VIDEOJET DataFlex 6530 Service Manual

Videojet

DataFlex 6530

Service Manual

P/N 463041-01

Revision: AA, June 2017

Copyright June 2017, Videojet Technologies Inc. (herein referred to as Videojet). All rights

reserved.

This document is the property of

proprietary information owned by

without the prior written permission of

and CLARiNET

Videojet Technologies Inc. and contains confidential and

Videojet. Any unauthorized copying, use or disclosure of it

®

and, iAssuranceTM are registered trademarks.

Videojet is strictly prohibited. CLARiTY

®

, CLARiSOFT®

Videojet Technologies Inc.

1500 Mittel Boulevard
Wood Dale, IL
60191-1073 USA

www.videojet.com

Phone : [phone]
Fax : [phone]
Int’l Fax : [phone]

Offices - USA: Atlanta, Chicago
Int’l: Canada, France, Germany, Ireland,
Japan, Spain, Singapore, Netherlands, 
and The United Kingdom

Distributors Worldwide

Table of Contents

Compliance Information........................................................................................................................ i

For Customers in the European Union............................................................................................ i

For Customers in the USA............................................................................................................... i

For Customers in Canada............................................................................................................... ii

Pour la clientèle du Canada........................................................................................................... ii

Support and Training........................................................................................................................... iii

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

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

Customer Training......................................................................................................................... iii

Section 1 Introduction.........................................................................................................................1-1

1.1 Equipment Description...............................................................................................................1-1

1.2 About this Manual......................................................................................................................1-1

1.3 Related Publications..................................................................................................................1-2

1.3.1 Language Codes...............................................................................................................1-2

1.4 Content Presentation.................................................................................................................1-3

1.4.1 Positional References.......................................................................................................1-3

1.4.2 Units of Measurement.......................................................................................................1-3

1.4.3 Safety Information.............................................................................................................1-3

1.4.4 Notes.................................................................................................................................1-4

1.5 Abbreviations and Acronyms.....................................................................................................1-4

1.6 Chapters in the Manual..............................................................................................................1-5

Section 2 Safety...................................................................................................................................2-1

2.1 Introduction................................................................................................................................2-1

2.2 Equipment Safety Guidelines.....................................................................................................2-1

2.2.1 Printhead...........................................................................................................................2-2

2.3 Electrical Safety Guidelines.......................................................................................................2-3

2.3.1 Comply with Electrical Codes ...........................................................................................2-3

2.3.2 Electrical Power................................................................................................................2-3

2.4 Installation of the Printer............................................................................................................2-4

2.5 Print Ribbon Safety Guidelines..................................................................................................2-5

2.6 Other Important Guidelines........................................................................................................2-5

2.6.1 Cleaning Safety Guidelines...............................................................................................2-5

2.6.2 Warning Labels.................................................................................................................2-5

Section 3 Main Parts............................................................................................................................3-1

3.1 Equipment Description...............................................................................................................3-1

3.1.1 Printer ...............................................................................................................................3-2

3.1.2 CLARiTY HMI Display and Power Supply Unit (PSU)......................................................3-6

3.2 Working with Printer Connections............................................................................................3-10

3.2.1 Product Sensors/Print Signals........................................................................................3-10

3.2.2 Encoder...........................................................................................................................3-11

3.2.3 Interlocks and Annunciation............................................................................................3-12

3.2.4 Data Communication ......................................................................................................3-13

3.2.5 Cable Connections..........................................................................................................3-14

Section 4 Installation...........................................................................................................................4-1

4.1 Unpacking the Standard Printer.................................................................................................4-1

4.2 Installing the Printer...................................................................................................................4-1

4.3 Mounting Considerations...........................................................................................................4-2

4.3.1 Printer ...............................................................................................................................4-2

4.3.2 CLARiTY HMI Display and Power Supply Unit (PSU)......................................................4-4

4.3.3 Encoders...........................................................................................................................4-4

4.4 Installing the Ribbon in the Cassette.........................................................................................4-5

Videojet DataFlex 6530 Service Manual - Rev AA 2-1

Table of Contents

4.5 Switching the Power On.............................................................................................................4-5

4.6 Understanding Printhead LEDs..................................................................................................4-6

4.7 Configuring the Printer ...............................................................................................................4-6

4.7.1 CLARiTY Configuration Manager......................................................................................4-6

4.7.2 Installing the CLARiTY Configuration Manager.................................................................4-7

4.7.3 Connecting the CLARiTY Configuration Manager to the Printer.......................................4-8

4.7.4 Editing Parameters..........................................................................................................4-12

4.7.5 Saving the Changes in the Printer...................................................................................4-13

4.7.6 Archiving the Current Parameters...................................................................................4-13

4.7.7 Loading a Saved Archive.................................................................................................4-13

4.7.8 Creating, Editing and Restoring a USB Archive on Printer..............................................4-14

4.8 Working with the Configurable Inputs and Outputs..................................................................4-17

4.8.1 Configuring the Inputs.....................................................................................................4-17

4.8.2 Configuring the Outputs...................................................................................................4-18

4.9 Setting the End of Reel Detection............................................................................................4-22

4.10 Working with Print Allocations................................................................................................4-23

Section 5 CLARiTY Operating System...............................................................................................5-1

5.1 Getting started with the CLARiTY ..............................................................................................5-1

5.2 Using the Home Screen.............................................................................................................5-1

5.3 Using the Tools Screen..............................................................................................................5-2

5.3.1 Using the Setup Screen................................................................................................... ..5-3

5.4 Working with Passwords..........................................................................................................5-13

5.4.1 Password Protection Set-up............................................................................................5-14

Section 6 Replacement Instructions..................................................................................................6-1

Section 7 Maintenance.........................................................................................................................7-1

7.1 General Maintenance............................................................................................ .....................7-1

Section 8 Troubleshooting ..................................................................................................................8-1

8.1 Printer Faults......................................................................................................... .....................8-1

8.2 CLARiTY HMI-PSU Faults .........................................................................................................8-1

8.3 Fault Messages and Warnings...................................................................................................8-1

Section 9 Illustrated Parts List............................................................................................................9-1

9.1 How to Read the IPL..................................................................................................................9-1

9.1.1 Illustrations ........................................................................................................................9-1

9.1.2 Alphabets...........................................................................................................................9-1

9.2 Videojet DataFlex 6530 Parts.....................................................................................................9-2

9.3 Accessories........................................................................................................... ...................9-12

9.3.1 Cables .............................................................................................................................9-12

9.3.2 Power Cord................................................................................................... ........... ........9-12

9.4 Miscellaneous Accessories......................................................................................................9-13

9.4.1 Encoder...........................................................................................................................9-13

9.4.2 Mounting Accessories .....................................................................................................9-13

9.4.3 Slave Printer....................................................................................................................9-13

9.4.4 Conversion Kit.................................................................................................................9-13

Appendix A Menu Structure...............................................................................................................A-1

Appendix B External Serial Interfaces..............................................................................................B-1

B.1 Working with the External Serial Interface................................................................................B-1

B.1.1 Running the Text Communications system......................................................................B-1

B.1.2 Working with Communications Sessions.........................................................................B-1

B.1.3 Formatting the CIFF Data File........................................................................................ B-11

Appendix C Test Points ......................................................................................................................C-1

2-2 Videojet DataFlex 6530 Service Manual - Rev AA

Table of Contents

Appendix D Theory Of Printing......................................................................................................... D-1

Appendix E Master Slave Setup.........................................................................................................E-1

E.1 Working with Master/Slave........................................................................................................E-1

E.1.1 Master/Slave Benefits.......................................................................................................E-1

E.1.2 Master/Slave Applications................................................................................................E-1

E.1.3 Master/Slave Terminology ................................................................................................E-1

E.1.4 Printer Terminology..........................................................................................................E-1

E.1.5 Printer Communications...................................................................................................E-1

E.1.6 Physical Installation..........................................................................................................E-2

E.1.7 Software Configuration.....................................................................................................E-3

E.1.8 Master/Slave Basic and Advanced Configuration ............................................................E-3

E.1.9 Using Master/Slave Mode - Group Job Select Mode .....................................................E-13

E.1.10 The Master Printer........................................................................................................E-14

E.1.11 The Slave Printers........................................................................................................E-16

E.1.12 Using Master/Slave Mode - Group Control Mode.........................................................E-16

E.1.13 The Master Printer........................................................................................................E-16

E.1.14 The Slave Printers........................................................................................................E-19

E.1.15 Disabling Master/Slave Mode.......................................................................................E-19

Appendix F Availability.......................................................................................................................F-1

F.1.1 Introduction.......................................................................................................................F-1

F.2.2 Equipment Availability.......................................................................................................F-1

F.3.3 Operation Availability........................................................................................................F-2

F.4.4 Availability Page ...............................................................................................................F-3

F.5.5 Export to USB...................................................................................................................F-7

Videojet DataFlex 6530 Service Manual - Rev AA 2-3

Compliance Information

For Customers in the European Union

This equipment displays the CE mark to indicate conformance to the following legislation:

EU EMC Directive 2014/30/EU:
Essential health and safety requirements relating to electromagnetic compatibility.
EN 61000-6-2 Generic standards - Immunity for industrial environments.
EN 61000-6-4 Generic Emissions Standard for Industrial Environments.
EN61000-3-2 Limits for harmonic current emissions (equipment input

EN 61000-3-3 Limitations of voltage fluctuation and flicker in low voltage

EC Low Voltage Directive 2014/35/EU
Essential health and safety requirements relating to electrical equipment designed for use

within certain voltage limits.
EN 60950-1 Safety requirements for information technology equipment 

current up to and including 16A per phase).

supply systems for equipment with rated currents up to and
including 16A phase.

including electrical business equipment.

For Customers in the USA

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.

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PERSONAL INJURY.
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 reasonable 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 which case the user will be required to correct the interference at his own expense.

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

This equipment has been tested and certified for compliance with U.S. regulations regarding
safety and electrical emissions.

This equipment has been investigated in accordance with the standard for safety: 
UL 60950-1: Safety of information technology equipment.

Videojet DataFlex 6530 Service Manual - Rev AA i

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.

This equipment has been investigated in accordance with the standard for safety: 
CAN/CSA C22.2 No. 60950-1-03. Safety of information technology equipment.

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.

This equipment has been investigated in accordance with the standard for safety: 
CAN/CSA C22.2 No. 60950-1-03. Safety of information technology equipment.

WAR NI NG

PERSONAL INJURY.
This product is not intended for use in the immediate/direct visual field of the display work

place. To avoid disturbing reflections on the display work place, this product shall not be
placed in the immediate/direct field of vision.

ii Videojet DataFlex 6530 Service Manual - Rev AA

Support and Training

Contact Information

If you have any questions or need assistance, please contact Videojet Technologies Inc. at
1-800-843-3610 (for all customers within the United States). Outside the U.S., customers should
contact their Videojet Technologies Inc.

Videojet Technologies Inc.

1500 Mittel Boulevard

Wood Dale, IL 60191-1073 U.S.A.

Phone: [phone]

Fax: [phone]

International Fax: [phone]

Web: www.videojet.com

Service Program

Videojet service and support programs are designed to protect your investment in Videojet
printers and deliver the lowest total cost of ownership to your operations.

distributor or subsidiary for assistance.

Videojet offers comprehensive service programs, spare parts and training - all designed to help
you keep your lines up and running.

• A complete array of customer services and offerings tailored to meet your
operational needs

• A program designed to maximize your equipment uptime, allowing you to focus on
your most important mission - your company’s productivity

• A product and service program to support and deliver your ultimate purchase: a
high quality, reliable printed code on your finished product.

Customer Training

If you wish to perform your own service and maintenance on the printer, Videojet Technologies
Inc. recommends you complete a Customer Training Course on the printer.

Note: The manuals are intended to be supplements to (and not replacements for) Videojet Technologies Inc.

Customer Training.

For more information on Videojet Technologies Inc. Customer Training Courses, call
1-800-843-3610 (within the United States only). Outside the U.S., customer should contact a
Videojet subsidiary office or the local Videojet distributor for further information.

Videojet DataFlex 6530 Service Manual - Rev AA iii

Section 1 Introduction

Figure 1-1: Videojet DataFlex 6530 Printer and CLARiTY HMI Display

1. Interconnecting Cable

2. Printer

3. CLARiTY HMI Display and
Power Supply Unit (PSU)

This chapter contains the following topics:

• Equipment Description

• About this Manual

• Related Publications

• Content Presentation

• Abbreviations and Acronyms

• Chapters in the Manual

1.1 Equipment Description

The main parts of the Videojet DataFlex 6530 printer are described as follows:

• Printer: Houses the printhead and ribbon. The data is transferred to the printhead
from the controller. The printhead prints onto the packaging film.

• CLARiTY HMI Display: Houses the power supply unit and touch screen. You can
access jobs, setup jobs, set the various print parameters using the touch screen.

1.2 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.

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

Videojet DataFlex 6530 Service Manual - Rev AA 1-1

where it can be easily accessed for reference.

Introduction

1.3 Related Publications

The following manuals are available for reference:

Videojet DataFlex 6530 Operator Manual, Part Number: 463040.

1.3.1 Language Codes

When you order this manual, make sure to add the 2-digit language code at the end of the part
number. For example, the Danish version of the service manual is part number 463041-18.

Table 1-1 shows the list of language codes that you can use to identify the translated versions of

this manual.

