Ice PegasusHS User manual

PegasusHS
Service Manual
P/N 361854-21
Revision: AA, November 2006

Copyright 2006, Clearmark solutions LLP.(herein referred to as ICE). All rights reserved.
This document is the property of Clearmark solutions.and contains confidential and
proprietary information owned by ICE Any unauthorized copying, use or disclosure of it
without the prior written permission of ICE is strictly prohibited.
ICE (interactive coding equpiment)
Phone: [phone]
Fax: [phone]
Olympic House,Willow Drive
Sherwood Park,Nottingham
NG15 0DP
www.interactivecoding.com

Rev AA i
Compliance Information
For Customers in U.S.A.
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.
Warning
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 responsible 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 usedin 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 such cases, the users will be
required to correct the interference at their own expense.
Shielded cables must be used with this unit to ensure compliance with
Class A FCC limits.
The user may find the following booklet prepared by the Federal
Communications Commission helpful: How to Identify and Resolve
Radio-TV Interference Problems. This booklet is available from the
U.S. Government Printing Office, Washington, DC 20402, Stock No.
004-00-00345-4. This equipment has been tested and certified for
compliance with U.S. regulations regarding safety and electrical
emissions by TUV Rheinland of North America, Inc.
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 by
TUV Rheinland of North America, Inc.

ICE Pegasus Service Manual
ii Rev AA
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.
For Customers in the European Union
This equipment displays the CE mark to indicate conformance to the
following legislation.
• EN55022:1998
• EN55024:1998
• EN61000-6-2:2001
• FCC CFR 47 parts 15.107 and 15.109

Rev AA iii
Support and Training
Contact Information
If you have any questions or need assistance, please contact ICE
Technologies Inc. at 01159 640144
Interactive Coding Equipment (ICE)
Olympic House
Willow Drive
Sherwood Park
Nottingham
NG15 0DP
T: 01159 640144
F: 01159 639317
Service Program
About Total Source Commitment
Total Source® TOTAL SERVICE PLUS RELIABILITY, is the ICE.
commitment to provide you - our customer - the complete service
you deserve.
The Total Source Commitment
The ICE Service Program is an integral part of our business in
providing marks, codes, and images where, when, and how often
customers specify for packages, products, or printed materials. Our
commitment includes:
• Applications support
• Installation services
• Maintenance training
• Customer response center
• Technical support
• Field service
• Extended hours phone assistance
• Parts and supplies
•Repairservice

iv Rev AA
Customer Training
If you wish to perform your own service and maintenance on
the printer, ICE. highly recommends that you complete a
Customer Training Course on the printer.
Note: The manuals are intended to be supplements to (and not replacements
for) ICE. Customer Training.
For more information on ICE.Customer Training Courses, call 01159
640144.
ICE Pegasus Service Manual

Rev AA i
Table of Contents
Compliance Information
For Customers in U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
For Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Pour la Clientèle du Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
For Customers in the European Union. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Support and Training
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Chapter 1 — Safety
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Safety Conventions Used in the Manual. . . . . . . . . . . . . . . . . . . . . . . . 1–2
General Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
General Caution Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Comply with Electrical Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Do Not Remove Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Placement of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Using Printer Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Chapter 2 — Introduction
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Theory of Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Intermittent Motion Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Continuous Motion Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
Chapter 3 — Technical Description
Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Installing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
CLARiTY Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Installing the Ribbon in the Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Adjusting the Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12

ii RevAA
Working with Printer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .3–12
Product Sensors/Print Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–12
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–14
Interlocks and Annunciation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–15
Data Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–16
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–16
Switching the Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–18
Configuring the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–19
CLARiTYTM Configuration Manager. . . . . . . . . . . . . . . . . . . . . .3–19
Installing the CLARiTY Configuration Manager . . . . . . . . . . . .3–21
Connecting the CLARiTY Configuration Manager to the Printer3–21
Editing Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–23
Saving the Changes in the Printer . . . . . . . . . . . . . . . . . . . . . . . . .3–24
Archiving the Current Parameters. . . . . . . . . . . . . . . . . . . . . . . . .3–24
Loading a Saved Archive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25
Working with the Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . .3–25
The Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25
The Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–25
Default Options Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–26
Chapter 4 — CLARiTY Operating System
Getting started with the CLARiTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1
Using the Tools Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–2
Working with Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3
Working with Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–8
Working with Passwords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–25
Password Protection Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–26
Chapter 5 — Maintenance
Maintaining the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–2
Replacing the Mains Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–2
Maintaining the CLARiTY Controller . . . . . . . . . . . . . . . . . . . . . . . . . .5–3
Replacing the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . .5–3
Replacing the CLARiTY Processor PCB and LCD Touchscreen
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–5
Maintaining the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–11
Replacing the Compact Flash Card . . . . . . . . . . . . . . . . . . . . . . . .5–11
Replacing the Main PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–12
Replacing the Peel Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–15
Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–17
Setting the Printhead Resistance . . . . . . . . . . . . . . . . . . . . . . . . . .5–18
Maintaining the Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–19
ICE Pegasus Service Manual

