Dover markem-imaje SmartDate 5 User manual

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06/08 SmartDate 5
TABLE OF CONTENTS
1 General Information 1-1
1.1 Uptime™ Total Services 1-2
2 Setup and Timing Issues 2-1
2.1 Introduction 2-1
2.2 Setup Issues 2-2
2.2.1 Air Pressure Settings 2-2
2.2.2 Print Anvil 2-2
2.2.3 Printhead Gap 2-3
2.2.4 Ribbons 2-3
2.3 Important Printer Settings 2-4
2.4 Print Darkness 2-4
2.4.1 Print Speed 2-5
2.5 Print Signal Issues 2-6
2.5.1 Debounce Time 2-6
2.5.2 Debounce Distance 2-6
2.5.3 Print Delay 2-6
2.6 Print Quality Issues 2-7
2.6.1 Head Out Time 2-7
2.6.2 Start Border 2-8
2.6.3 End Border 2-8
2.6.4 Head In Time 2-8
2.6.5 Ribbon Advance Distance 2-8
2.7 Moving the Printed Image 2-9
2.7.1 Registration 2-9
2.7.2 Offset 2-9
2.8 Timing issues 2-10
2.8.1 Print Timings 2-11
2.8.2 SmartDate 5 - Intermittent Mode 2-13
2.8.3 Printing Time - Intermittent Printers 2-14
2.8.4 Print Cycle Time - Intermittent Printers 2-14
2.8.5 SmartDate 5 - Continuous Mode and SmartDate 5s 2-15
2.8.6 Printing Time - Continuous Printers 2-15
2.8.7 Print Cycle Time - Continuous Printers 2-15
2.8.8 Speed Profile Recorder 2-16
2.9 Distance between prints on the ribbon 2-21
2.10 Distance between prints on the substrate 2-21
2.10.1 Minimum Distance between prints in DRS mode 2-22

SmartDate 5 06/08
TABLE OF CONTENTS
3 Maintenance 3-1
3.1 Introduction 3-1
3.2 Cleaning and Care 3-2
3.3 Maintenance Scheme 3-3
3.3.1 Quick/Regular Checks 3-3
3.3.2 Monthly Checks 3-4
3.4 Care of the Printhead 3-5
3.5 Cleaning the Printhead 3-6
3.6 Replacing the Printhead 3-7
3.6.1 Removing the damaged printhead 3-7
3.6.2 Setting the correct Printhead voltage 3-9
3.7 Replacing the Peel Roller 3-11
3.8 Replacing the Ribbon Guide Rollers 3-13
3.9 Replacing the Ribbon Movement Roller 3-14
3.9.1 Replacing the Roller Magnet 3-14
3.9.2 Replacing the Movement Roller 3-15
3.9.3 Replacing the Ribbon Movement Sensor 3-16
3.10 Replacing the Ribbon Tension Roller 3-17
3.11 Replacing the Ribbon Tension Sensor 3-18
3.12 Replacing the Micro Switches 3-19
3.13 Replacing the Solenoid Valves 3-20
3.14 Replacing the Drive Belts 3-21
3.14.1 Replacing the Drive Belt - Combined Printer 3-21
3.15 Replacing the Drive Belt - Shuttle Printer 3-23
3.16 Changing the Printer Hand - Combined Printer 3-27
3.17 Changing the Printer Hand - Shuttle Printer 3-30
3.18 Changing the Cassette Hand 3-33
3.19 Replacing the Printer PCBs 3-34
3.20 Replacing the Controller PCB 3-37

