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ASTRO-MED QuickLabel Systems QLS 4000 Installation & Setup Manual

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™
4
Operation & Setup Guide
L
®
S
Q
ABEL
YSTEMS
UICK
A DIVISION OF ASTRO-MED
address
600 East Greenwich Ave., West Warwick, RI 02893
telephone
401.828.4000
fax
401.822.2430
tech support 800.343.4039
toll free
877.757.7978
Printed in the United States of America
000
/
4001
Digital Color Printers
Part No. 22834-456
®
12/99

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  • Page 1 Digital Color Printers Operation & Setup Guide Part No. 22834-456 12/99 ® ABEL YSTEMS UICK ® A DIVISION OF ASTRO-MED address 600 East Greenwich Ave., West Warwick, RI 02893 telephone 401.828.4000 401.822.2430 tech support 800.343.4039 toll free 877.757.7978 Printed in the United States of America...
  • Page 2 QuickLabel Systems makes no warranty, either express or implied, with respect to this product’s fitness for a particular purpose. QuickLabel Systems, Division of Astro-Med, Inc. is not responsible for your product if it is lost or damaged in transit. Ownership Information Congratulations and thank you for your business.

  • Page 3: Table Of Contents

    ™ 000/4001 Table of Contents 1: P HAPTER HYSICAL ETUP Unpacking the printer printer orientation Features of the QLS-4000 Color Printer Port and power connections Dip switch settings Loading label media Loading thermal transfer ribbon 1-13 Adjusting ribbon tension 1-15 2: S HAPTER OFTWARE...
  • Page 4 2-21 ERFECTING OLOR LIGNMENT Making print line adjustments 2-23 Cross-web adjustment 2-26 Evaluating print quality 2-28 2-29 YSTEM AINTENANCE Performing a factory reset 2-29 System Upgrade 2-29 QLS-4000/4001 Settings 2-30 System Baseline 2-31 3: O HAPTER PERATION QLS-4000/4001 RINTING WITH THE Advancing the media Setting the printer speed Printing labels or test patterns...

  • Page 5: Chapter 1: Physical Setup

    ™ 000/4001 Chapter 1: Physical Setup The physical setup of the QLS-4000 or QLS-4001 Printer entails the proper loading of the transfer media (ribbon) and label stock. This chapter provides the following information: instructions on unpacking the printer and making proper connections an overview of the components and features of the printer...

  • Page 6: Unpacking The Printer

    Unpacking the printer Remove the printer from the packing carton. In the packing carton, locate and remove the follow- ing items shipped with the printer: power cord ® Centronics parallel cable serial cable media retainer Windows ® driver disk Ensure that the printer is in good condition and has suffered no visible damage during shipment.

  • Page 7: Printer Orientation

    printer orientation The illustration below is provided to orient you to the QLS-4000 or QLS-4001 Printer. The keypad with display is the printer’s user interface. rear of printer front of printer printer keypad (user interface) QLS-4000/4001 Physical Setup...

  • Page 8: Features Of The Qls-4000 Color Printer

    Features of the QLS-4000 Color Printer Facing the front of the QLS-4000 with its cover lifted, you can view the printheads and related mechanical parts. The QLS-4001 contains the same parts, only with one inverted print station. The callouts below identify the QLS-4000 parts shown in the illustration on the next page.
  • Page 9 9 10 13 12 QLS-4000/4001 Physical Setup...

  • Page 10: Port And Power Connections

    Port and power connections On the back of the printer, the parallel and serial port connectors and the power input are readily observable. Connect the proper cable(s) to the port or ports you intend to use: parallel, serial, or both. Communica- tions to the printer can be either serial or parallel;...

  • Page 11: Dip Switch Settings

    Dip switch settings Use the instructions below and the table on the next page to set the dip switches to your printing requirements. Set dip switch 4 off for serial communications; set dip switch 4 on for parallel or dual (parallel into printer/serial out) communications.
  • Page 12 Baud Rate 1 on 1 off 1 on 1 off 2 off 2 on 2 on 2 off 4800 9600 19200 38400 Handshake Port 4 off 4 on 3 off 3 on serial parallel DTR/DSR XON/XOFF 5 off 6 off factory factory set to off...