For more information, contact the Videojet customer service or your local distributor.

Note: The availability of the Operator Manual is indicated by an asterisk (*). Availability of the Service

Manual is indicated by a plus sign (+). For more information, contact the Videojet customer service
or your local distributor.

Code Language Availability (see note)

01 English (US) * +

02 French *

03 German *

04 Spanish *

05 Portuguese *

06 Japanese *

07 Russian *

08 Italian *

09 Dutch *

10 Chinese (Simplified) *

11 Arabic *

12 Korean *

15 Norwegian *

16 Finnish *

17 Swedish *

18 Danish *

19 Greek *

21 English (UK) * +

23 Polish *

24 Turkish *

25 Czech *

26 Hungarian *

Table 1-1: List of Language Codes

1-2 Videojet DataFlex 6530 Service Manual - Rev AA

Code Language Availability (see note)

34 Bulgarian *

36 Chinese (Traditional) *

Table 1-1: List of Language Codes (Continued)

1.4 Content Presentation

This Service Manual contains different types of information like safety guidelines, additional
notes, user interface (UI) terminology and so on. To help you identify the different types of
information, different writing styles are used in this manual.

1.4.1 Positional References

Positions and directions like left, right, front, rear, to the right and to the left are with respect to
the CLARiTY display when you see it from the front.

1.4.2 Units of Measurement

This manual uses metric units of measurement. The equivalent English measures are included in
parenthesis. For example, 240 mm (9.44 inches).

Introduction

1.4.3 Safety Information

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

1.4.3.1 Warning

• The warning statements indicate hazards or unsafe practices that can cause severe
personal injury or death.

• They have a triangular symbol with an exclamation mark to the immediate left of the
text.

• They are always preceded by the word “Warning”.

• They are always found before the step or information referring to the hazard.

For example:

PERSONAL INJURY.

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

WA RN IN G

Videojet DataFlex 6530 Service Manual - Rev AA 1-3

Introduction

1.4.3.2 Caution

• The caution statements indicate hazards or unsafe practices that result in equipment
or property damage.

• They have a triangular symbol with an exclamation mark to the immediate left of the
text.

• They are always preceded by the word “Caution”.

• They are always found before the step or information referring to the hazard.

For example:

EQUIPMENT DAMAGE.

Read this chapter thoroughly before attempting to install, operate, service, or maintain this
equipment.

1.4.4 Notes

Notes provide additional information about a particular topic.

For example:

CAUTION

Note: You can set the password protection for some functions to prevent any access that is not authorised.

1.5 Abbreviations and Acronyms

Abbreviation Expansion

AC Alternating Current

GUI Graphical User Interface

HMI Human Machine Interface

I/O Input/Output

LCD Liquid Crystal Display

LH Left Hand

MCB Main Control Board

PCB Printed Circuit Board

PLC Programmable Logic Controller

PSU Power Supply Unit

RH Right Hand

UI User Interface

USB Universal Serial Bus

WYSIWYG What You See Is What You Get

Table 1-2: Abbreviations and Acronyms

1-4 Videojet DataFlex 6530 Service Manual - Rev AA

1.6 Chapters in the Manual

This manual is divided into fifteen chapters. An introduction to the topics that each chapter
covers is shown in Table 1-3.

Chapter No. Chapter Name Description

1 Introduction Contains the information about this manual, the related 

2 Safety Contains the safety and hazard information.

3 Main Parts Describes the main parts of the printer.

4 Installation Contains the information about installation of the main

Introduction

publications, and writing styles used in this manual.

components of the printer.

5CLARiTY

Operating System

6Replacement

Instructions

7 Maintenance Contains the information on service and maintenance.

8 Troubleshooting Contains the service level diagnostic and troubleshooting 

9 Illustrated Parts

List

Appendix A Menu Structure Contains the menu structure of the CLARiTY 

Appendix B External Serial

Interface

Appendix C Test Points Contains informations about Mains board test points.

Appendix D Theory of

Printing

Appendix E Master Slave

Setup

Contains the information about CLARiTY operating
system.

Explains the procedures to remove and replace the parts
of the printer.

procedures.

Contains the illustrated parts list of orderable parts.

Configuration Manager.

Contains information about the communication protocols 
followed by the printer.

Contains the theory of printing.

Contains information about master/slave setup.

Appendix F Availability Contains information about availability tools.

Table 1-3: List of Chapters

Videojet DataFlex 6530 Service Manual - Rev AA 1-5

Section 2 Safety

This section contains the following information:

• Introduction

• Equipment Safety Guidelines

• Electrical Safety Guidelines

• Installation of the Printer

• Print Ribbon Safety Guidelines

• Other Important Guidelines

PERSONAL INJURY.

Read this section thoroughly before attempting to install, operate, service, or maintain this
product otherwise, it may cause serious injury.

2.1 Introduction

The policy of Videojet Technologies Inc. is to manufacture printing/coding systems and supplies
that meet high standards of performance and reliability. Therefore, we employ strict quality
control measures to eliminate the potential for defects and hazards in our products.

WA RN IN G

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

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

2.2 Equipment Safety Guidelines

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

PERSONAL INJURY.

The equipment should be operated by an authorized personnel who can use the machine
independently and without causing damage to the equipment or a personal injury. The
operating personnel should be trained and informed regularly about safety and environmental
hazards.

PERSONAL INJURY.

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

WA RN IN G

WA RN IN G

Videojet DataFlex 6530 Service Manual - Rev AA

Safety

WAR NI NG

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.

WAR NI NG

PERSONAL INJURY.

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

WAR NI NG

PERSONAL INJURY.

Observe all safety and warning labels on the device for the safe operation of the system.

CAUTION

EQUIPMENT DAMAGE.

Do not, under any circumstances, remove or obstruct any warning, caution, or instruction
labels present on the equipment. If any part of these labels become damaged, worn or removed
they must be immediately replaced.

2.2.1 Printhead

PERSONAL INJURY.

Do not place your fingers under the printhead when the equipment is operating.

EQUIPMENT DAMAGE.

The device must be switched off when the printheads are being installed, connected or
disconnected.

EQUIPMENT DAMAGE.

The printhead may become hot during normal operation. Observe necessary precautions
before attempting to touch the printhead.

WAR NI NG

CAUTION

CAUTION

2-2 Videojet DataFlex 6530 Service Manual - Rev AA

2.3 Electrical Safety Guidelines

This section explains the safety guidelines related to electrical power supply, electrical cables,
bonding, and grounding.

2.3.1 Comply with Electrical Codes

PERSONAL INJURY.

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

2.3.2 Electrical Power

ELECTRICAL HAZARD.

Voltages used to connect the printer to other equipment must not be greater than 50 V dc or
peak ac.

Safety

WA RN IN G

WA RN IN G

WA RN IN G

ELECTRICAL HAZARD.

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

WA RN IN G

PERSONAL INJURY.

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

WA RN IN G

PERSONAL INJURY.

There will be sections of the printer control board that will be permanently powered via the
on-board lithium battery - therefore it is essential that the board should never be placed onto,
nor stored in or on any conductive surface (including conductive, plastic bags etc.) as this
would flatten the battery and/or potentially result in battery overheating. The battery is not to
be replaced by the operator.

WA RN IN G

PERSONAL INJURY.

If the battery is replaced by an incorrect type, it may lead to an explosion. Always dispose off
the used batteries according to the instructions and local regulations.

Videojet DataFlex 6530 Service Manual - Rev AA

Safety

PERSONAL INJURY.

Do not unplug any connector on the equipment when the mains power is on (except USB and
ethernet cables).

2.4 Installation of the Printer

PERSONAL INJURY.

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

PERSONAL INJURY.

Do not place the printer in a hazardous location. Hazardous locations might create an
explosion, leading to personal injury.

CAUTION

WAR NI NG

WAR NI NG

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

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

ANSI/NFPA 70–1993.

WAR NI NG

PERSONAL INJURY.

Place the printer so that no access to the print mechanism is possible after installation.

WAR NI NG

PERSONAL INJURY.

Do not remove the side covers from the printer after installation.

Using Printer Accessories

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

2-4 Videojet DataFlex 6530 Service Manual - Rev AA

2.5 Print Ribbon Safety Guidelines

EQUIPMENT DAMAGE.

Print ribbons should be stored at a temperature range of 5 ºC to 35 ºC, and at a non-condensing
humidity range of 20% to 80%. Refer to guidelines provided with each ribbon.

EQUIPMENT DAMAGE.

The use of incompatible ribbon can seriously damage your printer and such damage will not
be covered by your printer warranty. Use only the ribbon approved by your dealer.

2.6 Other Important Guidelines

2.6.1 Cleaning Safety Guidelines

EQUIPMENT DAMAGE.

Do not apply excessive force to the printhead while cleaning, as this can cause damage and can
void the warranty.

Safety

CAUTION

CAUTION

CAUTION

EQUIPMENT DAMAGE.

Use approved dealer cleaning supplies for cleaning. Do not use high pressure air or cotton.

EQUIPMENT DAMAGE.

The use of an incompatible cleaning kit can seriously damage your printer. Such damage will
not be covered by your printer warranty. Use only cleaning kits approved by your supplier.

2.6.2 Warning Labels

Label Description

CAUTION

CAUTION

Equipment not intended for use at altitude exceeding 2000m.

Equipment not intended for use in tropical climate regions.

Table 2-1: Warning Labels

Videojet DataFlex 6530 Service Manual - Rev AA

Section 3 Main Parts

Figure 3-1: Videojet DataFlex 6530 Printer and CLARiTY HMI Display

1. Interconnecting Cable

2. Printer

3. CLARiTY HMI Display and
Power Supply Unit (PSU)

This section contains information about the integral parts and accessories of the printer.

3.1 Equipment Description

The main parts of the Videojet DataFlex 6530 printer are described as follows:

•Printer

• CLARiTY HMI Display and Power Supply Unit (PSU)

Videojet DataFlex 6530 Service Manual - Rev AA 3-1

Main Parts

10

24

1

358 7 6

9

1. Printhead PCB

2. iAssure Light Box

3. iAssure Lens

4. Carriage Assembly

5. Printhead

6. Ribbon Detector PCB

7. Linear Slide

8. Belt and Idler Pulley Assembly

9. Motor (x4)

10. Main PCB

Figure 3-2: Printer

3.1.1 Printer

The Videojet DataFlex 6530 printer uses high-resolution thermal transfer technology with a
unique electronic ribbon drive and printhead control, eliminating the need for compressed air. It
consists of the following parts:

• Printhead

• Printhead PCB

• iAssure Light Box and Lens

•Ribbon Detector PCB

• Carriage Assembly and Linear Slide

• Belt and Idler Pulley Assembly

•Motors

•Main PCB

3-2 Videojet DataFlex 6530 Service Manual - Rev AA

3.1.1.1 Printhead

Figure 3-3: Printhead

Printhead PCB

Figure 3-4: Printhead PCB

Figure 3-5: iAssure Light Box and Lens

3.1.1.2 Printhead PCB

Main Parts

3.1.1.3 iAssure Light Box and Lens

iAssure Lens

iAssure Light Box

Videojet DataFlex 6530 Service Manual - Rev AA 3-3

Main Parts

Figure 3-6: Ribbon Detector PCB

Figure 3-7: Carriage Assembly and Linear Slide

1

2

3

4

5

6

Figure 3-8: Belt and Idler Pulley Assembly

1. Printhead Drive Pulley

2. Carriage Idler Pulley

3. Carriage Belt

4. Carriage Drive Pulley

5. Printhead Idler Pulley

6. Printhead Belt

3.1.1.4 Ribbon Detector PCB

3.1.1.5 Carriage Assembly and Linear Slide

3.1.1.6 Belt and Idler Pulley Assembly

Linear SlideCarriage Assembly

3-4 Videojet DataFlex 6530 Service Manual - Rev AA

3.1.1.7 Motors

Figure 3-9: Motors

1. Printhead Stepper Motor with
sensor

2. Ribbon Stepper Motor with
sensor

3. Ribbon Stepper Motor

4. Carriage Stepper Motor

Main Parts

4

1

3

2

Note: The ribbon motor with sensor changes position depending on hand of the printer. The sensor is

always on the waste ribbon side.

Videojet DataFlex 6530 Service Manual - Rev AA 3-5

Main Parts

Micro SD Card

Main PCB

Figure 3-10: Main PCB

1

3

2

5

Figure 3-11: Display and Power Supply Unit

1. Touch Screen Display

2. Power Supply unit (PSU)

3. PSU-HMI Connector

3.1.1.8 Main PCB

3.1.2 CLARiTY HMI Display and Power Supply Unit (PSU)

The HMI-PSU consists of a removable touch screen display and power supply unit. The
connections to the HMI-PSU is as shown in the Figure 3-15.

3-6 Videojet DataFlex 6530 Service Manual - Rev AA

EQUIPMENT DAMAGE.

1 2 3

5

4

Figure 3-12: CLARiTY HMI Display

1. LCD Power Cable

2. Touch Screen Cable

3. LCD Data Cable

4. USB Port

5. LCD Touch Screen

Ensure that the interconnecting cables are fitted correctly before power on.

PERSONAL INJURY.

The CLARiTY display should be mounted in a convenient location to eliminate the potential
entanglement with the exposed rotating parts.

Note: The touch screen display and the PSU can be connected remotely using the supplied cable.