RevAA iii
Updating the CLARiTY Operating Software. . . . . . . . . . . . . . . . . . . 5–23
Chapter 6 — System Events
Chapter 7 — Troubleshooting
Chapter 8 — Illustrated Parts List
How to Read the IPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Alphabets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Printer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Cassette Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
Printer Ribbons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
Chapter 9 — Drawings
Printer Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Electrical Wiring Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
ICE Pegasus Service Manual

Rev AA Introduction 1-1
1
Safety
This chapter contains the following topics:
• Safety conventions used throughout this manual
• Important safety guidelines to follow while operating the equipment
Warning
EQUIPMENT MAINTENANCE. Read this chapter thoroughly
before attempting to install, operate, service, or maintain this
product.
Introduction
The policy of ICE. is to manufacture printing/coding systems and
supplies that meet high standards of performanceand reliability.
Therefore, we employ strict quality control measures to eliminate the
potential for defects and hazards in our products.
The intended use of this printer is to print information directly onto the
product. Use of this equipment for any other purposes may lead to serious
personal injury.
The safety guidelines provided in this chapter are intended to educate the
operator on all safety issues, so that the operator can operate the printer
safely.

1-2 Safety Conventions Used in the Manual Rev AA
Safety Conventions Used in the Manual
Specific safety information is listed throughout this manual in the form of
Warning statements. Pay close attention to these statements as they
contain important information that help in avoiding potential hazards to
yourself or to the equipment.
General Warning Notices
The following warnings supplement the specific warnings that appear
elsewhere in the manual. These are general warnings which must be read,
completely understood, and applied by all the personnel involved in the
operation, and/or the maintenance of the machine.
Warning
PERSONAL INJURY. Only trained service or maintenance
personnel should perform these installation procedures. Qualified
personnel have successfully completed the training courses, have
sufficient experience with this printer, and are aware of the potential
hazards to which they may be exposed.
Warning
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.
Warning
PERSONAL INJURY. Before connecting the compressed air supply
to printer, ensure that the air supply has been isolated. Turn the
regulator adjustment knob counter-clockwise.
Warning
PERSONAL INJURY. The printer uses an operator control console.
Ensure that this panel is mounted at an appropriate working height
and orientation for comfortable operation.
ICE Pegasus Service Manual

Rev AA Safety Conventions Used in the Manual 1-3
Warning
PERSONAL INJURY. Keep hands and clothing clear of the printer
while it is on.
Warning
PERSONAL INJURY. To ensure that the connecting cables and pipes
do not become a trip hazard or become entangled in any machinery,
all connecting cables and pipes must be secured safely during
installation.
Warning
ELECTRICAL HAZARD. Voltages used to connect the printer to
other equipment must be limited to no greater than 50 V DC or peak
AC.
Warning
ELECTRICAL HAZARD. Always wear a properly ground wrist-
ground strap when handling printed circuit boards. Failure to do so
can result in damage to the board components due to static
electricity.
General Caution Notices
The following caution statements supplement the specific cautions that
appear elsewhere in the manual. These are general cautions, which must
be read, completely understood and applied by all the personnel involved
with the operation, and/or the maintenance of the machine.
ICE Pegasus Service Manual

1-4 Safety Guidelines Rev AA
Caution
EQUIPMENT MAINTENANCE. Before and after performing any
maintenance or repair on the product, check that the two safety
labels are clearly visible. One is on the power supply cover and the
other by the potential nip point next to the pulley in the printer
body.
Caution
EQUIPMENT DAMAGE. The use of incompatible ribbon can
seriously damage your printer and such damage is not covered by
your printer warranty. Use only ribbon approved by your dealer.
Safety Guidelines
This section contains important safety guidelines pertaining to the
operation and handling of the printer and associated equipment.
Warning
SAFETY GUIDELINES. Always observe the following safety
guidelines when operating and handling the printer and associated
equipment.
Comply with Electrical Codes
All the electrical wiring and connections must comply
with applicable local codes. Consult the appropriate
regulatory agency for further information.
ICE Pegasus Service Manual

Rev AA Placement of the Printer 1-5
Do Not Remove Warning Labels
Do not, under any circumstances, remove or obstruct any
warning or instruction labels on the printer.
Placement of the Printer
Warning
PERSONAL INJURY. Do not place the printer in a hazardous
location. Hazardous locations might create an explosion, leading to
personal injury.
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
ANSI/NFPA 70–1993.
Outside the United States, you must ensure compliance with all local
regulations regarding equipment placement in potentially hazardous
locations.
Using Printer Accessories
To maintain regulatory approval for the printer, use only Videojet
approved accessories when attaching any device to the equipment.
ICE Pegasus Service Manual

