous print signals

when a sensor or signal is not giving a clean switch.

Works in conjunction with Print Sensor Debounce

Time - the first to expire wins.

Using the distance method of debouncing

guarantees print registration, the time based

system doesn't.

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Table 3-1: Videojet 6210 Printer Configuration Manager (Continued)

ICE Pegasus Service Manual

3-29

Default Options Configuration

Rev AA

Devices,

Phds,1

Print

Information

Print Sensor

Debounce Time

None mS 10 Sets the time to wait before accepting a valid print

signal input as being logically 'On'.Used to avoid

multiple erroneous print signals when a sensor or

signal is not giving a clean switch when the film

speed may drop to zero or near zero when the print

signal is issued - in this situation the distance

based method of debounce would not work

because the print signal would go away before the

film distance is advanced.

Works in conjunction with Print Sensor Debounce

Time - the first to expire wins.

Using the distance method of debouncing

guarantees print registration, the time based

system doesn't.

Devices,

Phds,1

Print

Information

Print Speed Print Speed mm

per

sec

200 The print speed to be used in intermittent mode

printing

Printer Hand Printer Hand None No default-

requires

setting

LH or RH configuration

Printer Type Printer Mode None Intermittent Sets whether the printer is running in intermittent or

continuous print mode

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Table 3-1: Videojet 6210 Printer Configuration Manager (Continued)

ICE Pegasus Service Manual

Rev AA Default Options Configuration 3-30

Devices,

Phds,1

Print

Information

Unprinted Pack

Behavior

None None No Fault There are 3 options.

1)

No fault. The coder carries on wit

hout error if

th

ere are uncoded or under speed packs

2) Fault

on all undersized packs. Stop with

fault

whenever the film

speed drops below 40mm/s AND

a second print signal is received before the first

print completes.

3) Fault on unprinted packs. Stop with a fault when

a second print signal is received before the first

print is completed, regardless of film speed.

Vertical

Registration

Vertical

Registration

mm 0 Moves the image across the width of the printhead

Profiler Capture

Encoder Profile

Capture

Encoder

Profile

None None Triggers the capturing of an encoder profile

Imaging

Printhead

Mapping

None None Printhead 1 Required parameter -do not adjust

Printer Codes

Factory ID None None 1 Allows the setting of a unique special code for the

Factory ID. It is a global setting for the printer and

all layouts that reference a factory ID code print this

value

Line ID None None 1 Allows the setting of a unique special code for the

production Line ID. It is a global setting for the

printer and all layouts that reference a Line ID code

print this value

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Table 3-1: Videojet 6210 Printer Configuration Manager (Continued)

ICE Pegasus Service Manual

3-31

Default Options Configuration

Rev AA

Imaging

Printer Codes

Machine ID None None 1 Allows the setting of a unique special code for the

production Machine ID. It is a global setting for the

printer and all layouts that reference a Machine ID

code print this value

Shift Codes

Number of

Shifts

None None 0 The number of shifts per day

Imaging

Shift Codes

Start of Day None None +00:00:00 Sets the start of the day when all automatically

calculated date codes change e.g. the factory 'day'

can be set to start at 2.00am or 6.00am

Update Queue

Max Queue

Length

None None 1 Sets the limit on the number of jobs that can be in

the selection queue when Allocation printing is

enabled

Operations

Cycle Head

Position

None None None Cycle moving the printhead from its parked position

to its printing position

Cycle Print None None None Cycle the unit printing continuously

Generate Log

Files

None None None Triggering this Operation will cause log files to be

generated in the Log File Folder within the coder.

These files would be requested by Technical

Support in the event of the coder have persistent

issues.

Perform Motor

Calibration

None None None Calibrate the stepper motors

Print Test

Image

None None None Print a test image

System ComPort1

Baud Rate Baud Rate Bits/

sec

115200 Sets the baud rate of serial comm port

Flow Control None None None Sets hardware or software handshaking

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Table 3-1: Videojet 6210 Printer Configuration Manager (Continued)

ICE Pegasus Service Manual

Rev AA Default Options Configuration 3-32

System

ComPort1 Usage Usage None CLARiTY

comms

Sets the protocol running on the port (None,

CLARiTY comms)

Enable User

Test Print

None None Yes Decides whether the printer Test Print function is

available from the CLARiTY home screen

User

Interfaces

CLARiTY Language Language None English Sets the active language being used by CLARiTY

Passwords

Enable

Passwords

None None Disabled Enables or disables password protection. If

enabled, the 3 levels of passwords must be set up

using the following 9 parameters

Level 1: Mask None None None Check which functions are to be available to Level

1 users

Level 1: Name None None None The name of a level 1 user e.g. Operator

Level 1:

