Hover-Davis PL1200 User manual

PL1200 Thermal Transfer
Printer Product Guide
PL1200 Thermal Transfer
Printer Product Guide
www.hoverdavis.com
www.hoverdavis.com
© 2002 Hover-Davis. All rights reserved.
Revision 1 6 Aug 02
No. PL1200D-E01

Hover-Davis, Inc. has checked the contents of this printed document to verify that it is in
agreement with the product described inside. However, discrepancies can and do occur.
Therefore Hover-Davis, Inc. cannot assume responsibility for complete agreement between
this printed document and the product described inside.
The information contained in this document was thoroughly reviewed before going to print,
and is subsequently reviewed and / or revised on a regular basis. Necessary corrections are
included in future editions.
We welcome any comments or suggestions for improvements.
All rights reserved. No part of this book may be reproduced in any form, by print,
Copyright © 2002 by Hover-Davis.
photoprint, microfilm, or any other means without written permission from Hover-Davis.
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Table of Contents
How to Use This Guide ........................................................................................ 3
Chapter 1: Safety ............................................................................................... 5
1.1 Symbol Index ........................................................................................................ 5
1.2 Safety Labeling and Location Information ............................................................... 5
1.3 Proper Usage ......................................................................................................... 6
1.4 Environmental Requirements .................................................................................. 6
Chapter 2: Introduction ....................................................................................... 7
2.1 PL1200 Features .................................................................................................... 7
2.2 PL1200 Hardware Description ................................................................................. 8
2.3 Docking Station ...................................................................................................... 8
2.4 The Labeler Unit .....................................................................................................9
2.5 Mounting and Removing the PL1200 Unit ................................................................. 9
2.6 Mandrels and Reels ................................................................................................ 12
2.7 Labeling Mechanics .................................................................................................13
2.8 Sensors ..................................................................................................................16
2.9 Switches .................................................................................................................20
Chapter 3: Installation ......................................................................................... 23
3.1 Installing the PL1200 Docking Station ...................................................................... 23
3.2 PL1200 Software .................................................................................................... 23
Chapter 4: Operations .......................................................................................... 25
4.1 Docking and Removing the PL1200 Labeling Unit ..................................................... 25
4.2 About Changing Media Reels ................................................................................... 26
4.3 Installing the Label Media Reels .............................................................................. 29
4.4 Removing the Label Media Reels ............................................................................ 31
4.5 Installing the Thermal Transfer Media Reels ............................................................ 31
4.6 Removing the Thermal Transfer Media Reels ........................................................... 33
4.7 About the Calibration Sequence .............................................................................. 33
4.8 About Label Positioning Logic ................................................................................. 34
4.9 About Labels and Printing ...................................................................................... 34
(continued on next page)

Table of Contents (continued)
Chapter 5: Maintenance ...................................................................................... 35
5.1 Rollers .................................................................................................................. 35
5.2 PL1200 Labeling Unit ............................................................................................. 35
Chapter 6: Troubleshooting ................................................................................37
6.1 Print Smudging ..................................................................................................... 37
6.2 Inconsistent Print Length ....................................................................................... 37
6.3 Labels Won’t Calibrate ........................................................................................... 38
6.4 Testing Stock Reel Low Sensors ............................................................................. 40
6.5 Communication Problems ...................................................................................... 40
6.6 No Power to the PL1200 when Docked ................................................................... 40
Chapter 7: Schematics and Wiring ...................................................................... 41
Chapter 8: Spares, Parts and Decommissioning ................................................. 45
8.1 Recommended Spares Kit ...................................................................................... 45
8.2 Decommissioning .................................................................................................. 45
8.3 Product Specifications ........................................................................................... 45
Chapter 9: Technical Bulletins .......................................................................... 47

