Datamax I-Class User manual

I
Maintenance Manual

Copyright Information:
CG Triumvirate is a trademark of Agfa Corporation.
CG Times based upon Times New Roman under license from the Monotype Corporation.
Firmware (Software) Agreement:
The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and is licensed for use
only on a single printer in the user’s Trade or Business. The User agrees not to, and not to authorize or permit
any other person or party to duplicate, or copy the Firmware or the information contained in the non-
volatile or programmable memory. The firmware (Software) is protected by applicable copyright laws and Licensor
retains all rights not expressly granted. In no event will Licensor or its suppliers be liable for any damages or loss,
including direct, incidental, economic, special, or consequential damages, arising out of the use or inability to use the
Firmware (Software).
WARNING
Lithium Battery: There is a danger of explosion or fire if the battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer. Discard used
batteries according to the manufacturer’s instructions.
Information in this document is subject to change without notice and does not represent a commitment on the part of
Datamax-O’Neil. No part of this manual may be reproduced or transmitted in any form or by any means, for any
purpose other than the purchaser's personal use, without the expressed written permission of Datamax-O’Neil.
All rights reserved.
Part Number 88-2321-01 Rev. J
COPYRIGHT © 2010, DATAMAX-O’NEIL

i
Contents
1 Overview
2 Adjustments and Maintenance
3 Troubleshooting
4 Removal and Replacement

ii

i
1
Overview
1.0 Introduction........................................................................................ 1
1.1 About the Printer ................................................................................. 2

ii

Overview
1-1
1.0 Introduction
This manual, which primarily includes technical information relating to the electrical and mechanical
components, is intended for use by qualified service personnel in the maintenance and repair of I-
Class printers. For related information, refer to the following documents, available at
http://www.datamax-oneil.com/
• For operating information, reference the Operator’s Manual (part number 88-2241-01).
• For software information, reference the Class Series 2 Programmer’s Manual (part number 88-
2341-01).
Important Information:
The exclamation point inside an equilateral triangle is intended to alert the technician
to the presence of important operating, maintenance or servicing information. Always,
as with all electrical equipment, follow basic safety precautions to avoid personal injury
or printer damage.

Overview
1-2
1.1 About the Printer
The following drawing highlights the user-assessable components of the printer.
Access Cover
Printhead
Media Sensor
Ribbon Supply Hub
Ribbon Take-Up Hub
Front Panel
Printhead Assembly
Fill Block
Media Hub
Internal Rewinder
Printhead Latch
Leveling Cam
Media Idler
Ribbon Idler
Media Guide
Platen

i
2Adjustments and Maintenance
2.0 Introduction........................................................................................ 1
2.1 Media Sensor Calibration ...................................................................... 1
2.1.1 Quick Calibration ........................................................................ 1
2.1.2 Standard Calibration ................................................................... 2
2.1.3 Advanced Entry Calibration .......................................................... 4
2.2 Printhead Adjustments ......................................................................... 8
2.2.1 Leveling Cam Adjustment ............................................................8
2.2.2 Pressure Adjustment ................................................................... 9
2.2.3 Burn Line Adjustment................................................................ 10
2.2.4 Voltage Adjustment................................................................... 11
2.3 Ribbon Path Alignment ....................................................................... 12
2.4 Maintenance ..................................................................................... 15
2.4.1 Cleaning the Printhead .............................................................. 16
2.4.1.1 Cotton Swab Procedure................................................ 16
2.4.1.2 Cleaning Card Procedure .............................................. 17
2.4.1.3 Cleaning Film Procedure............................................... 18
2.4.2 Cleaning the Platen................................................................... 18
2.4.3 Cleaning the Media Path, Media Sensor, and Interior...................... 19
2.4.4 Cleaning the Ribbon Path........................................................... 20
2.4.5 Cleaning the Exterior Surfaces.................................................... 21

ii
2.5 Application Version Updates ................................................................ 21
2.5.1 Updating from READY................................................................ 22
2.5.2 Updating from Download Mode ................................................... 23
2.5.3 Resolving Update Issues ............................................................ 24
2.6 Boot Loader Program Updates ............................................................. 25
2.7 Resetting the Printer .......................................................................... 26
2.7.1 Soft Reset................................................................................ 26
2.7.2 Level One Reset ....................................................................... 26
2.7.3 Level Two Reset ....................................................................... 26