  • Page 13: Loading Label Media

    Loading label media If you will be printing spot color, you can load any color film you wish on the printheads in any sequence. If you will be printing process color, the film must be loaded on the printheads in the following sequence: Print Station 1 —...
  • Page 14 Flip the drive roller pressure cam lever counterclock- wise to relieve pressure on (open) the drive roller. drive roller pressure cam open Remove the media retainer from the media supply mandrel; install a roll of media on the mandrel. Ensure that the roll is fully seated on the mandrel. Re-install the media retainer to secure media roll.
  • Page 15 Feed the media through the media travel sensor housing and over the media travel roller. Thread the media through the print stations, over the platen rollers (under the platen roller on an inverted print station). guide blocks drive platen roller rollers QLS-4000 After threading the media over the platen roller for...
  • Page 16 For the standard printheads, flip each printhead cam lever counterclockwise to apply pressure to (close) the printheads; for an inverted printhead, flip the cam lever clockwise to close the printhead. inverted printhead closed standard printhead closed 12 Flip the drive roller pressure cam lever clockwise to apply pressure to (close) the drive roller.

  • Page 17: Loading Thermal Transfer Ribbon

    Loading thermal transfer ribbon This procedure describes how to load thermal transfer ribbon at each print station. As an aid, a diagram of the thermal transfer ribbon (TTR) path for coated-side-in ribbon is screened onto the printer’s main plate at each ribbon loading station. To load TTR at a standard print station: Fully seat a roll of coated-side-in TTR on the station’s supply mandrel.
  • Page 18 To load TTR at an inverted print station: Fully seat a roll of coated-side-in TTR on the TTR supply (left-most) mandrel. Ensure that the ribbon unwinds to the left of and above the roll. Fully seat a cardboard take-up core on the associ- ated TTR take-up (right-most) mandrel.

  • Page 19: Adjusting Ribbon Tension

    Adjusting ribbon tension Once you have loaded the label stock and the film, you are ready to begin printing. However, if while printing you notice one of the following problems, it may be necessary to adjust the ribbon tension: Ribbon on one or more of the take-up mandrels is wrinkling. Increase the ribbon tension for the station(s).

  • Page 20: Chapter 2: Software Setup

    ™ 000/4001 Chapter 2: Software Setup Prior to printing, you must perform the following functions: Define the type of media loaded on the printer. Specify the image dimensions, label dimensions, any offsets, and whether top-of-form indicators are present. Calibrate the printer for the type of media being used. This step is essential and is the first procedure that must be performed after every change of label size or type.

  • Page 21: Setup Menus And Keypad Controls

    Setup Menus and Keypad Controls The following menus are accessible through the front panel: TTR Sensor Calibrate Speed Intensity (temperature of printheads 1 through 4) Print Offset Counter Windows Print (if Windows Mode is enabled) Mirror Mode (if Windows Mode is not enabled) Cutter Flag Cutter Offset (if cutter is enabled) Print Line Adjustment (for printheads 1 through 3)
  • Page 22 The keypad pushbuttons perform the following general functions: pushbutton function PRINT/PAUSE toggles the printer between “printing” and “paused.” FORM FEED/ advances the media by one full label length ADVANCE each time the button is pressed, or continu- ally advances the media when the button is held.

  • Page 23: Form Feed / Advance Media

    Form feed / advance media The [FORM FEED / ADVANCE] pushbutton is used to either advance the label media to the top-of-form index mark, notch, or gap of the next label or to continually advance the media. The form feed function will not work unless the QLS-4000/4001 has been calibrated.

  • Page 24: Enabling/Disabling The Ttr Sensor

    Enabling/disabling the TTR sensor This menu is for use by QuickLabel Systems' technicians when running diagnostics at the factory. In general use, the TTR Sensor should always be set to "enabled." CAUTION This capability is intended for factory diagnostics only. Do not disable the sensor.