PL1200 Thermal Transfer Printer
How to Use This Guide
3
How to Use This Guide
This guide is designed to help you install, operate and maintain your PL1200 labeling system.
Each chapter begins with a brief overview followed by a complete discussion of each topic.
Chapter 1: Safety
This chapter provides information on the symbol index used in this manual, safety sticker
information, usage of the PL1200 labeling system and environmental requirements.
Chapter 2: Introduction
This chapter describes the PL1200 labeling unit product features and the hardware
component descriptions to help you become familiar with the PL1200 labeling system.
Chapter 3: Installation
This chapter covers the installation of the PL1200 docking station and labeling unit,
installation of the required software to run the PL1200 labeling system and how to connect
the PL1200 Labeling unit to your PC.
Chapter 4: Operation
This chapter covers removing and replacing the PL1200 labeling unit from the docking
station, changing the label and thermal transfer print media reels, as well as a discussion of
the print operation of the PL1200 labeling unit
Chapter 5: Maintenance
This chapter describes the maintenance required for dependable operation of the PL1200
labeling system.

4
Chapter 6: Trouble shooting
This chapter provides information for problem diagnosis and correction for the PL1200 labeling
unit.
Chapter 7: Schematics & Wiring
This chapter contains the schematic and wiring diagrams for the PL1200 labeling system.
Chapter 8: Spare Parts, Decommissioning, and Product Specifications
This chapter contains a parts list, information on decommissioning the PL1200 labeling unit, and
the product specifications for the PL1200 labeling system.
Chapter 9: Technical Bulletins
This chapter contains any technical information for the PL1200 labeling system that has been
issued by the factory after the release of this manual.
PL1200 Thermal Transfer Printer
How to Use This Guide

1
Safety

5
Chapter 1: Safety
This chapter provides information on the symbol index used in this manual, safety labeling
and location information for the PL1200 labeling unit, proper usage of the PL1200 labeling
system and environmental requirements for reliable operation of the PL1200 labeling unit.
1.1 Symbol Index
The symbols listed below are found within this manual.
PL1200 Thermal Transfer Printer
Safety
CAUTION
WARNING
CAUTION : SEE EXPLAINATION IN MANUAL.
WARNING : POSSIBLE PINCH POINTS KEEP HANDS CLEAR.
1.2
Safety Labeling and Location Information
Diagram 1.2a show the location of operational and safety-labeling information found on the
PL1200 labeling unit.

6
PL1200 Thermal Transfer Printer
Safety
1.3 Proper Usage
The PL1200 labeling system is expressly designed and intended to be used to print and present
labels for automated labeling applications.
It is intended to manipulate label dimensions that range in length from .250” to 1.500” and range
in width from .125” to .500”.
It is recommended that Identco brand labels be used with the PL1200 labeling unit. For
information on ordering Identco brand labels, please contact your local distributor or contact
Identco directly at 1-800-533-2559. For information on the use of other labels, please contract
Hover-Davis Inc.
Do not use this device for any other purpose than that for which it is intended. Usage of this
device for any other purpose than that which is stated in this manual may cause injury and/or
damage to the unit. To do so will void all warranties expressed or implied.
1.4 Environmental Requirements
Install the PL1200 labeling unit in an area where the ambient temperature remains within the
range of 10 to 35 degree C and the humidity does not exceed 75% RH (with no condensation).
Failure to comply with these conditions can cause trouble in the electrical system and/or lead to
machine malfunctions.
Do not install the PL1200 labeling unit in direct sunlight as this can increase the PL1200 labeling
units’ temperature and may effect the optical sensors in the labeling unit, causing adverse and
erratic labeling operations and accuracy.

2
Introduction

7
PL1200 Thermal Transfer Printer
Introduction
Chapter 2: Introduction
The PL1200 labeling system is a thermal transfer printer and label presenter in one and is
designed to print and present your label requirements on demand. Label text is downloaded
from the host computer, printed and then presented in a “zero que’ environment, thereby
eliminating the need for pre-printed labels and leaders.
With the PL1200’s compact size and light weight design, it can easily integrated into your
automated manufacturing environment. It snaps on and off the docking base with ease to
provide quick and easy loading of label and print media reels.
The PL1200 labeling system has been designed with you in mind, to provide simple
installation and integration into your automated environment.
This chapter will describe
in greater detail the product features and the hardware component
descriptions so that you can become familiar with the PL1200 labeling system.
2.1 PL1200 Features
The PL1200 labeling system provides the following features:
•Print speeds of 1.5 seconds per inch at 180 x 200 DPI.
•A refresh rate of 4.5 seconds depending on label size/length.
•The labeling unit is capable of printing bar codes and date stamps.
•Precision repeatability of label presentation for pick up by the host machine with +/-
.020”.
•No hand tools are needed for installation or removal of the labeling unit to/from the
docking station when mounted to the host machine.
•All power is delivered to the docking station eliminating the need to power the labeling
unit on and off to replace label or print media reels.
•The labeling unit snaps on and off the docking station with ease providing complete
access for quick label and print media reel changes.
•
RS232 interface for ease of use with Windows based 3rd party software.

