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AstroNova QuickLabel QL-250 Service Manual

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  • Page 2 QL-250 Service Guide Part Number 22834727-EN-E Revision 1.0 9/2024 AstroNova, Inc.® 600 East Greenwich Ave., West Warwick, RI 02893 Tel: (877) 757-7978 Fax: (401) 822-2430 info@astronovaproductid.com www.AstroNovaProductID.com...
  • Page 3 This manual is copyrighted with all rights reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without written permission of AstroNova. Trademarks QL-250®...

  • Page 4: Table Of Contents

    Contents Contents Chapter 1: Introduction ............9 Intended Audience .
  • Page 5 Contents Chapter 3: Functional Operation ..........28 Sequence of Operation .
  • Page 6 Contents Chapter 4: Disassembly / Assembly Procedures ........67 Printer Basic Disassembly .
  • Page 7 Contents Potentiometer Assembly..........130 Recalibrate Unwinder .
  • Page 8 Contents Appendix D: Adjusting Sensor Readings for Various Types of Media ....190 Settings to be Changed..........190 Finding the Right Reading Levels for your Gaps / Markers .

  • Page 9: Introduction

    Introduction Chapter 1: Introduction Intended Audience This service guide is intended for use by qualified service and maintenance personnel. For operation and configuration information, refer to the QL-250 User Guide. This Service Guide assumes you have read the QL-250 User Guide and that you have it available for reference. Note: This service guide is for use by authorized service and maintenance personnel.

  • Page 10: Protective Clothing

    Introduction Protective Clothing If a possible danger to your eyes is present, wear protective goggles, especially in the following cases: • When knocking in or knocking out pins and similar parts with a hammer. • When using spring hooks. • When loosening or inserting springs, snap rings, and gripping rings.

  • Page 11: Additional Precautions For Devices With Exposed Energized Parts

    Introduction Additional Precautions for Devices with Exposed Energized Parts • Give another person the task of remaining near the workplace. This person must be familiar with the location and operation of the emergency stop and power switches and be able to switch off the power if danger arises.

  • Page 12: Troubleshooting

    Troubleshooting Chapter 2: Troubleshooting This section is arranged by first the condition that might occur, and then by possible problems, causes, and recommended solutions. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 13: Power Problems

    Troubleshooting Power Problems Condition Problem Solution Power is ON, nothing No power to printer. Check that the power cord is plugged in. happens. Check that the power outlet is live. Replace the AC adapter. Interface Communication Problems Condition Problem Solution Printer does not respond to Connection Problems.

  • Page 14: Service Station

    Troubleshooting Service Station Condition Problem Solution Motor stalls. Jammed gear train due to a Check each of the possible causes and broken post, or improperly correct if possible. (e.g. re-seat gears and/or seated gears. squeegee, clean debris from the blade and rollers, etc.).
  • Page 15 Troubleshooting Condition Problem Solution ink mixing - mixed or muddy Caused by ink flooding, air in Clean the printhead using a Cleaning Levels colors. the printhead, or a dirty in the Driver or Toolbox. printhead. Wipe the printhead with distilled water and a wet, clean, lint-free cloth.

  • Page 16: Printing Problems

    Troubleshooting Printing Problems CONDITION PROBLEM SOLUTION Ink Tank installed, no Ink Level Ink Tank contacts are dirty, Remove the ink tank(s). Clean the indication in Toolbox. preventing printer / ink tank prism and the QA Chip contacts. communication. See “Cleaning Ink Tank Contacts” on page 147.

  • Page 17: Errors And Warnings

    Troubleshooting CONDITION PROBLEM SOLUTION At the start of the job, the media The printer is not set for the type Reset the printer for type of media runs and stops without printing. of media being used. used. The Blackmark Sensor is not Blackmark: Set the printer for reading blackmark on the media thicker media in the Toolbox.
  • Page 18 Troubleshooting MESSAGE SOLUTION Incorrect...Ink Tank Replace the ink tank. Ink tanks must be purchased from an authorized supplier for this printer model..Ink Low Reorder ink. Example: Black Ink Low ..Out of Ink Replace the empty ink tank. Example: Cyan Ink Out Load Paper.