  • Page 25: Calibrating The Printer For The Media

    Calibrating the printer for the media Note Calibrating the printer for the type of media being used is essen- tial and is the first procedure that must be performed after every change of label size or type. If the printer is not properly cali- brated, any of the following may occur: media advances, but no image is printed.
  • Page 26 Make sure that the printer is paused. (Press the PAUSE/PRINT pushbutton, if necessary.) Press the [FORM FEED / ADVANCE] pushbutton until the gap, notch, or index mark separating the labels on the roll of media is positioned within two inches of the media travel sensor housing.
  • Page 27 Make sure that the gap, notch, string hole, or punchout is aligned with the pointer on top of the media gap sensor: The notch, string hole or punchout must be aligned with the pointer on top of the media gap sensor. If the media has a gap between labels, pointer...
  • Page 28 Press the [SELECT] pushbutton again. The QLS-4000/4001 will immediately perform an auto- matic calibration. When the calibration is complete, a message will be displayed that shows two values that indicate the relative reflectivity or transmissiveness between the label and index mark or gap. There should be a difference of at least 60 between the two values;...

  • Page 29: Selecting A Print Speed

    Selecting a print speed This parameter sets the speed of the printer, which ranges from 2 inches per second to 5 inches per second. Whether the printer is in the ready or paused state, press the [NEXT] or [PREVIOUS] pushbutton until the SPEED menu is displayed.

  • Page 30: Adjusting Printhead Heat Intensity

    Adjusting printhead heat intensity The printhead temperature intensity determines the temperature of the printhead. The amount of heat applied to the film determines the darkness or intensity of the print. The amount of heat that is actually applied to the film by the printhead is determined by two factors: the length of time that power is applied to the printhead the rate at which the stock passes below the printhead The intensity setting determines the first factor;...
  • Page 31 The Intensity menu allows you to set the heat intensity at the printer's keypad. Bear in mind, however, that setting the intensity via software will always override this setting. You can set the intensity via Color QuickLabel ® , the QLS Windows ®...

  • Page 32: Adjusting The Print Offset Setting

    Adjusting the print offset setting By default, when printing on media with registration marks (gaps, reflective marks, etc.), the printer will place the label image between the registration marks. You can, however, use the print offset adjust- ment to adjust print registration in fine increments or to move the printed image completely with respect to the sensor mark.

  • Page 33: Counter

    Print offset settings are measured in single pixel incre- ments. Twelve (12) pixels equal one (1) millimeter in length. Press the [SELECT] pushbutton to confirm your choice. An asterisk will appear in the display. Counter The QLS-4000/4001 can automatically and dynamically display either the ongoing total number of labels that have been printed or the number of labels that have been printed within any specific batch.
  • Page 34 Press the [SELECT] pushbutton to select the counter option you want. Press the [SELECT] pushbutton again. The selected counting display will appear in the menu. When the “total” setting is selected, the Counter menu dynamically displays the ongoing total of labels printed.

  • Page 35: Windows Print

    Windows Print You can print to the QLS-4000/4001 Printer from within any Win- dows ® application (such as CorelDRAW! ® , Microsoft Word ® , etc.) ® ® with the QuickLabel Systems printer driver for Windows . The driver is installed from within the Windows ®...
  • Page 36 If available, use the procedure below to enable/disable mirror mode. Press the [NEXT] or [PREVIOUS] pushbutton until the Mirror Mode menu is displayed. P a u s e : M i r r o r M o d e O f f Press the [+] or [-] pushbuttons until the setting that you want is displayed.

  • Page 37: Enable Cutter

    Enable Cutter This option applies only if your printer is equipped with a cutter or cutter-stacker. The cutter or cutter-stacker must be properly posi- tioned and connected to the printer, and the media must be properly threaded through the printer and into the cutter before you enable the cutter.
  • Page 38 After the cutter unit has been set up and enabled, you can enable or disable the insertion of extra blank tickets to demarcate (flag) the end of a batch. When enabled, the printer will automatically insert a long and a short blank ticket between batches. The long ticket is approximately of an inch (~10 millimeters) longer than the current ticket length.