06/08 SmartDate 5
TABLE OF CONTENTS
4 Technical Information 4-1
4.1 Introduction 4-1
4.2 The SmartDate 5 Printers 4-2
4.3 Printer Components 4-3
4.3.1 Linear Slides 4-5
4.3.2 Intermittent Drive System - SmartDate 5 Printer 4-8
4.3.3 Continuous Drive System - SmartDate 5 Printer 4-9
4.3.4 Continuous Drive System - SmartDate 5s Shuttle Printer 4-10
4.3.5 Ribbon Drive System 4-12
4.4 Printhead Module 4-13
4.4.1 Print Module Components 4-14
4.4.2 Printhead Module Operation 4-15
4.5 Printhead Assembly 4-16
4.5.1 Printhead Type Detection 4-17
4.5.2 Printhead Temperature Control 4-17
4.5.3 Printhead Voltage Control 4-17
4.6 Printer Orientation 4-18
4.6.1 Orientation - SmartDate 5 Printer 4-20
4.6.2 Orientation - SmartDate 5s Shuttle Printer 4-23
4.7 Printer Calibration 4-25
4.7.1 Print Module / Shuttle Carriage Calibration 4-27
4.7.2 Ribbon Calibration 4-30
4.7.3 Printer Cassette 4-32
4.7.4 Cassette Components 4-33
4.7.5 Ribbon Calibration / Movement Roller 4-35
4.7.6 Ribbon Tension Roller 4-36

SmartDate 5 06/08
TABLE OF CONTENTS
4.8 Printer Electrical Components 4-37
4.8.1 Stepper Motors 4-38
4.8.2 Ribbon Movement Sensor 4-39
4.8.3 Ribbon Tension Sensor 4-40
4.8.4 Micro Switches 4-42
4.8.5 Solenoid Operated Cylinders 4-45
4.8.6 Encoder 4-46
4.8.7 Printer PCB 4-47
4.8.8 Printer PCB Components 4-48
4.8.9 Printer PCB Connectors 4-48
4.8.10 Printer PCB Test Points 4-50
4.8.11 Printer PCB Fuse 4-50
4.8.12 Printer PCB LEDs 4-51
4.9 The SmartDate 5 Controller 4-52
4.9.1 Controller Components 4-53
4.9.2 Mains Power Switch 4-54
4.9.3 Power Supply 4-55
4.9.4 Controller PCB 4-56
4.9.5 Controller PCB Micro-processor 4-56
4.9.6 Controller PCB Components 4-57
4.9.7 Controller PCB Connectors 4-58
4.9.8 Controller PCB Test Points 4-59
4.9.9 Controller PCB LEDs 4-60
4.9.10 Controller PCB Links 4-62
4.9.11 Controller PCB Fuses 4-62
4.9.12 SmartDate 5 Interfaces 4-63
4.9.13 Controller to Printer Interface 4-63
4.9.14 Controller PCB to User Interface 4-64
4.9.15 Auxiliary Serial Comms Interface 4-64
4.9.16 Ethernet Interface 4-64
4.9.17 External I/O Interface 4-65

06/08 SmartDate 5
TABLE OF CONTENTS
5 Troubleshooting 5-1
5.1 Introduction 5-1
5.2 Status LEDs 5-2
5.3 Fault and Warning Messages 5-2
5.3.1 Fault Messages 5-3
5.3.2 Warning Messages 5-14
5.4 Common Issues 5-21
5.4.1 No Power to the Printer 5-21
5.4.2 Printhead Cables 5-21
5.4.3 Encoder 5-21
5.5 No Information Is Printed 5-22
5.6 The Printhead Does Not Move Out 5-22
5.7 Drive System Issues 5-23
5.7.1 Ribbon is not driving 5-23
5.7.2 Ribbon Drive Problems 5-23
5.7.3 Ribbon Creasing 5-23
5.7.4 Ribbon Breaking or Scuffing Prints 5-24
5.7.5 Ribbon Coning (Continuous Printers) 5-24
5.7.6 Peel Roller Problems 5-24
5.7.7 Head not returning to home position 5-25
5.7.8 Shuttle not driving 5-25
5.7.9 Drive Belt Issues 5-25
5.8 Printhead Module / Shuttle Carriage Drive Problems 5-26
5.9 Cassette Problems 5-27
5.9.1 Cassette Release Problems 5-27
5.10 Cassette Insertion Problems 5-27
5.10.1 Cassette Rollers Alignment 5-27
5.11 Display Issues 5-28
5.11.1 Back light only lit 5-28
5.11.2 LCD only, no Back light 5-28
5.11.3 Display is totally blank 5-28