3.1.2.1 CLARiTY HMI Display

Main Parts

CAUTION

WA RN IN G

Videojet DataFlex 6530 Service Manual - Rev AA 3-7

Main Parts

1 2

3

Figure 3-13: PSU

1. PSU PCB

2. Power Supply Switch Unit

3. PSU

3.1.2.2 Power Supply Unit (PSU)

3-8 Videojet DataFlex 6530 Service Manual - Rev AA

PSU PCB

Figure 3-14: PSU PCB

2

3

1

457

6

8

Figure 3-15: PSU Connections

1. Interconnecting Cable

2. USB Port

3. Ethernet Port (x3)

4. 15 Pin I/O

5. Mains Power Supply

6. Fuse 5 Amp (x2)

7. Power Switch

8. RS 232

Power Supply Unit Connections

Main Parts

PSU PCB

Pin Purpose

Interconnecting Cable Connects the CLARiTY display to the printer. Provides 

communication between the printer and the CLARiTY display.

USB USB ports allows the connection of a USB memory stick for 

functions such as system software updates, transferring jobs
and backup/restore of system archive or clone files.

Ethernet Ethernet port for connecting the printer to a TCP/IP network.

15 Pin I/O Refer to “Interlocks and Annunciation” on page 3-12.

Mains Power Supply Provides power to the printer.

RS 232 Refer to “Data Communication” on page 3-13.

Table 3-1: PSU Connections

Videojet DataFlex 6530 Service Manual - Rev AA 3-9

Main Parts

1

24VDC

0V

SIG

8

15 9

1

2

Figure 3-16: PNP Sensor Wiring (Print Sensor)

1. PNP Sensor

2. 15-pin Male D-type Connector

3.2 Working with Printer Connections

3.2.1 Product Sensors/Print Signals

There is a 15 pin D-type on the printer that has an I/O cable fitted within the low profile
assembly that is available for input and output connections. There is a second 15 pin D-type
available on the PSU box for I/O connections. Use whichever is the most convenient based on
the install.

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 4-6.

Connect the wiring for the sensor or mechanical contact operation, as shown in Figure 3-16 and

Figure 3-17 on page 3-11.

3-10 Videojet DataFlex 6530 Service Manual - Rev AA

24VDC

Figure 3-17: Mechanical Contact Wiring (Print Sensor)

1. Print Signal Relay Contact

2. 15-pin Male D-type Connector

SIG

15 9

Main Parts

1

18

2

3.2.2 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, but is capable of using a
single-phase encoder. The use of a quadrature mode encoder enables the printer to react if the
packaging material is travelling backwards. This prevents the occurrence of breaks in the ribbon
and possible damage to the printer. The use of a quadrature mode encoder is strongly
recommended.

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 4-6.

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Main Parts

3.2.3 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.

Pin Purpose

1+24 V

2 External input #1 PNP 24 V

30 V

4 External input #2 PNP 24 V

5 External input #3 PNP 24 V

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 PNP 24 V Output #2

14 Encoder Phase B input

15 Encoder Phase A input

Table 3-2: Input and Output Connections

Note: For more information on configuring the inputs and outputs, refer “Working with the Configurable

Inputs and Outputs” on page 4-17.

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3.2.4 Data Communication

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

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

• Ethernet 10baseT/100baseTX High Speed Network Port (RJ45 Connector)

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

Pin Purpose

1 Data Carrier Detect (DCD)

2 Receive Data (Rx)

3 Transmit Data (Tx)

4 Data Terminal Ready (DTR)

5Ground

6 Data Set Ready (DSR)

7 Request To Send (RTS)

Main Parts

8 Clear To Send (CTS)

9Ring Indicator (RI)

Table 3-3: RS232 Serial Communications Port Connections

The printer is primarily designed to communicate with the CLARICOM Package Coding
Management Software, such as the CLARiSOFT Image Design Software and CLARiNET Coder
Networking Software (supplied separately). CLARiTY is supplied with some default images
installed in its database memory.

CLARiTY can be configured to work in one of the following modes:

•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.

•Network Mode

Create images on a PC using CLARiSOFT.

Download to CLARiTY using the Ethernet TCP/IP network and CLARiNET network
software.

Images (Jobs) can be requested from the CLARiTY panel or can be selected and
downloaded from any networked PC workstation that is running CLARiNET.

Videojet DataFlex 6530 Service Manual - Rev AA 3-13

Main Parts

PRINTER

PSU

HMI

0 1

Mains
Power

RS232

PSU-HMI

Connector

USB

USB

Power

Switch

Encoder

Input/

Output

Ethernet (x3)

Interconnecting

Cable

Figure 3-18: Cable Connections

3.2.5 Cable Connections

Figure 3-18 displays the details of the printer cable connections.

3-14 Videojet DataFlex 6530 Service Manual - Rev AA

Section 4 Installation

Introduction

This chapter contains the following topics:

• Unpacking the Standard Printer

• Installing the Printer

• Mounting Considerations

• Installing the Ribbon in the Cassette

• Switching the Power On

• Switching the Power On

• Switching the Power On

• Understanding Printhead LEDs

• Configuring the Printer

• Working with the Configurable Inputs and Outputs

• Setting the End of Reel Detection

• Working with Print Allocations

4.1 Unpacking the Standard Printer

Inspect the kit for any damage carefully. Refer the list of parts in Table 4-1. If any item is damaged
or missing, call Videojet customer service.

No. Printer Parts

1 Printer and Cassette

2 GUI Cable (3M)

3CLARiTY HMI Display

4PSU

5Power Cable

6 Low Profile Cable Assembly

7 CLARiTY Configuration Manager/Documentation USB

9 Wall Mount Bracketry and Screws

10 QA Documentation and CE Certificate

Table 4-1: Printer Configuration Parts List

4.2 Installing the Printer

Ensure that the following services are available where the printer is being installed:

• Power: 100 -240 VAC, 50/60 Hz, 1.56 A

• 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

Videojet DataFlex 6530 Service Manual - Rev AA 4-1

Installation

178 mm

(7.0 inches)

(8.03 inches)

204 mm

(7.08 inches)

75 mm PRINTHEAD

STROKE

53 mm PRINTABLE

AREA

180 mm

Figure 4-1: 53 mm LH Standard Printer Dimensions

• An encoder assembly is required to monitor the speed of the packaging film on
continuous motion packaging machines.

4.3 Mounting Considerations

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

4.3.1 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 4-1 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 that
connect to the unit.

4-2 Videojet DataFlex 6530 Service Manual - Rev AA

Installation

Figure 4-2: Right-handed and Left-handed Printer

Right-handed Printer

Left-handed Printer

178 mm

7 inches

184 mm

7.2 inches

185.5 mm

7.3 inches

Printer Pad or Roller

Figure 4-3: Printer Pad or Roller Position

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 4-2).

The print platten rubber (for printers in intermittent mode) or the roller (for printers in
continuous mode) should be positioned such that it is at 184 mm and 185.5 mm (7.25 inches to

7.30 inches) distance from the back edge of the printer (Figure 4-3). Also, print platten rubber or
the roller should be adjusted such that there is a nominal gap of 2 mm (0.07 inch) between the
printhead and the roller/platten rubber when the printhead is in the Ready to Print position.

Videojet DataFlex 6530 Service Manual - Rev AA 4-3

Installation

Figure 4-4: Standard CLARiTY HMI Display-Mounting Hole

4.3.2 CLARiTY HMI Display and Power Supply Unit (PSU)

The CLARiTY operator interface can be mounted at a convenient location so that the operator
has adequate access to the panel. The CLARiTY HMI display has a removable PSU.

The unit has two M6 mounting holes located at the sides of the unit, as shown in Figure 4-4 for
the standard CLARiTY HMI display.

143.5 mm

(5.65 inches)

176 mm

(6.92 inches)

240 mm

(9.44 inches)

Mounting Hole

The maximum distance of the PSU from the printer body is 5 m (16.4 ft). The standard cable
length is 3 m and 1.2 m, 4 m and 5 m are available as options.

The maximum distance of the HMI display from the PSU is 5 m (16.4 ft). The standard cable
length is 3 m and 5 m is available as optional.

The HMI display can be mounted in any convenient location, provided that the maximum lead
length of is not exceeded. The mounting brackets provided allow you to position the HMI
display and PSU against a convenient vertical flush surface.

4.3.3 Encoders

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

The encoder output can be one of the following:

• Open collector, quadrature

• Push-pull, 24 V

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.

4-4 Videojet DataFlex 6530 Service Manual - Rev AA

4.4 Installing the Ribbon in the Cassette

Power Switch

Figure 4-5: Standard Printer Power Switch

Figure 4-6: CLARiTY Home Screen in Offline State

Installing the ribbon in the cassette involves the following procedure:

1. Remove the cassette from the printer.

2. Load the new ribbon in the cassette.

3. Reinstall the cassette on the printer.

Note: Navigate to Tools > Setup > Consumables and ensure that ribbon size, ribbon type and ribbon

colour are setup correctly.

Refer to Operator manual for more information on installing the ribbon.

4.5 Switching the Power On

To switch the printer on, turn the power switch on the PSU to the I (On) position (Figure 4-5).

Installation

Figure 4-6 displays the CLARiTY Home screen in the OFFLINE state.

Videojet DataFlex 6530 Service Manual - Rev AA 4-5

Installation

Figure 4-7: CLARiTY Configuration Manager

4.6 Understanding Printhead LEDs

Table 4-2 lists the printhead LEDs that indicate the status of the printer.

Color On Flashing Off

Red Printer Offline Printer in fault —

Amber Warning Printer is printing

with warning

Green Printer Online Printhead is printing —

Blue Power on — No power to printhead

Table 4-2: LED Indicators

Note: The red LED also flashes when the printer is being powered on and the printhead is initializing.

4.7 Configuring the Printer

4.7.1 CLARiTY 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 HMI display 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.

No warning or fault

4-6 Videojet DataFlex 6530 Service Manual - Rev AA

Installation

The CLARiTY Configuration Manager (Figure 4-7) 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

• Downloading a set of variables 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 HMI display 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 access to the printer,
while line operators are limited to accessing only the operating variables that are relevant to
them.

4.7.2 Installing the CLARiTY Configuration Manager

CLARiTY Configuration Manager is available in the USB with the Operator Manual. To operate
the USB, the system requires Windows XP, NT or Windows 7.0 operating system with minimum
5 MB capacity and ethernet or serial port. The installation routine commences automatically. To
install the CLARiTY Configuration Manager on a PC:

1. Insert the Operator Manual USB.

2. Click on CLARiTY Configuration Manager in the home page.

3. Run the CLARiTYConfig.exe file.

4. Follow the on-screen instructions to install the software.

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

Videojet DataFlex 6530 Service Manual - Rev AA 4-7

Installation

Status Panel

Figure 4-8: CLARiTY Configuration Manager

4.7.3 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 PSU 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.

2. Run the CLARiTY Configuration Manager on the PC (Figure 4-8).

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 4-8, 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).

Note: It is possible to setup the IP address using the CLARiTY user interface Archive feature with

USB. Refer to “Creating, Editing and Restoring a USB Archive on Printer” on page 4-14.

4-8 Videojet DataFlex 6530 Service Manual - Rev AA

Installation

Figure 4-9: IP Address Settings on the PC

Connecting the CLARiTY Configuration Manager to the Printer using an Ethernet Cable

Connecting the printer to CLARiTY Configuration Manager via Ethernet requires the following

• A correct Ethernet cable:

- If connection is being made directly between the PC and the printer, a crossed
Ethernet cable must be used

- If the connection is being made via an office LAN or Ethernet hub, an ordinary

uncrossed patch cable is required

• Correct configuration of the PC ethernet port

• Correct configuration of the printer’s ethernet port

To connect the CLARiTY Configuration Manager to the printer, the following settings have to be
done on the PC ethernet port and printer’s ethernet port:

PC

The PC Ethernet port must be set up to connect at a specific IP address. If you are connecting via
an office LAN, consult with your IT manager before assigning IP addresses to your PC. If you
are making a direct connection, you may specify any IP address.

Note: The printer IP address will default within the local IP range to automatically connect over the local

link.

To establish a specific IP address, please follow the steps below:

1. Open the PC Ethernet port properties and modify the TCP/IP not to assign an IP address
automatically. Then specify the new address (for example 10.27.55.130 in Figure 4-9) and the
subnet mask (Usually 255.255.255.0).

Note: The screen above shown varies depending on the operating system installed on your PC.

2. Click OK to apply the settings.

Videojet DataFlex 6530 Service Manual - Rev AA 4-9

Installation

Figure 4-10: IP Address Settings on the Printer

Printer (Coder) Ethernet Port

3. Connect the CLARiTY Configuration Manager to the printer using an RS232 connection and

upload the printers parameters.

4. Locate the TCP/IP configuration parameters as shown in Figure 4-10.

5. Set the BinaryCommsNetworkPort parameter to 3001.

6. Set the IP address to be in the same range as the PC port (for example 10.27.55.131 in

Figure 4-10).

Note: The printer IP address should not be the same as the IP address of the PC.

7. Set the subnet mask to match that of your PC port.

8. Click the Download button to download the parameters to the printer.

4-10 Videojet DataFlex 6530 Service Manual - Rev AA

Installation

Figure 4-11: Printer Settings

Figure 4-12: Printer Settings

9. Click the New printer icon and change the method of connection to Network. Enter the
correct IP address and Port number to match the values downloaded into the printer
(Figure 4-11).

