Tharo Systems Gemini User manual

Gemini
Thermal / Thermal Transfer
Windows Label Printer
Operator's Manual
Edition 6/00

2 cab - Produkttechnik GmbH / Tharo Systems, Inc.
copyright by cab / 900 8004 / I06 / 250
Technische Änderungen vorbehalten
In accordance with our policy of continual product improvement, we reserve the right to alter specifications without notice
Données technique modifiables sans prévais
Gesellschaft für
Computer- und Automations-
Bausteine mbH
cab-Produkttechnik GmbH
Postfach 19 04 D-76007 Karlsruhe
Haid- und-Neu-Straße 7 D-76131 Karlsruhe
Telefon + 49 (0) 721 / 66 26-0
Telefax + 49 (0) 721 / 66 26-249
Internet : http://www.cabgmbh.com
E-mail: [email protected]
Tharo Systems, Inc.
2866 Nationwide Parkway
P.O. Box 798
Brunswick, OH 44212-0798
Web : http://www.tharo.com/tharo/
E-mail: [email protected]
Tel. : + 1 330-273-4408
Fax: + 1 330-225-0099

3cab - Produkttechnik GmbH / Tharo Systems, Inc.
Gemini
Thermal Transfer Printer
Operator's Manual
Thermal Transfer Printer
Operator's Manual
All rights reserved, including those of the translation
No part of this manual nor any translation may be reproduced or transmitted in any form
or by any means, for any purpose other than the purchaser's personal use, without the
express written permission of cab - Produkttechnik GmbH Karlsruhe.
Edition 6/00
Printed in Germany

4 cab - Produkttechnik GmbH / Tharo Systems, Inc.
Table of contents
1. Introduction ................................................................................................................. 6
Introducing the Gemini Windows Barcode Printer ......................................................... 6
Agency Compliance and Approvals............................................................................... 7
Technical Specifications ................................................................................................ 8
2. General Safety Regulations ...................................................................................... 11
3. Unpacking and Delivery Contents............................................................................ 12
4. Printer Component Location .................................................................................... 13
5. Connecting the Printer.............................................................................................. 17
Connection to a Computer........................................................................................... 17
Connection to Power Supply ....................................................................................... 17
6. Media loading ............................................................................................................ 18
Processing Mode ....................................................................................................... 18
Loading Labels............................................................................................................ 19
Ribbon Loading ........................................................................................................... 22
7. Adjustments Concerning the Labels........................................................................ 23
Adjustment of the Printhead Support........................................................................... 23
Adjustement of the Transfer Ribbon Feed ................................................................... 24
8. Installing and Using the Software ............................................................................ 25
Introduction ................................................................................................................. 25
Installation information ................................................................................................ 25
Updates ...................................................................................................................... 25
The Gemini Control Panel Application ......................................................................... 26
Gemini Test Print......................................................................................................... 27
Printer Setup............................................................................................................... 28
Printing from Windows Applications ............................................................................ 32

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9. Error Messages ......................................................................................................... 33
10. Maintenance / Cleaning ........................................................................................... 34
General Cleaning ........................................................................................................ 34
Cleaning the Media Feed Roller .................................................................................. 34
Cleaning the Thermal Printhead .................................................................................. 35
Removing Labels from the Dispenser Roller................................................................ 36
11. Printhead Horizontal Alignment ............................................................................... 37
12. Troubleshooting ........................................................................................................ 39
EC-Conformity Declaration ............................................................................................. 40
Trademarks
Centronics ® is a registered trademark of Centronics Data Computer Corporation.
Microsoft ® is a registered trademark of Microsoft Corporation.
TrueType  is a registered trademark of Apple Computer, Inc.
Easylabel ® is a registered trademark of Tharo Systems, Inc.