  • Page 19: Toolbox System Status Messages

    Troubleshooting MESSAGE SOLUTION Unauthorized Printhead. Printhead cartridges must be purchased from an authorized supplier for this printer model. Toolbox System Status Messages Valid for printers with firmware version R15.1 or higher installed. Use the Toolbox System Status screen to quickly determine and locate a problem in the Printers. The Status Indicator ERROR shows in the red box.
  • Page 20 Troubleshooting Listed below are some of the messages that may appear in System Status: SYSTEM STATUS PROBLEM SOLUTION PAPERPATH_END_OF_ROLL Out of media. Add a new roll of media to the Unwinder. The Unwinder Label Tension Arm has hit its Load media into the printer and upper or lower limit.
  • Page 21 Troubleshooting SYSTEM STATUS PROBLEM SOLUTION DATA_PATH_UNDERRUN The media is not getting from Check / clean the Transport the Entry Sensor to the Exit Rollers. Sensor in the allotted time. Check/ clean the Sensors. Slow data transmission. Select Buffer from MC Series Dirty Encoder Wheel or a Driver.
  • Page 22 Troubleshooting SYSTEM STATUS PROBLEM SOLUTION System Status: The ink tank is missing or not Insert the missing ink tank, or pop CARTRIDGE_MISSING_MULT recognized (obtained from an the ink tank in and out to improve unauthorized reseller). the connection. Mech State: STANDBY If correct, check contacts.
  • Page 23 Troubleshooting SYSTEM STATUS PROBLEM SOLUTION System Status: Mechanical error. Visually inspect the components MECH_FAIL_PERMANENT stated as a “Reason” for failure. One of the printer’s Mech State: STANDBY mechanical components was Using the Scan Sensors screen not properly registered at the in the Toolbox, perform a toggle Mech Status: expected position.
  • Page 24 Troubleshooting SYSTEM STATUS PROBLEM SOLUTION System Status: The printhead is missing and The printhead is missing and one PRINTHEAD_MISSINGQA one or more ink tanks are or more ink tanks are missing. missing. Mech State: STANDBY When this error occurs, Multiple When this error occurs, EWS monitoring is disabled.

  • Page 25: Air In The Ink Lines

    Troubleshooting SYSTEM STATUS PROBLEM SOLUTION MECH_CANCELPAGE The job was canceled by the Wait until the print job has cleared user pressing the CANCEL/ from the printer, then manually CUT button. clear the job from the computer’s print queue. Send the new print Job was interrupted by the job.

  • Page 26: Software Problems

    Troubleshooting 5. Uncheck the dpv_fix box. 6. Click Submit. 7. Select Circulate Ink again, and check for air bubbles in the Ink Lines. If everything looks OK, leave dpv_fix unchecked, exit the service menus and continue printing. If the condition persists, a worn DPV valve or other problem may be indicated. Note: * This procedure is primarily relevant for printers manufactured prior to mid-2015.

  • Page 27: Misfeeds

    Troubleshooting 2. Release and lift up the two latches [A] (one on each side of the Print Engine Clamshell) at the same time to raise the Print Engine Clamshell [B]. 3. Clear the jam, then carefully lower and relatch the print engine. 4.

  • Page 28: Chapter 3: Functional Operation

    Functional Operation Chapter 3: Functional Operation Sequence of Operation The user prepares the printer: 1. Installs the Ink Tanks in the proper locations. 2. Loads media and adjusts the side guide to within 1/32” of media. 3. Turns the printer ON The user prepares the layout and creates a job: 1.

  • Page 29: Printer Controls

    Functional Operation Printer Functional Description 1. The photosensor located at the entry to the print engine sees the lead edge of the media and signals the print engine on the main board that the piece is ready for printing. 2. When the Print button is pressed, the print engine draws the media into the print section. 3.
  • Page 30 Functional Operation PRINT / PAUSE (PAUSE JOB / RESUME) - Temporarily stops the feed or resumes printing. • Press to Pause Job Temporarily - The printer finishes printing media in progress, then stops and holds. Press once to pause jobs for up to 30 seconds to clear jams or other quick maintenance (does not cap the printhead).
  • Page 31 Functional Operation CONTROL PANEL LED SEQUENCE PRINTER STATUS RECOMMENDED OPTIONS Job submitted, Wait for the process O - Power Down printing. to finish. powering O - Pause Printing down. O - Pause Printing, Pause: The printer stops and holds Cancel Job (Printhead not capped).