Adjustments and Maintenance
2-1
2.0 Introduction
This section covers the necessary maintenance and alignment procedures for the printer.
2.1 Media Sensor Calibration
This printer can use many different media compositions, configurations and colors. In addition to
adjusting the Media Sensor and selecting the SENSOR TYPE, calibration is required. There are three
different calibration methods.
2.1.1 Quick Calibration
 Note: This procedure is not required for continuous media unless UNCALIBRATED is displayed;
see Section 2.1.2.
This calibration method is effective for most media types. Perform Quick Calibration as follows:
1. Ensure that media is loaded, that the Media Sensor is adjusted and that the printer is idle.
2. Press and hold the Key. The printer will advance media; allow at least one label gap or
mark to pass through the sensor.
Upon successful completion, CALIBRATION COMPLETE will be displayed, the printer will feed to the
next label TOF and READY will be displayed. (WARNING LOW BACKING may appear if using notched
media or media on a transparent liner; however, the calibration was successful).
 Note: Die-cut media containing large gaps may require a change in the PAPER OUT DISTANCE
setting; see the Operators Manual for details.
Calibration Hints
In certain cases, the printer may have trouble differentiating between the label and liner.
If CANNOT CALIBRATE is displayed, or if the printer stops feeding mid-label then try the following:
• Press and hold the Key to allow two gaps (or marks) to pass through under the sensor.
If CANNOT CALIBRATE is displayed again, or if the printer stops feeding mid-label, retry the
procedure -- this time allowing three or more gaps (or marks) to pass through the sensor;
otherwise, if this fails, see Section 2.1.2.

Adjustments and Maintenance
2-2
2.1.2 Standard Calibration
During calibration, the printhead assembly can be raised for visual access, which can be helpful when
using small, position-critical TOF notches or marks. Three sample readings are required:
• Empty: No media in the sensor.
• Gap (or Mark): Only the backing (liner), notch, or reflective mark in the sensor.
• Paper: The label (with liner) in the sensor.
Make sure that the appropriate SENSOR TYPE has been selected, and then perform a Standard
Calibration following the steps below:
Step Action Displayed Message Comment
1Turn ON the printer. UNCALIBRATED Wait briefly, about six
seconds, for the printer to
initialize.
2Press the Key, and then
raise the printhead assembly.
MENU MODE
MEDIA SETTINGS You are in MENU MODE.
3
Press the Key.
MEDIA SETTINGS
MEDIA TYPE You are in MEDIA
SETTINGS.
4Press the Key then
scroll to SENSOR
CALIBRATION and press the
Key.
MEDIA SETTINGS
SENSOR CALIBRATION Press the Key to
cancel this procedure.
5Press the Key. SENSOR CALIBRATION
PERFORM CALIBRATION You are beginning the
procedure.
6After making sure no media is
in the sensor, press the
Key.
REMOVE LABEL STOCK
PRESS ESC KEY <yyy>
No media should be in the
sensor. This sets the Empty
value, where “yyy” is the
current sensor reading.
(continued)

Adjustments and Maintenance
2-3
Step Action Displayed Message Comment
7
Proceed according to the
media type:
• Die-cut – peel media from
the backing and place the
backing under the Sensor
Eye Mark then press the
key.
• Notched – place the notch
under the Sensor Eye Mark
then press the key.
• Reflective – place the black
mark facedown under the
Sensor Eye Mark then press
the key.
• Continuous – go to Step 8.
SCAN BACKING
PRESS ESC KEY <yyy>
Or, for reflective media:
SCAN MARK
PRESS ESC KEY <yyy>
Never position a perforation
in the sensor when
recording a reading.
This sets the backing, gap,
or mark value where “yyy”
is the current sensor
reading.
8
Position the label (and
backing, if any) under the
sensor then press the
key.
SCAN PAPER
PRESS ESC KEY <yyy>
If using preprinted media
ensure that the sampled
label area is free of
preprinted text, graphics or
borders.
This sets the paper value,
where “yyy” is the current
sensor reading.
9Observe the LCD.
GAP MODE
CALIBRATION COMPLETE
Or, for reflective media:
REFLECTIVE MODE
CALIBRATION COMPLETE
Or, for continuous media:
CONTINUOUS MODE
CALIBRATION COMPLETE
The calibration was
successful if CALIBRATION
COMPLETE appears.
Also, WARNING LOW
BACKING is a normal
message when calibrating
notched media or media on
a transparent backing; see
Section 3.3 for other
possible messages.
10
Press the Key three
times to exit the menu.
Load media. Position the Media
Sensor. Press and hold the
Key until at least
one label advances.
READY
The printer is ready.
If this calibration was
unsuccessful, go to Section
2.1.3.