SmartDate 5 06/08
TABLE OF CONTENTS
5.12 Print Quality Problems 5-29
5.12.1 Poor Print Quality (when in DRS Mode) 5-30
5.12.2 Faded print 5-30
5.12.3 Faded on one side 5-31
5.12.4 Blurred edges 5-31
5.12.5 Missing lines perpendicular to printhead 5-31
5.12.6 Text missing at start of print 5-32
5.12.7 Text missing at end of print 5-32
5.12.8 Print rubs off 5-32
5.12.9 First Dots Missing or Ragged 5-33
5.12.10 Last Dots Missing or Ragged 5-33
5.12.11 Elongated or compressed print 5-33
5.12.12 Double printing 5-34
5.12.13 Prints occur on every other product (or less) 5-34
5.12.14 Overlapping prints 5-34
5.12.15 Cropped Prints 5-34
5.13 Job Selection Problems 5-35
5.13.1 Selecting a Job 5-35
5.13.2 Host PC 5-35
5.13.3 Image corruption problems 5-35
5.14 Checking Database Information 5-36
5.14.1 Local 5-36
5.14.2 Host 5-36
5.14.3 Database mode 5-36
5.15 Communication Problems 5-37
5.15.1 Communications Do Not Work 5-37
5.15.2 Selecting RS-232/RS-485 operation 5-38
5.15.3 RS-485 Node Numbers and Network ID 5-38
5.15.4 RS-232 (NGPCL) Communication 5-38
5.15.5 Networking Issues 5-39
5.15.6 Communication ports 5-39
5.15.7 Communications connection 5-39
5.15.8 Broken wires or shorts 5-39
5.16 Disaster Recovery 5-40
5.16.1 Recovery Using CoLOS Create Pro 5-41
5.16.2 Recovery Using CoLOS Control 5-42
5.16.3 Recovery Using SmartTouch 5-43
5.16.4 Recovery using the PC Tools Application 5-43
5.16.5 Recovery using Compact Flash 5-43
6 Recommended Spares 6-1
6.1 Consumables 6-1
6.2 Replacement Parts 6-1
6.3 Spares Kits 6-2

SmartDate 5
Maintenance Manual
SECTION 1
GENERAL INFORMATION

SECTION 1 - GENERAL INFORMATION
1-1
SmartDate 5 08/08
1 General Information
This manual is designed to assist with keeping your SmartDate 5 in good working
order.
Topics covered in the following sections include:
• General maintenance and cleaning.
• Technical information about the SmartDate 5.
• Fault finding and troubleshooting problems.
• Replacement parts and recommended spares.
Additional information regarding mechanical drawings or electrical schematics
can be found on the CD in the relevant folders.

SECTION 1 - GENERAL INFORMATION
1-2 SmartDate 5 08/08
1.1 Uptime™ Total Services
• Application Specialists
• Installation
•myMARKEM
• Repair Centre
• Training
As part of the Markem.Imaje continuous commitment to helping customers
succeed, Markem.Imaje has introduced the Uptime Total Solutions Program, a
comprehensive array of services to maximize uptime, productivity and customer
satisfaction. These value-added services focus in the following critical areas:
Maximizing the reliability of your coding systems. The Markem.Imaje
Reliability Program supports our customers with resources committed to the
"science of reliability." Our Reliability Engineering team works integrally with the
product development process to deliver best-in-class performance for all
Markem.Imaje products. For real life simulation, the program also incorporates
laboratory application testing as well as ongoing customer field reliability
monitoring and testing. Markem.Imaje customers can register at
myMARKEM.com and view real-time reliability data, including MTB's on our most
popular machine products.
Ensuring a dependable supply chain. Markem.Imaje utilizes a fully Integrated
Logistic Management System supported by strategic partnerships with other
world-class companies like UPS Worldwide Logistics. Our regional repair centres
offer a cost-effective solution for modular exchange or repairs of Markem.Imaje
machines to keep your line running. Combining these capabilities with a strong
local presence around the globe and consistent product availability and delivery
performance all help keep you up and running.
Strengthening your relationship with us. Markem.Imaje representatives are
the industry-leading experts in marking and coding solutions. We work with the
vast majority of packaging equipment manufacturers (OEMs) to provide a
seamless integration and deliver you the right solution. Comprehensive support
programs include print samples on your actual packaging materials, on-line trials
or extended long-term trials to reinforce the high level of quality and reliability that
Markem.Imaje can bring to your application.
The program includes, but is not limited to, the following services: sample printing,
training, technical support, logistics support, financing, on-line support, contracts,
and project management. At the core of Uptime is our corporate reliability
program, unrivalled in our industry and the reason products such as the
SmartDate 5, SmartDate® and 5000 Series case coders are the undisputed
industry leaders.