Password

None None None The password for level 1 (numeric only)

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Table 3-1: Videojet 6210 Printer Configuration Manager (Continued)

ICE Pegasus Service Manual

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Default Options Configuration

Rev AA

User

Interfaces

Passwords

Level 2: Mask None None None Check which functions are to be available to Level

2 users

Level 2: Name None None None The name of a level 2 user e.g. Supervisor

Level 2:

Password

None None None The password for level 2 (numeric only)

Level 3: Mask None None None Check which functions are to be available to Level

3 users

Level 3: Name None None None The name of a level 3 user e.g. Technician

Level 3:

Password

None None None The password for level 3 (numeric only)

Prompt On

CLARiTY

Update Detect

None None Yes When a USB memory stick is inserted and USB is

enabled, CLARiTY automatically runs the CLARiTY

update if there is a valid file on the stick. When the

USB is disabled, the user has to manually initiate

the action from the CLARiTY screen

Re calibrate

Touchscreen

Re calibrate

Touchscreen

None None Triggers re calibration of the touchscreen

User

Interfaces

Set Screen

Contrast To

Default

None None Not used on the Videojet 6210 Coder

CLARiTY

Config

Archive None None Flags whether this setup has ever been archived

(auto set)

Last Updated None None Flags when the setup was last changed (auto set)

Section Sub-Section Parameter

Name

CLARiTY

Name

Units Default Functionality

Table 3-1: Videojet 6210 Printer Configuration Manager (Continued)

ICE Pegasus Service Manual

Rev AA Getting started with the CLARiTY 4-1

4

CLARiTY Operating
System

This chapter contains the following topics:

• Getting started the CLARiTY Operating System

• Using the Tools page

• Working with Passwords

Getting started with the CLARiTY

CLARiTY is an icon-based operator control system. It has an easy-to-use
touch screen and most areas of the display are "active", that is, touching an
area on the screen is like pressing a "button" on a traditional control panel.
The basics of the CLARiTY operator system are explained in the Videojet
6210 Operator Manual (P/N 361853). All technical aspects of the printer
setup and control are accessed through the Tools button.

Figure 4-1 shows the home screen of the CLARiTY operator sytem.

Figure 4-1: CLARiTY Home Screen

1. Machine Status Bar

2.Tools Button

3. Current Job Status Details Button

4. Co

ntrol Frame Buttons

5. Ho

me Button

1

2

3

4

5

4-2

Using the Tools Page

Rev AA

Using the Tools Page

Touch the Tools button on the home screen to access the Tools page
(Figure 4-2).

The tools page allows you to access the following pages:

• Setup page: Permits you to modify a small subset of the printer setup
parameters

• Diagnostics page: Provides on-line fault finding routines and
diagnostic functions

• Databases page: Provides control over the jobs database of the coder.

Figure 4-2: Tools Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-3

Working with Setup Page

Touch Setup button on the tools page to access the setup page (Figure 4-3).

The Setup page allows you to access the following parameters:

• Printhead and printing operations

• Consumables (ribbon)

• General Control (e.g. time, date, language)

•Options

Figure 4-3: Setup Page

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4-4

Using the Tools Page

Rev AA

Printhead Setting in Intermittent Mode

Touch the Printhead button on the setup page to access the printhead
parameters.

The Printhead page in intermittent mode allows you to access the
following parameters:

• Horizontal Registration: The position of the print

in the printers

overall printing window,

measured in mm across the width of

the

printhead. It enables you to positi

on the print along the width of

the

printhead.

•

Vertical Registration: The position of the print in the printers overall
print window,

measured in mm in

the direction perpendicular to the

printhead.

•

Print Orientation: Allows rotation of the whole image throug

h 180

degrees

•

Print Delay: The delay between the print signal and

the commencing
of the print. Measured in milliseconds, it allows time for the
packaging film to come to a complete

rest before the printhead

comes

in contact. It

should be set

to the smallest possible value that gives a

good quality

print.

• Print Speed: The target printing speed of the head in mm/sec.

It

should

be set to the lowest speed that allows completion of

the print

in the available dwell ti

me of the packaging film

Figure 4-4: Printhead Parameters in Intermittent Mode

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-5

• Print Darkness: The amount of energy being transferred into the
printhead. It should be set

to the lowest

value that provides acceptable

quality of print at the

required throughput.

• Interleaved Images: Enables a lower quality draft mode

of printing

with a 50% saving in ribbon consumption

•

Printhead Resistance: Matches the drive electronics of the printer

to

the resistance characteristics of the

printhead.