Adjustments and Maintenance
2-4
2.1.3 Advanced Entry Calibration
Advanced Entry is the alternate calibration method for special-case media types. In the procedure,
sensor readings for the label and TOF values are taken using different sampling algorithms. From this
compiled list of values the best algorithm is selected and then used to generate new readings for
manual entry into memory.
 Note: Use this method only when Standard Calibration was unsuccessful.
With the SENSOR TYPE enabled, perform an Advanced Entry Calibration by following the steps below:
Step Action Displayed Message Comment
1Turn ON the printer. UNCALIBRATED Wait briefly, about six
seconds, for the printer to
initialize.
2Press the Key, and then
raise the printhead assembly.
MENU MODE
MEDIA SETTINGS You are in MENU MODE.
3
Press the Key.
MEDIA SETTINGS
MEDIA TYPE You are in MEDIA
SETTINGS.
4Press the Key then
scroll to SENSOR
CALIBRATION.
MEDIA SETTINGS
SENSOR CALIBRATION Press the Key to
cancel this procedure.
5Press the Key, and
then the Key. SENSOR CALIBRATION
ADVANCED ENTRY Press the Key to
cancel this procedure.
6Press the Key, and
then the Key. ADVANCED ENTRY
SENSOR GAIN You are beginning the
procedure.
7
Press the Key.
Place the label under the
Sensor Eye Mark, and then
lower the printhead assembly.
GAIN TRAN <yyy>
*00 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*00 <0 - 31>
If using preprinted media,
ensure the label area under
the Sensor Eye Mark is free
of text, graphics, or
borders.
Never position a perforation
in the sensor when
recording a reading.
(continued)

Adjustments and Maintenance
2-5
Step Action Displayed Message Comment
8
Use the Key to scroll to
the 00 GAIN setting and then
press the Key.
Record the sensor reading as a
Label Value in a table similar
to the one shown below.
GAIN TRAN <yyy>
*00 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*00 <0 - 31>
Selection is denoted by an
asterisk (*).
The sensor reading equals
the “yyy” value.
Sampling Table
Gain
Number Label Value TOF Value Difference Value
00 255
01
02
…
31
Step Action Displayed Message Comment
9
Press the Key to
increment the Gain Number
then press the Key and
record the resulting Label
Value.
Repeat this step for each of the
remaining Gain Numbers (01-
31).
GAIN TRAN <yyy>
*31 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*31 <0 - 31>
10
Proceed according to your
media type:
• Die-cut – peel media from
the backing and place the
backing under the Sensor
Eye Mark.
• Notched – place the notch
under the Sensor Eye Mark.
• Reflective – place the black
mark facedown under the
Sensor Eye Mark.
Use the Key to scroll to
the 00 GAIN setting and then
press the Key. Record
the sensor reading as a TOF
Value.
GAIN TRAN <yyy>
*00 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*00 <0 - 31>
Never position a
perforation in the sensor
when recording a reading.
(continued)

Adjustments and Maintenance
2-6
Sampling Table
Gain
Number Label Value TOF Value Difference Value
00 255 254
01 251
02 241
……
31 112
Step Action Displayed Message Comment
11
Press the Key to
increment the Gain Number
then press the Key and
record the resulting TOF Value.
Repeat this step for each of the
remaining Gain Numbers (01-
31).
GAIN TRAN <yyy>
*31 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*31 <0 - 31>
12
From the collected data, where
both the values are above 20,
subtract the Label Value from
the corresponding TOF Value to
find the Difference Value.
Note the Gain Number of the
largest Difference Value.
GAIN TRAN <yyy>
*31 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*31 <0 - 31>
For example in the table
below, Gain Number 08 is
chosen because it has the
highest Difference Value
(146) where both the Label
and the TOF Values are
above 20.
Sampling Table
Gain
Number Label Value TOF Value Difference Value
00 255 254 1
01 251 240 11
02 241 213 28
03 231 182 49
04 219 150 69
05 212 119 93
06 200 88 112
07 189 58 131
08 178 32 146
09 167 19 N/A
10 156 17 N/A
…………
31 116 14 N/A
(continued)

Adjustments and Maintenance
2-7
Step Action Displayed Message Comment
13 Using the Key, scroll to
the Gain Number determined in
Step 12, and then press the
Key.
GAIN TRAN <yyy>
*08 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*08 <0 - 31>
14
a) Place the media in the
sensor. Record the reading
and label it “P” (paper).
b) Place the backing, notch, or
mark in the sensor. Record
the reading and label it “G”
or “M” (Gap or Mark).
c) Remove media. Record the
reading and label it “E”
(Empty).
GAIN TRAN <yyy>
*08 <0 - 31>
Or, for reflective media:
GAIN REFL <yyy>
*08 <0 - 31>
The samplings using the
selected Gain Number are
taken.
15 Press the Key, and
then press the Key. ADVANCED ENTRY
SENSOR LEVELS The sensor readings must
be entered into the printer.
16
Press the Key.
Using the Key or the
Key, set the Paper
Sensor Level to the value
determined in the previous
step. Then press the
Key to select the entry and
advance the menu.
Repeat for the Gap Sensor
Level (or Mark Sensor Level)
and the Empty Sensor Level
entries.
PAPER SENSOR LEVEL
P*198 G*084 E*014