10. Click Apply and the new settings are activated and the printer icon turns green (Figure 4-12).

11. 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).

Videojet DataFlex 6530 Service Manual - Rev AA 4-11

Installation

Figure 4-13: Parameter Settings

4.7.4 Editing Parameters

Figure 4-13 displays the list of parameters that are available in the printer settings.

Parameters List

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

4-12 Videojet DataFlex 6530 Service Manual - Rev AA

4.7.5 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.

4.7.6 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.

Installation

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.

3. Change the default Archive name by overwriting the name in the pop up dialog box as

required. Select OK. A file for the new save appears under the archives folder with a name
containing the current time and date.

4. Once saved, the name of the archive can be changed in the bottom panel, by selecting the file,

changing the name as required and clicking the Apply button.

4.7.7 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.

3. Click the printer icon from the left-hand panel and click the Download button to load the

archive of parameters to the printer.

Note: To put the new settings into effect, the CLARiTY user interface must be rebooted. If you have any

questions concerning your network, contact your IT administrator.

Videojet DataFlex 6530 Service Manual - Rev AA 4-13

Installation

Figure 4-14: CLARiTY Parameter Archives Screen

4.7.8 Creating, Editing and Restoring a USB Archive on Printer

This procedure describes how to save an archive of printer’s settings to a USB memory stick so
that it can be transferred to printer, or opened and edited with CLARiTY Configuration
Manager. This feature is useful for setting the IP address of the printer, or other initial settings, if
user don’t have the capability to connect serially (RS-232).

4.7.8.1 Creating the Archive

Do the following tasks to create the archive:

1. Insert a USB memory stick into the printer’s USB port.

2. Navigate to Tools > Setup > Control > CLARiTY Parameter Archives (Figure 4-14).

3. Select the Create Archive button at the bottom of the screen.

4. Name the Archive file (or keep the default name) and press OK.

5. Once the screen indicates the Archive was created successfully, press OK.

6. Remove the USB memory stick from the printer.

4-14 Videojet DataFlex 6530 Service Manual - Rev AA

4.7.8.2 Editing the Archive in CLARiTY Configuration Manager

Figure 4-15: CLARiTY Config

Figure 4-16: Load Archive File

Do the following tasks to edit the archive in CLARiTY Configuration Manager:

1. Insert the USB memory stick into a USB port of the computer running CLARiTY
Configuration Manager.

2. Locate the “Archives” folder for the USB memory stick on the left side of the CLARiTY
Configuration Manager window (i.e. “D:\Archives”) and press the “+” next to the folder.

3. Locate the archive file you wish to edit from the list and right-click on the file name.

4. Select Load from the pop up menu.

Installation

5. Make the required changes to the setting on the right hand side of the CLARiTY
Configuration Manager window.

6. Right-click on the name of the archive file and select Save.

Videojet DataFlex 6530 Service Manual - Rev AA 4-15

Installation

Figure 4-17: Confirm Archive Replacement

7. Select OK after confirming that the correct archive has been selected.

8. Close the CLARiTY Configuration Manager software.

9. Remove the USB memory stick from the computer.

4.7.8.3 Restoring the Archive to the Printer

Do the following tasks to restore the archive to the printer:

1. Insert the USB memory stick containing the desired archive into the printer’s USB port.

2. Navigate to Tools > Setup > Control > CLARiTY Parameter Archives (Figure 4-14 on page 4-14).

3. Locate the desired archive from the list on the screen and select it.

4. Select the Restore Archive button at the bottom of the screen.

5. Select Yes if you are sure that you want to continue with the restore process after reading the

message on the printer’s screen.

6. Select Yes or No depending on whether or not you want to restore the network settings from
the archive.

7. Select Yes or No depending on whether or not you want to restore the password settings
from the archive.

8. Once the screen indicates the Archive was restored successfully, press OK.

4-16 Videojet DataFlex 6530 Service Manual - Rev AA

4.8 Working with the Configurable Inputs and Outputs

Figure 4-18: Input Configuration Window

The printer has a fully software configurable input/output system for interfacing the printer to
the packaging equipment or the packaging line.

The configuration system allows the installer to define:

• Which logical printer events are assigned to each input

• When any input is logically On (in its high or low state)

• Which logical printer events cause each output to switch on

• Which logical printer events cause each output to switch off

• Whether an output is latched on or whether it is a 100 mS pulse event

The inputs and outputs are all configured using CLARiTY Configuration Manager.

4.8.1 Configuring the Inputs

To configure the inputs, proceed as follows:

1. Connect CLARiTY Configuration manager to the printer and upload the parameters.

2. Open the input configuration folder.

Installation

3. The three physical inputs are displayed in the lower area of the screen. Click the one you

wish to configure. The available options for that input are displayed in the Usage List.

4. Click the usage you wish to assign to that input and then click the radio button to set whether

that input should be considered 'On' when it goes high or low.

5. Click Apply to save these settings.

Videojet DataFlex 6530 Service Manual - Rev AA 4-17

Installation

Figure 4-19: Output Configuration Window

The available Usage options are:

• Print Sensor 1: Using a 24 V PNP input to trigger the printer to start printing

• Print Sensor 2: Using a 24 V PNP input to trigger the printer to start printing

• Print Input Select: Uses an input to determine if Print Sensor 1 or Print Sensor 2 is the

• External error: Using a 24 V PNP input to inform the printer that the host packaging

• Clear print queue: Using a 24 V PNP input to inform the printer that the job

•Product Ready

• IP Address Reset

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

Note: The printer supports the use of two print sensor options. Only one may be in use at a given

time. The purpose of this is to accommodate two different methods of print triggering, for
example a registration mark on printed film and a cam proximity sensor for use on unprinted
film.

active print sensor for this print job.

machine or line has an error and the printer should not run.

allocation queue should be cleared.

4.8.2 Configuring the Outputs

To configure the outputs, proceed as follows:

1. Connect the CLARiTY Configuration manager to the printer and upload the parameters.

2. Open the output configuration folder.

3. Click on the output you wish to configure. The logical conditions that activate or deactivate

the output are viewed in the lower area of the screen.

4-18 Videojet DataFlex 6530 Service Manual - Rev AA

Installation

Figure 4-20: External Outputs

4. Select the event that you wish to activate or deactivate the output and click the radio box if

you wish the output to be latched high/low or to operate as a 100 ms pulsed signal upon
activation.

5. Click Apply to save the settings.

The available options for activation/deactivation are as shown in Figure 4-20:

Options Description

Job Allocation Aborted Refer to Section 4.10 Working with Print Allocations on

page 4-23

Job Allocation Complete Refer to Section 4.10 Working with Print Allocations on

page 4-23

Job is Active The current job is in progress

Job is Not Active The current job is not in progress

Job Updated Queue Is Empty The jobs queue is empty

Job Updated Queue Is Full The maximum permitted number of jobs in the queue

has been reached

Job Updated Queue Is High The number of jobs in the queue is high

Job Updated Queue Is Low The number of jobs in the queue is low

Job Updated Queue Is Not Empty The jobs queue is not empty

Table 4-3: External Output Options

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Installation

Options Description

Job Updated Queue Is Not Full The maximum permitted number of jobs in the queue

Job Updated Queue Is Not High The number of jobs in the queue is not high

Job Updated Queue Is Not Low The number of jobs in the queue is not low

Labeller May Feed Labels

Labeller May Not Feed Labels

Low Ribbon Is Active The ribbon is low

Low Ribbon Is Not Active The ribbon is not low

Low Speed Pack

Multi Print Job Is Active The multi printing job is in progress

Multi Print Job Not Active The multi printing job is not in progress

New Job Allocation Received A new job allocation message has been received by the

has not been reached

printer

New Job Allocation Rendered A new job allocation message has been rendered by the

printer

Not Used The output has no function

Print Cycle Completes The printer can now start a new print (motors and

ribbon are now stationary)

Print Cycle Starts Print signal has been received and any registration

delay has expired

Print Failed A request to print was not successfully completed.

Possible causes are:

• Aborted print

• No allocation available but print signal received

• No print job is selected but a print signal received

Print Signal Ignored The print signal has been ignored by the printer. A

print signal was received whilst a registration delay
was being counted. The printer can be printing and
counting down the next registration delay from a new
print signal (that is processing two print signals
simultaneously) but one of the print signal events must
be in the printing phase whilst the other is in the
registration phase. Two print signals cannot be in the
same phase of printing or registration

Printer Enters Fault A fault condition has occurred

Printer Enters Warning A warning condition has occurred

Printer Finishes Printing The printer has stopped physically printing onto the

product

Table 4-3: External Output Options (Continued)

4-20 Videojet DataFlex 6530 Service Manual - Rev AA

Installation

Options Description

Printer Is Busy The printhead is out in its printing position

Printer Is Not Busy The printhead is retracted from its printing position

Printer Is Offline The Stop button has been pressed and the printer is not

ready to run

Printer Is Online The Start button has been pressed and the printer is

ready to run

Printer Leaves Fault The fault condition has been cleared

Printer Leaves Warning The warning condition has been cleared

Printer Starts Printing The printer has started to physically print onto the

product

Radial Traverse Direction Is Active

Radial Traverse Direction Is Not
Active

Radial Traverse Step Is Active

Radial Traverse Step Is Not Active

Reject Is Active The printer has rejected a print/product

Reject Is Not Active The 'reject' output has been cleared

Table 4-3: External Output Options (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 4-21

Installation

Figure 4-21: End of Reel Detection

4.9 Setting the End of Reel Detection

The printer can detect the end of ribbon reel in one of two ways, reactive or predictive.

• Reactive mode: Stops the printer when the end of a reel of ribbon is reached and the
last section of ribbon detaches from the supply spool. This mode of detection may
suit majority of the applications, however, it is not possible to completely guarantee,
that the final product gets coded correctly as the ribbon breaks.

• Predictive mode: Monitors the amount of ribbon remaining on the supply reel and
stops the printer when approximately 5 metres of ribbon (+/- 2.5 metres) remains.
Operating in this mode ensures no products remain unprinted when the end of reel
is reached.

In case the ribbon breaks in the mid-reel, the reactive mode is always enabled to detect the break.
The predictive mode only takes precedent at the end of the reel.

To ensure that both detection modes work to their optimum, it is necessary to input the correct
values of the width and the color of the ribbon being used as different colors have different
thicknesses.

The ribbon operating mode parameter, Predictive or Reactive, can only be accessed via CLARiTY
Configuration Manager and the parameter called End Of Reel Detection must be set
appropriately. The default is Reactive mode.

The configured mode is displayed.

4-22 Videojet DataFlex 6530 Service Manual - Rev AA

4.10 Working with Print Allocations

Some coding applications demand strict control of batch sizes for example controlled
pharmaceutical products.

To work in such production situations it is useful to set the coder so that it only prints a precise
number of codes before shutting down and waiting for the next batch instruction.

This is called a Print Allocation and it is administered by another computer or line controller.

When the production control PLC or PC authorises a new production batch, a special message can
be sent to the printer using the External Serial Interface. This message selects the Job to print, any
variable data in the job, and the allocation count, which is the production batch size. These
messages can be stored in a queue in the printer and the size of the permitted queue is
configurable.

The printer prints the current job until the number of products printed equals the allocation count
sent by the controller, at which point it stops. When one allocation batch has been completed, the
next job is automatically selected by the printer if there is a pending job in the queue. If there is no
pending job in the queue the printer will not execute any further printing operations until a new
allocation is sent to it.

Setup of the allocation operation for the printer is performed via the CLARiTY configuration
manager, where the following parameter can be set:

Installation

• Max Queue Length: Defines how many jobs are permitted to be in the Job queue. 
The configurable inputs and outputs also can be setup to trigger on certain events
related to Print Allocations (refer “"Setting the End of Reel Detection" on page 4-22).

• Clear Print Queue (Input): Reset the print job queue and delete all jobs in the queue

• Job allocation has completed (Output): The current allocation of prints has been
completed

• Job Update queue is full (Output): The maximum permitted number of jobs in the
queue has been reached

• Job Update Queue is not full (Output): The maximum permitted number of jobs in
the queue has not been reached

• New Job allocation is received (Output): A new job allocation message has been
received by the printer

When allocations are enabled, it is possible to view the job queue at the CLARiTY panel in two
different ways.

Videojet DataFlex 6530 Service Manual - Rev AA 4-23

Installation

Figure 4-22: Job Preview Page

Job Queue

Figure 4-23: Job Queue Page

To view job queue, proceed as follows:

1. Touch the Job Preview button on the Home screen to access the Job Preview page.

2. Touch the job queue button, to display the Job Queue page. The queue of jobs can be viewed

and the progress of the current job and allocation can be seen.

3. Touch the Edit button beside each of the jobs in the queue, to delete a job or view print
information from the queue.

Alternately, navigate to Tools > Diagnostics > Control and touch Image Update Queue.

This shows the image queue in the same way as the Job Preview screen but there is also the option
to delete an entry in the job queue by selecting an option and touching delete.

The printer requests confirmation of the deletion before the entry is deleted from the queue.