Printhead Setting in Continuous Mode

Touch the Printhead button on the setup page to access the printhead
parameters.

The Printhead page in continuous mode allows you to access the
following parameters:

• Print Position: Changes the angle of the printhead against

the target

material. This angle affects

the print quality. If the angle is not

suitable,

the resulting print may appear faded.

Note: Other parameters are same as intermittent mode.

Figure 4-5: Printhead Parameters in Continuous Mode

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4-6

Using the Tools Page

Rev AA

Working with the Consumables Setup Page

Touch Consumables button on the setup page to access the consumables
parameters (Figure 4-6).

The consumables page allows you to set the following parameters:

• Ribbon Width: Sets the ribbon tension to

the optimum value

depending

on the ribbon width (narrow ribbons st

retch more than

wide ones and should run

at lower tension)

• Ribbon Color: Allows the printer to accurately

predict the end of reel

condition when using the predictive

end of reel detection

systems

Figure 4-6: Consumables Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-7

Working with the Control Setup Page

Touch the control button on the setup page to access the control page
(Figure 4-7).

The control page allows you to set the following parameters:

• I

nternationalisation: Sets the language of the CLARiTY screen and the

international

region which control date/time formats

displayed

within CLARiTY

• Recalibrate Touchscreen: Allows

the user to recalibrate the
touchscreen, if touching the screen does not accurately locate the
correct

CLARiTY button or Icon. The printer requests

the user to

touch several crosses which

are displayed on the screen, on

e after the
other. The screen is recalibrated when the automated process is
complete.

Note

: If the calibration of the machine has too many

errors and does not
allow a user to navigate to this screen via the CLARiTY panel, the same
functionality

can be triggered from

within CLARiTY Configuration

ma

nager.

• Set Screen Orientation: Rotates the entire display through 180 degrees
in the event that the CLARiTY panel is installed in an inverted
orientation

•

Date and Time: Sets the system date and time of the coder

• Communications: Enables resetting of all

serial communication

reports

in the event that their setup has become corrupted.

Figure 4-7: Control Page

ICE Pegasus Service Manual

4-8

Using the Tools Page

Rev AA

Working with the Options Setup Page

There are no options available at this time, it may be introduced in the
next versions of the CLARiTY.

Working with Diagnostics

Touch diagnostics button on the tools page to access the diagnostics page
(Figure 4-8).

The diagnostics page allows you to access the following pages:

• Printhead and printing operations diagnostics

• Consumables (ribbon) diagnostics

• General control (e.g. software versions, communications port

status)

diag

nostics

• O

ptions

Figure 4-8: Diagnostics Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-9

Working with Printhead Diagnostics

Touch Printhead button on the Diagnostics page to access the printhead
diagnostics page (Figure 4-9).

The printhead diagnostics page allows you to access the following
parameters:

•Inputs

•Outputs

•Optics

•General

• Encoder Profiles

• Timings

• States

Use the Up and Down arrow keys to navigate through the options.

Figure 4-9: Printhead Diagnostics Page

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4-10

Using the Tools Page

Rev AA

Touch Inputs on the Printhead diagnostics page to access the input
parameters (Figure 4-10).

The input diagnostics page allows you access the following parameters:

• Encoder: Touch the encoder

button to access the encoder diagnostics
page. The encoder diagnostic page allows you to access the following
encoder parameters (Figure

4-11)

Figure 4-10: Printhead Inputs Diagnostics Page

Figure 4-11: Encoder Diagnostics Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-11

- Encoder Speed: Shows the actual real-time speed of the film being
measured by the encoder

- Encoder Scaling: A parameter set to run the printing ribbon at a
slightly lower speed to the packaging film. This can improve
printing quality at very high packaging film speeds.

• External Inputs 1, 2, 3: Shows the real-time status

of each of the two

inputs and

the unused spare input.

• Printhead Position: Indicates whether the

printhead home sensor is

detecting

the head as parked or not

• Cassette Open: Indicates whether the cassette home

sensor is

recognising the cassette

as being open or closed

• Motor Volts: Shows the voltage supply to the stepper motors

(must be

36V)

•

Printhead Volts: Shows the drive voltage to the printhea

d. This varies,

dep

ending on the printhead resistance but should be in the range

of

22V-27V depending

on printhead resistance.

• 24 Volt Supply: Shows the voltage supply for the printers I/O (m

ust

be 24V)

•

Printhead Temperature: Shows the real-time reading of the

thermistor

on the thermal printhead

•

Printer Ambient Temperature: Shows the real-time temperature

of the

hottest component inside the printer unit.