SmartDate 5
Maintenance Manual
SECTION 2
SETUP AND TIMING ISSUES

SECTION 2 - SETUP AND TIMING ISSUES
2-1
SmartDate 5 08/08
2 Setup and Timing Issues
2.1 Introduction
The following section provides general advice for ensuring that your SmartDate 5
is working at its most efficient.
Topics covered in this section include:
• Air pressure
• Printhead Gap
• Print Anvils
• Ribbons
• Printer Settings
• Print Signals
• Print Quality Issues
• Moving the printed image
• Timing Issues
• Speed Profiles
•DRSissues

SECTION 2 - SETUP AND TIMING ISSUES
2-2 SmartDate 5 08/08
2.2 Setup Issues
2.2.1 Air Pressure Settings
Make sure that the air is connected on the side of the printer body.
The setting of the air pressure is critical to the performance of the printhead.
• Check that the air pressure regulator is set to the required pressure (typically
between 3.0 to 4.5 bar.
• The regulator setting required depends upon the printhead gap; the distance
between the printhead, in it’s home position, and the print platen, or print
roller.
• Too little pressure will result in poor quality or no print.
• Too much pressure may result in increased physical wear on the printhead
and platen. The substrate is marked where the printhead has dug in.
• Exceeding the stated pressure will over stress the printhead.
• Togettheoptimumairpressurefortheapplication,itisrecommendedthatthe
printhead to substrate gap is set between 1.0 and 2.0 mm. See below for
exact details.
• The air pressure should then be set to 3 bar and gradually increased until a
good quality print is apparent.
• The operation of the solenoid may be tested by using the Manual functions or
toggling the output on the I/O screen.
2.2.2 Print Anvil
The print roller and print platen are wear parts, and should be checked regularly
for damage.
If the print roller has become damaged this will cause print quality problems. For
example a flat spot on the roller rubber will appear as a repeated blank area on
the Test pattern. A worn area on the print platen rubber may cause the print to be
faded on one side.

SECTION 2 - SETUP AND TIMING ISSUES
2-3
SmartDate 5 08/08
2.2.3 Printhead Gap
This is the distance between the printhead in its prime position and the contact
point on the substrate. This should be measured with the Cassette in its closed
position.
Do not use metal objects to test the gap distance, use only wood, plastic or other
non conductive materials.
Adjustment to the print gap can be made by adding or removing the shims
provided with the mounting bracket. The gap between the printhead and the print
platen or print roller is critical to the performance of the printer.
The following settings are recommended:
SmartDate 5 - 1.00 mm to 2.00 mm
SmartDate 5s - 1.00 mm to 2.00 mm
SmartDate 5s - 0.5 mm to 1 mm (High throughput applications)
In situations where it is necessary to increase the printhead gap above 3 mm
(zipper bags) the “Tension adjust” setting should be reduced. See Section 6 -
Menus - Ribbon Setup.
2.2.4 Ribbons
SmartDate 5 uses inside wound ribbon; If this is webbed incorrectly (wound the
wrong way around) no printing can occur. The correct substrate/paper to ribbon
match is also important for print quality.
Different conditions will require different types of ribbon.
Some examples follow:
Wax/Resin, Wax/High Resin and Resin
For full details on ribbon please contact you local Markem.Imaje representative or
visit the Markem.Imaje Web site.