4-24 Videojet DataFlex 6530 Service Manual - Rev AA

Section 5 CLARiTY Operating System

Figure 5-1: CLARiTY Home Screen

1. Status Bar

2. Tools Button

3. Current Job Details Bar

4. Consumables

5. Performance Information

6. Print Position

7. Print Button

8. System Control Buttons

9. Home Button

10. Job Select Button

This chapter contains the following topics:

• Getting started with the CLARiTY

• Using the Home Screen

• Using the Tools Screen

•Working with Passwords

5.1 Getting started with the CLARiTY

CLARiTY is an icon-based operator control system. It has an easy-to-use touch screen. The basics
of the CLARiTY operator system are explained in the Videojet DataFlex 6530 Operator Manual
(P/N 463040-01). All technical aspects of the printer setup and control are accessed through the
Tools button.

Figure 5-1 shows the Home screen of the CLARiTY operator control system.

Note: If password protection is enabled, the options available may be restricted dependent on user level.

Refer to “Working with Passwords” on page 5-13 for more information.

5.2 Using the Home Screen

Videojet DataFlex 6530 Service Manual - Rev AA 5-1

CLARiTY Operating System

Figure 5-2: Tools Screen

PERSONAL INJURY.

The printer starts printing if you touch the status bar when the printer is in OFFLINE mode.
Make sure that you do not touch the status bar if the printer is not required to run.

5.3 Using the Tools Screen

Touch on the Home screen to access the Tools screen (Figure 5-2).

WAR NI NG

The Tools screen provides access to the following:

Option Description

Setup Options to view and modify the printer setup parameters. Refer to “Using

the Setup Screen” on page 5-3.

Diagnostics Information on the current values of key parameters for the printer setup

as well as that support the printer operation and can assist in 
troubleshooting issues. Refer to Operator manual for more information.

Databases Information on available databases, their capacity and the stored jobs.

Refer to Operator manual for more information.

Help The tutorial videos and documentation for specific tasks and basic 

troubleshooting. Refer to Operator manual for more information.

Table 5-1: Tools Screen Description

5-2 Videojet DataFlex 6530 Service Manual - Rev AA

5.3.1 Using the Setup Screen

Figure 5-3: Setup Screen

Touch on the Tools screen to access the Setup screen (Figure 5-3).

CLARiTY Operating System

The Setup screen provides access to the following parameters:

Option Description

Printhead Sets the basic printhead parameters. Refer to “Using the Printhead

Screen” on page 5-4.

Consumables Sets the basic ribbon parameters. Refer to “Using the Consumables

Screen” on page 5-8.

Control Sets the basic printer parameters like date and time, language, network

communications etc. Refer to “Using the Control Screen” on page 5-10

Options There are no options available at this time.

Table 5-2: Setup Screen Description

Videojet DataFlex 6530 Service Manual - Rev AA 5-3

CLARiTY Operating System

Figure 5-4: Printhead Parameters in Intermittent Mode

5.3.1.1 Using the Printhead Screen

The printhead 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)

Printhead Setting in Intermittent Mode:

Touch on the Setup screen to access the printhead parameters (Figure 5-4).

Note: Use finger to slide the screen up and down. The scroll bar indicates the position on the screen.

The Printhead screen in intermittent mode provides access to the following parameters:

Option Description

Horizontal Registration Adjusts the print position (in 

millimeters) horizontally (in the 
direction perpendicular to the 
printhead).

Vertical Registration Adjusts the print position (in 

millimeters) vertically (along the
width of the printhead).

Table 5-3: Printhead Parameters in Intermittent Mode Description

5-4 Videojet DataFlex 6530 Service Manual - Rev AA

CLARiTY Operating System

Option Description

iAssure Enables or disables iAssure function.

iAssure scans the image printed on the
label and compares it to the job and
records the success/failure count of the
printed label.

Print Delay (ms) Sets 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 Sets 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 time of
the packaging film.

Print Darkness Sets the print darkness. The print 

darkness is set between 50% and 100%.

Print Force Sets the force to be applied while 

printing.

Note: It is recommended to retain at
default value with adjustment required
only if light print/poor ink transfer found.

Table 5-3: Printhead Parameters in Intermittent Mode Description (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 5-5

CLARiTY Operating System

Option Description

Ribbon Saving Mode The following ribbon saving modes are

available:

• None: No ribbon saving mode
enabled.

• Interleaved Images: Enables a
lower quality draft mode of
printing with a 50% saving in
ribbon consumption.

• Radial Printing: Enables multiple
prints to be printed across the
width of the ribbon. The number
of prints is automatically
calculated by the system
depending on the image height
and the ribbon width.

• Intermittent Stripes: Enables prints
to be printed with gaps between
lines.

Print Orientation Sets the print orientation to 0 or 180

degrees depending on requirement.

Table 5-3: Printhead Parameters in Intermittent Mode Description (Continued)

5-6 Videojet DataFlex 6530 Service Manual - Rev AA

CLARiTY Operating System

Figure 5-5: Printhead Parameters in Continuous Mode

Printhead Setting in Continuous Mode:

Touch on the Setup screen to access the printhead parameters (Figure 5-4).

The Printhead screen in continuous mode provides access to the following parameters:

Option Description

Print Position Sets the angle of the printhead against the target material by

changing the position of the printhead on the print roller. This
angle affects the print quality. If the angle is not suitable, the 
resulting print may appear faded.

Table 5-4: Printhead Parameters in Continuous Mode Description

Note: Other parameters are same as intermittent mode.

Videojet DataFlex 6530 Service Manual - Rev AA 5-7

CLARiTY Operating System

Figure 5-6: Consumables Screen

5.3.1.2 Using the Consumables Screen

Touch on the Setup screen to access the consumables parameters (Figure 5-6).

The Consumables screen provides access to set the following parameters:

Option Description

Ribbon Width Sets the ribbon tension to the optimum

value depending on the ribbon width.

Table 5-5: Consumables Screen Description

5-8 Videojet DataFlex 6530 Service Manual - Rev AA

CLARiTY Operating System

Option Description

Ribbon Colour Allows the printer to accurately

control the ribbon and the correct
operation of iAssure.

Note: It is important to ensure that the
correct ribbon colour is selected.

Ribbon Type By selecting the correct ribbon type the

printer is setup to provide the 
optimum control of the printhead and
ribbon drive to produce best print 
performance.

Note: It is important to ensure that the
correct ribbon type is selected.

Table 5-5: Consumables Screen Description (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 5-9

CLARiTY Operating System

Figure 5-7: Control Screen

5.3.1.3 Using the Control Screen

Touch on the Setup screen to access the control parameters (Figure 5-7).

The Control screen provides access to set the following parameters:

Option Description

CLARiTY Parameter Archives Displays the saved printer 

configurations. The following options
are available:

• Create Archive - Saves current
printer configurations.

• Restore Archive - Restores
previously saved printer
configurations.

CLARiTY Printer Clones Creates or restores a clone file to and

from the USB memory stick. A Clone
file contains all of the printer settings
and job files.

Note: Only present when a USB memory
stick is inserted.

Table 5-6: Control Screen Description

5-10 Videojet DataFlex 6530 Service Manual - Rev AA

CLARiTY Operating System

Option Description

CLARiTY Update Selects from a list of available updates.

Update files must be saved in 
clarityupdate folder on the root of the
USB memory stick to be recognized.

Note: Only present when a USB
memory stick containing update files is
inserted.

Internationalisation Sets the language of the user interface

and the international region which
control date/time formats displayed
on the screen along with the required
measurement units.



Date and Time Sets the system date and time of the

coder.

Table 5-6: Control Screen Description (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 5-11

CLARiTY Operating System

Option Description

Recalibrate Touch Screen Allows the user to recalibrate the

Set Screen Orientation Rotates the entire display through 180

touchscreen, if touching the screen
does not accurately locate the correct
button or Icon. The printer requests
the user to touch several crosses which
are displayed on the screen, one 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 control
panel, the same functionality can be
triggered from within CLARiTY
Configuration manager.

degrees in the event that the control
panel is installed in an inverted

orientation.

Communications The following options are available:

Table 5-6: Control Screen Description (Continued)

5.3.1.4 Using the Options Screen

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

• Manufacturer’s Password is
required for access - Resets all
serial communication reports in
the event that their setup has
become corrupted.

• Remote Service - Connects to the
Videojet Remote Service Portal.

5-12 Videojet DataFlex 6530 Service Manual - Rev AA

5.4 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

•Setup

•Diagnostics

• Databases

This is can be easily explained by means of an example (Table 5-7):

Job Registration Setup Diagnostics Databases

CLARiTY Operating System

Level 1
(Operator)

Level 2
(Line Supervisor)

Level 3
(Maintenance)

Table 5-7: Password Protection - Example

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 5-7 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.

X

X XXX

XXX

Videojet DataFlex 6530 Service Manual - Rev AA 5-13

CLARiTY Operating System

Figure 5-8: Password Set - up

5.4.1 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.

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

Figure 5-8.

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

• Mask: This enables/disables 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'. Users can select to download passwords along with
parameters by selecting the 'Update Passwords on Download' option on the right-click menu on a
coder. Finally right-click on the 'New Coder' icon and select 'Download' to change the set-up of
the printer. Alternatively, users can update passwords immediately by using the 'Update
Passwords' option on the same menu. Password protection is now be enabled.

5-14 Videojet DataFlex 6530 Service Manual - Rev AA

Menu Structure

Menu

Setup Printhead Horizontal Registration

Vertical Registration

iAssure Disabled

Menu Structure

Enabled

Print Delay (ms)

Print Speed

1

Print Position

Print Darkness

Print Force

Ribbon Saving Mode None

Print Orientation

Consumables Ribbon Width

Ribbon Colour Black

1

2

Interleaved Images

Radial Printing

Intermittent Stripes

White

Other

Ribbon Type Basic

Standard

Super Standard

Premium

Ultra

Control CLARiTY Parameter Archives

CLARiTY Printer Clones

CLARiTY Update

Table 5-8: Menu Structure

1 - For Intermittent Mode only 
2 - For Continuous Mode only

Videojet DataFlex 6530 Service Manual - Rev AA 5-1

Menu Structure

Menu

Setup (Continued) Control (Continued) Internationalisation Language Arabic...

Region/Country Australia...(Language Dependent)

Measurement Units Metric

Inches

Recalibrate Touchscreen

Set Screen Orientation

Date And Time Date

Time

Communications Manufacturer’s Password

Remote Service Enabled

Options

IP Address

Serial Number

Friendly Name

Model Name

Model Number

VNC Enabled

Table 5-9: Menu Structure

5-2 Videojet DataFlex 6530 Service Manual - Rev AA

Menu

Diagnostics Printhead Inputs Input Configuration Usage of Input 1

Usage of Input 2

Usage of Input 3

External Print Signal 1

External Print Signal 2

Inhibit Print

Active Print Sensor

External Error

Clear Job Queue

Product Ready

Reverse Image Sequence

Reset Image Sequence

Menu Structure

External Input 1

External Input 2

External Input 3

Printhead Position

Cassette Open

Printhead to Platten Distance

Table 5-9: Menu Structure (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 5-3

Menu Structure

Menu

Diagnostics (Continued) Printhead (Continued) Inputs (Continued) Printhead Position Sensor

Ribbon Waste Position Sensor

Optical Calibration Sensor

iAssure Sensor

Motor Volts

24 Volts Supply

Printhead Volts

Printhead Temperature

Controller PCB Temperature

Outputs Printhead Position

Printhead In/Out

External Relay Output 1 (7 & 8)

External Relay Output 2 (9 & 10)

External PNP Output 3 (11)

External PNP Output 4 (13)

Green LED

Red LED

Optical Calibration LEDs

iAssure LEDS

General Printer Mode

Printer Hand

Printer Width

Printing Mode

High Throughput Mode

Print Test Image

Table 5-9: Menu Structure (Continued)

5-4 Videojet DataFlex 6530 Service Manual - Rev AA

Menu

Diagnostics (Continued) Printhead (Continued) Printhead Health Display Health Graph

Printhead ID

Printhead Resistance

Total Distance Printed

Manufacturer’s Password

iAssure View Latest Image

Manufacturer’s Password

iAssure Consecutive Faults Mode

iAssure Shift and Reject Mode

Event Log

Timings Minimum Print Speed (mm/s)

Maximum Print Speed (mm/s)

Menu Structure

Cycle Time (ms)

Printing Time (ms)

Job Selection Time

Job Data Update Time

Counter Update Time

Time/Date Update Time

Table 5-9: Menu Structure (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 5-5

Menu Structure

Menu

Diagnostics (Continued) Printhead (Continued) Encoder Profiles Capture Encoder Profile

Profiling Starts Automatically

On Print Signal

On Print Underspeed

Profile Type Standard

Printer Performance

Inputs and Outputs

Profile X Axis Distance

Time

Smartphone Support Ticket

Consumables Ribbon Supply Diameter

Ribbon Waste Diameter

Ribbon Tension

Printing Mode

Control Versions Software Part Number

CLARiTY

CLARiTY Boot Loader

Printhead 1 Firmware

Printhead 1 Firmware Date

Printhead 1 Co-processor

Operating System Version

Operating System Build Date

System Information PCB Serial Number

PCB Revision

CPU Speed

Equipment Reference

Table 5-9: Menu Structure (Continued)

5-6 Videojet DataFlex 6530 Service Manual - Rev AA

Menu

Diagnostics (Continued) Control (Continued) Contact Information Name

Address Line 1

Address Line 2

Address Line 3

Serial Number

Telephone Number

Email

Communications Communication Port 1 Usage

TCP/IP IP Address

Menu Structure

Baud Rate

CLARiTY Comms on ComPort

Subnet Mask

Options

Databases Internal

Capacity Available Files

Help Tutorial Videos

Documentation

CLARiTY Communications Port 1

Port 2

Text Communications Port

ZPL Emulation Port

SATO Emulation Port

Wolke Communications Port

Network Status

Production Audit Log

Image Update Queue

Available Storage

Consumables Ribbon Percentage

Estimated Empty Time

Estimated Time Remaining

Last Changed

Table 5-9: Menu Structure (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 5-7

Menu Structure

Menu

Print Position Horizontal Registration

Performance Throughput

Vertical Registration

Batch Count

Total Count

Availability Fault Pareto Event Parameters

iAssurance

iAssurance Bad Code Count

iAssurance Total Bad Code Count

iAssurance Production Stops

Ignored Print Signals

Short Term Speed

Short Term Efficiency

Long Term Speed

Long Term Efficiency

Trend Speed

Trend Efficiency

Nominal Speed

Table 5-9: Menu Structure (Continued)

5-8 Videojet DataFlex 6530 Service Manual - Rev AA

Section 6 Replacement Instructions

Introduction

When you order a spare part kit, the replacement instructions of the respective spare part are
provided along with the kit. For more information, contact Videojet Technologies Inc. Refer to

“Support and Training” for the contact information.