ICE Pegasus Service Manual

4-12

Using the Tools Page

Rev AA

Touch Outputs on the Printhead Diagnostics page to access the output
parameters (Figure 4-12).

Each button shows the status of a physical output on the printer. Touching
the Toggle button allows you to force the state of an output, high or low
which is useful for diagnostic purposes.

• Printhead Position: Moves the printhead from its park

ed to its

printing position

•

Printhead In/Out: Drives the air solenoid that moves the printhead in
and out towards the print platen or

roller

• External Relay and PNP Outputs: The printer has 2 relay outputs

and

2

PNP 24V outputs.

Figure 4-12: Printhead Outputs Diagnostics Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-13

Touch the Optics button on the Printhead Diagnostics page to access the
ribbon calibration system page.

The ribbon calibration systems works on a shadowgraph principle. A pair
or LED's are mounted inside the printer and a receiver is mounted onto
the back of the printhead carriage. When the ribbon cassette is placed in
the printer, the calibration process moves the printhead up and down its
carriage such that the receiver can detect the edges of the shadow cast by
the rolls of ribbon. Using geometry, the printer can then accurately
calculate the diameter of both the supply and waste rolls.

• Emitter 1, 2 allows you to toggle the LED's.

• Receiver gives a real-time reading

of the output. High numbers of

greater than 250 are

read when one of the LED's are shining directly

at

the receiver. Low

numbers (less than 10) are read when there is

an
obstruction between the LED and the receiver. Test the optics by
toggling each one on in turn.

• Gain Setting is the gain applied by

the electronics to keep the LED
signals within the correct limits. As the LED's become old, more gain
needs to be

applied to the circuit, which is represented

by a lower

number in

the diagnostic. New LED's must have a gain of

around 50

and old LED's must have a gain si

gnificantly less than this

number,

indicating that the LED needs to be replacement.

Figure 4-13: Printhead Ribbon Calibration Page

ICE Pegasus Service Manual

4-14

Using the Tools Page

Rev AA

Touch the General button on the Printhead Diagnostics page access to the
general diagnostic parameters.

The printhead general diagnostics page allows you access the following
parameters:

• Printer Mode: Indicates if the

printer is configured as intermittent or

continuous motion

•

Printer Hand: Indicates what handing the printer is configured as

• Print Signal Logic: Indicates whether the

print signal is Positive or

Negative Edge Triggering.

•

Print Test Image: Triggers the printing of a test image.

Encoder Profiling

Encoder profiling is designed for continuous motion applications where
there may be doubt over suitability of the application for the VJ6210
printer due to excessive linear speed or acceleration problems.

Encoder profiling allows the VJ6210 printer to capture the behavior of the
packaging film from the encoder and plot the information onto a useful
CLARiTY screen which also shows an 'on-line oscilloscope' of the machine
inputs and outputs at the same time.

Figure 4-14: Printhead General Diagnostics Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-15

Figure 4-15 shows a typical screen display of an encoder profile.

The graph displayed on the CLARiTY Operator Interface takes into
account, settings for 'Maximum Print Speed', current 'Registration'
settings and the image size printed.

Using these values, the graph shows where the print signal was received
and where the print would occur within the profile, as shown in Figure 4-

15.
This feature can be used to solve problems such as, drifting print

registration caused by the packaging film travelling above the maximum
print speed of the printer during the registration phase.

Figure 4-15: Encoder Profiles Graph

ICE Pegasus Service Manual

4-16

Using the Tools Page

Rev AA

To capture the Encoder profiling on the CLARiTY screen, proceed as
follows:

1 Touch the Encoder Profiles button on the Printhead Diagnostics page

access to the Encoder Profiles parameters (Figure 4-16).

2 To set up the options for the profile you are want to capture, touch the

following buttons:

• Profiling starts: Has three options

- Automatically allows you to capture the profile after you touch the
Capture Encoder Profile button

-

On Print Underspeed allows you to only capture a profile if the film
speed drops below the minimum limit of the printers specification

- On Print Signal allows you to only capture a profile after a print
signal has been received

• Profile Type: Has three options which present the information in
slightly different graphical forms. Choose the one which best suits
your needs

•

Profile X Axis: Allows you to set the X Axis of the

chart to be either

time or distance

3 Once the options have been setup, start the capture process by

touching the Capture Encoder Profile button.

Note: Encoder profiles are not captured during the ribbon calibration
sequence.

Figure 4-16: Encoder Profiles Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-17

In addition, if CLARiTY Configuration Manager is communicating with
the printer, the encoder profile may be uploaded to a PC for analysis.

