ASTRO-MED QLS-3000XE SERIES User manual

Digital Color Label Printer
Operation & Setup Guide
Part Number 22834-527
Version 1.0
05/05
Firmware V 1.0
Specifications are subject to change without notice
___________________________________________
QuickLabel Systems®
an Astro-Med, Inc. Product Group
600 East Greenwich Ave., West Warwick, RI 02893
Tel: [phone] • Fax: [phone]
E-mail: [e-mail]
www.QuickLabel.com
___________________________________________
Technical Support
Tel: [phone]
[email protected]
www.QuickLabel.com/support/

Copyright © 2005 Astro-Med, Inc.
This manual is copyrighted with all rights reserved. No part of this manual
may be reproduced, transmitted, transcribed, stored in a retrieval system, or
translated into any language in any form by any means without written
permission of QuickLabel Systems.
Trademarks
Windows™ is a trademark of Microsoft Corporation
TrueType™ is a trademark of Apple Computer, Inc.
AS/400™ is a trademark of International Business Machines Corporation.
QuickLabel® is a registered trademark of Astro-Med, Inc.
Custom QuickLabel™ and MicroCell™ are trademarks of Astro-Med, Inc.
Limited Warranty
QuickLabel Systems, An Astro-Med Inc. Product Group, warrants this
product against defects in materials or workmanship for a period of one year
from the date of original purchase. This warranty excludes printhead and
print platen, which are separately warranted. If the customer discovers a
defect, this defect must be reported promptly to QuickLabel Systems.
QuickLabel Systems will, at its option, repair or replace the defective
component at no additional charge. Repair parts and replacement parts will
be furnished on an exchange basis and will be either reconditioned or new.
All replaced parts become the property of QuickLabel Systems. Travel,
freight and other expenses related to warranty repairs are not covered.
Service Agreements are available for purchase and may provide on-site
service and/or loaner equipment.
QuickLabel Systems warrants the printhead from the date of purchase for a
period of 90 days or for 1 million inches of thermal transfer ribbon,
whichever comes first, based upon the use of QuickLabel Systems thermal
transfer ribbon. QuickLabel Systems printheads are calibrated for use with
QuickLabel Systems thermal transfer ribbon and perform correctly only
when used with this ribbon. This specific printhead warranty does not apply
to printheads damaged by accident, abuse, neglect, misapplication or the
like.

This warranty is void if the product has been damaged by accident, abuse,
neglect or misapplication, or if the product has been improperly installed, or
if the product has been modified without the express written permission of
QuickLabel Systems.
QuickLabel Systems makes no warranty, either express or implied, with
respect to this product’s fitness for a particular purpose.
Obtaining Service
To obtain warranty service, call QuickLabel Systems Technical Support at
401-828-4000 or Toll-Free in the USA and Canada at 877-757-7978.
QuickLabel Systems, An Astro-Med Inc. Product Group, is not responsible
for products lost or damaged in transit.
Ownership Information
Congratulations and thank you for your business. Your purchase of a quality
QuickLabel Systems product is an investment in the finest of state-of-the-art
printing and labeling technology. Please use the spaces below to list the
model name/number and serial number of your product.
Model Name/Number: ____________________
Serial Number: ____________________

DECLARATION OF CONFORMITY
Manufacturer’s Name: Astro-Med, Inc.
Manufacturer’s Address: Astro-Med, Inc.
600 East Greenwich Avenue
West Warwick, RI 02893 USA
declares that the product
Product Name: QLS-2000 Xe QLS-2001 Xe
QLS-3000 Xe QLS-3001 Xe
conforms to the following product specifications:
Safety: EN 60950-1:2001
CAN/CSA C22.2 No. 60950-1-03
EMC: EN 55022:1998, Class A
EN 55024:1998
EN 61000-3-2:2000
EN 61000-3-3:1995
Relevant Directives are 89/336/EEC and 73/23/EEC
Steven Holbrook / Quality Assurance Manager
05/02/2005
European Contact: Your local Astro-Med, Inc. Sales and Service Office.
FRANCE – Astro-Med SNC, Parc dʹActivities de Pissaloup, 1, rue Edouard Branly,
78190 Trappes (Tel. [phone] Fax: [phone]
Email:[e-mail])
GERMANY – Astro-Med GmbH, Senefelderstrasse 1/T6, D-63110 Rodgau (Tel. 49-
6106-75033 Fax: [phone]
Email: AstroMedDeut[email protected])
UNITED KINGDOM – Astro-Med, Inc., Astro-Med House, 11 Whittle Parkway,
Slough, SL1 6DQ. (Tel. [phone] Fax: [phone]
Email: [email protected]om)
ITALY –Astro-Med S.R.L, Via Plezzo 8, 20132 Milano. (Tel. [phone] Fax: 39-02-
26412828 Email: [email protected])