  • Page 39: Cut Offset

    Cut Offset When printing on media with registration marks (gaps, reflective marks, etc.), the printer will place the label image area between the registration marks. If necessary, you can adjust the location of the cut line relative to the printed image. The Cut Offset can be used to move the cut line forward or backward with respect to the top of the label.

  • Page 40: Perfecting Color Alignment

    Perfecting Color Alignment Color alignment refers to the alignment of each color with respect to the other colors: “Print line adjustment” refers to the vertical adjustment of a color’s print position on the media. “Cross-web” refers to the horizontal adjustment of a color’s print position on the media.
  • Page 41 You will also examine the block patterns to observe both the horizontal and vertical alignment. If any color appears horizontally misaligned, the cross web values require adjustment; if any color appears vertically misaligned, the print line adjustment values require adjustment. horizontal misalignment vertical misalignment requires cross web...

  • Page 42: Making Print Line Adjustments

    Making print line adjustments The point of making print line adjustments is to align the print locations of all printheads with one another. These adjustments finely adjust the registration of print stations 1, 2, and 3 with refer- ence to print station 4. Because print station 4 (closest to the media supply spindle) is used as the reference station, it cannot be adjusted.
  • Page 43 Press the [SELECT] pushbutton again. The printer will immediately begin to print labels showing the block test pattern. Printing will continue during the adjustment process and will not stop unless the printer is paused or the operating state of the printer is changed. The pattern on the test labels will show each of the current print locations providing a visual indication of how much adjustment each print location needs.
  • Page 44 Press the [+] or [-] pushbuttons to shift the selected print location. Note Print line adjustment settings are measured in single pixel increments. Twelve (12) pixels equal one (1) millimeter in length. An efficient way to shift the print line for a given print station is to measure the variation from the reference bar in the test pattern.

  • Page 45: Cross-Web Adjustment

    Cross-web adjustment The best method for evaluating web alignment is to examine the block test pattern. Lack of alignment in the test print indicates poor web alignment. Press the [PRINT / PAUSE] pushbutton to pause printing. Press the [NEXT] or [PREVIOUS] pushbutton until you select the Cross Web Adj menu.
  • Page 46 Examine the process black box. It should appear black, without any other color along an edge. If a color shadow appears along an edge, that print station is in need of alignment. Also examine the block patterns to observe the horizontal alignment.

  • Page 47: Evaluating Print Quality

    Evaluating print quality Press the [PRINT / PAUSE] pushbutton to put the printer into the “pause” mode. Press the [NEXT] or [PREVIOUS] pushbutton until the “Test Print” menu is displayed. Press the [+] or [-] pushbuttons to scroll through the test patterns and select "Test Pattern: x in."...

  • Page 48: System Maintenance

    System Maintenance The following settings allow you to make system-wide adjustments to the QLS-4000/4001. Performing a factory reset The factory reset feature of the printer returns all parameters avail- able through the printer’s keypad interface to their factory default values. Use the procedure below to perform a factory reset. Press the [PRINT / PAUSE] pushbutton until the printer is in the paused state.

  • Page 49: Qls-4000/4001 Settings

    QLS-4000/4001 Settings If you wish to know all the current settings for the QLS-4000/4001 printer, print out this brief report as follows: Press the [PRINT / PAUSE] pushbutton until the printer is in the paused state. Press the [NEXT] or [PREVIOUS] pushbutton until the QLS-4000/4001 Settings display is shown.

  • Page 50: System Baseline

    System Baseline This parameter is used to synchronize printing when using multiple QLS-4000/4001 Printers. If you are sending the same image file to two or more printers and notice that the image prints in different locations, you can use this parameter to move the system baseline of a printer.

  • Page 51: Chapter 3: Operation

    ™ 000/4001 Chapter 3: Operation Once the QLS-4000/4001 Printer has been set up properly, you can send labels to the printer from your application of choice. The QLS- 4000/4001 will begin printing as soon as the label is downloaded, as long as it is in the ready state.

  • Page 52: Printing With The Qls-4000/4001

    Printing with the QLS-4000/4001 When you turn on your printer, it will quickly run an initialization procedure and self-test. After “selftest complete” is displayed, the display should show “Ready.” When you download a label, the printer will begin printing the label as long as the printer is in the “Ready” state.