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1. Introduction
Introducing the Gemini Windows Barcode Printer
The Gemini is an innovative printer designed to work only in a Windows
environment. Instead of buttons on a printer's front panel, printer configuration and
control is provided by the Gemini Control Panel Application running under
Windows. The Gemini driver allows printing from almost any Windows
application, such as MS Word, Write, WordPad, Access® and Visual Basic,
as well as Lotus® Approach®, Paradox® and dBASE® among others. Bar code
labels can be created with existing Windows applications using the special barcode
fonts built into the driver, eliminating the need for special labeling software.
Gemini uses the true type fonts available with your Windows applications, and
accepts all graphic types supported by Windows, resulting in exceptional flexibility
in font and graphic choices. Fonts and graphics are downloaded as needed with
the high-speed bi-directional Centronics interface, providing an exceptionally quick
time to first label printing.
The Gemini is built to work only with Windows, and takes full advantage of
Windows features. Its simple design requires a minimum of effort and expertise
for loading and maintaining the printer. From configuration and setup to ongoing
operation, use of the online Gemini Control Panel Application simplifies the
operator's job. Extensive Online Help is provided covering all features and
functions available within the Control Panel Application and Printer Setup. In
addition, help topics covering 'Printing from Windows Applications' and 'Barcode
and Symbology information' are included.
The Gemini Thermal Transfer Printer is offered in two versions:
Gemini T : The device is equipped with a tear-off edge to aid the removal of
the labels or continous material by hand after printing.
Gemini TD : This device has an additional dispensing feature for labels. Directly
after printing the label is removed from the liner and placed in a
dispense position ready for further use. The presence of a label in
the dispense position is regognized by a sensor which interrupts
the printing until the label is removed.
Both versions are available as 230 Volt or 115 Volt devices.

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Agency Compliance and Approvals
Gemini complies with the following safety regulations:
CE : The printer complies with the following safety requirements
- EC Low Voltage Directive (73/23/EEC)
- EC Machinery Directive (98/37/EEC)
- EC Electromagnetic Compatibility Directive
(89/336/EEC)
FCC : Gemini complies with Part 15 of FCC rules.
Note: 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 reasonable 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 used in accordance with the instructions in this manual, it may cause
harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user
will be required to correct the interference at his own expense.
WARNING !
This is a Class A product. In a domestic environment this product may cause
radio interference in which case the user may be required to take adequate
measures.

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Technical Specifications
Printing
Type : Direct thermal / Thermal transfer printer
Printhead: Resolution 203 dpi = 8 dots / mm
Print Speed : 2, 2.8 ips (50, 70 mm/s)
Label Backfeed : Label is automatically pulled back into the printer
after a tear-off or peel-off operation to allow for printing
on the entire label
Maximum Print Width : 4.1" (104 mm)
Maximum Print Length : 11.8" (300 mm)
Printed Images :
Character Sets : All character sets supported by Microsoft Windows
Font Expansion: Dependent on font selected, as supported by Microsoft
Windows.
Bar Code Symbologies: Barcode symbologies along with a variety of check
character options are provided as fonts in the Gemini
Driver. These include: Codabar, Code 128, Code 39,
Code 39-Mod 43, EAN13, EAN8, Interleaved 2 of 5,
Interleaved 2 of 5-Mod 10, MSI+10, PDF417, POSTNET,
UCC, UPC/EAN 2 digit Add On, UPC/EAN 5 digit AddOn,
UPC-A, UPC-E0, UPC-E1
Bar Code Density: Fixed choices are available which further define the font
being selected. Depending on the symbology, ratios
including 2:1, 3:1 and 5:2 may be selected. Also
dependent on the symbology, the bar width multipliers
range from 1 to 8.
Graphics: All monochrome graphic types supported in Windows.
Label Rotation: Portrait and Landscape, Reverse Portrait and Reverse
Landscape with Flip Format option.

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Media
Label Width: 1" - 4.5"(25 - 116mm)
Label Length: .3" - 11.8" (6 - 300mm)
Label Type: Roll-fed, die-cut or continuous labels, tags or tickets;
most direct thermal or thermal transfer materials.
Supply Roll: Up to 6" (150mm) diameter on 1.6" - 3" (40 - 75mm)
cores. Labels may be wound face-in or face-out on the
roll.
Label Material: Standard labels and Cardboard / Tags
Thickness: 0.0024" to 0.0098"
(0.06mm to 0.25mm)
Direct Thermal, Thermal Transfer and various Synthetics
including: thermal transfer plaincoated papers, vinyl,
Mylar, metalized paper, non-woven fabric, fine woven
fabric, thermal visible light scannable paper, infrared
scannable paper, thermal ticket/tag stock, thermally
sensitive plastic stock.
Transfer Ribbon: Width up to 4.5" (114mm);
Length 1182' (360m);
Rolls up to 3" (75mm) diameter on 1" (25mm) cores.
Printer
Memory: Internal memory 256KB
Interface: High-speed bi-directional Centronics Parallel (max 70 KB/s)
Indicators/Switches: Power-on LED above Power Switch
Physical
Dimensions: Height: 8.9" (226mm)
Width: 9.4" (239mm)
Depth: 12.8" (326mm)
Weight: 17.6 lbs (10Kg)