  • Page 32: Printer Default Printing Modes

    Once the job is set up, select Print. Ensure that the QuickLabel QL-250 Driver is selected. Clicking on Properties opens the Properties Window. QL-250 Service Guide...

  • Page 33: General Tab

    Functional Operation General Tab The General Tab lets you select: • Orientation - Portrait (default), Landscape, Rotate 180, and Mirrored. Page Management: • • Stitch is for printing on continuous media (no gaps) • Buffer loads the entire print job before printing starts. Mask Optimization (checked is default) optimizes images for printing in most •...
  • Page 34 Functional Operation • Media - Adjusts the Printer for the media being used for a job. • Type - Choose a type of media to be used. Size - Set a different size of media than the document was originally designed for. The •...

  • Page 35: Layout Tab

    Functional Operation Layout Tab Layout allows you to change how the document prints without changing the original document. • Resizing - Specify Original Size or Custom Resize. Custom Resize resizes the original as a percentage of the normal size. The printer prints the document in the size you selected regardless of the paper size selected.
  • Page 36 Functional Operation Example of a Label Frequency of “2” QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 37 Functional Operation Using Layout Tab Printing Adjustments Image Position - Left Adjustment moves the image area away (-3mm left to +200mm right) • from the left edge of the media. • Top Adjustment - Moves the image up or down (-5mm up to -200mm down) from the top left corner of the media used (0.1mm increments).

  • Page 38: Color Tab

    Functional Operation Color Tab Color is used to adjust the color output of the printer. Use the sliders to adjust Color, Tone, Brightness, and Saturation. The C,M,Y,K sliders adjust individual colors. Use Defaults to reset to 0 settings. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 39: Import / Export Tab

    Functional Operation Import / Export Tab Import / Export is used to preserve any custom Media Sizes, Watermarks, and/or Print Settings you may have developed and saved for various jobs when you update the Printer firmware. • Export - Send custom settings to a holding file before downloading new firmware. •...

  • Page 40: Services Tab

    Functional Operation Services Tab The Services tab allows you to: • Print Configuration Page - Prints out the current configuration of the Printer including current Firmware Version, Network Connection, Printer Serial Number, and more. • Print Colorbar Page - Prints type and color bands to check the print quality. Print Diagnostic Page - Displays basic Printer Information, memory, Network Settings, Event •...

  • Page 41: Using The Printer Toolbox

    Functional Operation Using the Printer Toolbox Once the Printer Driver is installed, you can access the Printer Toolbox. You can check the status of the printer, monitor ink usage, perform diagnostic checks, print reports, and run maintenance tasks on the printer from your computer. The Toolbox works with both conventional and touchscreen computer screens.
  • Page 42 Functional Operation When the System Status Window opens, you will see the following: • System Status Indicator and Drop-Down Menu Options (at the top of the screen). Check Printer Status (across the middle of the screen). • • Seven often-used control buttons (at the bottom of the screen). Within the Printer Toolbox, there are four Drop-Down Menus: View, Maintenance, Service, and Print.

  • Page 43: View Drop-Down

    Functional Operation View Drop-Down The View Drop-Down gives you four choices (shown below): • System Status • User Interface • Ink Usage • Service Menus QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 44: System Status

    Functional Operation System Status The following screen opens when you access the Toolbox. It provides information about the status of the printer. • Status Indicator -- shows the printer’s activity as ONLINE, ERROR, MAINTENANCE, PRINTING, or PAUSED. The gray box below the Status Indicator shows the name of the job being processed.
  • Page 45 Functional Operation Note: Tapping or rolling over any of the status icons with your cursor pops up a description of that icon. Control Buttons are located along the bottom of the screen: • Pause / Resume -- Tap to temporarily stop printing. Tap again to resume printing. •...