The replacement instructions are available for the parts included in the following table.

Spare List

MCB and SD Card

Printhead PCB

Ribbon Detector PCB

CLARiTY Controller PCB and LCD

PSU PCB

PSU and Power Switch

Pivot Assembly, Carriage Assembly and Linear Slide

LH and RH Conversion Kit

Ribbon Motor and Printhead Motor

Belt and Idler Pulley Assembly

Printhead and Printhead Mount

iAssure Emitter and Lens

Belt Tensioning

Table 6-1: Available Instructions

Videojet DataFlex 6530 Service Manual - Rev AA 6-1

Section 7 Maintenance

7.1 General Maintenance

Videojet DataFlex 6530 requires minimum ongoing maintenance.

EQUIPMENT DAMAGE.

The use of an incompatible cleaning kit can seriously damage your printer. Such damage will
not be covered by your printer warranty. Use only cleaning kits approved by your dealer.

Note: Harsh or dirty environments may require shorter intervals between preventive maintenance

routines.

Do the following inspections and perform the measures as per the scheduled frequency.

Inspection Check Point Frequency Measures

CLARiTY Display

CAUTION

Check if the touch screen is
clean

Printhead

Printhead With every ribbon

Lightbox With every ribbon

Peel Roller As required (for 

As Required Clean the touch screen by wiping

change (minimum
frequency)
Note: Harsh or dirty 
environments may
require shorter intervals
between cleaning

change (minimum
frequency)
Note: Harsh or dirty 
environments may
require shorter intervals
between cleaning

example, when ink has
transferred to the roller)

with a dry soft cloth or cotton pad.

Clean with pre-soaked swabs or
wipes that are available from the
approved cleaning kits. For more
information on cleaning the 
printhead.
Refer to Operator manual for more
information.

Clean with pre-soaked swabs or
wipes that are available from the
approved cleaning kits. For more
information on cleaning the 
printhead.
Refer to Operator manual for more
information.

Clean with pre-soaked swabs or
wipes that are available from the
approved cleaning kits.

Cable

Check all screw-fastened 
plug-and-socket
connectors for tight fit.

Table 7-1: General Maintenance Schedule

Refer to operator manual for detailed procedure on cleaning the printhead and lightbox.

Videojet DataFlex 6530 Service Manual - Rev AA 7-1

As Required If necessary, re-tighten them.

Section 8 Troubleshooting

Figure 8-1: Warning Message

Figure 8-2: Fault Message

This chapter contains information on error messages, its possible causes and the remedies.

•Printer Faults

• CLARiTY HMI-PSU Faults

• Fault Messages and Warnings

8.1 Printer Faults

Refer to operator manual for printer error messages, its possible causes and the remedies.

Note: The test points location details are available in Appendix C, "Test Points".

8.2 CLARiTY HMI-PSU Faults

Refer to operator manual for CLARiTY HMI-PSU faults, its possible causes and the remedies.

8.3 Fault Messages and Warnings

The errors are divided into two groups:

• Warning Errors - These errors indicate a warning condition. The printer continues to
print until the warning condition becomes a fault condition.

• Fault/Alarm Errors - These errors indicate a fault condition. During a fault
condition, the printer stops printing.

Table 8-1 lists the faults and warnings.

Error 
Reference

E1000 Job Update 

E1001 Count Limit

Name Remedial Action

The printer was unable to update the current Job before the

Failure

Reached

next print was required. This usually occurs because products
are too close together. Press the Clear button to enable 
printing to be restarted.

One or more of the counters in the image has reached the end
value set in the image design. Please select a new Job and
press the Clear button to enable printing to be restarted.

Table 8-1: Faults and Warnings

Videojet DataFlex 6530 Service Manual - Rev AA 8-1

Troubleshooting

Error 
Reference

E1002 Operation

E1003 Realtime Clock

E1004 Backup

E1005 Print Limit

Name Remedial Action

Aborted

Fault

battery is flat

Exceeded

The operation of the printer was intentionally aborted by a
host control system. When ready to do so, the host control
system will clear this abort condition, and then this fault 
message will automatically clear and the printer will resume
operation.

There is a problem with the Real time Clock which is required
for the system to operate correctly.

The battery which powers the printer's clock is flat. This
means that the date and time, the currently selected Job and
some performance data will be lost when the printer is
switched off.

The current Job was selected with a print limit (i.e. a limit on
the number of times the Job can be printed). This limit has
been reached but the printer has received a further print 
signal that would have exceeded the limit.

This error will become clearable after selecting a new job. 
Alternatively, a Job selection command or variable data
update from an external source will also make this error 
clearable.

E1006 Image Update

Failure

E1007 Image Update

Failure

E1008 Power Failure

Detected

E1009 Corrupt MAC

Address

E1010 Invalid Line The line selection inputs have requested a line that is not 

CLARiTY was unable to update the image that will be printed
next. This usually occurs because products are too close
together. Press the Clear button to enable printing to be
restarted.

CLARiTY was unable to update the image that will be printed
next. This usually occurs because products are too close
together. Press the Clear button to enable printing to be
restarted.

A serious drop in the mains power has been detected. In
order to protect the printer from damage, the high voltage 
circuits have been switched off. You must now repower the
printer in order to resume printing. If the problem persists,
contact your maintenance engineer.

The MAC address of this printer is corrupt and the printer 
cannot function without a valid MAC address. Contact your 
maintenance engineer.

configured. Use CLARiTY Configuration Manager to check
that the correct number of lines have been setup for this 
system. Also check that the line selection inputs are connected
properly. Press the Clear button, to clear this warning 
message.

Table 8-1: Faults and Warnings (Continued)

8-2 Videojet DataFlex 6530 Service Manual - Rev AA

T roubleshooting

Error 
Reference

E1011 Production 

E1012 No Line

E1013 BETA Expired The beta period for the release has expired.

E1014 Time and Date

Name Remedial Action

A request to print a product has been received for a line that

Disabled

Selected

may be
incorrect

production has been disabled on. Please press the Job button
on the home screen and check that the line configuration is
correct. Press the Clear button, to clear this fault message.

A print signal has been received for a product without any
line selection. Please check that the line selection system is 
functioning correctly. Press the Clear button, to clear this fault
message.

Contact your maintenance engineer to correct this problem.

The printers time and date may not be correct. The most 
common cause for this is that the battery used to backup the
printers clock is flat. If this problem returns the next time the
printer is power on then the battery should be replaced. If the
battery is flat the date and time, the currently selected job and
some performance data will be lost when the printer is
switched off.

Press the Clear button, to clear this warning message.

E1100 Invalid Job

File­bad field 

reference

E1101 Invalid Job

File-missing
data source
field

E1102 Invalid Job File

- duplicate
named fields

E1103 Invalid Job File

- invalid
graphic

The Job file is invalid and needs to be corrected using 
CLARiSOFT. There is a circular reference between fields in
the Job file. Use CLARiSOFT to check and correct the 
relationships between fields in this Job file. Then, download
the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A field in the Job file refers to another field for
its source of data, but that field is missing from the job file.
Use CLARiSOFT to ensure that all data source fields used in
the Job file are present and correct in the Job file. Then, 
download the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. Duplicate field names were found in the Job file.
Use CLARiSOFT to remove or rename fields so that there are
no duplicates. Then, download the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. The Job file refers to a missing or invalid graphic
bitmap file. Use CLARiSOFT to check and ensure that all 
bitmap files, used by this Job file, display properly in 
CLARiSOFT. Then, download the corrected file.

Press the Clear button, to clear this fault message.

Table 8-1: Faults and Warnings (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 8-3

Troubleshooting

Error 
Reference

E1104 Invalid Job File

E1105 Invalid Job File

E1200 Invalid Job File

Name Remedial Action

- invalid date
field

- Multiple
Transmitted
Fields

- invalid 
barcode 
character

The Job file is invalid and needs to be corrected using 
CLARiSOFT. The Job file you are trying to select contains an
incorrectly specified Date Calculation. The Default Offset for
the date falls outside of the date range specified by the 
Minimum and Maximum user concession. Use CLARiSOFT
to correct this error in the Job file. Then, download the 
corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A Transmitted Field attribute was found on
more than one field. Only one field can be tagged as the 
transmitted field. Use CLARiSOFT to correct this error in the
Job file. Then, download the corrected file to CLARiTY.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A barcode in the Job file contains characters
which are not in the character set of the barcode type being
used. Use CLARiSOFT to check and correct the barcode fields
in the Job file. Then, download the corrected file.

Press the Clear button to clear this fault message.

E1201 Invalid Job File

- invalid 
barcode check
digit

E1202 Invalid Job File

- EAN barcode
out of 
specification

E1203 Invalid Job File

- EAN barcode
out of

specification

Table 8-1: Faults and Warnings (Continued)

The Job file is invalid and needs to be corrected using 
CLARiSOFT. The check digit supplied for a barcode in the Job
file is invalid. Use CLARiSOFT to check and correct the bar­code fields in the Job file. Then, download the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. An EAN barcode in the Job file contains more
than 48 characters, which is the maximum length for this type
of barcode. Use CLARiSOFT to check and correct the EAN
barcode fields in the Job file. Then, download the corrected
file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. The field for an EAN128 barcode does not

contain enough data to form a valid Application Identifier.
Use CLARiSOFT to check and correct the EAN128 barcode
fields in the Job file. Then, download the corrected file.

Press the Clear button, to clear this fault message.

8-4 Videojet DataFlex 6530 Service Manual - Rev AA

T roubleshooting

Error 
Reference

E1204 Invalid Job File

E1205 Invalid Job File

E1206 Invalid Job File

Name Remedial Action

- EAN barcode
out of

specification

- EAN barcode
out of

specification

- EAN barcode
out of

specification

The Job file is invalid and needs to be corrected using 
CLARiSOFT. An EAN128 barcode field contains an
application identifier containing non-numeric data, but
EAN128 application identifiers must be numeric. Use

CLARiSOFT to check and correct the EAN128 barcode fields
in the Job file. Then, download the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. EAN128 barcode fields with an application
identifier of 23 should contain a length digit following the
application identifier. Use CLARiSOFT to check and correct
the EAN128 barcode fields in the Job file. Then, download the
corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. An EAN128 barcode field in the Job file does not
have the number of characters that are specified by its 
application identifier. Use CLARiSOFT to check and correct
the EAN128 barcode fields in the Job file. Then, download the 
corrected file.

Press the Clear button, to clear this fault message.

E1207 Invalid Job File

- EAN barcode
out of

specification

E1208 Invalid Job File

- EAN barcode
out of

specification

E1209 Invalid Job File

- EAN barcode
out of

specification

The Job file is invalid and needs to be corrected using 
CLARiSOFT. An EAN128 barcode field in the Job file contains
variable length data followed by a separator character; 
separator characters should not be used to terminate data in
an EAN128 barcode. Use CLARiSOFT to check and correct
the EAN128 barcode fields in the Job file. Then, download the 
corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. An EAN128 barcode field in the Job file contains
data that is out of range (e.g. an hour field set to 25 or a month
field set to 13). Use CLARiSOFT to check and correct the
EAN128 barcode fields in the Job file. Then, download the 
corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. An EAN128 barcode field in the Job file contains
an application identifier that requires a digit to specify the 
position of the decimal point, but this digit is not present. Use
CLARiSOFT to check and correct the EAN128 barcode fields
in the Job file. Then, download the corrected file.

Press the Clear button, to clear this fault message.

Table 8-1: Faults and Warnings (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 8-5

Troubleshooting

Error 
Reference

E1210 Invalid Job File

E1211 Invalid Job File

E1212 Invalid Job File

Name Remedial Action

- EAN barcode
out of

specification

- EAN barcode
out of

specification

- barcode
length

incorrect

The Job file is invalid and needs to be corrected using 
CLARiSOFT. An EAN128 barcode field in the Job file contains
an application identifier that requires a check digit, but this
check digit was either missing or invalid. Use CLARiSOFT to
check and correct the EAN128 barcode fields in the Job file.
Then, download the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT An EAN128 barcode could not be rendered at a
size of 165 mm or less which is the maximum length for this
type of barcode. Use CLARiSOFT to check and correct the
EAN128 barcode fields in the Job file. Then, download the 
corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A barcode field in the Job file does not have the
expected number of characters. Use CLARiSOFT to check and
correct the barcode fields in the Job file. Then, download the
corrected file.