QLS-3000/2000 Xe Series i
Table of Contents
Chapter 1: Before You Get Started .......................................................1-1
QuickLabel Systems Media ......................................................................................1-2
Quick Start Guide ...................................................................................................... 1-3
Chapter 2: Printer Setup ........................................................................2-1
Unpacking the Printer...............................................................................................2-2
Assembly..................................................................................................................... 2-3
Printers ...................................................................................................................2-3
Cutter, Cutter-Stacker, or External Rewinder................................................... 2-3
QLS-3000/2000 Xe Series Features ...........................................................................2-4
Front View .............................................................................................................2-4
Side Panel View..................................................................................................... 2-5
Power Connection .....................................................................................................2-6
Computer Connections ............................................................................................. 2-7
Parallel Port............................................................................................................2-7
RS-232 Serial Port..................................................................................................2-7
Communications........................................................................................................2-8
Printer Drivers.......................................................................................................2-8
Comm Protocol...................................................................................................... 2-8
Comm Port........................................................................................................... 2-10
Baud Rate / Handshaking .................................................................................. 2-11
Utility Port Connection ........................................................................................... 2-13
Media......................................................................................................................... 2-14
Loading Thermal Transfer Ribbon ................................................................... 2-14
Loading Label Media.......................................................................................... 2-16
Specify Media Type ............................................................................................ 2-19
Calibration ................................................................................................................ 2-20
New Media........................................................................................................... 2-20
Label Length ........................................................................................................ 2-22
Chapter 3: Keypad Controls and Menus ..............................................3-1
Keypad Layout and Functions................................................................................. 3-2
Menu Overview .........................................................................................................3-3
Intensity Menu ...........................................................................................................3-7
Printhead Intensity ............................................................................................... 3-7
Print Menu.................................................................................................................. 3-9
Previous.................................................................................................................. 3-9
Recall..................................................................................................................... 3-10
Test........................................................................................................................ 3-11

ii QLS-3000/2000 Xe Series
Speed.....................................................................................................................3-13
Memory Menu..........................................................................................................3-14
Total ......................................................................................................................3-14
Available...............................................................................................................3-15
Mode Menu...............................................................................................................3-16
Cutter ....................................................................................................................3-16
Mirror....................................................................................................................3-17
TTR Sensor ...........................................................................................................3-18
Align Menu...............................................................................................................3-19
Down-Web ...........................................................................................................3-19
Cross-Web ............................................................................................................3-20
Media Menu..............................................................................................................3-21
Type ......................................................................................................................3-21
Image ....................................................................................................................3-22
Label......................................................................................................................3-23
Offset.....................................................................................................................3-24
Comm Menu.............................................................................................................3-25
Port........................................................................................................................3-25
Handshaking .......................................................................................................3-26
Protocol.................................................................................................................3-28
Prefix.....................................................................................................................3-29
Delimiter...............................................................................................................3-30
System Menu ............................................................................................................3-31
System Baseline ...................................................................................................3-31
Upgrade................................................................................................................3-33
Language..............................................................................................................3-34
Chapter 4: Printing................................................................................. 4-1
Printer Status ..............................................................................................................4-2
Initialization...........................................................................................................4-2
Current Settings.....................................................................................................4-2
Operation ....................................................................................................................4-4
Start Printing..........................................................................................................4-4
Printing Multiple Batches ....................................................................................4-4
Print/Pause.............................................................................................................4-4
Advance Media .....................................................................................................4-4
Print Quality ...............................................................................................................4-5
Test Print Quality..................................................................................................4-5
Heat Intensity ........................................................................................................4-8
Printhead Pressure................................................................................................4-9
Thermal Transfer Ribbon Tension ....................................................................4-11