To upload encoder profile to a PC, proceed as follows:

1 Click on the new coder icon and navigate through devices and select

Capture Encoder Profile from the list as shown in Figure 4-17.

2 Click on Trigger button, the profile is captured in a file which is in a

special encoder profile format (.enc).

Figure 4-17: Encoder Profiles - CLARiTY Configuration Settings

ICE Pegasus Service Manual

4-18

Using the Tools Page

Rev AA

3 To access this file, select Log Files folder from new coder as shown in

Figure 4-18.

This file can be used for diagnostic purposes by the Development
Team for advanced diagnostics purposes.

Figure 4-18: Encoder Profiles - Log Files

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-19

Working with Printhead Timings

Touch the Timings button on the Printhead Diagnostics page access to the
timings page (Figure 4-19). This diagnostic page provides information
about the last print or print job selection that was made. It is useful in high
throughput applications to understand what the printer is trying to do,
especially in continuous motion applications.

The following parameters can be accessed in the printhead timings
diagnostics page

• Minimum speed (mm/s): Indicates the minimum film speed during
the previous printing cycle

• Maximum speed (mm/s): Indicates

the maximum film speed during

the previous

printing cycle

• M

inimum print speed (mm/s): Indicates the actual minimum printing

speed during the

previous printing cycle

• Maximum print speed (mm/s): Indicates the actual

maximum

printing speed during th

e last printing cycle

• Cycle Time (ms): Indicates the total time from the end of

the print

registration delay to the end of

the printing operation

• Printing Time (ms): Indicates the actual time taken to print the imag

e

in the previous printing

cycle

• Job Selection Time (ms): Indicates the time taken in selecting

the last

job from t

he moment the image was confirmed, to

being ready to

print.

Figure 4-19: Printhead Timings Diagnostics Page

ICE Pegasus Service Manual

4-20

Using the Tools Page

Rev AA

• Job Data Update Time (ms): Indicates the total time taken to update all
the dy

namic variables in the image (time, date, counters)

• Counter Update Time (ms): Indicates the time taken to update all

the

counter fields in the image

•

Time/Date Update Time (ms): Indicates the time taken to update all
the time/date fields in the image

The States

button in the printhead diagnostics screen is for software

debugging only and is not described in this manual.

Working with Consumables Diagnostics

Touch Consumable button on the Diagnostics page to access to the
Consumables diagnostics page (Figure 4-20).

The following parameters can be accessed in the consumables diagnostics
page:

• S

pool 1, 2 Diameters (0.1mm) are the measured diameters of the

ribbon

and can be compared

to the actual ribbon diameters after
calibration to determine the accurate functioning of the calibration
sy

stem.

• Tension demand and measurement parameters are

for debugging

only and

are not described here

• Ribbon Tension Statistics: This is for soft

ware debugging only and is

not described here

Figure 4-20: Printhead Consumables Diagnostics Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-21

Working with Control Diagnostics

Touch Control button on the Diagnostics page to access the system
Control page.

The following parameters can be accessed in this page:

• Versions: Displays the

software versions of the various software

components installed in the prin

ter.

The most important number
displayed when this button is touched is the Software Part Number.
This

is the master version number and all the other

data displayed is

of secondary

import

ance.

Note

: If there is any inconsistency among the software components that

are

installed

in the printer, the Software Part

Number displays the message

'Incompatible

Software Versions'. If

this is seen, a CLARiTY software

update must

be performed, otherwise the coder may

perform in an

unpredict

able manner.

• Communications: Touch this button to check the functions

of the

Communication Port on the printer. The following

pa

rameters can be

accessed

in this page:

- Communication Ports: Displays the status of the serial

ports,

including the Baud

rate the port is set to

• Image Queue Update: Allows you to vi

ew all the print jobs that are in

the allocation queue.

Figure 4-21: Control Parameters

ICE Pegasus Service Manual

4-22

Using the Tools Page

Rev AA

Working with Options

There are no diagnostics for the Options menu.

Working with Database

Touch Database button on the Diagnostics page to access the Database
page.

The following parameters can be access in this page.

• Internal: Shows the job stored in the printer.

• Capacity: Shows the details like the space used in the

internal

database

and space available.

When an external USB memory device is connected to the printer, it is
accessed in the same page.

Figure 4-22: Database Page

ICE Pegasus Service Manual

Rev AA Using the Tools Page 4-23

Connecting the USB Database

Instead of connecting a PC/laptop to the printer via a null modem cable in
order to download jobs, the USB device can be connected directly into the
USB port on the CLARiTY Operator Interface (Figure 4-23).