Press the Clear button, to clear this fault message.

E1213 Invalid Job File

- barcode out of
limits

E1214 Invalid Job File

- Invalid
Checksum
Data

E1215 Invalid Job File

- invalid
barcode height

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A barcode field in the Job file overruns the edge
of the image and it is not possible to extend the image area to
accommodate the barcode Use CLARiSOFT to check and 
correct the barcode fields in the Job file. Then, download the
corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A field in the Job file uses a checksum (e.g. an
EAN13 barcode with a price verifier digit) but the data 
supplied to calculate the checksum were not valid. Use
CLARiSOFT to check and correct fields using checksums in
the Job file. Then, download the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. The height supplied for a barcode in the Job file
is smaller than the minimum allowed by the barcode 
specification. Use CLARiSOFT to check and correct the 
barcode fields in the Job file. Then, download the corrected
file.

Press the Clear button, to clear this fault message.

E1216 Invalid Job File

- Barcode
Symbology
Not Installed

Table 8-1: Faults and Warnings (Continued)

8-6 Videojet DataFlex 6530 Service Manual - Rev AA



The Job file contains a barcode symbology that is not installed
in this printer. Use CLARiSOFT to remove the barcode from
the Job file. Then, download the corrected file to the printer.

Press the Clear button, to clear this fault message.

T roubleshooting

Error 
Reference

E1217 Invalid Job File

E1218 Invalid Job File

E1219 Invalid Job File

E1220 Invalid Job File

Name Remedial Action

- Undefined
Format

Identifier

- Data too long

- Invalid
Barcode Size

- Invalid
Barcode ECC

Type

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A Data Matrix Barcode field in the Job file uses a
Public Format ID which is not currently defined.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A Data Matrix Barcode field in the Job file 
contains too many data characters for the selected 
dimensions.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A Data Matrix Barcode field in the Job file has
invalid dimensions.

Press the Clear button to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A Data Matrix Barcode field in the Job file has
an unsupported ECC type. Only ECC 200 is currently 
supported.

Press the Clear button to clear this fault message.

E1221 Invalid Job File

- Barcode uses
unsupported 
coding

E1222 Invalid Job File

- Barcode
encoding failed

E1223 Invalid Job File

- Invalid Date
Reference

E1224 Invalid Job File

- Invalid Date
Rounding

E1225 Invalid Job File

- Invalid Coun­ter

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A Data Matrix Barcode field in the Job file uses a
form of data compression not currently supported by 
CLARiTY.

Press the Clear button to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A Data Matrix Barcode field in the Job file failed
to encode into a valid image.

Press the Clear button to clear this fault message.

The Job file contains a date reference not supported by this
printer. Use CLARiSOFT to set the 'Reference Date' for all 
Calculated Dates to 'Current Date'. Then, download the 
corrected file to the printer.

Press the Clear button, to clear this fault message.

The Job file contains a date with a rounding calculation that is
not supported by this printer. Use CLARiSOFT to remove the
Rounding for all Calculated Dates. Then, download the 
corrected file to the printer.

Press the Clear button, to clear this fault message.

The Job file contains a counter that is not supported by this
printer. Use CLARiSOFT to remove all counters from the job.
Then, download the corrected file to the printer.

Press the Clear button, to clear this fault message.

Table 8-1: Faults and Warnings (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 8-7

Troubleshooting

Error 
Reference

E1226 Invalid Job File

E1227 Invalid Job File

E1228 Invalid Job File

E1229 Invalid Job File

Name Remedial Action

- Invalid Price

- Invalid Trans­mitted Field

- Invalid
Graphic Field

- Invalid
Graphic

The Job file contains a price field that is not supported by this
printer. Use CLARiSOFT to remove all price fields from the
job. Then, download the corrected file to the printer.

Press the Clear button, to clear this fault message.

The Job file contains a transmitted field that is not supported
by this printer. Use CLARiSOFT to disable the 'Transmitted
Field' option for all fields in the job. Then, download the 
corrected file to the printer.

Press the Clear button, to clear this fault message.

The Job file contains a graphic field that is not supported by
this printer. Use CLARiSOFT to remove all Logo and 
Drawing fields in the job. Then, download the corrected file to
the printer.

Press the Clear button, to clear this fault message.

The Job file contains a graphic field that is not supported by
this printer. Use CLARiSOFT to remove all Logo fields in the
job. Then, download the corrected file to the printer.

Press the Clear button, to clear this fault message.

E1230 Invalid Job File

- Invalid Draw­ing

E1231 Invalid Job File

- Invalid
Paragraph

Field

E1232 Invalid Job File

- PDF417
Barcode out of

Specification

E1233 Invalid Job File

- PDF417
Barcode out of 

Specification

The Job file contains a Drawing field that is not supported by
this printer. Use CLARiSOFT to remove all Drawing fields in
the job. Then, download the corrected file to the printer.

Press the Clear button, to clear this fault message.

The Job file contains a Paragraph field that is not supported
by this printer. Use CLARiSOFT to remove all Paragraph
fields in the job. Then, download the corrected file to the
printer.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A PDF417 or Micro-PDF417 barcode field in the
Job file contains more columns than the barcode symbology
supports. Use CLARiSOFT to check and correct the PDF417
and Micro-PDF417 barcode fields in the Job file. Then, 
download the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A PDF417 or Micro-PDF417 barcode field in the
Job file contains more rows than the barcode symbology 
supports. Use CLARiSOFT to check and correct the PDF417
and Micro-PDF417 barcode fields in the Job file. Then, 
download the corrected file.

Press the Clear button, to clear this fault message.

Table 8-1: Faults and Warnings (Continued)

8-8 Videojet DataFlex 6530 Service Manual - Rev AA

T roubleshooting

Error 
Reference

E1234 Invalid Job File

E1235 Invalid Job File

E1236 Invalid Job File

Name Remedial Action

- PDF417
Barcode out of

Specification

- EAN13 Price
Too Large

- Invalid Font

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A PDF417 or Micro-PDF417 barcode field in the
Job file contains more characters than can be encoded with the
specified column and maximum row sizes. Use CLARiSOFT
to increase the number of columns or rows in the PDF417 and
Micro-PDF417 barcode fields in the Job file. Then, download
the corrected file.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. The EAN13 barcode contains a price that is too
large to be encoded within the barcode. Use CLARiSOFT to
check and correct the maximum price value for price field that
is referenced by the barcode.

Press the Clear button to clear this warning message.

The Job file contains a bitmap font field that is not supported
by this printer. Use CLARiSOFT to remove all bitmap font
fields in the job. Then, download the corrected file to the
printer.

Press the Clear button, to clear this warning message.

E1237 Invalid Job File

- Invalid Font

E1238 Invalid Job File

- Invalid
Global Count
Value

E1239 CLARiTY Data

File Complete

E1240 Missing

CLARiTY Data
File

The Job file refers to a missing or invalid bitmap font file. Use
CLARiSOFT to check and ensure that all text fields used by
this Job file, display properly in CLARiSOFT. Then, 
download the corrected file to the printer.

Press the Clear button, to clear this warning message.

The Job file uses a global counter that is not compatible with
the current global count value. The current global count value
is either too long for the counter specified in the job or 
contains characters that are not valid. The global count value
will be reset when this job is selected. Use CLARiSOFT to
ensure that all jobs contain the same configuration for this
global counter.

Press the Clear button, to clear this warning message.

All data has been printed in the current CLARiTY Data File.
Please select a new Job to resume printing. Note you will have
to install a new CLARiTY Data file before selecting the Job if
that job uses a CLARiTY Data file.

Press the Clear button, to clear this fault message.

There is no CLARiTY Data File installed in this printer and
the selected Job uses a CLARiTY Data file to lookup the data it
prints. Please select a new Job or install a CLARiTY Data file
to resume printing.

Press the Clear button, to clear this fault message.

Table 8-1: Faults and Warnings (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 8-9

Troubleshooting

Error 
Reference

E1241 CLARiTY Data

E1242 Invalid Job File

E1243 Invalid Job File

E1300 Slave Printer

Name Remedial Action

File Failed

- Barcode data
too long

- Avoidance
Date

Absent

There is a problem with the installed CLARiTY Data file.
Please select a new Job or install a new CLARiTY Data file to
resume printing.

Press the Clear button, to clear this fault message.

The Job file is invalid and needs to be corrected using 
CLARiSOFT. A QR Barcode field in the job file contains too
many data characters for the selected dimensions.

Press the Clear button, to clear this fault message.

The Job file contains a calculated date that is an avoidance
date. Use CLARiSOFT to check and correct the calculated
dates in the job. Then, download the corrected file to the
printer.

Select a valid Job and then press Clear button, to clear this
fault message.

This printer is configured as the Master to a group of Slave
printers, Slave printer %1 is assigned to this Master, but it is
not responding. Please check the wiring connections between
this Master printer and Slave %1 printer, then power both this 
Master and Slave %1 off then on, to try and clear this fault. If
the problem persists, Contact your maintenance engineer. 
If you want to continue production without Slave %1, please
go to Tools > Setup > Printheads > Slave%1 and un-assign
Slave%1.

E1301 Master Printer

Absent

E1302 Slave Job Select

Failed

E1303 Slave Database

Full

Table 8-1: Faults and Warnings (Continued)

This printer is configured as a Slave printer to a Master
printer in a group of printers, The Master printer is not
responding to this Slave printer. Please check the wiring
between this printer and the Master printer, then power both
printers off then on, to try and clear this fault. If the problem
persists, contact your maintenance engineer.

Slave Printer %1 failed to select the current job.
Please check the wiring between this printer and the Master

printer, then power both printers off then on, to try and clear
this fault. If the problem persists, Contact your maintenance
engineer.

Slave Printer %1 has failed to receive a file because it has run
of space. This usually occurs when a slave printer has a
smaller database capacity than the master, if this is the case
then it is recommended that the slave database is upgraded.
To ensure trouble free operation, delete some jobs out of the
master printer database and then repower the master printer.
This will cause the master and slave databases to be 
resychronised.

Press the Clear button, to clear this fault message.

8-10 Videojet DataFlex 6530 Service Manual - Rev AA

T roubleshooting

Error 
Reference

E1304 Slave Software

E1305 Slave Job

E1500 Log File

E1501 Log File Space

E1502 Log File Space

Name Remedial Action

Version

Update Failed

Corruption

Critical

Limited

Slave Printer %1 has failed to communicate with the Master
Printer because its software is too old. Please perform a 
CLARiTY Update to the latest revision of software to resolve
this problem.

Slave Printer %1 failed to update the printing data for the 
current job. Please check the wiring between this printer and
the Master printer, then power both printers off then on, to try
and clear this fault. If the problem persists, contact your 
maintenance engineer.

Corruption has been detected in the log file. Please navigate
to Tools > Diagnostics > Control > Log Files for more details.

Press the Clear button, to clear this warning message.

The available space for logging has reached a 
critical level. Please archive the log file or delete unnecessary
files from the Job database to free up some space. This fault 
message will clear automatically when the free space is
increased.

The available space for logging becoming limited. Please
archive the log file or delete unnecessary files from the Job 
database to free up some space.

Press the Clear button, to clear this warning message

E1503 Logging Space

Exhausted

E1504 Log File Save

Failed

E1505 Logging Job

Events
Disabled

E3200 iAssure Setup

Required

E3201 Motor 

Characteriza­tion Required

The available space for logging is exhausted. Please archive
the log file to free up some space.

Press the Clear button, to clear this fault message

Failed to save log file information. Some log file information
has been lost.

Press the Clear button, to clear this fault message.

Logging of Job events has been disabled. This is because Job
selections and Job updates are happening too frequently. The
printer can only log Job events once every 10 seconds.

Logging of Job events can be re-enabled via the 
IncludeJobEvents parameter in CLARiTY Configuration 
manager if the frequency of Job events is reduced.

Press the Clear button, to clear this warning message.

Please press the Start Setup button to setup the iAssure
sensor.

The ribbon motors have not been characterized. To 
characterize the ribbon motors:

- Install the ribbon cassette with no ribbon fitted to the ribbon
mandrels.

- Press the Characterize Ribbon Motors button.
Once the characterization completes, this fault will clear 

automatically.

Table 8-1: Faults and Warnings (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 8-11

Troubleshooting

Error 
Reference

E3202 Cassette Open The ribbon cassette is not installed, or has not been pressed

E3203 Ribbon Break The print ribbon has broken or run out.

Name Remedial Action

fully home. Check that the cassette has ribbon correctly
installed and insert it fully into the printer. Once the cassette
is installed properly this error will automatically clear.

The ribbon cassette detect sensor is showing that the cassette
is not installed. If the cassette is installed then there could be a
fault with the sensor itself. Check that the sensor cabling or
housing is not damaged and check that the magnet is present
on the cassette itself. Once the cassette is installed properly
this error will automatically clear.

- Remove the cassette.

- Replace the ribbon.

- Replace the cassette.

- Wait for the 'Clear' button to become available and
press it to return to normal operation.
The printer has detected a break in the ribbon. If the ribbon

hasn't broke but has become slack, check there are no 
obstructions to the ribbon path, check that there is no damage
to either ribbon motor, their connectors or cabling. Check that
the ribbon drive encoder is not damage and is rotating freely.
Once done, replace the cassette and the fault will become 
clearable.