Rev AA Equipment Description 2-1
2
Introduction
This chapter contains the following topics:
• A description about the intended use of the product
• Information about the audience for whom this manual is intended
• A description of how the manual is organized
• Information about other manuals that are associated with this printer
• A description of the theory of printing
Warning
PERSONAL INJURY. Read Chapter 1, “Safety” before attempting to
operate the equipment.
Equipment Description
The Videojet 6210 printer uses high-resolution thermal transfer
technology with a unique electronic ribbon drive system. The printer
offers greater reliability and ease of operation compared to earlier
systems. It can print barcodes, dates, text, and graphics onto flexible
packaging films and labels.
The printer is a suitable replacement for either hot stamp or rotary
printers. It 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)
It is suitable for use on most horizontal form/fill/seal, vertical form/
fill/seal, and self-adhesive labeling machines.
The product is available in either left-handed or right-handed versions to
suit different configurations of the packaging machine.

2-2 About this Manual Rev AA
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, including an
illustrated parts breakdown.
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 where it can be easily
accessed for reference.
Related documents
The Videojet 6210 Operator Manual (P/N 361853) is intended for the
operator and contains information on routine operation of the printer.
Unless specified, all procedures in this manual can be performed by the
operator of the printer. It is mandatory that the personnel read the
Operator Manual before reading the Service Manual.
This manual is a supplement to (and not a replacement for) formal
training.
Warning
PERSONAL INJURY. Customers who intend to service and
maintain the printer themselves must use only qualified personnel
to perform these procedures. Qualified personnel have successfully
completed the training courses, have sufficient experience with this
printer, and are aware of the potential hazards to which theymay be
exposed.
ICE Pegasus Service Manual

Rev AA Theory of Printing 2-3
Theory of Printing
The information on how the thermal transfer printer works is as follows
(Figure 2-1):
• The printhead contains miniature heating elements under a glass
coating (300 dpi - 12 dots/min)
• A carrier ribbon, with ink bonded to one side is used as the printing
media
•The printhead presses against the thermal transfer ribbon with the ink
side of ribbon in contact with the substrate, creating an image.
• Print elements heat small areas of the ribbon and this transfers the ink
to the target substrate
• The printhead and the substrate move relative to each other
• The print elements are programmable and controlled to create an
image
Intermittent Motion Printing
Intermittent motion printing (Figure 2-2 on page 2-4) is the concept used
for printing on stationary packaging films in packaging equipment that
has a start/stop action each time a product is packed. Such applications
can be found in intermittent Vertical Form Fill Seal (VFFS) or bagging
machines, and self adhesive label applicators.
Intermittent motion printing has the following features:
• The substrate is stationary
12
3
4
56
1. Ribbon Transferred Carbon
2. Substrate
3. Platten Rubber
4. Ink
5. Base Film
6. Thermal Printhead
Figure 2-1: Printing Process
ICE Pegasus Service Manual

2-4 Theory of Printing Rev AA
• The printhead traverses across the ribbon, causing print to transfer
onto substrate.
•The printhead presses against a flat platten pad.
Continuous Motion Printing
Continuous motion printing (Figure 2-3 on page 2-5) is the concept used
forprintingon moving packaging films in packaging equipment that has a
continuous moving action each time a product is packed. Such
applications can be found in Continuous Vertical Form Fill Seal (VFFS)
and Horizontal Form Fill Seal (HFFS) or flow-wrap machines.
Continuous motion printing has the following features:
• The substrate moves while the printhead is stationary
• Speed of the substrate is monitored by an encoder
• The ribbon and the substrate speeds are matched by the ribbon drive
• The printhead presses against a rotating print roller
1
2
3
4
1. Ribbon Transferred Carbon
2. Substrate
3. Platten Rubber
4. Thermal Printhead
Figure 2-2: Intermittent Printing Motion
HEAD OUT
HEAD IN PRINT
ICE Pegasus Service Manual

Rev AA Theory of Printing 2-5
1
2
3
4
RIBBON FEED
MATERIAL FEED
1. Ribbon Transfer Carbon Print
2. Platten Roller
3. Substrate
4. Thermal Printhead
Figure 2-3: Continuous Print Motion
ICE Pegasus Service Manual

Rev AA Unpacking the Printer 3-1
3
Technical Description
This chapter contains the following topics:
• Unpacking the Printer
• Installing the Printer
• Mounting Considerations
• Installing the Ribbon in the Cassette
• Adjusting the Air Pressure
• Working with Printer Connections
• Switching the Power On
• Understanding Printhead LEDs
•ConfiguringthePrinter
• Working with the Configurable Inputs and Outputs
Unpacking the Printer
Inspect the kit for any damage carefully. Refer the list of parts in
Table 3-1 and Figure 3-1 on page 3-2. If any item is damaged or
missing,call ICE., Customer Service Department at 01159 640144.
Printer Part
Printer
Cassette
CLARiTY Controller
Air Regulator
Power Cable
I/O Low Profile Cable Assembly
Table 3-1: Printer Configuration Parts List