  • Page 46: User Interface

    Functional Operation User Interface BASIC PRINTER SETTINGS Adjusts the printer for different types of media, automated service and cleaning intervals, and feeder speed for a job. • Media Feed -- Sets the Printer Sensors to read the type of media and/or gaps between media: continuous, die-cut, or black-mark.
  • Page 47 Functional Operation • Print Mode -- Selections to choose from: • Automatic -- Use the Automatic setting when using the UW-250 and/or the RW-250. • Manual -- Use the Manual setting when using the printer with another brand of unwinder or winder to access manual controls of certain printer functions.
  • Page 48 Functional Operation have four sets of 5 labels, and one set of 3 labels. • Mid Job Servicing -- Sets the frequency of automatic maintenance cycles run during a job after a set amount of media is run. Settings are Default (14m), Level 4 (100m), Level 3 ...
  • Page 49 Functional Operation FIRMWARE DOWNLOAD Allows you to find and load the latest firmware (“.fbf”) files for your printer using the Printer Toolbox. Warning: This procedure should only be performed by qualified service personnel. In some cases, firmware must be loaded using the Firmware Migration Tool. If this process is not performed properly, the printer is rendered inoperable.
  • Page 50 Functional Operation INK USAGE Displays the amount of ink used and other information for each job sent to the printer. This tab also tracks the estimated Page and Job Costs if information is entered into Job Cost Settings. • Upload Table -- Creates and opens a linkable tabular file using programs such as Microsoft Excel (default).
  • Page 51 Functional Operation Click Submit to activate the mode after being selected. Note: The estimating process takes as long as the job would take to print. If the job would take one hour to print, then the estimate will also take one hour to display. •...

  • Page 52: Service Menus

    Functional Operation Service Menus Selecting View then Service Menus opens the Service Menus screen. • Diagnostics button -- Click to check the status of the printer. See “Diagnostics” on page 53. • System Settings button -- Click to view, enter, or change settings to connect the printer to your network.

  • Page 53: Diagnostics

    Functional Operation Diagnostics The Diagnostics screen allows you to view the current status of the printer. QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 54 Functional Operation You can also: • Upload Debug Log -- Download and save a log of the printer status (for each printer) to send to a technician to help diagnose a problem. Clicking this button creates a snapshot log showing everything going on with the printer since powering up (see Sample Log below). Note: If a problem arises, try to recreate the problem, then press Upload Debug Log without performing any other actions to make it easier for the technician to determine the problem.

  • Page 55: System Settings

    Functional Operation System Settings The System Settings screen allows you to set up a network connection for the printer as well as to set and configure the Date and Time visible on the printer’s screen. The Network Settings fields allow you to view, enter, or change settings in order to connect the printer to your desired network.
  • Page 56 Functional Operation 5. Enter the correct settings for the network you want to connect to in the Network Settings fields. 6. Click Submit. 7. Connect an Ethernet cable to the Network Port on the rear panel of the printer. QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 57 Functional Operation The Date and Time fields allow you to enter or change the way that the date and time will appear in the Printer Status section of the Toolbox screen. To enter or change the Date and Time settings: 1.

  • Page 58: Media Scan

    Functional Operation Media Scan Use Media Scan if the media is not printing correctly. With Media Scan, you can scan media to determine if you need to use the Thick Media setting (see Basic Printer Settings in the User Interface section). You can also determine if a type of media is going to have problems printing, generally due to sensors having trouble differentiating between the label surface and the backing / gap.
  • Page 59 Functional Operation 5. Under Media Scan Setup, set the Scan Mode: LabelGap_Tickmark, LabelGap_TOFBOF, or Tickmark_TOFBOF. 6. Set Sensor: Select which sensor is active, either LabelGap (diecut) or Tickmark. 7. Set Label Length mm by entering the length of label to be measured. 8.
  • Page 60 Functional Operation 11. Click Scan Media. The blank media moves across the sensors to create the graph shown on the screen. Rolling your cursor over the graph provides readouts of different points on the graph. See examples below. Generally, use the Thick Media setting on the User Interface screen when there is little difference between high points (gaps/backing) and flats (label media).

  • Page 61: Scan Sensors

    Functional Operation Scan Sensors Provides status and log on the sensors located throughout both printers (see chart). Click the Stop button to stop scanning, or click out of Scan Sensors. SENSOR DESCRIPTION Entry Sensor (Paper Interrupted (media present) = 0-60. Path Entry) Uninterrupted (no media) = 255 Blackmark Sensor...