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Electrical
Operating Voltage: 115V / 60 Hz or 230V / 50 Hz
Voltage cannot be altered on the machine
Circuit Protection: 115VAC / 60Hz use 1.6 AT fuses;
230VAC / 50Hz use 800 mAT fuses;
Environmental
Operating Temperature: 50°F to 95°F (10°C to 35°C)
Humidity: 30% to 85%.
Other Features
Status Indication: LED on front panel uses slow blink to indicate pause and
rapid blink to indicate error.
Status provided through the on-screen Gemini Control
Panel application includes:
Number of labels left in printer
Out of labels / Out of ribbon
Printer state - paused or not paused
Demand Mode indication
Miscellaneous error messages
Sensors: "See-through" media photosensor at 0.7" (17.5 mm) from
the paper edge
Demand sensor (Gemini TD only)
Ribbon-out sensor
Software : Gemini Windows Printer Driver
and Control Panel Application

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2. General Safety Regulations
- The Gemini is built exclusively to print die-cut labels, continuous media, and
similar materials as listed in the Technical Specifications.
- Connect the printer only to an outlet with the proper voltage. The Gemini is
configured for either a 115V or 230V power supply, which can be determined by
checking the specification label on the machine. Connect only to a power outlet
with a grounded contact.
- Power must be off before plugging in any accessory, connecting to a computer and
before performing any maintenance on the printer.
- Do not expose the printer to any moisture, or use in damp or wet areas.
- The printer will operate with the cover open when necessary. This is not
recommended, as it might allow debris to collect within the printer. If the printer
must be operated with the cover open, extra care must be taken to avoid allowing
hair, jewelry, clothing, etc. near the rotating parts.
- During the printing process the printhead will become hot. Use extra caution when
touching the printhead.

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3. Unpacking and Delivery Contents
Unpacking
Please inspect the Gemini's packaging and contents immediately after receipt for
possible damage during shipment. The Gemini is shipped in a styrofoam package
and is enclosed in plastic to reduce the chance of moisture damage during
shipment.
Please keep the original packaging in case the printer must be returned.
Equipment Supplied
Your Gemini shipping container will contain the following standard components:
- Gemini Thermal Transfer Printer
- Power Cord
- Cardboard Core for the transfer ribbon rewinder
- Gemini User Manual
- Gemini Windows Software Diskette
Note : We offer additional items that may be included in your initial shipment.
Compare the delivered accessories with your order.
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4. Printer Component Location
Figure 4 a Frot view
1- Cover
2- Power LED
3- Power Switch
1
2
3
Gemini

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1- Ribbon Take Up Hub
2- Ribbon Supply Hub
3- Media Retainer
4- Media Hub
5- Media Retainer Knurled Screw
6- Media Guide
7- Media Assist Bar
Figure 4 b Side view (with cover open)
1 2 53 4
7 6

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Figure 4 c Detailed View of the Print Mechanism
Gemini TD Gemini T
1- Thermal Printhead
2- Printhead Adjustment Screw
3- Printhead Locking Lever
4- Label Edge Sensor
5- Dispenser Locking Lever
6- Dispenser Locking Roller
7- Dispenser Drive Roller
8- Media Feed Roller
9- Tear-Off / Peel-Off Plate
10 - Transfer Ribbon Shield
11 - Present Sensor
12 - Tear-Off Plate
10
12
8
2 47 6
8
9
10
11
1 2 3 1 3
45

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1- Centronics Parallel Port
2- Specifications Label (power supply and voltage information)
3- Power Cord Connection
4- Fuse Holder
Figure 4 d Rear View
1
2
3
4