QLS-3000/2000 Xe Series iii
Print Position............................................................................................................ 4-12
Print and Cut Offset............................................................................................ 4-12
Web Alignment ................................................................................................... 4-13
Mirror Images...................................................................................................... 4-14
Image Area........................................................................................................... 4-15
Speed ......................................................................................................................... 4-16
Job Reprints .............................................................................................................. 4-17
Chapter 5: Printer Maintenance ............................................................5-1
Recommended Maintenance Schedule...................................................................5-2
Routine Cleaning ....................................................................................................... 5-3
Replacing Parts........................................................................................................... 5-5
Printheads ..............................................................................................................5-5
Platen Rollers......................................................................................................... 5-7
Drive Roller............................................................................................................ 5-9
Index Roller.......................................................................................................... 5-11
Media Sensor Assembly..................................................................................... 5-13
Anti-Static Brushes.............................................................................................. 5-19
Keypad/Display................................................................................................... 5-21
Controller Board.................................................................................................. 5-23
Power Supply ...................................................................................................... 5-25
Stepper Motor...................................................................................................... 5-27
Drive Belt.............................................................................................................. 5-29
Ribbon Rewind Motors ...................................................................................... 5-30
Microswitches...................................................................................................... 5-31
Ribbon Sensor...................................................................................................... 5-32
Fan......................................................................................................................... 5-33
Boot PROM .......................................................................................................... 5-34
Wiring Harnesses................................................................................................ 5-34
Firmware Upgrades................................................................................................. 5-35
Upgrading additional printers with the CompactFlash card ....................... 5-38
Chapter 6: Troubleshooting ..................................................................6-1
Printing Problems...................................................................................................... 6-2
Missing print (No print or a clear vertical line in the label)............................ 6-2
Light or Broken Print (Color prints but doesnʹt fill-in completely) ...............6-4
Ribbon wrinkle (Angular or small curved lines in the label)..........................6-5
Ribbon Breakage ...................................................................................................6-7
Ribbon/Media drag (Faded print and smearing).............................................. 6-8
Color registration (Alignment of colors)............................................................ 6-9
Colors do not match (Color matching from monitor to printed label)........ 6-10
Logo, Image, or Text is not clear (Blurry, not sharp) ..................................... 6-10

iv QLS-3000/2000 Xe Series
Logo or Image does not print ............................................................................6-10
Fields do not print as they appear on the monitor (Not positioned correctly
on the label)..........................................................................................................6-11
Media not exiting printer smoothly / Media Hesitates / Media Slips .........6-12
Feeds Blank Labels..............................................................................................6-13
Print Station will not Print .................................................................................6-15
Skips Labels in a Batch .......................................................................................6-16
No Power..............................................................................................................6-16
No Communications...........................................................................................6-16
Error Messages .........................................................................................................6-17
MEDIA FAULT! - Out of labels or motor has stalled.....................................6-17
MEDIA FAULT! - Verify calibrated media type.............................................6-18
TTR OUT ON [Front, Bottom, Center, or Rear] PRINT STATION! - Reload
thermal transfer ribbon ......................................................................................6-18
[Front, Bottom, Center, or Rear] PRINTHEAD IS UP! - Do you wish to
disable it? NO/YES..............................................................................................6-18
DRIVE ROLL IS UP! - Close drive roll to resume printing ...........................6-19
CUTTER FAULT! - Cutter motor stall or stacker is full.................................6-19
DRAM Error.........................................................................................................6-21
Troubleshooting Procedures ..................................................................................6-22
Routine Cleaning.................................................................................................6-22
Loading Ribbon ...................................................................................................6-24
Loading Label/Tag Media..................................................................................6-26
Enabling/Disabling Printheads .........................................................................6-29
Replacing Printheads..........................................................................................6-30
Swapping Printhead Cables ..............................................................................6-32
Selecting a Printhead Intensity..........................................................................6-33
Adjusting Printhead Pressure ...........................................................................6-35
Adjusting Platen Rollers.....................................................................................6-37
Adjusting Ribbon Tension .................................................................................6-38
Adjusting the print speed ..................................................................................6-39
Replacing Platen Rollers.....................................................................................6-40
Setting Color Registration/Alignment..............................................................6-42
Adjusting Printhead Angularity .......................................................................6-43
Replacing the Drive Roller.................................................................................6-44
Positioning the TOF (Gap) Sensor ....................................................................6-46
Calibrating the Printer........................................................................................6-47
Adjusting the System Baseline ..........................................................................6-49
Cleaning the TOF (Gap) Sensor.........................................................................6-51
Adjusting Communication Settings .................................................................6-52
Changing the Fuse / Fuse Voltage ....................................................................6-54