8
2.2 PL1200 Hardware Description
This section will describe the PL1200 docking station and labeling unit in detail to help you
become familiar with the PL1200 system.
2.3 Docking Station
The two major components of the PL1200 labeling system are the dockin
g station and the
labeling unit. The docking station is designed to be mounted to the host machine.
All power and communications with the labeling unit are provided through the docking station
mounted within the BP3100/BP3500. For more information on the BP3100/BP3500 system,
please refer to the BP3100/BP3500 manual. The docking station consists of the docking plate and
the docking plate PCB as shown in diagram 2.3a below
The docking plate has a notched edge along the top and a groove down the front with an
alignment bushing at the base as shown in diagram 2.3b. These features enable the user to
remove and return the labeling unit to the docking plate as often as needed without
compromising the precision with which the labels are dispensed.
Docking Plate
Lock down knob
Docking plate PCB
Diagram 2.3a
PL1200 Thermal Transfer Printer
Introduction

9
2.4 The Labeler Unit
The PL1200 labeling unit for purposes of discussion will be divided into four areas. The first
covers mounting and removing the labeler to or from the docking station, the second will cover
the mandrels and reels, the third area covers the labeling mechanics and the fourth describes
sensors and switches.
2.5 Mounting and Removing the PL1200 unit
The mounting points on the PL1200 labeling unit consist of a dock clamp block, a guide pin and a
tooling ball as shown in diagram 2.5a.
Notched edge
Groove
Alignment bushing
Docking plate PCB
Diagram 2.3b
PL1200 Thermal Transfer Printer
Introduction

10
To mount the labeling unit to the docking station, align the guide pin within the top of the groove
in the dock base plate and place the bottom edge of the dock clamp block onto the notched edge
of the dock base plate. With the dock clamp block and guide
pin lined up to the dock base plate,
the tooling ball with snap into place and the labeling unit is now mounted onto the docking plate
as shown in diagram 2.3b.
To remove the labeler from the docking station, firmly grasp the handle found on the top of th
e
labeling unit. Lift the labeling unit up and out to release the tooling ball from the alignment
bushing. The labeler can now be lifted out and away from the docking station.
PL1200 Thermal Transfer Printer
Introduction
Guide pin
Handle
Dock clamp block
Tooling ball
Diagram 2.5a

11
PL1200 Thermal Transfer Printer
Introduction
This photo shows how easy
it is to remove the labeling
unit from the docking station.
This photo shows how to
line up the labeling unit
with the docking station
for easy installation.
This photo shows the
labeling unit mounted
to the docking station.
Diagram 2.5b

12
2.6 Mandrels and Reels
The PL1200 labeling unit has four mandrels. These mandrels accommodate the reels of material
for labeling and printing. Two mandrels are dedicated to the thermal transfer print ribbon reels,
these are the smaller of the two sets, and the two larges ones are for the label reels.
Each set of mandrels consists of a ‘stock’ mandrel and a ‘take-up’ mandrel. The ‘stock’ mandrels
hold the thermal transfer tape ribbon reel and the label ribbon reel for dispensing. The ‘take up’
mandrels
contain the used ribbon and label material reels for collection. Please see diagram 2.6a
below
Thermal tape
'stock' mandrel Thermal tape
'take-up' mandrel
Label 'stock'
mandrel
Label 'take-up'
mandrel
Diagram 2.6a
PL1200 Thermal Transfer Printer
Introduction

