Open Date Thermocode 2 Operator Instructions Manual

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THERMOCODE SERIES 2

OPERATOR INSTRUCTIONS

CIRCUIT DIAGRAMS

INSTALLATION DETAILS

Continuous “53CR” Left Hand

Thermal Transfer Printer

Designed and manufactured by: -

OPEN DATE EQUIPMENT LIMITED

Units 8 & 9 Puma Trade Park

145 Morden Road

Mitcham

Surrey CR4 4DG

UNITED KINGDOM TEL: - 0044 (0) 20 8655 4999 FAX: - 0044 (0) 20 8655 4990

Web Site: - http://www.opendate.co.uk/

Technical website: - http://www.opendateinfo.com/

Email: - sales@opendate.co.uk

Thermocode 2 Printer manual Version 2.04 January 2011 2

EC DECLARATION OF CONFORMITY

We hereby declare that the following machinery complies with the essential health and safety requirements of the Machinery Directive 89/392/EEC enacted in the United Kingdom by the Supply of Machinery (Safety) Regulations 1992. Amended 1999 (URN 99/1232) Amended 2005

Machine Description:

Thermal Transfer Printer.

Model:

Type: Thermocode Series 2

Serial Number:

Manufactured by:

Open Date Equipment Limited. Units 8 & 9 Puma Trade Park, 145 Morden Road, Mitcham, Surrey. CR4 4DG England

Telephone: - 0208 655 4999

This machinery has been and manufactured in accordance with the following transposed harmonised European standards.

EN ISO 12100: parts 1 and 2, 2003.

Safety of Machinery - Basic concepts, general principles of design.

EN 294: 1992. Safety of Machin ery

- Safety distances to prevent danger z ones being reached by the

upper limbs.

EN 60204: part 1, 2006.

Safety of Machinery - Electrical equipment of machines - Specification for

general requirements.

EN 61000 – 6 - 2: 1999.

Electromagnetic compatibility - Generic immunity standar d.

EN 61000 – 6 – 3: 2001

Electromagnetic compatibility - Generic emission standard.

(IEC 61000-6-2: 1999,modified)

EN 61000: 3 - 2, 2001.

Harmonic Emissions.

EN 61000: part 3 – 3, 1995.

Voltage Flicker.

FCC Part 15, Conducted & Radiated Emissions, Class A .

In addition, this machinery has been designed and manufactured in accordance with British Standard

PD 5304: 2005

, Safety of Machinery.

A technical construction file for this machinery is retained at the above address.

Signed: Date: Name:

Position: Being the responsible person appointed by Open Date Equipment Limited. This Declaration of Conformity complies with Regulation 22 of The Supply of Machinery (Safety)

Regulations 1992 Amended 1999 (URN 99/1232)

Thermocode 2 Printer manual Version 2.04 January 2011 3

Index

Page No

This Page 3 Standard Warranty Terms and conditions 4 Safety Instructions. 5 Introduction. 6

System Overview. 6 Optional Extras. 6 Printer Technical Information 6

Installation Procedures 7 - 10 Setting the Five Volts 11 Control Relays 12

Power Supply (I/O Board connections) 13 Power Supply (PNP / NPN Sensor s & Vol t Free print si gnals) 14 Power Supply (fuse details etc) 15 Power Supply (LED details) 16

Encoder Description 17 Encoder & Lower Roller Unit, Power Supply Wiring Connections 18 Encoder Types and Wiring Connections 19

System Start Up Sequence 20 - 21 Mini-Terminal Key Mapping 22

Mini Terminal Flow Charts 23 - 29 Quick Selection Reference Sheets 30 - 32

Thermal Ribbon Specification 33 Threading Diagram 34

Cleaning 35 - 36 Fault Finding. 37 - 40

Ribbon Not Indexing Enough, Ribbon Indexing Excessive 37 Ribbon Breaking or Perforated, Ribbon Tracking. 37 - 39 Print Quality Problems 39 Clearing Printer Error Messages 39 Thermocode Diagnostics Sheet 1 40 Thermocode Diagnostics Sheet 2 40

Error Codes 41 -48 Automatic Burn Compensation As Speed Changes 49 Magazine Spares 50 Dimensions

Printer Dimensions 51

Standard Frame Dimensions 52

Lower Roller Unit Dimensions 53 Power Supply (Dimensional and Installati on Details) 54

Computer Connection leads. 55 Airborne Noise Emissions 55

Open Date Group Companies Addresses 56

Thermocode 2 Printer manual Version 2.04 January 2011 4

Standard Warranty Terms and Conditions – Thermocode Series 2 Printers

Open Date thermal transfer printers carry a twelve (12) month return to base (at our discretion) warranty, with the exception of the following parts: -

1. Thermal Printhead.

2. Lower Roller. (Rubber covered Roller)

3. Cassette Springs and Belts.

4. Cassette Rubber Drive Roller.

Static Electricity

Warning, static electricity may damage the printer or pr inthead. On many film type installations, the material produces static electricity and possibly causes printer problems or printhead failure. Open Date does not accept any type of warranty claims, if any damage to the printer or Printhead is caused by static electricity.

If you are in doubt about your installation, please contact our service department.

Printhead Warranty

The Printhead assembly (ASY762199, ASY762200, ASY762345 or ASY762346) carries a 50 kilometres or 12 months warranty which ever is the soonest. Should the Printhead fail during this period, the replacement Printhead will carry the balance of the existing warranty.

Please refer to the ribbon specifications sheet on page 33, check the correct width of thermal transfer ribbon is being used and has the appropriate silicone back coating to protect the Printhead.

The Printhead warranty will not be valid if: -

1.The full width ribbon is not being used, as excessive wear on the edges of the Printhead can be found. (See page 33)

2. Mechanical damage is apparent from abuse.

3. The Spy Chip Board has been removed or damaged in any way.

4. Cleaning Procedures have not been followed. (See pages 35 & 36

5. Installation and maintenance procedures are not correct. (See pages 6 – 10)

6. The print base used (Lower roller unit) or roller is not as specified. (See page 53)

7. The Printhead angle has not been set up correctly. (See page 7 – 10)

8. Static Electricity is found.

9. Recommended Open Date ribbon is not being used. (See page 33 Ribbon Specifications)

10. Printing substrate or ribbon is found to be abrasive.

The print base or lower roller assembly carries no warranty, as it is considered to be a consumable item.

We reserve the right to charge for components replaced during the warranty period, which are found damaged due to any of the above conditions not being followed or met.

Printhead Spy Chip

Contained within the Printhead assembly, is a small microchip this is programmed when the head is first assembled and tested to retain the following information: -

1. Printhead resistance value (ohms).

2. Printhead width (Dots).

3. Printhead serial number.

4. Printhead data lines.

5. Programmed factory date.

6. Printhead angle.

During start up of the printer, the Spy Chip is accessed by the software, determining the width of printhead and automatically adjusts the resistance value to compensate for the correct print burn calculations. Whilst printing, the spy chip is written to, allowing automatic recording of the print distance achieved during the life of the printhead.

All the Printhead recorded settings may be viewed at any time, by accessing the Service menu on the miniterminal Display.

Thermocode 2 Printer manual Version 2.04 January 2011 5

IMPORTANT SAFETY INSTRUCTIONS

1. Read these instructi ons carefull y . Follow all warnings and instructions marked on the product.

lways disconnect the pri nter and Power Suppl y f rom t he mai ns electric al supply before att empti ng

to clean or service t he pr oduc t.

3. Never operate the pr inter, unl ess it is instal led within t he mounting f ram e supplied. W hen instal led

correctl y , the gap between the print er and print base should be nominally 1mm.

4. Do not use the product near water. Never spill liquid of any kind on to the product.

5. Do not place this product on an unstable stand, table or machine. It may fall causing serious injury to

the operator or damage to the product .

6. Never i nsert objects of any kind into t his product through any openings or gaps as they may touch

dangerous vol tage points or short ci r c uit parts that could result in fire or electric shock.

7. This product should only be connected to t he type of elec trical suppl y as i ndicated on the l abel

located on the top of the Power Supply. (See CE label)

8. Ensure that the pri nter connection cable is fully secured to the printer and power supply with the

screws supplied. Failure to do this will result in the machine not being properly earthed.