  • Page 53: Advancing The Media

    Advancing the media pushbutton can be used to advance [FORM FEED/ADVANCE] the label media by one label length, or to continually advance the media. Press the [FORM FEED/ADVANCE] pushbutton once and release to advance the media by one label length. Press and hold the [FORM FEED/ADVANCE] pushbutton to continually advance the media.

  • Page 54: Setting The Printer Speed

    Setting the printer speed The printer can print at speeds from 2 inches per second to 5 inches per second. When setting the motor speed, consider the requirements of the media and TTR you are using and the heat setting you are selecting.

  • Page 55: Printing Labels Or Test Patterns

    Printing labels or test patterns To print labels, you need to send a label from QuickLabel Systems’ Color QuickLabel software program, or from any other label creation or graphics application. Before sending a label to the printer, make sure that the printer is turned on and is in the “Ready”...

  • Page 56: The Printer's Indicators

    The Printer’s Indicators When power is on, the printer has four indicator lights that provide a visual cue to the printer’s current activities or state: indicator function When the green POWER indicator light is POWER illuminated, the printer is ready to operate. Assuming the printer is properly set up and a label or test pattern is currently selected, pressing pushbutton will cause print-...

  • Page 57: Using Test Patterns To Evaluate Print Quality

    Using test patterns to evaluate print quality The printer can print four types of test patterns: process block, horizontal line, test patterns, and block (all): pattern function Proc. Block / The block test patterns are most useful for assessing color registration by ensuring that the Block (All) colors are aligned with each other.
  • Page 58 Use the procedure below to select and print a test pattern. Press the [PRINT/PAUSE] pushbutton to put the printer into the “Pause” mode. Press the [NEXT] or [PREVIOUS] pushbutton until the “Test Print” menu is displayed. Press the [+] or [-] pushbuttons to scroll through the test patterns and select the pattern you wish to print.

  • Page 59: Chapter 4: Maintenance

    ™ 000/4001 Chapter 4: Maintenance To keep your printer in optimal operation, you should perform a few routine maintenance procedures: The printer should be kept clean and free of residue. The printheads should be cleaned in place after 5000 lineal inches of stock have been printed. After 50,000 lineal inches have been printed, the printheads may need to be removed and cleaned more thoroughly.

  • Page 60: Routine Cleaning Of Printer Parts

    Routine cleaning of printer parts The parts of each print station, especially those that come in direct contact with the film, will accumulate residue. To maintain clear and crisp printing, these parts should be cleaned frequently. The printheads in particular require regular cleaning. The frequency of cleaning depends on the number of labels you print.
  • Page 61 Remove any label media and thermal transfer ribbon loaded on the printer. Obtain a cleaning pad (Astro-Med part number 13832-000) or wet a cotton swab or a soft lint-free cloth with isopropyl alcohol. Raise each individual printhead assembly with your hand.
  • Page 62 CLEAN PRINTER PARTS edge of printhead strut film guide shafts print line platen roller pressure roller drive roller Run the damp swab over each of the following printer parts: platen rollers guide rollers film guide shafts pressure roller drive roller Reinstall any label media and thermal transfer ribbon.

  • Page 63: Adjusting Printhead Pressure

    Adjusting printhead pressure If your printing tasks require you to switch between very wide label media and very narrow label media, it may become necessary to adjust the downward pressure on either side of the printheads. Similarly, if you switch between relatively thick media (such as card stock) and thin media, printhead pressure adjustments may be necessary.
  • Page 64 Note This procedure is specifically concerned with printhead pressure and its effect on print quality. Be aware that other factors such as printhead temperature and type of TTR stock also affect print quality. Use the procedure below to adjust the pressure on any of the printheads: Examine printed labels to determine the necessary adjustments.
  • Page 65 To make adjustment easy, press down the silver clip holding the printhead cam and pull the cam com- pletely out. clockwise turns silver clip inner increase printhead thumbwheel pressure counterclockwise outer turns decrease thumbwheel printhead pressure PRINTHEAD CAM With the cam in hand, make minor adjustments to printhead pressure by turning the thumbwheels as required to maximize the clarity and detail of the label.
  • Page 66 Slide the cam back in place, making sure that the silver clip is securely seated. Flip the printhead cam closed to restore pressure to the printhead. Repeat the process for each printhead. Turn the printer on and print labels to examine whether pressure is correct or if further adjustments are necessary.