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5. Connecting the Printer
4
3
2
1
6
5
Figure 5 Connecting the Printer
Connection to a Computer
The Gemini is fitted with a Centronics parallel interface which uses a 36-pin
port (1).
Obtain a standard parallel cable in a length suited to your needs (not exceed 10
feet in the length) and use it to connect the printer to your computer.
Ensure that the interface cable is correctly grounded.
Connection to Power Supply
Check that your available power supply voltage corresponds with the
voltage shown on the printer's specification label (2). The voltage
requirement shown will designate either 230 V/50 Hz order 115 V/60 Hz.
Do not connect the printer to the power supply until the voltage has been
verified.
After inserting the power cord into the power supply socket (3) at the rear of the
printer, connect the power cord to a grounded power outlet.
Switch the printer ON with the power switch (6). If the status LED (5) does not light
up, check the fuse inserted in the power supply module (3) by removing the fuse-
holder (4). Ensure that a fuse of the correct rating is installed :
800 mAT for 230 V 1,6 AT for 115 V
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6. Media loading
Processing Mode
The Gemini can be operated in two different processing modes. In addition, two
methods of operation are possible. The mode and method of operation desired
dictate the method of loading the label stock.
When in the Batch Mode, the labels are printed without pausing. The labels exit
the printer out the front, still attached to the backing strip.
When in the Demand Mode, labels are printed one at a time. The printing cycle is
then stopped until the label has been removed. When the present sensor registers
the label has been removed, an automatic backfeed is performed and the next label
is printed and fed forward to the demand position.
The Demand Mode operations are available with Gemini TD only.
Note: When editing the labels in the dispense mode, make sure that the label area
that lies directly underneath the sensor is only printed up to 50% (black). A further
blackening may cause malfunctions of the present sensor.
While processing in Demand Mode, the following operation methods are available :
For Tear-off operations, the labels are loaded so that they exit the printer straight
out the front, as in Batch Mode. The label exits the printer, still attached to the
backing. (How far the label protrudes can be adjusted with Presentation Position
parameter in Printer Setup). When the label has been torn off, the present
sensor registers the removal and the next label is printed.
For Peel-off operations, the labels with the backing strip fed down below the
peel plate before it exits the printer. For succesfull peel-off, the backing strip
must not be perforated between the labels. As the backing strip is pulled down,
only the label exits the front of the printer. In effect, the label is peeled-off of the
backing, while remaining attached by only a narrow edge. (The edge width can
be adjusted with the Presentation Position parameter in Printer Setup). When
the label is removed, the present sensor detects the removal and the next label is
printed.
The following steps describe media loading for the Gemini. Steps 1-7 are common
to all processing modes and methods of operation. In the remaining steps, loading
for the different operating modes and methods of operation is detailed separately.
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Loading Labels
1. Raise the printhead by rotating the printhead lever (1) clockwise until it stops.
2. Loosen the media retainer knurled screw (5) and swing the media retainer (3)
upwards.
3. Place the roll of label stock (2) onto the media supply hub (4).
4. Swing the media retainer (3) downward and inward until it rests on the media
supply hub (4), against the side of the label roll.
Retighten the knurled screw (5) .
5. Slide the media guide (6) outward, allowing enough clearance for the label
stock's width when loaded.
6. Unroll a length of label stock from the media roll. From the side, slide the
media under the media assist bar and inside the media guide (6) as shown in
Figure 6a. It is particularly important to ensure that the media strip slides
correctly under the arm of the photocell assembly (7).
2 3 4 51
7 6
Figure 6 a Media Loading - Part 1

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8 1
12
11
Figure 6 b Media Loading - Part 2
7. Continue feeding the label strip between the tear/peel plate (12) and the
thermal printhead (8) as shown in Figure 6b.
Batch Mode Loading and Demand Mode with Tear-Off Loading
8. Route the media strip forward straight through the front of the printer as shown
in Figure 6a.
9. Check the position of the media guide (6) and if necessary, slide it inward until
it lightly touches the sides of the media strip.
10. Adjust the media roll to remove any slack, then lower the printhead by rotating
the printhead lever (1) counterclockwise until it stops.
Make sure that the dispenser locking roller (10) is open. This helps to keep the
wear at the roller low.
10 9 6
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