9. Use only the power cable suppli ed with the product. T he cable supplied i s t hr ee c or e, utilising one

wire as a grounding conductor . This must be connected to a suitable ear th point at t he electric al

supply. Thi s i s a safety feat ur e. If any doubt arises in trying to connect the power cable, please

contact the manufacturer or the agent who supplied t he product.

10. Do not allow anyt hing to r est on the power cable. Do not locate the product where people could walk

on the cable.

11. If an extension cabl e is used with this product, make sure that the t otal ampere r atings of the

equipment plugged into the extension cabl e does not exceed the extension cable am per e r ating.

Also make sure that the total r ating does not exceed the fuse rating.

12. Do not service thi s product yourself as openi ng or remov ing guards may ex pose you t o danger ous

voltages, maj or bur ns and other r isks. Refer al l servicing to qualifi ed per sonnel .

13. Do not attempt to use to use thi s produc t in areas where explosive gases or substances are present.

14. Under the following conditions always disconnect the electrical supply and refer to a qualified service

engineer.

a. If the power cable is damaged or frayed. b. If the pr inter connection cables are damaged in any way. c. If li quid has been spilled i nto the product has been exposed to water.

d. If the produc t does not operate norm ally when the operati ng instructions are followed.

15. Adjust only those controls covered by these instructions. Improper adjustment could result inpermanen

damage, requiring qualified t echnicians to restor e the product to normal operati ng c onditions.

16. Do not touch the printer or contr ol box with wet or moist hands.

17. Do not use the Pri nter without Thermal Transfer Ribbon, as the printhead maybe damaged.

Thermocode 2 Printer manual Version 2.04 January 2011 6

Introduction

This operator manual describes how to operate and maintain a

Thermocode Series 2 (Model 53CR

) on a basic level. The mechanical adjustments that can be made to the printer are minimal. Normally the printer is installed in a standard frame, which allows the correct clearance from the lower roller unit and the alignments deemed needed.

Operation of the printer is either by selection of a stored format within the printer memory, or by designing a dedicated format from the windows software and then downloading from a standalone computer.

Using the mini-terminal, formats can then be selected and edited by the operator as required. If you are making your own frame or installing into a specific type of machine, you must consult the

manufacturer to ensure you receive the correct detailed dimensions required for your installation.

SYSTEM OVERVIEW

The following components are supplied ready for installation.

1 Thermocode Model 53CR 1 Power Supply Unit (240 Volt or 110 Volt) Selectable inside the unit 1 Mini-Terminal display 1 Power Supply Interconnection Lead 1.5 metres long

(Available in 3, 5 or 6 metre lengths see page 11) 1 Roll of Thermal Transfer Ribbon (300 me tres x 55 wide, Wax Resin quality) 1 Operator Manual 1 Printhead Cleaning Kit, Consisting off 50 Print head Cleaning Wipes (Isopropyl Alcohol) 1 Programming lead (3 Metre length, 9 way “D” connector)

. 1 Recover Mode software backup program (Allows customer to back up all printer data)

OPTIONAL EXTRAS

Windows based Software (Codesof t Prem ier package with Installation & details manual). Encoder, rotary incremental (see pages 17 – 19) Lower Roller Unit. (Custom Designed to fit the Open Date Frame) Standard or custom designed mounting frame. Ethernet & USB Communications (RS232 is standard)

PRINTER TECHNICAL INFORMATION

Maximum print area = 53.3mm X 500mm. Printhead resolution in dots 12 dots/mm or 305 dots per inch.

3.5 Megabytes (approximately) memory for storing fonts, graphics and custom designed formats. Print designs are stored along with all parameters, allowing quick access for printing. Automatic updating of printer memory when editing formats. Supply Voltage 110 or 220 / 240 V 50/60hz.

Real Time/Date printing with specified offsets if required. Sequential Numbering and Barcode printing All text, graphics, lines and boxes can be printed in all four orientations. (0, 90, 180, 270 degrees)

Thermocode 2 Printer manual Version 2.04 January 2011 7

INSTALLATION PROCEDURES

Installing the 53CR Continuous Printer on a Standard Continuous Frame

1. Install the right hand printer into the Standard Continuous frame, utilising the “

location sleeves

” and

then lock t he “

clamp handle

” (see below)

2. Fit the retaini ng screws for the linear block adjustment. (See below)

LOCATION SLEEVE & FIXING SCREW

CLAMP HANDLE & WASHER

LINEAR ADJUSTMENT BLOCK

LINEAR BLOCK FIXING SCRE

FRAME TOP SLOTTED BAR

Checking the Printhead Angle

1. Check the “

printhead angle

” has been set correctly r emove the magazine to visually check the

mechanic al angle setti ng. Within the mini-display unit, sel ec t the “

Service Menu”

number 4

Print head data

, and check the printhead angle has been set correctly.

If t he angle does not correspond, release the “

Printhead Locking Screws

” and adjust unti l the pointer i s set corr ectly (See fig 2a Page 8) I t may be necessary to switch off al l electrics and remove the printer to a well-lit area to car ry out this fine adjustm ent.

Thermocode 2 Printer manual Version 2.04 January 2011 8

Enlarged View of Printhead and Pressure Roller Alignment

1.00 mm

CENTRE LINE ROLLER

PRINTHEAD LOCKING SCREWS

CHECK PRINTHEAD ANGLE

FIG 2a

Thermocode 2 Printer manual Version 2.04 January 2011 9

FIG 2B

PRINTHEAD SUPPORT ASSEMBLY

ADJUSTMENT

UPPER SCREWS A & B

LOWER ROLLER UNIT

LOWER SCREW D

LOWER SCREW C

CHECK PRINTHEAD ANGLE

CLAMP HANDLE

PRINTHEAD LOCKING SCREWS

CENTRE LINE ROLLER

1.00 mm

FIG. 2

Align t he P r inter to be adj usted c or r ec tly in t he S tandard frame, set the Pri nthead to be behind the print roller c entre-line at “

1.0 mm

” dimensi on. (See abov e)

A. Release the “

Clamp Handle

” by a quarter turn. (See abov e)

B. Adjust the “

Lower Screw D

”, undo by half a turn. (See above)

C. Adjust the “

Lower Screw C

”, do up by half a turn. (See above)

(Lower Screw C is the opposite side of the fr ame)

D. Lock up Clam p Handle. (Once cor r ect, lock up l oc k nuts)

Thermocode 2 Printer manual Version 2.04 January 2011 10

Alignment of right hand Printer to the Lower Roller Unit

A. Release the “

Clamp Handle

” by a quarter turn. (See below)

B. Adjust the “

Upper Screw B

”, undo by half a turn. (See below)

C. Adjust the “

Upper Screw A

”, do up by half a turn. (See below) D. Lock up Clamp Handle. E. Test a print an image, to show the printer is aligned to the Lower roller Unit.

CLAMP HANDLE

CLAMP WASHER

UPPER SCREW "A"

UPPER SCREW "B"

If the printer is aligned opposite to the above shown diagram, just reverse the adjustment procedure. By Adjusting the “Upper Screw A” before “Upper Screw B”.

You may have to repeat the procedure to ensure the printhead is aligned to the lower Roller unit correctly.

Installation Notes

1. Installing the

Thermocode 53CR

printer in a Standard mounting frame may not be required, but please check that all frame dimensional details needed are attained. It is very important that the alig nment to the print roller is correct (see pages 8, 9 & 52

2. frame details etc.)

3. Connect the printer and power supply using the interconnection lead supplied. The lead has been specifically designed, so it cannot be fitted incorrectly. Please ensure that the plugs and sockets are inserted fully before tightening the fixing screws. Orientation of the mounting plate can be changed, by removing the two fixing screws. Then rotating the mounting plate.

4. Each installation must have an automatic print signal from the parent machine, this is normally a relay (voltage free) or 24 Volt pulsed output signal.