QLS-3000/2000 Xe Series v
Appendix A: Physical Data................................................................... A-1
Appendix B: Specifications.................................................................. B-1
Appendix C: Replacement Parts.......................................................... C-1
Appendix D: Custom QuickLabel Setup ............................................. D-1
Appendix E: Windows Printer Driver Setup....................................... E-1
Appendix F: Format Error Codes..........................................................F-1

vi QLS-3000/2000 Xe Series

QLS-2000/3000 Xe Series 1-1
Chapter 1:
Before You Get Started
The QLS-2000/3000 Xe Series thermal transfer printers print in vibrant spot
color. In addition, the QLS-3000 Xe model prints full process color.
QLS-2000 Xe...........................Prints two spot colors on top of the media.
QLS-2001 Xe...........................Prints one spot color on each side of the media
simultaneously.
QLS-3000 Xe...........................Prints three spot colors or full process color on
top of the media.
QLS-3001 Xe...........................Prints two spot colors on top of the media and
one spot color on the bottom simultaneously.

1-2 Before You Get Started
QuickLabel Systems Media
Your QLS-2000/3000 Xe Series printer will provide correct print quality only
when used with Genuine QuickLabel Systems Labels, Tags and Thermal
Transfer Ribbon. QuickLabel Systems Thermal Transfer Ribbon is designed
to function as an integral part of the QLS-2000/3000 Xe Series printing system
and is formulated to provide the most vibrant and durable image while
helping to maintain long printhead life.
QuickLabel Systems offers a unique media purchase program called a Media
Requirements Contract (MRC). With an MRC, your media costs will be
tailored to annual usage, not individually-purchased quantity. The benefit to
you is fixed low pricing for the products you plan to purchase anyway. The
benefit to us is the ability to plan our production more efficiently. You will
also receive free printhead replacement for the duration of the contract.
Some benefits of an MRC include:
Flexible Ordering - Order what you need, when you need it. An MRC never
locks you into purchasing media you don’t want. There is no minimum
spending requirement, no frequency requirement, no advance payment, and
you may add new items at any time.
Freeze Your Costs - Your one-year commitment to purchase your ribbons
and labels commits us to sell you media only at the contracted price. And,
with an MRC your costs will remain fixed, so you can safely budget expenses
as far as a year in advance.
Free Printhead Replacement - As an added incentive, QuickLabel Systems
guarantees you free and unlimited replacement of all printheads worn by
normal use during the life of your contract. You can be confident that your
printhead wear will be “normal” because you will be using only the ribbons
and labels for which your printer was designed.
Fast Delivery - Your MRC is designed to let you place your label and ribbon
orders as you need them, anywhere from a week to a year in advance of
shipping. You decide the products you need and leave the rest to us. Your
ribbon and labels will arrive on schedule so you never experience production
downtime.
Contact your QuickLabel Systems Media Sales Specialist for more
information or to enroll in the MRC program.