  • Page 62: Service Menus

    Functional Operation SENSOR DESCRIPTION Sled Index Cap Position = 0 Print/Wipe positions = 1 Sled Home False = 0 True = 1 Valve Position Displays operating positions of the Dual Pinch Valve: “OpenAir”, “OpenInk”, and “Closed.” “Unknown” will display as the Valve transitions between positions.
  • Page 63 Functional Operation Printer Control Configuration • Allows you to make fine adjustments as to how a job is fed into and through the printer and how it will print. You can also return to the default printer settings by selecting Reset to Factory Settings.

  • Page 64: Maintenance Drop-Down

    Functional Operation Maintenance Drop-Down Perform maintenance tasks: • Circulate Ink -- Purges air from lines and primes the system after replacing the Ink Tanks or the Printhead Cartridge. Quick Clean Printhead -- Circulates ink, wipes, and cleans the Printhead Cartridge (also •...

  • Page 65: Service Drop-Down

    Functional Operation Service Drop-Down Contains control functions that require the Printer to be out of service for extended periods of time while they are being performed. • Replace Ink Tanks -- Disconnects the Printer’s communication with the Ink Tank Sensor, allowing for safe removal of the Ink Tanks.

  • Page 66: Print Drop-Down

    Functional Operation Print Drop-Down The Print Drop-Down contains options that allow you to print various reports and Printer tests. Each printout displays information about the Printer. • Print Setup -- Prints a printing pattern used for positioning the image on the page. •...

  • Page 67: Chapter 4: Disassembly / Assembly Procedures

    Disassembly / Assembly Procedures Chapter 4: Disassembly / Assembly Proce- dures Printer Basic Disassembly Turn power OFF. • • Disconnect the Power Cord. • Disconnect the Interface Cable. Service Disassembly Procedures Warning: The following disassembly should only be performed by a qualified, trained service representative Warning: Always power down the printer before connecting or disconnecting any wiring harnesses or cable connections to avoid serious shock or injury.

  • Page 68: Components Under The Left-Hand Side Cover

    Disassembly / Assembly Procedures 2. Pull the cover away from the machine slightly. 3. Disconnect the wires attached to the Power, Paper, and Cancel buttons. 4. Carefully remove the cover. Note: Wires are labeled to simplify reconnection. Reassemble by completing the above procedure in reverse order. Make sure that wires are connected to the correct Control Panel button.

  • Page 69: Right-Hand Side Cover

    Disassembly / Assembly Procedures Right-Hand Side Cover 1. Remove the two screws at the top of the cover. 2. Remove the two screws at the bottom of the cover. Major Components under Right-Hand Side Cover 1. Winder Connector. 2. Power Supply. 3.

  • Page 70: Replacing Power Supply

    Disassembly / Assembly Procedures Replacing Power Supply 1. Remove the Right-Hand Side Cover. Note: To remove the motor, remove the six screws holding the Rear Panel Cover. 2. Remove the four mounting screws. Note: Before Disconnecting the Power Supply, note where each wire is connected before disconnecting.

  • Page 71: Replacing The Interface Pc Board

    Disassembly / Assembly Procedures Replacing the Interface PC Board 1. Remove the right-hand side cover. 2. Unplug the PC Board Power Cord [1] from the power inlet on the PC Board. 3. Unplug the four connectors for the fans, interface, and motor wires. Note: Wires are labeled for easy reconnection.
  • Page 72 Disassembly / Assembly Procedures 4. Shut the printer down by first pressing the Control Panel Power button, then the Main Power Switch on the rear side panel. 5. Unplug the printer. 6. Remove the two screws at the top and bottom of the left-hand side cover. 7.
  • Page 73 Disassembly / Assembly Procedures 9. Remove the two screws at the top and bottom of the right-hand side cover. 10. Remove the four screws holding the Exit Cross Bar in place (one on operator side, three on the non-operator side). 11.
  • Page 74 Disassembly / Assembly Procedures 12. Unplug the USB, Network, Main Power, and Service Port connectors from the Print Engine Circuit Board. 13. To remove the Ink Station Door, carefully unhook the two springs, then remove the mounting screw on the control panel side of the machine. Remove the door, and set aside. 14.
  • Page 75 Disassembly / Assembly Procedures 16. Remove the Media Guide Shaft Mounting Screw from the control panel side [A]. 17. Remove the Exit Shaft Mounting Screw from the control panel side [B]. 18. Remove the three screws on the left-hand side of the printer that secure the Center Plate [C]. 19.
  • Page 76 Disassembly / Assembly Procedures 23. Carefully remove the inner side frame from around the print engine and ink lines. 24. Lift and support the printer so that you are able to reach underneath to access and remove the four screws holding the bottom of the print engine to the base plate. 25.