Thermocode 2 Printer manual Version 2.04 January 2011 11

Five Volt Adjustment

If a Printer is to be fitted with a special length interconnection cable (3, 5 or 6 Metres), please ensure that the

5 Volt DC

supply at the Printer is adjusted to

5.1 Volts,

otherwise the Printer may not function correctly. This can be measured on Pin 5 and Pin 9, of the 9way “D” serial socket. The voltage is adjusted via the Potentiometer on the front right hand side of the power supply. See page 15

Test Connector not supplied

Plug in to the Serial Port of the Printer

Check the voltage with a Multi-meter

For more information on the Power Supply see: -

Page 12 & 13 for relay connections. Page 13 & 14 for print signal connections. Page 15 & 18 for power supply plan view (Page 15 with covers removed)

Page 18 & 19 for power supply Encoder Connections The print signal can be delayed upon installation if required. Within the Supervisor menu on the mini-

terminal display, there is a “Delay Menu” which allows the operator to change the print signal delay time. (Range 0 to 999 milliseconds)

Thermocode 2 Printer manual Version 2.04 January 2011 12

Thermocode Series 2 Controlling Relays

Within the

Thermocode Series 2

Power supply are three relays, which can provide controlling

signals to the parent machine. Each relay has three connections,

Normally Open, Normally

Closed

, and

Common

. (Also see page 13) The relays have a maximum rating of 240 Volt, 7 Amp. Through the Mini-Terminal software the installation engineer can configure each of the relays as required. (To set the options see page 28)

Relay 1

(4 options)

<0> Stop Machine

The relay operates after each print cycle giving a trigger/inhibit signal to the parent machine after printing or when the cassette is removed.

<1>

Sequence

(default software setting) The relay operates after each print cycle giving a trigger/inhibit signal to the parent machine after printing.

<2>

Ready

The relay operates when print images are being generated etc. (When the printer is off line)

<3> Future Development

<4>

100ms pulse

The relay is pulsed for a 100 milliseconds

Relay 2

(5 options)

<0>

Start Machine

The relay operates after each print cycle giving a trigger/inhibit signal to the parent machine after printing or when the cassette is removed.

<1>

Low Foil

(default software setting) The relay operates when the amount of Thermal Ribbon left in metres reache s a preprogrammed amount, and is visually indicated to the operator “Low Foil” on the status line of the Mini-Terminal Display.

<2>

Ready

The relay operates when print images are being generated etc. (When the printer is off line)

<3>

100ms pulse

The relay is pulsed for a 100 milliseconds

<4>

100ms pulse

The relay is pulsed for a 100 milliseconds

Relay 3

(4 options)

<0>

Fault Only

The relay operates when the printer’s internal sensors detect a fault or error condition. Typical examples of this are when the Cassette is removed or if the Thermal Ribbon is broken.

<1>

Fault & Ready

(default software setting) The relay operates as option 1, but will also operate when print images are being generated etc. The relay should be connected to inhibit the parent machine should any printer fault occur.

<2>

Future Development

<3>

100ms pulse

The relay is pulsed for a 100 milliseconds

<4>

100ms pulse

The relay is pulsed for a 100 milliseconds

Thermocode 2 Printer manual Version 2.04 January 2011 13

Power Supply

(I/O Board connections)

(fit Print Signal Selectors to positions "J" & "L" only)

Input (6 - 35 volt AC):- Connect wires to terminals 3 & 4, polarity unimportant.

(fit Print Signal Selectors to positions "J" & "L" only)

Input (9 - 50 volt DC):- Connnect wires to terminals 3 & 4, polarity unimportant.

(fit Print Signal Selector to "M" only as shown)

Voltage Free Connections:- Connect wires to terminals 1 & 2.

Print Signal Inputs

2 = "Ready"

1 = "fault & Ready" (Default)

Spare Link

Default Software Setting 0 = "fault"

RELAY

N/C

N/O

COM

1 = "Low Foil" (Default)

0 = "Start Machine"

1 = "Sequence" (Default)

0 = "Stop Machine"

Default Software Setting

C = Standard Relay

A = Reed Relay

Relay 1 Output Choice.

2 = "Ready"

B = Transistor

RELAY

N/O

COM

N/C

N/O

COM

B C

RR1 RR2 TRO TRN

contact bounce. ie heavy

Print Signal Selector Link

duty relays or switches etc.

PCB 763068

3 2

JH MLK

Reed Relay Connection

(Max 350V ac/dc 0.75A, 1.5ms)

Reed Relay Connection

(Max 350V ac/dc 0.75A, 1.5ms)

Fit link for input signals with

Link E & F for "Falling Edge"

Link D & G for "Rising Edge"

Auxillary Contacts:-

(Rated 100v DC, 3 amp max.)

Transistor NPN output

(Link to the machine "O" volt)

Transistor "O" Volt.

8 7

D F

Thermocode 2 Printer manual Version 2.04 January 2011 14

PNP / NPN Sensor or Volt Free Connections

Note: -

The above drawings, are for 24V DC sensor deriving their power from the Thermal power supply.

When th e sensor has its own power supply, leave off the +24V connection

Thermocode 2 Printer manual Version 2.04 January 2011 15

Power Supply

Note: -

All Stepper drive boards are the same.

Part No. PCB 763004

I/O Board Part No. PCP763005

Pressure Motor Set to low power

Lower Roller Unit Set to high power

Ribbon Motor set to high power

Linear Motor leads Not used.

Mains fuse 5 amp Anti-surge Part No FUS

753016

24 Volt DC Switching Board Part No PCB 763006 Fuse 20 am

& USA 15 amp

Thermocode 2 Printer manual Version 2.04 January 2011 16

THERMOCODE SERIES 2 (Power Supply LED details)

24 VOLT PRINTHEAD OPERATION LED

PRINTHEAD 24 VOLT SUPPLY LED

PRINT INPUT SIGNAL LED

STEPPER MOTOR 40 VOLT SUPPLY LED

POWER SUPPLY 5 VOLT LED

PRINTER 5 VOLT SUPPLY LED

PRINTER DISPLAY 9 VOLT LED

24v PH

OPPHSIG

9vPR5v

PS5vM

40v

Thermocode 2 Printer manual Version 2.04 January 2011 17

Encoder Description

Incremental encoders are commonly used as feedback devices for motor controllers. They also serve as operator interfaces and are sometimes called rotary pulse generators.

An incremental encoder is made up of 2 major parts: the internal disk and the sensor. The disk of an incremental encoder is patterned with a single track of repeating identical lines near the outside edge of the disk. The number of line pairs on the disk determines the encoder resolution.

Our standard encoder wheel has a circumference of 200mm and runs on the surface of the substrate. Thermocode Series 2 requires 2400 pulses per revolution.

Since the resolution of the Printhead is 12 dots per mm, we also require 12 pulses per mm down the web. Therefore one revolution of the encoding wheel is 200mm X 12, equals 2400 pulses.

Principles of an Incremental Encoder

The Open Date Equipment standard encoder assembly is fitted with a measuring wheel on the output shaft, you will have to provide specific sprung loaded designed brackets to mount the unit on the parent machine. (Open Date Equipment Ltd can supply standard mounting brackets. Contact your local supplier)

You must ensure that no slipping happens between the substrate and the measuring wheel, otherwise printing quality, print registr ation or printer errors could occur.

If you need to fit an encoder inside a parent machine, not just running against the substrate I suggest you contact Open Date Equipment Ltd for technical assistance.

Thermocode 2 Printer manual Version 2.04 January 2011 18

Power Supply Shaft Encoder & Lower Roller Unit Connections

Cable Assembly Part No. ASY 765188 Fitted with 8 Way Female Socket Pin 1= Black (Screen), Pin 2 = Green, Pin 3 = White, Pin 4 =Red

Set to High Power

Thermocode 2 Printer manual Version 2.04 January 2011 19

Encoder Type and Connections

Principle Engineering Kubler (Black &Orange) Scancon

Wire Colour Plug Pin No Wire Colour Plug Pin No Wire Colour Plug Pin No

Screen/Shield 1 & Case Screen/Shield 1 & Case Screen/Shield 1 & Case

Brown 2 Green 2 Pink 2

Black 3 White 3

Blue, Grey,

Brown, Yellow

White 4 Brown 4 Red 4

Note

Plug / Socket Pin 1 Connects to the power supply case (Screen) Plug / Socket Pin 2 Connects to the power supply terminal 10 Signal Plug / Socket Pin 3 Connects to the power supply terminal 8 0 Volts Plug / Socket Pin 4 Connects to the power supply terminal 9 5 Volts DC

Encoder Make Model / Type Part Number & Plug

Encoder, Plug & Driver

Roller

Principle Engineering 758-58mm N/A ENC765304 Kubler (Black) 5820.1288.2400.0020

No longer supplied

Replaced with above

Kubler (Orange) 8.5802.128B.2400.0020

No longer supplied

Replaced with above

Scancon 2RK2400-606904 No longer supplied Replaced with above

Drive roller

5 Way Male - Plug

Thermocode 2 Printer manual Version 2.04 January 2011 20

SYSTEM START-UP SEQUENCE

Ensure if a standard mounting frame is used, it is fully closed before switching on the printer. After switching on the following start up sequence screens will be displayed, this screen displays the

communication baud rate that has been set.