GAP SENSOR LEVEL
P*198 G*084 E*014

EMPTY SENSOR LEVEL
P*198 G*084 E*014
Or, for reflective media:
PAPER SENSOR LEVEL
P*015 M*181 E*213

MARK SENSOR LEVEL
P*015 M*181 E*213

EMPTY SENSOR LEVEL
P*015 M*181 E*213
Selection is denoted by an
asterisk (*).
The displayed message will
change and the selection
will flash to indicate the
next entry.
(continued)

Adjustments and Maintenance
2-8
Step Action Displayed Message Comment
17
After all entries have been
made, press the Key
to back out of the menu and
then press the Key to
save the settings when
prompted.
Load media. Position the Media
Sensor.
SAVE CHANGES?
ENTER KEY = YES
Press and hold the
Key until at least
one label advances.
 Note: If the Advanced Entry Calibration is unsuccessful, enter MEDIA SETTINGS / CALIBRATION
/ ADVANCED ENTRY / SENSOR GAIN and lower the selected Gain Number by one. Select
the new Gain Number then save the changes and exit the menu. Retest your media. If
unsuccessful, repeat the procedure until a usable gain is obtained.
2.2 Printhead Adjustments
To ensure even and consistent print quality across a wide range of media types and sizes, the
printhead is adjustable.
2.2.1 Leveling Cam Adjustment
The Leveling Cam ensures that even pressure is maintained across the label. Whenever using media
that is less than the full width of the platen, proceed as follows:
1. Load the printer with media. Download a label format or choose a Quick Test Label and begin
printing.
2. While observing the right side of the label, rotate the Leveling Cam clockwise, or counter-
clockwise, until even print is achieved across the width of the label (see examples below).

Adjustments and Maintenance
2-9
Example 1 –
Over-adjustment
produces an image
that fades across the
label, requiring a
decrease in the setting
of the Leveling Cam.

Example 2 –
Correct adjustment
produces a complete
image, with even
print contrast across
the label.
 Note: Under-adjustment can cause ribbon wrinkling, tracking problems, and excessive wear on
printer components.
2.2.2 Pressure Adjustment
To maintain print quality across the variety of media types, the printhead pressure is adjustable. This
adjustment should only be performed, however, after attempting improvement using the HEAT and/or
PRINT SPEED settings. Use only the minimum pressure needed, following the steps below:
1. Load 4 inch (102mm) wide media (and ribbon, if needed). Then, disengage the Leveling Cam and
latch the Printhead Assembly.
2. Enter the Quick Test Mode then select 100 Print Quality Labels and press the Key to
begin printing.
3. Turn each Pressure Adjustment Cam equally (counterclockwise to increase pressure or clockwise
to decrease it) until even print quality is achieved across the label.
Pressure
Adjustment Cams
Indicator
Minimum
Maximum
 Note: Excessive pressure can cause ribbon wrinkling, tracking problems, and excessive wear on
printer components.

Adjustments and Maintenance
2-10
2.2.3 Burn Line Adjustment
 Note: This adjustment is NOT REQUIRED during a normal printhead replacement.
The Burn Line, a row of thermal elements that creates the image, is adjusted to compliance using 6.5-
mil (.0065 inch) media to maintain print quality across a majority of types. In extreme cases,
however, when media with a different thickness or rigidity is used (e.g., heavy tag stock) this
relationship can change. If the print quality cannot be improved using HEAT and/or PRINT SPEED
changes, then a Burn Line may be required as follows:
1. Load media (and ribbon, if needed). Disengage the Leveling Cam and latch the Printhead
Assembly.
2. Enter the Quick Test Mode then select 100 Print Quality Labels.
3. Loosen the two Locking Screws ½ to ¾ of a turn.
4. Turn the Adjustment Screws counter-clockwise until the Burn Line is past the platen vertex. Print
a Validation Label from the Quick Test Menu. The label should look light and uneven.
5. Tighten the Locking Screws just until they are “snug”– tight enough to remove any play in the
printhead assembly, yet loose enough to allow the Adjustment Screws to move the printhead.
6. Turn each Adjustment Screws clockwise about ¼ a turn (or 1/8 a turn for finer adjustments). Print
another Validation Label and examine the print quality. Repeat this step until labels with even
print contrast (darkness) and acceptable print quality are produced.
 Note: Use care. When the Locking Screws are snug, turning the Adjustment Screws
counter-clockwise will not move the printhead outward. If the printhead has been
adjusted inward too far, the entire procedure must be restarted.
7. Tighten the Locking Screws then print a final test label to verify the adjustment.