  • Page 77: Aligning The Print Engine

    Disassembly / Assembly Procedures Aligning the Print Engine It is critical that the Print Engine is evenly aligned with the exit end of the printer to keep media properly aligned with the Winder (Use 42-301-18 Alignment Gauges). 1. Open the top cover. 2.

  • Page 78: Print Engine Basic Disassembly

    Disassembly / Assembly Procedures 2. Turn the Print Engine slightly until both of the gauges fit. 3. Retighten the Four Print Engine Mounting Screws while holding the Print Engine in place. 4. Remove the gauges. 5. Close the Clamshell and the top cover. Print Engine Basic Disassembly The Print Engine must be removed from the printer for these procedures.

  • Page 79: Print Engine Components Underside

    Disassembly / Assembly Procedures 2. Remove the Engine Base by removing the six T-10 screws of the Print Engine Assembly (3 on each side of the machine). Set aside for reassembly. Print Engine Components Underside 1. Peristaltic Pump [A]. 2. Dual Pinch Valve [B] 3.

  • Page 80: Replacing Peristaltic Pump Assembly

    Disassembly / Assembly Procedures Replacing Peristaltic Pump Assembly Remove the old Pump Assembly: 1. Remove the four screws that attach the bracket to the chassis [A]. 2. Cut the cable tie holding the wiring harness to the assembly [B]. 3. Unplug the connector from the Pump Motor Circuit Board [C] 4.
  • Page 81 Disassembly / Assembly Procedures Install New Pump Assembly 1. Plug the wire connector into the new Pump Assembly Motor Circuit Board. 2. Attach the Chassis with four screws [A]. 3. Cable tie the wire harness to the assembly as shown in [B]. 4.

  • Page 82: Replacing The Dual Pinch Valve Assembly

    Disassembly / Assembly Procedures Replacing the Dual Pinch Valve Assembly Remove the Old Pinch Valve Assembly 1. Remove the four screws that attach the bracket to the chassis [A]. 2. Cut the cable tie holding the wiring harness to the top flange on the Bracket Assembly [B]. 3.

  • Page 83: Cleaning Dual Pinch Valve Sensors

    Disassembly / Assembly Procedures Cleaning Dual Pinch Valve Sensors If “Ink Valve: Unknown” (displays as “’?’”) appears for more than a few seconds in the printer icon on the Status screen in the Toolbox, it may indicate that the Dual Pinch Valve (DPV) Sensors are dirty or blocked.

  • Page 84: Replacing Dual Pinch Valve Sensor Pc Board

    Disassembly / Assembly Procedures Replacing Dual Pinch Valve Sensor PC Board The Dual Pinch Valve Sensor PC Board Replacement Kit (#42-900-85) includes a new Sensor Printed Circuit Board, three inserts, and a Pinch Valve Wrench. The inserts prevent the Sensor PC Board from being misaligned during replacement.
  • Page 85 Disassembly / Assembly Procedures Replace Pinch Valve Sensor PC Board 1. Secure the spring-loaded shaft using the Dual Pinch Valve Wrench included in the Kit. Position the wrench exactly as shown: Note: The wrench fits around the shaft (as shown). See that the wrench head and the screw head [A] fit around the Pinch Valve Housing Rib (as shown).
  • Page 86 Disassembly / Assembly Procedures 2. Remove the three screws [A] holding the Pinch Valve Motor Assembly on the Pinch Valve Body. 3. Remove the Motor Assembly. 4. Remove the screw to remove the Pinch Valve Sensor PC Board. 5. Install the new Pinch Valve Sensor PC Board using the screw removed in the previous step. Ensure that the PC board is installed flush against the Pinch Valve body.
  • Page 87 Disassembly / Assembly Procedures 6. With the rounded end of the insert facing down, press the three inserts into the Motor Assembly Mounting Holes as shown. Note: The Insert is self aligning, but to ensure it is evenly aligned with the mounting hole, and to prevent accidental damage, use a flat surface to provide even pressure to press the insert in partially.