Baud Rate

The following screen shows: - Open Date Equipment,

Series 2 range V0.0F Firmware Version number

After a few seconds, the machine will check the printer through a standard sequence of operations to determine the maximum print length and then automatically select the printer size.

Printer model

After determining the model of machine, automatically the height of the lower roller unit is detected. This measurement is used by the software and automatically adjusts the printer for the correct height above the lower roller unit. The screen shown on page 21 is after the start up sequence has finished, showing the actual model of the machine and the format that is ready to print.

Open Date Trying to load 115200 Press key for test

THERMOCODE 53 1-[S]Parking 2 [F]Document1 3 Select format

“Press key for Test”

You are advised to only change the Baud rate & Time if required.

The other functions are for

fully trained Engineers.

Thermocode 2 Printer manual Version 2.04 January 2011 21

Cursor Status line

Current Format

[F] Status Line This line on the display shows the current status of the printer. If errors have occurred the display

shows “error” and by either pressing the enter key when the cursor is next to the error or by just pressing “1” on the keypad all errors will be listed.

[F]Document1 This line on the display shows the current format image that is ready to print, pressing number 2 on

the keypad will allow the user to edit all functions relevant to the design. Note! Accessing of all menu functions can be done by either of two ways: -

1. Move the cursor next to the function you wish to use and press “Enter”.

2. Simply press the required number next to the function you require.

See next page for a full description of the keys on the mini-terminal display unit.

THERMOCODE 53C 1 > [S] Print on line 2 [F] Document1

Sel

ect format

Thermocode 2 Printer manual Version 2.04 January 2011 22

MINI TERMINAL (Key ma ppin g)

SHIFT KEY

When editing text f ie lds, allo ws the

user to select between upper or

lower case characters

Moves the cursor to the top of lists

When editing parameter or system

variables pressing once

increments the value by one

ALPHANUMERIC KEY

When editing allows the user to

change betw ee n alpha and numer ic

characters

Moves the cursor to the end of lists

When editing parameter or system

variables pressing once decrease the

value by one

DELETE KEY

Delete s character when editing

variable fields.

Used to select a format with

PSMT Mini Termi nal

CHARACTER INPUT KEYS

Used to access menu options

When editing text fields, allows the

input of characters shown on the

keys .This depe ndent on how the

shift and alphanumeric keys have

been activated.

The key may need pressing more

than onc e to display the required

alpha character

RI G HT AR R OW K E Y

Moves the cursor to the right

when editing, or to toggle

different fields

Format selection display Z to A

LEFT ARROW KEY

Moves the cursor to the left

when editing, or to toggle

different fie lds

Format selection display A to Z

ESCAPE KEY

Returns to t he previous menu

Does not save any data

changed

DOWN ARROW KEY

Moves the cursor down

to the ne xt field on the

screen

UP AR RO W KE Y

Moves the cursor up to

the next field on the

screen

INSERT KEY

When editing text fields, allows the insertion of

special char acters not show n on the key pad.

When pressed will display a list of options

allowing a choice of character styles.

(Punctuation, French, German etc

ENTER KEY

Accepts your selection.

Returns to the previous menu

and saves any data changed

after editing

CHARACTER INPUT KEYS

Used to access menu options

When selecting formats allow the

user t o move through the page s

1 = mo ve 1 page up (3 lines)

6 = mo ve 1 page dow n (3 lines)

Thermocode 2 Printer manual Version 2.04 January 2011 23

THERMOCODE 53C 1> [S] Print On Line 2 [F] LABEL1 3 S el ect Format 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Pa sscodes

WARNING THIS ACTION CANCELS PRINTING, PROCEED ?

NO YES

[F]LABEL1 1> Offset 2 Set Parameters 3 Edit Fie lds 4 Set Quantity 5 Save As…. 6 Crossweb set tings

[F]LABEL1 Print Off. : (mm) < 090 > 0 - 999 Range Edit and press ENTER

[F]LABEL1

Set the Quantity < 000000 > (0=infinite) Edit and press ENTER

STATUS DISPLAY SOFTWARE FLOWCHARTS (Level 1: OPERATOR)

30/08/2007 12:36:48 Version : 2.07 Meterage: 2471 Cycles : 584219

TEST PRINT

Press ENTER to PRINT

Open Date Equipment

Tel: 020 8655 4999

Fax: 020 8655 4990

sales@opendate.co.uk

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

SELECT FORMAT > LABEL1 LABEL2 LABEL3

WARNING THIS ACTION CANCELS PRINTING, PROCEED ?

NO YES

OPERATOR

Set the Passcode

and press ENTER

< if activated >

OPERATOR

Set the Passcode

and press ENTER

< if activated >

OPERATOR

Set the Passcode

and press ENTER

< if activated >

OPERATOR Set the Passcode and press ENTER

< if activated >

Crossweb Settings Qty: ( 1-1000 ) < 0000 > Distance: < 0000. 0 > mm Automatic: < 0 > Off

For more information

See Multi Printing

documentation

Thermocode 2 Printer manual Version 2.04 January 2011 24

[F]LABEL1 1>Texts 2 Counters

[F]LABEL1 >LotNumber Batch Expiry

[F]LABEL1 Field: LotNumber < 1234567 > ENTER to save ( 1 )

CHARGEHAND

Set the Passcode

and pr ess ENTER

< if activated>

THERMOCODE 53C 1> [S] Print On L i ne 2 [F] L ABEL1 3 Select Fo rmat 4 Service 5Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

[F]LABEL1 1> Offset 2 Set Parameters 3 Edit Fields 4 Set Quantity 5Save As…. 6 Crossweb se ttings

[F]LABEL1 Print Off.: (mm) < 090 > 0 — 999 Range Edit and press ENTER

[F]LABEL1

Set the Qua ntity < 0000 00 > (0=infinite) Edi t and press ENTER

STATUS DISPLAY SOFTWARE FLOWCHARTS (Level 2: CHARGEHAND)

30/08/2007 12:36:48 Version : 2.07 Meterage: 2471 Cycles : 584219

TEST PRINT

Press ENTER to PRINT

Open Date Equi pment

Tel: 02 0 8655 4999 Fax: 020 8655 4990

sales@opendate.co.uk

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

SELECT FORMAT >LABEL1 LABEL2 LABEL3

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

OPERATOR

Set the Passcode

and pres s ENTER

< if activated >

OPERATOR

Set the Passcode

and pr ess ENTER

< if activated >

OPERATOR

Set the Pa sscode

and press ENTER

< if activ ated >

Thermocode 2 Printer manual Version 2.04 January 2011 25

THERMOCODE 53C 1 [S] Print On Li ne 2> [F] LABEL1 3 Select Format 4 Service 5 Information 6 Super visor 7 Contact 8 Test Print 9 Passcodes

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

ENGINEER

Set the Passco de

and pr ess ENTER

< if activated >

SERVICE 1> Time/Date 2 Daylight saving 3Printer Setup 4 Print head data 5 Ribbon Settings 6Network 7 Pause printing 8 Unlock system 9Encoder

SET TIME AND DATE DD/MM/YY <05/08/2000> HH:MM:SS <20:05:46>

Press ENTER to save

SET DAYLIGHT SAVING Day 1 < 28/03 > < + >1 Day 2 < 28/10 > DD/MM

PRINTER SETUP 1> Print Height 2Image 3Cassette

SE T PRINTER DATU MS Pri nt Height < 1.0 > mm ENTER to save

SET the IMAGE VALUES Mirror: ( Y/N ) <N>

ENTER to save

CASSETTE Settings Roller: < 31.83 > mm Cassette < 1 > On

Press ENTER to save

PRINT HEAD INFO. 1 Resistance 1264 2 P.distance 25 3 Serial No 92074 4 4 4 Fac.dat.09/07/2000 5 1st.dat.26/08/2000 6 Print Angle 27

SET RIBBON SETTINGS length: < 50 0 > m wa rning: < 015 > m gap: < 0 > mm

SET NETWORK VALUE Network: < 00 > 00-99 (00= no Network)

Press ENTER to save

STATUS DISPLAY SOFTWARE FLOWCHARTS (Level 3: ENGINEER)