To download a job from the USB device, proceed as follows:

1 Copy the Image CIFF file into a root directory called \jobs on the USB

memory device.

2 Insert the USB memory device into the USB port (Figure 4-23).
3 Touch the Tools button on the home page and touch Database button

to access the database page.

Figure 4-23: Printer USB Port

USB Port

I

CE Pegasus Service Manual

4-24

Using the Tools Page

Rev AA

The database page displays the External Database (Figure 4-24).

4 Touch External Database button to view all the jobs in the USB device

(Figure 4-25).

Figure 4-24: External Database

Figure 4-25: Jobs List on USB Device

ICE Pegasus Service Manual

Rev AA Working with Passwords 4-25

Using the buttons in the bottom of the page (Figure 4-25 on page 4-24)
you can either view the job, or send a file to the local database, or
delete the job from the USB device.

5 Touch on the send a file to the local database button. A confirmation

appears (Figure 4-26). Touch ok to confirm.

Working with Passwords

Password protection on the CLARiTY user interface allows different
protected access levels for the various operational features of CLARiTY
for up to three different user groups. For example, the three user groups
may be classified as Operators, Production Supervisors and Maintenance
Personnel, each group requiring access to either all or a subset of the total
functions of CLARiTY.

Protection may be globally enabled or disabled through the CLARiTY
Configuration Manager. The password protection is disabled in the
default factory settings.

CLARiTY has five different functions that may be optionally password
protected:

•Job Select

• Registration

Figure 4-26: Confirmation Screen

ICE Pegasus Service Manual

4-26

Working with Passwords

Rev AA

•Set-up

• Diagnostics

• Databases

This is can be easily explained by means of an example (Table 4-1):

In this example, registration is not selected for any of the three user access
levels, therefore available to all the users to use without any password
protection.

If there is at least one X in a column, then that function is only available to
a user level against which a X appears. Example: Set-up column in the
Table 4-1 is accessible (via a password) only to Level 2 and Level 3
personnel.
Each user level has a different numeric password that can be between 4
and 10 digits.

Password Protection Set-up

Set-up of password protection for CLARiTY is done using the CLARiTY
Configuration Manager.

Run CLARiTY Configuration Manager on the PC and upload the printer
parameters.

Job Registration Set-up Diagnostics Databases

Level 1
(Operator)

X

Level 2
(Line Super­visor)

XXXX

Level 3
(Mainte­nance)

XX X

Table 4-1: Password Protection - Example

I

CE Pegasus Service Manual

Rev AA Working with Passwords 4-27

The menu tree to reach password protection set-up is shown in the
CLARiTY screen in Figure 4-27.

In addition to the global enable/disable of passwords there are three
parameters for each of the three user levels available:

• Mask: This enables/disab

les user access to each of the 5 CLARiTY
functions - Job selection, Image registration, Set-up, Diagnostics and
Databases. Use

the tick boxes at the bottom of

the above CLARiTY

Configuration Manager

screen to

select the required options and
CLARiTY Configuration Manager generates the appropriate mask
number.

•

Name: A name that may be optionally given to each user level as

a

reminder of the user group during set-up of password protection.

•

Password: The password required for each user access level.

For each level, select each of these parameters in turn as shown and set
them as required. When each parameter has been set, select 'Apply'.
Finally right-click on the 'New Coder' icon and select 'Download' to
change the set-up of the printer. Password protection is now be enabled.

Figure 4-27: Password Set - up

ICE Pegasus Service Manual

Rev AA 5-1

5

Maintenance

This chapter contains the following topics:

• M

aintaining the Power Supply

• Maintaining the CLARiTY Controller

• Maintaining the Printer

•Maintaining the Cassette

•

Updating the CLARiTY Operating So

ftware

Warning

PERSONAL INJURY. Before attempting any maintenance or repair
on any part of the product, disconnect the printer from the main
power supply and isolate the printer from any external energy
sources including other connected equipment.

5-2

Maintaining the Power Supply

Rev AA

Maintaining the Power Supply

This section contains the information on how to replace the fuse.

Replacing the Mains Fuse

The fuses are the only user-serviceable parts in the power supply unit.
To replace the mains fuse, proceed as follows:

1 Using a small screwdriver, press and turn the fuseholder

anticlockwise, and remove the fuseholder (Figure 5-1).

2 Replace the five ampere fuse if it is defective (Figure 5-2).

Fuseholder

Figure 5-1: Fuseholder

Fuse

Figure 5-2: Fuse

IC

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Rev AA Maintaining the CLARiTY Controller 5-3

3 Refit the fuseholder in its original position.

Maintaining the CLARiTY Controller

Replacing the Power Supply Unit

To open and replace the Power Supply Unit, proceed as follows:

1 Remove the top cover from the base of the CLARiTY Unit by

unscrewing the 5 screws shown in Figure 5-3.