  • Page 67: Replacing The Printheads

    Replacing the printheads If a printhead fails, it is easily replaced as described in this section. A printhead may occasionally have to be removed for thorough cleaning — in general, after 50,000 lineal inches of stock have been printed. The following procedure explains how to remove and replace any individual printhead.
  • Page 68 Loosen the selected printhead’s center captive retaining screw by turning it counterclockwise until it is sufficiently unscrewed so that you can easily detach the printhead. Ensure that the cable harnesses that attach to the printhead are not damaged when the printhead is removed.
  • Page 69 10 Position the replacement printhead against the printhead retaining plate for attachment to the plate. Make sure that the two side screws are fitted through the corresponding holes in the new printhead. Reinsert and tighten by hand the printhead’s captive retaining screw.

  • Page 70: Adjusting Ribbon Tension

    Adjusting ribbon tension In Chapter 1, adjustment of the ribbon tension was described as a procedure that would possibly be required after film loading. Nor- mally, this adjustment should not be required during the life of a film roll. However, if you notice film wrinkling or one of the colors smudging, you can adjust the tension to alleviate these conditions.

  • Page 71: Replacing The Drive Roller Or Pressure Roller

    Replacing the drive roller or pressure roller After prolonged use, the drive roller or pressure roller may develop flat areas, which will impede the smooth exit of label stock. When this occurs, the roller will require replacement. The following procedure explains how to remove and replace the drive roller or the pressure roller.
  • Page 72 Press down the silver clip holding the cam, pull it completely out, and set it aside. silver clip DRIVE ROLLER CAM To provide more room to maneuver, you may want to also remove the printhead cam on the print station to the left of the drive roller. To access the drive roller, lift the pressure roller off of the drive roller.
  • Page 73 If you need to replace the drive roller, perform steps 8 through 14; if you need to replace the pressure roller, proceed to step15. To remove the drive roller: On the outside of the drive roller, remove the retaining bracket by removing the Phillips screw on the lower portion of the plate.
  • Page 74 11 Insert the fresh drive roller, making sure that the roller is fully seated, with the flat edge of the shaft coming in contact with the Allen screw. 12 Replace the retaining plate, lining up the flange and two small pins and ensuring they are fully inserted into the plate.
  • Page 75 17 Remove and replace the pressure roller. 18 Replace the E-rings and washers to secure the pressure roller in the pressure roller assembly. 19 Replace the pressure roller assembly onto the pressure roller pivot shaft. Secure the assembly by replacing the larger E-ring and washers on the outer plate.

  • Page 76: Replacing The Platen Rollers

    Replacing the platen rollers Occasionally, you will also need to replace the printhead platen rollers. After prolonged use, one or more rollers may develop flat areas, which will affect print quality. When this occurs, the roller(s) will require replacement. The following procedures explain how to remove and replace the platen rollers.
  • Page 77 CAUTION Do not force the roller when removing or when replacing. Difficult removal or replacement generally occurs if the roller is held at an angle. Removal or replacement is easy when the roller is lifted straight out or dropped straight in. Hold assembly up Lift roller up and out Gently place the new roller(s) in position.
  • Page 78 To replace the platen roller on an inverted printhead: Turn the printer off and lift the printer’s cover. Flip the printhead cam down and lock into the “open” position. Remove any label stock that may be positioned under the platen roller. Using a Phillips-head screwdriver, remove the two #4 Phillips-head screws that secure the roller retain- ing bracket.
  • Page 79 Gently place the new roller in position and hold in place until you have reinstalled the retaining bracket. Slide the roller retaining bracket back into place, securing the inner edge into the printer’s main plate. Replace the two Phillips-head screws to secure the bracket into place.

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