PAUSE PRINTING Pause: (Y/N) <N> (o n line)

Press ENTER to save

ENCODER Settings Print Off : < 000.0 >mm Reverse Foil< 00.0 > mm

Press ENTER to save

Used with the function

CFRPT2

See Sy stem variables

Note

6 > Network Refers to Open Date’s Network system and is no longer available

Thermocode 2 Printer manual Version 2.04 January 2011 26

[F]LABEL1 Speed: <100> (mm/s) Burn: <200> [50 - 305] Edit and press ENTER

[F]LABEL1 Rotation: <0> (0) Edit and press ENTER

[F]LABEL1 Printhead Pressure <20> 20-35 Range

Edit and press ENTER

[F]LABEL1 Rotation: <2> (180) Edit and press ENTER

STATUS DISPLAY SOFTWARE FLOWCHARTS (Level 3: ENGINEER)

THERMOCODE 53C 1> [S] Print On Line 2 [F] LABEL1 3 Select For mat 4Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

[F]LABEL1 1> Print Speed/Burn 2 Pressure 3 Rotation 4 Move X / Y Position 5 Text sizes (Y,X)

[F]LABEL1 1> Offset 2 Set Parameters 3 Edit Fields 4 Set Quanti ty 5Save As…. 6 Cro s sweb Settings

[F]LABEL1 1> Texts 2 C ounters

[F]LABEL1 Move X Pos. < +0.0 > mm Move Y Pos. < +0.0 > mm

Edit and press ENTE R

[F]LABEL1 >LotNumber Batc h Expiry

[F]LABEL1 Field: LotNumber < 1234567 > ENTER = save ( 1 )

CHARGEHAND

Set the Pa sscode

and press ENTER

< if activated>

ENGINEER Set the Passcode and press ENTER

< if activated>

Ri ght Arr ow to change

[F]LABLE1 > y0077,X0038 - Arial y0153,X0038 - Arial y0153,X0125 - Arial

[F]LABLE1 Y:<0077> X:<0038> Font: Arial Height: <12> Points

With the system variable NOOVERFLOWMSG set to 1. You Select a line of text. Then can Edit the X & Y position also th e actual Point size. Use the up/down arrows to toggle the field to edit.

Thermocode 2 Printer manual Version 2.04 January 2011 27

STATUS DISPLAY SOFTWARE FLOWCHARTS (Level 4: MANAGER)

Counters: Counter1 Start no. < 12345678 > Leading Zero’s : < Y >

Press ENTER for NEXT

Counters: Counter1 Increment Amount < 1 > Increment After < 2 >

Press Enter for NEXT

Counters: LABEL1 >Counter1 Count er2 Count er3

Co unters: Counter1 Counter Rollover < Y > R.Number < 123456 > Batch Qty < 123456 >

MANAGER

Set the Passcode

and Pre ss ENTER

< if activated>

THERMOCODE 53S 1> [S] Print On Line 2[F] LABEL1 3 Select Format 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9Passcodes

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

[F]LABEL1 1> Print Speed/Burn 2 Pressure 3Rotation 4 Move X / Y Positi on

[F]LABEL1 1> Offset 2 Set Parameters 3 Edit Fields 4 Set Quantity 5Save As…. 6 Crossweb se ttings

[F]LABEL1 1> Texts 2 Counters

[F]LABEL1 Speed: <1 00> (mm/s) Burn: <200 > [50 - 305] Edit and press ENTER

[F]LABEL1 Rotation: <0> (0) Edi t and press ENTER

[F]LABEL1 Printhead Pressure <20> 20-35 Range

Edi t and press ENTER

[F]LABEL1 Move X Pos. < +0.0 > mm Move Y Pos. < +0.0 > mm

Edi t and press ENTER

[F]LABEL1 >LotNumber Batch Expiry

[F]LABEL1 Field: LotNumber < 1234567 > ENTER to save ( 1 )

CHARGEHAND Set the Passcode and press ENTER

< if activated>

ENGINEER

Set the Pa sscode

and pr es s ENTER

< if activated>

[F]LABEL1 Rotation: <2> (180) Edi t and press ENTER

Right Arrow to change

Thermocode 2 Printer manual Version 2.04 January 2011 28

STATUS DISPLAY SOFTWARE FLOWCHARTS (Level 5: SUPERVISOR)

THERMOCODE 53C 1> [S] Print On Line 2 [F] LABEL1 3 Select For mat 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

WARNING

THIS ACTION CANCELS

PRINTING, PROCEED ?

NO YES

SUPERVISOR

Set the Passcode

and press ENTER

< if activated >

Supervisor 1> Language 2 Relays 3 Delays 4 Default Values

Set the RELAYS Re l.1 : < 1 > Sequenc e Rel.2 : < 1 > Low foil Rel.3 : < 1 > Fault & Rdy

SET DEFAUL T B URN

Burn:

<170>

ENTER to save

Set the DELAY values Print delay: <100>ms Inhib. delay : <+00 >ms Press ENTER to save

Language 1> English 2 Deutsch 3 Français 4 Nederlands 5 Espanol 6 Italiano 7Dansk 8English (USA) 9Polski

Default Values 1> Offset 2 B urn Va l ue s 3 Other Parameters 4 Quant ity / Rotation

QUANTITY / ROTATION

Quantity: <000000>

(0 = infinite)

Rotation <0> (0)

SET DEFAUL T OFFSET Print Off.: < 000 > mm

Press ENTER to save

DEFAULT PARAMETERS Pressure: <20> Print Speed <100>mm/s

Enter to s ave

Thermocode 2 Printer manual Version 2.04 January 2011 29

4. Select 1,2 or3 to change

THERMOCODE 53C 1> [S] Print On Line 2 [F] Current_Format 3 Select For mat 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

1. Select 9 on Key Pad

WARNING

THIS AC TION CANC ELS

PRIN TING, PROCEED ?

NO YES

2. Press Right Arrow

3. Enter P assword

PROGRAMMING Set the Passcode

and press ENTER

< >

SETTING PASSWO RDS 1> Change 2 Activate 3 Display

Change a Passcode Level number <1> Old: < > New: < >

Example:- Use the Up/Down arrow keys to Change the fields To Ch a nge the level number <1> Ent er the Old Pass code < 1111 > Enter the New Passcode < **** >

Press Enter to save changes

Activate a Passcode Level number <1> Enable: <N> ENTER to save

Use the Up/Down arrow keys to Change the fields. Enter the Le vel number to Enable = Y Disabled = N

Use the left and right arrow keys to toggle “Y” or “N”

Display passwords 1> OPERATOR,1111 2 CHARGEHAND,2222 3 ENGIN EER,3333 4 MANAGER,4444 5 SUPERVISOR,5555

STATUS DISPLAY SOFTWARE FLOWCHARTS (Level 7: PROGRAMMING)

Thermocode 2 Printer manual Version 2.04 January 2011 30

1. Select 2 on K ey Pad

THERMOCODE 53C 1> [S] Print On Line 2 [F] Current_Format 3 Select For mat 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

[F]Current_Format 1> Home offset 2 Set Parameters 3 Edit Fields 4 Set Quantity 5 Save As…...

[F]Current_Format 1> Texts 2 Counters

[F]Current_Format > LotNumber BestBefore UseBy

Editing Text Fie lds

2. Press Right Arrow

WARNING

THIS AC TION CANCE LS

PRIN TING, PROCEED ?

NO YES

3. Select 3 on Key Pad

CHARGEHAND

Set the Passcode

and press EN TER

< if activated >

4. Enter Password

5. Select 1 on Keypad

6. Select fiel d to edit

7. Edit and press En ter

Use these.

[F]Current_Format Field: LotN umber <QWERTY123456>

[F]Current_Format > LotNumber BestBefore UseBy

8. Press Escape 3 times

Thermocode 2 Printer manual Version 2.04 January 2011 31

THERMOCODE 53C 1> [S] Print On Line 2 [F] Current_ Format 3 Select Form at 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

Selecting a New Format

1. Select 2 on K ey Pad

WARNING

THIS AC TION CANCE LS

PRIN TING, PROCEED ?