Figure 5-3: Controller Opening

1. Screws (x5)

2. Top Cover

1

1

1

1

1

2

I

CE Pegasus Service Manual

5-4

Maintaining the CLARiTY Controller

Rev AA

2 Disconnect the white power connectors from the front and back of the

PSU and from the main PCB as shown in Figure 5-4.

Figure 5-4: Power Connections Removal

Connectors

I

CE Pegasus Service Manual

Rev AA Maintaining the CLARiTY Controller 5-5

3 Next turn the base over and undo the four screws from the base plate.

The PSU can now be separated from the base plate.

4 To re-assemble reverse the above procedure ensuring that all electrical

connectors are securely pushed into place.

Replacing the CLARiTY Processor PCB and LCD Touchscreen Assembly

In order to replace the CLARiTY Processor PCB or the LCD/Touchscreen
Assembly, remove the top cover as described in the section “Replacing the
Power Supply Unit” on page 5-3".

Then follow the additional procedure below.

1 Remove the power connector from the main PCB.

Screws

Figure 5-5: Base Screw Removal

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2 Remove the six securing screws from the D-type connectors on the

bottom of the CLARiTY unit (Figure 5-6).

3 Carefully remove the three connectors from the PCB taking care not to

bend or twist the cables (Figure 5-6).

D-Type Securing Screws

Figure 5-6: Top Case Detail

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Rev AA Maintaining the CLARiTY Controller 5-7

4 Remove and retain the two screws securing the PCB (Figure 5-7).

5 Gently slide and lift the PCB away from the LCD and touch screen

assembly taking care not to damage the three cables coming from the
LCD/Touchscreen module.

If replacing the Processor PCB then refer to section 13 below. If replacing
the LCD/Touchscreen Assembly then continue below.

Replacing the LCD/Touchscreen Assembly

6 Remove and retain the three screws and anti-vibration washers

holding the whole assembly and inverter module. Remove this
module from the case, taking care not to remove the seal around the

Figure 5-7: PCB Connections

Screws

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case aperture (Figure 5-8).

7 Disconnect the backlight power cable (white/pink) connection.
8 Remove and retain the four screws holding the LCD/touchscreen

assembly to the metal support plate.

Figure 5-8: PCB Removal

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Rev AA Maintaining the CLARiTY Controller 5-9

9 Remove and retain the white ribbon cable from the now separated

LCD/touchscreen assembly (Figure 5-9).

10 Place the new LCD/touchscreen assembly face down on a clean, soft

surface and fit the support plate using the four screws removed
earlier. Ensure that the touchscreen signal ribbon cable is carefully
routed through the slot in the base plate without damage (Figure 5-

10).

Figure 5-9: Separated LCD Assembly

Figure 5-10: Touch Screen Ribbon Cable Routing

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11 Replace the white ribbon cable ensuring that the right angle is as

shown (Figure 5-11).

12 Slide/lower this assembly back into the top case, being careful not to

damage the seal or to trap the backlight power cable and re-fit the
three securing screws and the anti-vibration washers.

13 Refit the Processor PCB with its two securing screws again taking care

not to trap the backlight power cable.

14 Refit the three connectors to the PCB and the securing screws for the

D-type connections.

15 Refit the power connector.
16 Replace the Top cover over the base and secure with the five screws

on the sides.

Figure 5-11: LCD Ribbon Cable Detail

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Maintaining the Printer

This section contains the information on how to replace:

• The Compact Flash Card

• The Main PCB of the printer

• The Peel Roller

•The Printhead

• The Cassette Rollers

Replacing the Compact Flash Card

To replace the compact flash card, proceed as follows:

1 Remove the cassette and place the printer face down on a flat surface.

Remove the rear cover by unscrewing the 4 screws, one from each side
of the printer (Figure 5-12) and then lift the cover off.

Figure 5-12: Rear Cover Removal

1. Screws

1

1

1

1

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2 The Compact Flash card is located on the side with the mounting plate

(the opposite side to the printhead). Using a pair of long nosed pliers,
gently grip the Compact Flash Card and pull to extract (Figure 5-13).

3 Take the new card, orientate such that the face with the Windows

License sticker is facing away from the PCB and gently but firmly
push home.

4 Replace the rear cover.

Replacing the Main PCB

To replace the main PCB, proceed as follows:

1 Before removing the rear cover, place the printer on a flat surface

cassette side up and remove the cassette if this hasn't already been
removed.