13
Each of the mandrels contains two flexing pressure clips, which provide quick and easy
fastening/unfastening of reels to the mandrels. Diagram 2.6b show the pressure clips in both the
‘open’ and ‘closed’ position.
2.7 Labeling Mechanics
The PL1200 labeling unit contains seven major components for printing and dispensing labels for
pickup by your host machine. This section will describe in detail the hardware components that
make up the PL1200 labeling unit. The hardware descriptions and location information are
provided to help you familiarize yourself with the PL1200 labeling unit for operation and
maintenance.
Following this section you will find a photograph that shows in detail all of the parts information
described in this section. The number found next to each part description corresponds to the
number of the part shown in the photograph in diagram 2.7a
Diagram 2.6b
Pressure clip in 'closed' position
locks media reel in place on the mandrel Pressure clip in 'open' position,
media reels can be removed
from or returned to the mandrel
PL1200 Thermal Transfer Printer
Introduction

14
PL1200 Thermal Transfer Printer
Introduction
1. The ‘print head cover’. This houses the thermal print head and also contains a guide
roller or the thermal print tape and label tape.
2. The ‘label tension block’ is located just below the ‘print head cover’. It contains a single
roller and provides for the tensions of the label tape.
3. Located along side the ‘print head cover’ and ‘label tension block’ is the ‘transfer roller
arm’. It contains two rollers. Then it pivots into place and pressure is applied by the
rollers to the label and thermal print tape for printing and tape advancement.
4. Below the’ transfer roller arm’ is the ‘transfer pivot block’. It contains a single roller,
which supports the ‘transfer roller arm’. It guides the used label tape to the ‘take up’
mandrel.
5. Located alongside of the ‘transfer pivot block’ and the ‘transfer roller arm’ is the ‘drive
arm assembly’. It contains a single roller that provides the rotation force needed to
advance the label tape. This assembly also contains the ‘drive arm assembly’. By pulling
and swinging the drive arm ‘lock knob’ to the left, the ‘drive arm assembly’, ‘transfer
pivot block’ and ‘pivoting roller block’ open to allow the operator to load both the label
and thermal transfer print tapes into position. When the drive arm ‘lock knob’ is pressed,
the ‘drive arm assembly’, ‘transfer pivot block ‘ and ‘pivoting roller block’ snap back into
operating position.
DO NOT spin the ‘manual advance knob’ counter-
clockwise. The PL1200 is not
designed to spin in this direction.
CAUTION
6. The white Teflon part found directly above ‘drive arm assembly’ and ‘pivoting roller block’ is
the ‘label deck’. The labels that have been printed are placed here for retrieval either by
hand or your pick and place nozzle. The ‘anti static brush” is located along side the ‘label
deck’.
7. In the lower left corner of the labeling unit is the ‘manual advance knob’. When this knob is
turned clockwise, both sets of mandrels will spin and the thermal transfer and label tapes will
be advanced.
WARNING
WARNING : POSSIBLE PINCH POINTS KEEP HANDS CLEAR.

15
PL1200 Thermal Transfer Printer
Introduction
Diagram 2.7a
6 Label deck Anti-static brush
1 Print head cover
3 Transfer roller arm
2 Label tensioner block
4 Transfer pivot block
5 Drive arm assembly
7 manual advance knob

16
PL1200 Thermal Transfer Printer
Introduction
2.8 Sensors
There are five sensor locations in the PL1200 labeling unit. The ‘ribbon tape’ sensor is located
between the ‘print head cover’ and the ‘label tension block’ (see diagram 2.8a). This sensor is
used for detection of the thermal transfer ribbon tape. If a ‘no tape’ condition is detected the
PL1200 unit will not print or present labels.
The second sensor is the ‘label alignment’ sensor. This sensor is located between the ‘label tension
block’ and the ‘transfer roller arm’ (see diagram 2.8b). The ‘label alignment’ sensor detects the
labels to properly align the label for printing and pre
sentation.
'Ribbon tape'
sensor
Diagram 2.8a