NO YES

2. Press Right Arrow

OPERATOR Set the Passcode and press EN TER

< if activated >

3. Enter P assw ord

4. Select Format

5. Press Enter

SELECT FORMA T ALABEL1 BLABEL2 > CLABEL3

SELECT FORMAT > ALABEL1 BLABEL 2 CLABEL3

Right Arrow Z to A Left Arrow A to Z

SELECT FORMA T > ALABEL1 BLABEL2 CLABEL3

SELECT FORMA T > 1_ LABEL 2_LAB EL 3_LAB EL

SELECT FORMA T > 3_LABEL 2_LAB EL 1_LAB EL

SELECT FORMA T >CLABEL3 BLABEL 2 ALABEL 1

To Select a Format

Use these.

Thermocode 2 Printer manual Version 2.04 January 2011 32

Making Test Prints

Information Screen

THERMOCODE 53C 1> [S] Print On Line 2 [F] Current_ Format 3 Select Format 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

TEST PRINT

Press ENTER to Print

1. Select 8 on K ey Pad

2. Press Enter

THERMOCODE 53C 1> [S] Print On Line 2 [F] Current_Format 3 Select Format 4 Service 5 Information 6 Supervisor 7Contact 8Test Print 9 Passcodes

1. Select 5 on Key Pad

WARNING

THIS AC TIO N CANCE LS

PRIN TING, PRO CEED ?

NO YES

2. Press Right Arrow

3. Press Inser t key

28/0 6/2008 12: 36:47 Version: 305– 084 CA Meterage: 2083 Cycles: 8976

Thermocode 2 Printer manual Version 2.04 January 2011 33

THERMOCODE SERIES 2 RIBBON SPECIFICATIONS

Model “A” = Width “B” = Dia Max “C”=Core Dia Core Material

53CR 55mm 78mm Ø, (300 Meters) 25.4mm Cardboard

No leaders or trailers are required

Silicone based “Back Coating” Outside (Low coefficient of friction: Kd < 0.2)

Wax/Resin Pigment Inside Wound No leaders or Trailers required on Foi l.

Open Date Equipment stocks several grades, sizes and colours of Thermal Transfer Ribbon, please call our Sales office for furt her details specifying the model of Printer that you have. All Ribbons are available on a next day delivery if required.

Thermocode 2 Printer manual Version 2.04 January 2011 34

53CR Ribbon Threading Diagram

ENSURE THE NIP ROLLER IS ENGAGED ON DRIVE ROLLER AFTER RENEWING THE RIBBON

NEW FOIL

CARDBOARD CORE

Thermocode 2 Printer manual Version 2.04 January 2011 35

ROUTINE MAINTENANCE

(everyday)

1. To simplify cleaning procedur es, y ou may have to remove the pri nter from the fr ame.

2. Remove the therm al transfer r ibbon from the print er magazine.

3. On the cassette clean all f ixed rods and rollers using Isopropanol cleaning fluid and a lint free cloth. (As shown below)

Clean all the parts as indicated

5. On the Lower Roller Unit, clean the rubber roller thoroughly.

Foil Guide Roller

Foil Guide Roll

Foil Guide Rod

Foil Guide Ro

Assembly Nip Roller

Rubber Drive Roller

Foil Guide Rod

Foil Guide Roller

Foil Guide Rod

Location Rod

Thermocode 2 Printer manual Version 2.04 January 2011 36

ROUTINE MAINTENANCE

(Continued)

53CR PRINTER

CLEAN FIXED ROLLER ALONG FULL LENGTH

CLEAN PRINTHEAD ALONG FULL LENGTH, WHERE SHOWN

Note!

The Routine Maintenance procedures affect the Standard Warranty terms. If you do not clean the printer regularly , then do not expec t to get any warranty on printheads.

If you change a Printhead, do not forget to adjust the alignment of the Printhead to the print roller. As the Print head angle affects the printing positi on.

Thermocode 2 Printer manual Version 2.04 January 2011 37

FAULT FINDING

(Questions & Answers)

Ribbon Indexing insufficient

(Overlapping Prints)

Q. Cardboard core does not fit the rewind spool correctly, or is missing?

A. Fit correct cardboard core, ensure it is located on the spring clips correctly.

Q. Foil not attached to cardboard core correctly?

A. Use adhesive tape to attach the ribbon to the cardboard core and wind on a few turns.

Q. Printer rods or printhead assembly are dirty, through build up of wax/resin residue?

A. Clean printer rods and printhead as described in maintenance section.

Q. Brake belt on feed spool is damaged, worn or dirty?

Renew brake belt.

Q. Tension arm spring tension on brake belt not set correctly?

A. Adjust brake belt correctly, when functioning correctly the tension arm should be about 6mm from the stop pin.

Ribbon Indexing Excessive

Q The Format design has a space before printing any characters?

A. Change the format design so there is only 1mm from the “X” datum to the first characters to be

printed.

Q Ribbon may be sticking to substrate being printed, and being pulled along?

djust the printhead position from the substrate, possibly the clearance is insufficient and the foil is

being indexed along with the substrate. Service Engineer may be required.

Ribbon Breaking or Perforated

Q. Printhead rods, lower roller or printhead assembly is dirty through build up of wax/resin residue?

A. Clean printer and printhea d as de scribed in maintenance section. Q. Ribbon may be sticking to substrate being printed and being pulled along? A. Adjust the Printhead position from the substrate , po ssibly the clearance is insufficient and the foil is

being indexed along with the substrate. Service Engineer may be required.

Q. Temperature “BURN” values may be set to high for the substrate being printed?

A. Reduce “BURN” values of format to achieve acceptable print quality.

Q. Ribbon indexing problems, prints overlapping each other, weakening the ribbon?

A. See to the section on page 40 fo r overlapping prints remedies.

Thermocode 2 Printer manual Version 2.04 January 2011 38

Ribbon T r acki ng

Q. Printer fixed rods, lower roller or printhead assembly are dirty, through build up of wax/resin residue?

A. Clea n fixed rods, lower roller and printhead as described in maintenance section.

Q. Ribbon may be sticking to substrate being printed, and being pulled to one side?

A. Adjust the printhead position from the substrate, possibly the clearance is insufficient and the foil is

being indexed along with the substrate. Service Engineer may be required.

Q. Printer may have been dropped, damaging the lower roller or damaged tension arm?

A. Call for Service Engineer or send back to manufacturer for checking .

Print Quality Problems

Q. Print not consistent over printed area? A.

Ribbon not compatible with substrate. Temperature burn, settings too low. Low printing temperatures can give the effect of the edges of

characters appearing faint or r ag ged. Damaged or dirty print base or lower prin t roller, clean and check for any imperfections. Normal

Thermocode Series 2 print bases are 45-50 shore hardness r ub ber, which is bonded to an aluminium backing sheet and then ground. Fl atness of this pad or roller is very important, on some labelling machines if the backing web is not aligned correctly it will cut into the print base or actually miss-shape it due to the tension of the backing web.

Printer not correctly mounted in frame.

Printer frame not manufactured to correct dimensions, clearance under printer excessive. See Standard Frame measurements drawings at the end of this manual.

Printhead dirty or pixels burnt out. Clean the printhead and test print on plain fax paper to confirm the

condition of the printhead. Ribbon indexing not enough. See previous page. Ribbon tracking on printer, causing creasing. See previous page. Ribbon perforate d or broken, see previous page. Ribbon ink coa ting inconsistent.

Clearing Prin t er Errors

All errors that occur within the printer are shown as “Error” on the status line of the Mi ni-Terminal display. To view the actual error press No.1 or the Enter key of the keypad. Errors are shown as text messages along with a numerical number which must be noted if you are requesting a Service visit or assistance.

Once errors have been viewed they can then be cleared, page up to the top of the scr een and press “Enter” when the cursor is next to the option “Clear errors”.

Clearing errors can have two consequences, i f the errors are mechanical the error is clear ed and the format is retained in the image memory. If the error is a format design problem, as the error is cleared the format will be removed from the image memory.

The only way to correct format errors is to redesign the format this cannot be corrected by adjusting parameters within the Mini-Terminal parameters.

Thermocode 2 Printer manual Version 2.04 January 2011 39

THERMOCODE Continuous Printer (diagnostics sheet 1)

FAULT DESCRIPTION

REMEDY / ACTION

Printer keeps re-booting

Check printer 5 volt supply i s ad justed correctly

See page 11 & 15

Flashing cursor on mini-terminal screen.

1. Remove the Magazine, and then replace it.

2. Replace display curly cable.

3. Replace display.

4. Replace processor board and re-pro gram.

Error on start up (boot up). X or Y

overflow.