Windows License Sticker

Figure 5-13: Compact Flash Card Removal

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Rev AA Maintaining the Printer 5-13

2 Locate and remove the 2 screws (Figure 5-14).

3 Remove the rear cover as detailed above in the section “Replacing the

Compact Flash Card” on page 5-11.

4 Next remove the nuts securing the D-Type connectors to the side plate

still secured to the unit (Figure 5-15).

Screws

Figure 5-14: Cassette Screws Removal

Figure 5-15: D-Type Securing Nuts

Nuts

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5 Disconnect the 8 electrical connectors located around the edge of the

PCB.

6 Undo the 2 screws securing the PCB to the supports and carefully

withdraw the PCB including the 15way D-Type connector for the I/O
connections (Figure 5-16).

7 Remove and retain the I/O connection ribbon cable.
8 To replace the PCB firstly insert and secure the I/O D-Type connector

to the side plate (Figure 5-17).

Figure 5-16: Main PCB Removed

I/O Connection
Cable

Figure 5-17: Main PCB Replacement

I/O D-Type Connector

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9 Then connect the I/O ribbon cable to the PCB and slide it into place.

Ensure that the connector X9 is threaded through the access hole in
the heat sink (Figure 5-18).

10 Secure the PCB using the 2 screws and then reverse the procedure

from 5 to 1 above.

Replacing the Peel Roller

To replace the peel roller, proceed as follows:

1 Remove the cassette from the printer.

Figure 5-18: X9 Connector Access

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2 Remove the screw on the top of the peel roller as shown in Figure 5-

19.

3 Remove the peel roller.

4 Replace the peel roller and secure it using the screw removed in step

2.

5 Refit the cassette to the printer.

Figure 5-19: Peel Roller Screw Removal

1. Peel Roller

2. Screw

1

2

Figure 5-20: Peel Roller Removal

Peel Roller

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Replacing the Printhead

To replace the printhead proceed as follows.

1 Remove the printhead retaining screw as shown in Figure 5-21.

2 Move the printhead from the parked position.
3 Disconnect the printhead and remove.

Printhead Screw

Figure 5-21: Printhead Screw Removal

Figure 5-22: Printhead Removal

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4 Reconnect the printhead connector to the new printhead.
5 Place the printhead in the parked position and secure it with the

printhead screw.

6 Set the printhead resistance.

Setting the Printhead Resistance

Printheads are manufactured with variations in their resistance. The
printhead resistance is pre-set in the factory. The printer must be set up
with the correct printhead resistance.

Caution

PRINTHEAD RESISTANCE. If the printhead is changed, the new
printhead resistance must be set. If not set correctly, damage could
occur to the printhead, or poor quality images could result. Such
damage is not covered by your printer warranty.

To set the printhead resistance, proceed as follows.

1 Find and note the printhead resistance value from the label on the

printhead (e.g. R=1113 O) as shown in Figure 5-23.

2 Touch the Tools button on the Home page.
3 Touch the Setup button on the Tools page.

Printhead Label

Figure 5-23: Printhead Resistance Value

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4 Touch the Printhead button to open the Printhead Setup Page.
5 Select the Printhead Resistance parameter and enter the resistance

value that was displayed on the printhead label (Figure 5-24).

6 Use the arrows or the keypad to set the settings and touch OK to save

the settings.

7 A confirmation message is displayed to ensure that this parameter is

not changed inadvertently. Choose 'Yes' to proceed to set the new
value.

Maintaining the Cassette

Replacing the Cassette Rollers

To replace the cassette rollers, proceed as follows.

1 Remove the cassette from the printer.
2 Remove the ribbon from the cassette.

Figure 5-24: Printhead Resistance Setting

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3 Loosen and remove the ribbon guide, with a 12 mm spanner from the

cassette, as shown in Figure 5-25.

4 Remove the roller from the ribbon guide, as shown in Figure 5-26.

5 Place the new roller on the ribbon guide.
6 Install the ribbon guide on the cassette.
7 Replace the ribbon in the cassette.
8 Replace the cassette in the printer.

Figure 5-25: Roller Guide Removal

Roller

Figure 5-26: Roller Removal

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Adjusting the Cassette Latch

The latch components on the printer are set at the factory and normally do
not require adjustment.

If it is necessary to adjust the latch, proceed as follows.

1 Remove the cassette from the printer.
2 Remove any ribbon from the cassette.
3 Loosen the lock nut on the cassette latch (10 mm), as shown in

Figure 5-27.

Figure 5-27: Latch Screw Locking Nut Loosening

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