QLS-2000/3000 Xe Series 1-3
Quick Start Guide
If you are an experienced user of a QuickLabel Systems Digital Color Label
Printer or you have attended QuickLabel Systems College training, use this
Quick Start Guide as a reference to begin producing beautiful color labels
immediately.
In general, these operations should be performed in the sequence listed
below, skipping over any items that may have been previously completed.
Page 2-2 Unpack the printer
Page 2-6 Connect the AC power cord
Page 2-7 Connect the host computer interface
Page 2-14 Load thermal transfer ribbon
Page 2-16 Load label or tag media
Page 2-19 Specify a media type
Page 2-20 Calibrate the printer to the appropriate media type
Setup software parameters
Appendix D Printing from Custom QuickLabel
Appendix E Printing from a Windows application with the QuickLabel
Systems Windows Printer Driver

1-4 Before You Get Started

QLS-3000/2000 Xe Series 2-1
Chapter 2:
Printer Setup
This chapter will help you to familiarize yourself with the orientation and
components of the printer. This chapter also covers the various connections
that need to be made to the printer before it can be operated.
This chapter provides the following information:
•Instructions on unpacking and orienting the printer
•An overview of the features and components of the printer
•Instructions for connecting power and communication cables to the
printer
•Instructions for loading thermal transfer ribbon
•Instructions for loading label or tag stock
•Instructions for calibrating the printer for the installed media

2-2 Printer Setup
Unpacking the Printer
1Remove the printer from the packing carton.
2Ensure that the printer has suffered no visible signs of damage during
shipment.
3Verify that the following items have been included in the packing carton:
AC Power Cord
Centronics Parallel Cable
(IEEE-1284)
Media Retainer
Windows Printer Driver Diskette
Warranty Registration Card
Operation & Setup Guide
Memory Card
Note: Retain all packaging should the printer need to be transported at a
later time.

QLS-3000/2000 Xe Series 2-3
Assembly
Printers
Printers are shipped partially disassembled to prevent damage during
shipment. Locate the printer cover and five #6 screws shipped with the
equipment.
Attach the cover to the printer.
Cutter, Cutter-Stacker, or External Rewinder
Peripherals are documented separately. Refer to the documentation for the
appropriate option. The connection from the cutter or cutter-stacker to the
printer will be through the printer’s utility I/O port.

2-4 Printer Setup
QLS-3000/2000 Xe Series Features
Front View
All models contain mechanisms similar to those shown on the QLS-3000 Xe
model illustrated.
1
2
3
4
5
6
7
8 9 10 11 12 13 14 15
1. Thermal transfer ribbon
rewind mandrel (front
station)
9. Guide roller
2. Thermal transfer ribbon
tension switch
10. Print station cam lever
(open position)
3. Thermal transfer ribbon
unwind mandrel (front
print station)
11. Printhead
4. Silver clip holding the cam 12. Media index roller
5. Drive roller pressure cam
lever (closed position)
13. Media sensor (reflective/
gap-notch sensor inside)
6. Drive roller pressure
support assembly
14. Media guide roller

QLS-3000/2000 Xe Series 2-5
7. Drive roller 15. Media unwind mandrel
8. Platen roller
Side Panel View
Interface and power connections are located on the right side panel.
Utility Port
Serial Port
Parallel Port
Memory Card Slot
On / Off Switch
AC Power Input
115V

2-6 Printer Setup
Power Connection
1Locate the AC Power Input at the bottom of the right-side panel.
2Plug the power cord into the printer. Be sure to use only the AC Power
Cord supplied with the printer. Ensure that the power switch is in the
OFF position before proceeding to the next step.
3Connect the opposite end of the AC Power Cord into an earth grounded
AC receptacle. Do not power the printer on until you have finished
making the remaining connections described in this chapter.
Warning: Do not use any type of receptacle adapter or AC Power Cord that
has not been supplied with the unit. Doing so can result in damage to the
printer.
Note: The printer has been set at the factory for the correct line voltage for
your country. The voltage setting can be viewed in a window at the top of
the AC Power Input. If this setting needs to be changed, refer to the
procedure in Chapter 6 of this manual.
Note: It is recommended that an AC line conditioner / surge suppressor is
used. Select a unit that is capable of handling the power requirements of the
printer and protecting from surges and spikes. A VA rating of at least 350
VA is required.