SECTION 2 - SETUP AND TIMING ISSUES
2-4 SmartDate 5 08/08
2.3 Important Printer Settings
Various Printer Settings will affect the performance of the SmartDate 5
The initial setup of the machine would normally be performed by a qualified
Markem.Imaje Technician, but if not the following information should prove
helpful.
2.4 Print Darkness
The print darkness is adjusted by varying the amount of time heat is applied for
each row of dots printed and altering the amount of cooling time allowed between
rows.
Generally, increasing the Darkness% darkens the printing but can increase
smudging. Conversely, decreasing the Darkness% reduces smudging. Some
ribbon/substrate combinations may require a Darkness% other than the standard
100%.
SmartDate 5 automatically limits the amount of energy transferred to the
Printhead. This prevents the head being damaged by incorrect use of the
darkness value. If the print quality is not good refer to the Troubleshooting Section
for diagnosis.
Print darkness levels should be set in relation to the print speed.
• For example, if the print speed is high, the print darkness may have to be
raised to achieve good print quality.
• If the print speed is lowered the print darkness should be reduced accordingly.
• As a general rule darkness levels should be kept as low as the line speed and
print quality requirements will allow This will ensure that the print-head life will
be used to its optimum.
• Darkness levels that are too high may also contribute to poor print quality or
ribbon breakage (especially when printing bar-codes or horizontal lines.)
• The maximum darkness level for any print speed is 140%. SmartDate 5
automatically compensates for this if the print speed is raised or lowered.
• If a printhead dot has become damaged and no replacement is readily
available, raising the darkness level may be enough to spread the heat to
effectively close the gap. This would allow the printer to be used while a new
printhead arrived.
Note: The darkness level should be reduced when the new printhead is fitted.

SECTION 2 - SETUP AND TIMING ISSUES
2-5
SmartDate 5 08/08
2.4.1 Print Speed
The Speed that Printhead moves along the linear slide (SmartDate 5 Intermittent)
The speed the ribbon moves on the print part of the cycle. (SmartDate 5
Continuous and SmartDate 5s)
With Intermittent printers the speed is determined by the dwell time when the
substrate has stopped moving.
• If the print speed is set too low the substrate may start to move before printing
has finished.
• If the print speed is too fast the print quality may not be as good as it could be.
With Continuous printers the speed is automatic as an encoder is used to match
the speed of the substrate.
• The ribbon speed has to match the substrate speed before printing can occur.
If the substrate speed is too high or too low this will affect the print quality.
Note: If the Hi-Speed Operation is enabled, the maximum print speed can be
increased to 1000mm/s.

SECTION 2 - SETUP AND TIMING ISSUES
2-6 SmartDate 5 08/08
2.5 Print Signal Issues
2.5.1 Debounce Time
This is an Intermittent printer setting.
This is the time that the PRINT GO signal must be present before it is actioned.
This avoids double triggering of the print signal if the signal is particularly noisy
(e.g ringing on a relay contact)
If the signal used is arriving as a double pulse, set the Debounce time just high
enough to stop the printer double printing.
The print signal is sampled every 5 milliseconds, so if the Debounce Time is set to
10 milliseconds, the Print Signal must be at least 15 milliseconds.
2.5.2 Debounce Distance
This is a Continuous printer setting.
This is the distance that the substrate must travel after receiving a PRINT GO
signal. This is similar to the debounce time for Intermittent printers in that it
ensures that the print signal is valid and not double triggering.
Note: The Debounce Time and Debounce distance increase the overall cycle
time of the printer and should be kept as low as possible. On Continuous
printers, it is advisable, where possible, to set the debounce distance to
zero. Otherwise a time delay is introduced into the cycle which may
produce print drift.
2.5.3 Print Delay
This is an Intermittent printer setting.
With SmartDate 5 Intermittent printers, this sets a delay between a valid PRINT
GO signal and when the Printhead is moved out into position.
If the PRINT GO signal is received before the substrate is stationary, this allows
time for the substrate to settle before printing commences.
Set the print delay setting as low as possible as it increases the overall cycle time
of the printer.
Default - 0 ms