E3204 End Of Reel The print ribbon has run out.

- Remove the cassette.

- Replace the ribbon.

- Replace the cassette.

- Wait for the 'Clear' button to become available and
press it to return to normal operation.
The printer has detected that the ribbon has ran out. If the 

ribbon has not ran out please check that there is no damage to
either ribbon motor, their connectors or cabling. Check that
the ribbon drive encoder is not damage and is rotating freely.
Once done, replace the cassette and clear the fault.

E3205 Calibration

Failed

Table 8-1: Faults and Warnings (Continued)

Ribbon calibration has failed.
Remove the ribbon cassette and check that the correct ribbon

type is being used, and that the ribbon is wound properly on
the cassette. Also ensure that the ribbon cores are not slipping
on their mounting mandrels and that the cassette is 
undamaged. Refit the cassette and then press the Clear
button. The printer will automatically try to re-calibrate.
If the problem persists, contact your maintenance engineer.

8-12 Videojet DataFlex 6530 Service Manual - Rev AA

T roubleshooting

Error 
Reference

E3206 Ribbon Pull

E3207 Ribbon Feed

Name Remedial Action

Through

Fault

The ribbon supply is being pulled by the substrate.
Remove the cassette and check that the ribbon and substrate

are not stuck together.
Refit the cassette and then press the Clear button, to try and

clear the fault message. If the fault clears, the printer will 
automatically recalibrate.

This fault may be due to momentary adhesion of the ribbon to
the substrate, which can be caused if printhead pressure and
darkness are set excessively high. In turn, these may have
been set too high to overcome print quality problems that
may arise from a dirty printhead or an old printhead that is
due to be replaced.

Please clean the printhead and check that the darkness and
printhead pressure settings are nominal.

Once resolved and ready, press Clear button and re-try. If the
problem still persists, contact your maintenance engineer.

Ribbon Feed Fault. The ribbon is not feeding correctly. Check
that the ribbon is feeding correctly and that the cassette rollers
can rotate freely without obstruction.

If the problem persists, contact your maintenance engineer.

E3208 Ribbon Drive

Fault

E3209 Ribbon Drive

Fault

E3210 Ribbon Drive

Fault

E3211 Optical 

Calibration 
Sensor Fault

E3212 Dirty Optical

Calibration 
Sensor

Ribbon Drive Fault. contact your maintenance engineer.

Ribbon Drive Fault. contact your maintenance engineer.

Ribbon Drive Fault. contact your maintenance engineer.

Optical Calibration Sensor Fault. Contact your maintenance
engineer.

The optical sensors are dirty or obstructed.
Remove the cassette, wipe clean the optical sensors and check

for obstructions.
Refit the cassette and then press the Clear button. The printer

will automatically retry the calibration.
The optical calibration sensors are reporting that there is an

obstruction in their view. If this fault still appears after 
clearing any dirt or obstruction, please check that all the
LED's are illuminating correctly and check the connectors and
cabling for damage.

Refit the cassette and then press the Clear button. The printer
will automatically retry the calibration.

E3213 Optical 

Calibration
LED Fault

Table 8-1: Faults and Warnings (Continued)

Videojet DataFlex 6530 Service Manual - Rev AA 8-13

Optical Calibration LED Fault. Contact your maintenance
engineer.

Troubleshooting

Error 
Reference

E3214 Optical 

E3215 Print 

E3216 Printhead

Name Remedial Action

Calibration
Failed

Resolution 
Mismatch

Power Fault

Remove the cassette and ensure that the ribbon cores are the
correct size. If the ribbon has been replaced, check that the
waste has been removed and a new waste core fitted.

Refit the cassette and then press the Clear button. The printer
will automatically retry the calibration.

The printer has detected out of range diameters for the ribbon
spools. If the ribbon spool diameters are within spec, please
check that the optical calibration sensor and LED's are 
functioning correctly and that there is no damage to any of
the cabling or connectors for each.

Refit the cassette and then press the Clear button. The printer
will automatically retry the calibration.

The printer attempted to print an image that has a different
print resolution to the current printer configuration.

The print has been aborted.
Press the Clear button to dismiss this error.

Printhead power fault. Contact your maintenance engineer.

E3217 Printhead Fault A problem has been detected with the printhead.

Call your maintenance engineer.
Press the Detail button for maintenance assistance.
The printhead detection system is unable to measure the 

resistance of the printhead.
Power off the machine and check that the printhead cables are

not damaged and are firmly plugged into the printhead.
Power on to see if the fault has cleared.

If the problem persists, power of the machine and replace the
printhead. Power on to see if the fault has cleared.

If the problem still persists, contact your maintenance 
engineer. The machine will not run until this fault is resolved.

E3218 Printhead 

Sensor Fault

E3219 Printhead Over

Temperature

E3220 Incompatible

Printhead

Printhead temperature sensor fault. Contact your 
maintenance engineer.

Printhead Over Temperature. Contact your maintenance
engineer.

An incompatible printhead has been detected.
Press the Detail button for maintenance assistance.
An incompatible printhead has been detected. Power off the

machine and replace with a compatible printhead. Power on
to resume operation.

If the problem persists, or if you wish to purchase spare parts,
Contact your maintenance engineer. The machine will not run
until this fault is resolved.

Table 8-1: Faults and Warnings (Continued)

8-14 Videojet DataFlex 6530 Service Manual - Rev AA

T roubleshooting

Error 
Reference

E3221 Incompatible

E3222 Incompatible

E3223 Printer Ribbon

Name Remedial Action

Printhead

Printhead

Low

An incompatible printhead has been detected.
Press the Detail button for maintenance assistance.
An incompatible printhead has been detected. Power off the

machine and replace with a compatible printhead. Power on
to resume operation.

If the problem persists, or if you wish to purchase spare parts,
Contact your maintenance engineer. The machine will not run
until this fault is resolved.

An incompatible printhead has been detected.
Press the Detail button for maintenance assistance.
An incompatible printhead has been detected. Power off the

machine and replace with a compatible printhead. Power on
to resume operation.

If the problem persists, or if you wish to purchase spare parts,
Contact your maintenance engineer. The machine will not run
until this fault is resolved.

The printer ribbon is close to running out. There are less than
50 metres of ribbon remaining.

You can view the Consumables Details by pressing the 
Consumables panel on the Home screen. This information
will indicate the estimated time when the ribbon will com­pletely run out if production continues at the current rate.

E3225 Printhead 

Connection

E3226 Printhead

Health Monitor

E3230 Print Signal

Ignored

E3231 Print Queue

Overflow

Table 8-1: Faults and Warnings (Continued)

The connection to the printhead is not fully functional.
Please power down the printer and check that the printhead

is firmly plugged in and that there is no obvious damage to
the cable.

If the problem persists replace either the printhead or the 
Camera, Ribbon & Printhead PCB.

A problem has been detected on the main PCB with the 
connection to the printhead.

Please power down the machine and replace the main PCB.

Print signals are too close together, a new print signal is being
received before the previous print cycle has completed. Some
of the last few products may not have been printed.

If the problem persists, contact your maintenance engineer.

The printer has detected more than one hundred print
requests between the print sensor and the printhead. This
may be due to false sensor triggers, or a faulty print sensor.

Press the Clear button to clear this fault message and then try
to resume printing. If the problem persists, contact your 
maintenance engineer.

Videojet DataFlex 6530 Service Manual - Rev AA 8-15

Troubleshooting

Error 
Reference

E3232 iAssure File

E3233 iAssure Full

E3234 Print Cycle

E3235 Printer Busy The printer failed to print after the last print signal due to

Name Remedial Action

Transfer of iAssure calibration files has failed.
Transfer 
Failure

Calibration
Required

Error

Press the Detail button for maintenance assistance.

The transfer of calibration files to disk has failed. Press the

Clear button to clear this warning.

Could not find valid configuration files for iAssure. Please

remove cassette and carry out a full iAssure calibration.

Press the Detail button for maintenance assistance.

iAssure calibration files have not yet been generated, please

carry out an iAssure calibration by press the Calibrate button.

A critical print cycle error has occurred.

Please contact your local service representative for further 

information.

Press the Clear button to attempt to resume printing.

The print engine has encounted a critical error. Please check

for any obvious issues or damage in the printer.

Press the Clear button to attempt to resume printing.

other interactions with the machine.

This is usually caused by parameter changes being made

whilst the printer is Running and printing.

Press the Clear button to resume printing.

The printer has detected that it failed to print on the last print

signal. Please check that any external interactions with the

parameter system are not excessive.

Press the Clear button to resume printing.

E3236 Printhead 

Carriage 
Position Error

Table 8-1: Faults and Warnings (Continued)

The printhead carriage has failed to return to its correct 

position.

Switch the power off and remove the cassette. Check that the

printhead carriage movement is free from obstruction and

ensure that its drive belt is not loose.

Refit the cassette and switch the power on.

If the problem persists, contact your maintenance engineer.

8-16 Videojet DataFlex 6530 Service Manual - Rev AA

T roubleshooting

Error 
Reference

E3237 Incorrect Reel

E3238 Dirty iAssure

Name Remedial Action

Size

Sensor

The size of one or more reels of ribbon loaded onto the 
cassette is incorrect.

Remove the cassette and check that the ribbon waste core has
been fitted and that the ribbon rolls are within the supported
limits.

Refit the cassette and then press the Clear button. The printer
will then automatically calibrate.The size of one or more of
the reels of ribbon loaded onto the cassette is out of range.

The printer supports a reel diameter of up to 110mm for 
normal operation, and a maximum diameter of 85mm when
High Throughput mode is enabled. Also ensure that an
empty core has been fitted to the waste mandrel.

Refit the cassette and then press the Clear button. The printer
will then automatically calibrate.

The iAssure Light box and Sensor is dirty or obstructed and
this is likely to cause the iAssure system to fail images that
have printed correctly.

Remove the ribbon cassette, wipe clean the printhead, light
box, sensor and check for obstructions.

When the iAssure sensor is clean and unobstructed the light
box will stop flashing.

Press the Clear button.
If the problem persists, contact your maintenance engineer.

E3239 Incorrect

Ribbon Width

E3240 iAssure Sensor

Failure

E3241 iAssure

Lightbox
Failure

E3242 iAssure

Lightbox
Overheated

Table 8-1: Faults and Warnings (Continued)

The iAssure system has measured a ribbon width that is
significantly different to the ribbon width setting.

Please navigate to Tools -> Setup -> Consumables and ensure
that the “Ribbon Width” setting is configured correctly.

If the setting is correct remove the ribbon cassette, wipe clean
the printhead, light box and check for obstructions.

Press the Clear button below.

The printer has detected a failure of the iAssure sensor. Please
check its cabling, connectors and housing for any obvious
damage and repair if necessary.

The printer has detected a failure of the iAssure lightbox.
Please check its lightbox cabling, connectors and housing for
any obvious damage and repair if necessary.

The iAssure lightbox has overheated.
Ensure the lightbox is correctly assembled and mounted to

the printer, allow the printer to cool down and restart the
printer.

If the problem persists, contact your maintenance engineer.

Videojet DataFlex 6530 Service Manual - Rev AA 8-17

Troubleshooting

Error 
Reference

E3243 Consecutive

E4040 Allowed Login

Table 8-1: Faults and Warnings (Continued)

Name Remedial Action

iAssure has declared a print failure. To view the failed print
Print Defects
Detected

Attempts
Exceeded

press the View Bad Print button. Press the Clear button below

to clear this fault.

A user enter an incorrect password repeatedly and has been

disabled.

8-18 Videojet DataFlex 6530 Service Manual - Rev AA

Section 9 Illustrated Parts List

Main Assembly

Sub Assembly 1

Sub Assembly 2

The Illustrated Part List (IPL) contains the illustrations and the parts lists for the different
assemblies in the printer. The parts lists give the part numbers, description and quantity of all the
items and the modules in the printer. You can order the items and the modules for which the part
numbers are given.

This manual contains the following informations:

•How to Read the IPL

• Videojet DataFlex 6530 Parts

9.1 How to Read the IPL

This section describes how the higher assemblies are broken down to their related sub assemblies
and other separate parts.

9.1.1 Illustrations

Table 9-1 shows the symbols used to indicate the different levels of main assemblies in a printer,

and the sub assemblies under the main assembly.

9.1.2 Alphabets

A letter is assigned to the main assemblies of a printer and a number is assigned to each sub
assembly under the main assembly.

For example: If A, B, C and D identify the main assemblies of a printer, then letter-number
sequence A1, A2 and so on identify sub assemblies below each main assembly in a sequence.

• The alphabets “I” and “O” are not used because they look like the numbers 1 and 0.

Assembly Symbol

Table 9-1: Symbols Representation - Assemblies

Videojet DataFlex 6530 Illustrated Parts Breakdown - Rev AA 9-1

Illustrated Parts List

A

B

9.2 Videojet Data Flex 6530 Parts

Figure 9-1: Main Parts of Videojet DataFlex 6530

Item Descriptions Sub-assembly

A CLARiTY Human Machine Interface

(HMI) and Power Supply Unit (PSU)

BPrinter Refer to Table 9-6

Table 9-2: Videojet DataFlex 6530 Assemblies

Refer to Table 9-3

9-2 Videojet DataFlex 6530 Illustrated Parts Breakdown - Rev AA