If the mini-display shows 53 or 107, with a “0 after it, instead of the model letter?

1. Check 10 way ribbon connections, each end.

2. Contact your Supplier, to fix the Printh ead problem.

Printhead temperature. (Head Cold

Fault)

Change the wider ribbon cable between the printhead and processor board.

Printhead LED stays on. (Power Supply)

Change the 24 Volt DC switching board,

See page 15.

No display on the mini-terminal.

1. Check 1.6 amp fuse within power supply. See page 15.

2. Check the ribbon cable, beneath the stepper board

inside the power supply. See page 15.

Printhead LED, not working. (Power

Supply)

Check the15 or 20 amp fuse within power supply, located on the 24 Volt DC board. See page 15.

Printing Wavy Barcodes.

1. Brake arm loose on brake on brake lever.

2. Retaining washer loose or missing from foil rollers.

3. Increase the Print height above the substrate.

Ribbon Tracking (movement to one side)

1. Check brake is not set to tight.

2. Check brake arm is not loose.

3. Check any foil guides are n ot loose or bent.

4. Check Printhead is levelling correctly.

Broken Ribbon Sensor.

Check the brake arm is not loose, and passes through the sensor correctly.

Thermocode 2 Printer manual Version 2.04 January 2011 40

THERMOCODE Continuous Printer (diagnostics sheet 2)

FAULT DESCRIPTION

REMEDY / ACTION

No power to printer / No v olt ag e to power supply

1. Check fuses in mains plug and power supply.

2. Check supply voltage is at sourc e.

3. Check all the fuses in power s upply.

4. Check all electrical connec t ion s are correc t .

Ribbon broken.

1. Replace ribbon.

2. Check brake tension on cassette.

3. Replace or repair thermal rib bon.

Low foil warning.

Replace thermal ribbon on printer, ens ure t hat you press the “yes” key on the mini-terminal after engaging the nip roller, t o res e t the foil counter.

Count completed.

1. Select another format.

2. Edit quantity via m ini-t e rminal display

No format name displayed on screen.

1. Format has been de-select ed.

2. Select a new format .

No font loaded to printer, for format selected.

1. Load the font to printer and select t h e format again.

2. Load a different f o rm a t that has printer font s.

3. Check which font s have been loaded to printer, by

interrogating with the “Codesoft” software

Print on line, awaiting print s ignal. Normal condition

Pressure switch fault.

1. Check the mounting f ra m e is not open.

2. Check the gap betwee n p rinter and print base.

3. Check sensor assembly has not come loos e.

4. Check wire crimps and connections.

5. Check LED on sensor act ivates correctly.

6. Check print base rubber is not damaged or mis sing.

7. Check pressure set t in g w i t hi n format parameters.

Vertical home sensor fault.

1. Check sensor assembly has not come loos e.

2. Check wire crimps and connections.

3. Check LED on sensor activate s correc t ly.

Printhead Thermistor fault / disc onn ec ted

1. Check ribbon cables are fitted correctly to printh ead an d

interconnect PCB.

2. Faulty printhead, replace.

Thermocode 2 Printer manual Version 2.04 January 2011 41

Error Codes

This file contains a list of error texts and their associated error numbers. The error numbers are displayed

the error text, along with the source number, with the exception of the two shown below.

Example: Pressure not seen 66

This is error number o n line num ber 2266 of the source code file. This line number is only of use to the developers, but is worth recording along with the version of firmware.

Note-:

Error

Message

Reason Corrective Measures

after

21, 22

21,

The first

error shown with in the Mini Terminal is the fault. Any other error faults shown

on the display, maybe generated because of this fault shown

Run Program

Firmware corruption Switch the printer off. Then Reload the firmware.

No Program Loaded

Disconnection on communications lead, when down loading the Firmware.

Sending fonts or formats, whilst booting up the printer.

Press the enter key, reset the Baud rate, reset the RTC. Press accept. Switch the printer off. Then Reload the firmware.

Error

Number

Error Message Reas on Corrective Measures

Serial port fail

Problem with hardware.

Check cables & connections, if the cables are ok replace the Processor Board.

(14 Days notice

See note 1 page 8)

SPY chip fail

1. Failure in writing to the Spy chip from the boards.

2. The Ribbon Cable could be faulty.

1 & 2. Re program or change the Spy Chip Board. If you still have the same Fault Change the Ribbon cable.

SPY buff fail

Wrong Version of Software.

Re program or change the Spy Chip Board. If you have the same Fault Change the Ribbon cable.

SPY param fail

Wrong Version of Software.

Re program or change the Spy Chip Board. If you have the same Fault Change the Ribbon cable.

RTC fail

Faulty real time clock.

Check the battery 3.6v. Change the Processor Board. (Contact Supplier)

DAS can’t format

Problem with memory on processor card.

Change the Processor Board. (Contact Supplier)

Head overheated

1. Thermistor failed on Printhead.

2. The Ribbon cable could be faulty.

1 & 2. Change the Print Head. If you still have the same Fault Change the Ribbon cable. Then Refit the original Print head

Head Cold

1. Thermistor failed on Printhead.

2. The Ribbon cable could be faulty.

1 & 2. Change the Print Head. If you have the same Fault Change the Ribbon cable. Then Refit the original Print head.

Too fast 1

Web speed too fast for printer.

Reduce web speed.

Too fast 2

Web speed too fast for printer.

Reduce web Speed.

Pressure not seen

1. Pressure sensor Failed or dirty.

2. Frame open or Print pad missing

3. Incorrect Motor steps to the Print Pad. Occurs on Format Download & when printing.

4. Low voltage. Under 5 VDC to the Printer.

1. Clean or replace the sensor.

2. Switch the Printer off. Close the Frame or replace the Print Pad. Reboot the Printer.

3. Clear the error. Carry out some test prints.

4. Check the voltage and adjust to 5.1 volts. Fault 155 “No press confirmed” Will also been shown. Carrie out the above checks, when both faults are shown.

End sensor fail

The Print head has not seen the end sensor

1. Clean the Sensor or change if failed.

2. Check the ribbon cables are not fouling the guard of the Printer. Display may read as a 107S when the Printer is actually 107M.

Thermocode 2 Printer manual Version 2.04 January 2011 42

Error Codes

Error

Number

Error

Message

Reason Corrective Measures

Serial port overrun

Problem of serial port handshake.

Check your Com Port Setting. Try new serial port cable. If this makes no difference chang e the Processor Boards.

Serial buffer overrun

Problem of serial port handshake.

Check your Com Port Setting. Try new serial port cable. If that makes no difference change the Processor Boards.

Start sensor too close.

The start sensor is to close to the Print head

Move the start sensor way from the Print head.

Sys param unknown

Requested or sent a unknown System Variable

Request or send the correct one.

Relay delay out of range

Problem with variable SYSRELDEL

Check the setting in the Mini Terminal. Service menu no 6, menu no 3 Delay (Inhib delay)

Format param unknown

Format Parameters incorrectly entered in the format.

Correct the Parameters. The fault can only be created using Dos.

Sys string long

System Variable string has an incorrect entry. .i.e. 13 months instead of 12 entered in SYSMON etc.

Correct the System Variable and resend to the Printer.

List type unknown

Z? Requesting a nonexistent system variable

Clear the error. Enter the correct request code.

Delete type unknown

Deleting an Unknown request.

Incorrect escape code used when using the delete command.

List file unknown

Requesting a non existent Format Font etc.

Clear the error. Request the correct Format or Font etc.

Delete file unknown

Deleting an Unknown Format File.

Typing error or the Format, Font etc is not in the Printer.

Bad line

1. Communication Lead faulty.

2. Codesoft has been Networked

1. Check the communications lead is plugged in on the Computer & Printer. Check the lead for any dry joints.

2. If not Networked, check Codesoft is not set on Network in the Advanced menu.

Bad Format Line

Format information Incorrect Correct the format design.

Format line too long

1.Text line too long maximum of 149 character & spaces.

2. The text box used in Codesoft is larger than the required text. With no carriage return.

3. Codesoft, Word wrap has been checked.

4. Baud rate incorrect

1. Reduce the text line.

2. Reduce the text box to the size of the text length.

3. Uncheck the word wrap in Properties & Paragraph.

4.Check the Baud rate with in Codesoft.

Local graphic error

Problem with local graphic in a format.

Re-load format, or check graphic.

Graphic file missing

Format sent to the Printer with out the Graphic File. Global graphic has been deleted from the Printer.

In Codesoft Printer settings, General, Reload image at next print job should be checked. (Box ticked) Correct the Format Design & resend to the printer.

Too many local graphics

Too many local graphics designed with in the Format.

Reduce the number of graphics with in the Format design.

Too many graphics

Too many local and global graphics loaded to the Printer

Reduce the number global graphics.

Cant update format not selected

The Format has not been selected for Printing.

Select the format you wish to send Modified data only to.

Box to narrow for line width

Box design incorrect

Correct the Format design. The fault can only be created in Dos.

Box to low for line height

Box design incorrect

Correct the Format design. The fault can only be created in Dos.

Note-:

The first

error shown with in the Mini Terminal is the fault. Any other error faults shown on the

display, maybe generated because of this fault shown

Thermocode 2 Printer manual Version 2.04 January 2011 43

Error Codes

Error

Number

Error Message Reason Corrective Measures

Line/ box too wide

Box design incorrect

Correct the Format design. The fault can only be created in Dos.

Rotation out of range

Incorrect Rotation set in the Format should be 0,1,2 or 3

Correct the Format with correct rotation. The fault can only be created using Dos.

Scale factor wrong

Graphic Scaling factor incorrect should be 0,1 or 2

Correct the Format design.

Bar lines overflow

Incorrect barcode design.

Correct the barcode design. The fault can only be created in Dos.

Bad bar style

Selected a non-supported Barcode type.

Check the type of Barcode required. The fault can only be created in Dos.

Bad bar width

Bar width larger than 5 or less than 2.

Bar width Maximum 5, Minimum 2. The fault can only be created in Dos.

Bad bar ratio

Ratio within the Barcode Format design incorrect. Available Ratios are 0 =3,1=

2.5 & 2= 2

Correct the Format design. The fault can only be created in Dos.

Bad bar human

Human readable is larger than 1

Human readable maximum 1 Minimum 0. The fault can only be created in Dos.

Bad bar csum

Check Digit value larger than 1 Check digit Maximum 1, Minimum 0. The fault can

only be created in Dos.

Bad bar speed

Incorrect Speed flag. Should be Zero

Correct the Barcode design. The fault can only be created in Dos.

Bad bar data

Barcode data to many or few digits for the barcode type. Check Type of Barcode, whether numerical or Alphabetical or both.

Change the number of digits to suit the Barcode type, check the style of barcode and the data needed.

Graphic To Wide

Graphic to wide for the printer. Graphic file corrupted?

Resize or replace the graphic

X underflow

Format design is out side the Print area, on the left side of the

“X”

axis.

Move the Format design to be with in the Print area.

X overflow

Format design is out side the Print area, on the right side of the

“X”

axis.

Move the Format design to be with in the Print area.

Y underflow

Format design is out side the Print area, at the top of the page on the

“Y”

axis.

Move the Format design to be with in the Print area.

Y overflow

Format design is out side the Print area, at the bottom of the page on the

“Y”

axis.

Move the Format design to be with in the Print area.

Timeout in Binary

1. Incorrect Baud Rate Set

2. Noise on the Communication lead

3. Incorrect Network number set. (Network printers only)

1. Check the Baud Rate

2. Check the communication lead.

3. Check the Network number.

Timeout in format

1. Information in the Format Design, missing or incorrect

2. Network number set in the Printer. But not in Codesoft.

1. Correct the Format Design. Other error generated during the download of the format or fonts.

2. Set the Printer Network number to Zero if no Network. Then re-boot the Printer. If networked, set network number in Codesoft.

Note: -

X and Y overflows. Do not use Arial Black type font. The Codesoft WYSIWYG is incorrect when using this Font.

The first

error shown with in the Mini Terminal is the fault. Any other error faults shown on

the display, maybe generated because of this fault shown

Thermocode 2 Printer manual Version 2.04 January 2011 44

Error

Number

Error Message Reason Corrective Measures

Error Codes

Note-:

The first

error shown with in the Mini Terminal is the fault. Any other error faults

shown on the display, maybe generated because of this fault shown

Format not found

Requested a Format not downloaded to the Printer.

Requested the wrong Format name or the Format is not Loaded to the Printer.

Erasing font in use

Deleting a Font when used in the current format.

Stop Printing, delete the Font. Re-select a format.

Reverse field wrong

Reverse image text should be 0 or 1 (not supported)

Correct the field.

Proportional field wrong

Incorrect Proportional field. Value = 0 or 1

Correct the value. The fault can only be created in Dos.

Text field overflow

Maximum Text in variable = 0 to 59

Reduce text length in variable to less than 60.

Text lines overflow

Too many text lines with in the designed format

Reduce the amount of Text. Maximum of 120 lines.

Text fields overflow

Too many text fields in the format.

Reduce text fields in format to be below 150.

Too many counters

Format design has too many counters maximum of 20 counter fields.

Reduce the number of counter fields with in the Format design.

Too many Variable

Too many variable with in the format.

Reduce the number of variables.

Missing Variable

The variable has not loaded with the format

Correct the format design

Variable out of Limit

Variable field with high and low limits

Correct the variable field. The fault can only be created in Dos.

Global counter too wide for field

Incorrect counter field design

Correct the counter field. Enter a Padding Character in the Counter Field. Found in “Output” Enter “0” (Zero).

Local counter too wide for field

Incorrect counter field design

Correct the counter field. Enter a Padding Character in the Counter Field. Found in “Output” Enter “0” (Zero).

Font missing

The Font required is not loaded to the Printer

Load the appropriate Font to the Printer.

Font size unavailable

A Bit Map Font (SFP) has been down loaded. The Format design has an incorrect point size.

Correct the Format design. Or load the Bit Map font required.

Font file problem

Bit map font loaded to the Printer with out a font size.

Delete the font, correct your font file then reload the font to the Printer. Enter the font size The fault can only be created using Dos File to download fonts.

Font code problem

Corrupted Font File. Delete and then replace the corrupted Font.

Time out of range

Incorrect time form sent to the Printer.

e.g. 2530

Correct the field.

Date out of range

Incorrect date form sent to the Printer.

e.g. 321002

Correct the field.

Can’t update variable

Variable has not been designed in the format or is missing.

Correct the format Design.

Global variable unknown

The Global variable has not been loaded to the Printer. Or has been deleted.

Resend the Global variable to the Printer.

Daysave error

Incorrect information entered in the daylight save field.

Correct the Daylight saving field.

Sys param out of range

Changing a System Parameter with a value out range.

Correct the parameters with in your format design The fault can only be created using Termode or Service.

Too Many Horizontal Steps

1. The Home offset set too high for the size of Printer.

2. The Printer has not seen the End or has sensor failed. The one to the right of the Printer.

1. Reduce the Home offset.

2. Check the sensor is clean & working. The ribbon cables are not fouling the guard of the Printer. Top line may read as a 107S when the Printer is a 107M.

Thermocode 2 Printer manual Version 2.04 January 2011 45

Error Codes

Note-:

Error

Number

Error Message Reason Corrective Measures

The first

error shown with in the Mini Terminal is the fault. Any other error faults shown

on the display, may b e generated because of th is fault shown

Format has no image

The Format has not been generated for the Image Memory. When other Faults have occurred.

Rectify the faults within the Format.

Line with no network number

Format sent to the wrong network number.

Check the Network numbers are correct.

Line with unwanted network number

Network number selected in Codesoft. Printer has no Network number set.

Printer settings, then Advanced. Uncheck the “Network” box. Then click OK.

Burn file corrupt

Bad date written in the Burn File before being compiled, or corrupted on send.

Check & correct the Burn file

Burn file to long

Incorrect burn file design. Check & correct the burn fil e.

Burn duty too high

1. The Burn duty in the Format has been set too high.

2. The Burn duty in Set Parameters is too high.

3. The Burn duty is close to or set on the upper limit and the room or head temperature has raised.

1. Reduce the Burn duty within the Format and resend to the Printer. Or Change with in the Mini Terminal.

1. 2 & 3. Reduce the Burn duty within Set Parameters.

H table overrun

Internal software error. Report, with format to Open Date UK

R table overrun

Internal software error. Report, with format to Open Date UK

V table overrun

Internal software error. Report, with format to Open Date UK

Bad case

Internal software error. Report, with format to Open Date UK

Can’t write parameter update

Internal software error.