  • Page 88: Replacing Dpca Board

    Disassembly / Assembly Procedures Replacing DPCA Board 1. Remove the two screws on the outside of the chassis that attach the Circuit Board Bracket to the chassis. 2. Carefully move the DPCA Assembly out to unplug the wire harness connectors. Make sure that you know which connectors go with which socket.

  • Page 89: Replacing Buffer Boxes (3 Per Machine)

    Disassembly / Assembly Procedures Replacing Buffer Boxes (3 per Machine) 1. Each Buffer Box is held in place by two screws [A] accessed through the Ink Tank Station. Use a long Phillips Head screwdriver to remove the screws. 2. Pull up on the Buffer Box to remove it from the Chassis. 3.

  • Page 90: Replacing Qa Chip Assembly (3 Per Machine)

    Disassembly / Assembly Procedures 7. Push the new Buffer Box down onto the Ink Tubing Inserts [D] installed previously until the standoff posts are pressed firmly against the bulkhead. Replacing QA Chip Assembly (3 per Machine) 1. Each QA Chip Assembly is held in place by one screw accessed through the center of the Chip Assembly [A].

  • Page 91: Removing Pen Driver Printed Circuit Assembly

    Disassembly / Assembly Procedures 2. Remove the mounting screw [B]. To reinstall, repeat the above procedure in the reverse order. Ensure that wire harnesses are plugged into the correct circuit board. Refer to the image below for a guide as to the correct placement of Buffer Boxes and QA Chip Assemblies.
  • Page 92 Disassembly / Assembly Procedures 2. Disconnect the two Ethernet data cables, then unplug the power connector and the Main PCA harness connectors [B]. 3. Remove the three screws holding the Head Board Mount [C]. 4. Remove the Pen PCA from the unit [D]. 5.

  • Page 93: Removing The Starwheel Assembly

    Disassembly / Assembly Procedures Removing the Starwheel Assembly The Starwheel Assembly is located in the Upper Clamshell. Open the Print Engine Clamshell to access the Starwheel Assembly, located just inside the exit end of the Clamshell. Caution: Hold onto both latches when opening and closing the Print Engine Clamshell to prevent damage.

  • Page 94: Replacing The Ink Tanks

    Disassembly / Assembly Procedures 4. Remove the Starwheel Assembly. To reinstall, repeat the above procedure in the reverse order. Replacing the Ink Tanks Ink Tanks must be removed prior to replacing latches. SEE FIX. The Printer must be flat on a level surface.
  • Page 95 Disassembly / Assembly Procedures 2. Remove the two mounting screws from the bottom of the MPCA Panel. 3. Fold the Main Printed Circuit Assembly down out of the way. Note: Be careful - do not pull, pinch, or strain wiring. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 96: Replacing The Encoder Or Encoder Sensor

    Disassembly / Assembly Procedures Replacing the Encoder or Encoder Sensor 1. Remove the three screws holding the Encoder Cover [A]. 2. Unplug the wire harness from the Encoder Sensor [B]. 3. Carefully pivot the cover away from the Encoder Wheel. Be careful of the spring [C]. 4.

  • Page 97: Replacing The Service Station Lifter Arm Sensor

    Disassembly / Assembly Procedures Replacing the Service Station Lifter Arm Sensor 1. Unplug the wire harness from the Lifter Arm Sensor [A]. 2. Remove the screw attaching the Sensor to the Print Engine Frame [B]. 3. Slide the Sensor out of the retainer clip [C]. 4.
  • Page 98 Disassembly / Assembly Procedures 3. If removing the Drive Belt, remove the Encoder Assembly. See “Replacing the Encoder or Encoder Sensor” on page 96. 4. Remove the Drive Belt. 5. Install the Drive Belt and / or Motor in reverse order. See “Adjusting Paper Path Motor Drive Belt Tension”...

  • Page 99: Adjusting Paper Path Motor Drive Belt Tension

    Disassembly / Assembly Procedures Adjusting Paper Path Motor Drive Belt Tension 1. Loosen the Drive Belt Tensioner Locking Screw [A]. 2. Push and release the Belt Tensioner Roller to release tension on the Drive Belt [B]. 3. Use your finger to push the belt clockwise one full revolution around the rollers [C]. Note: This step equalizes tension around the full length of the Drive Belt.
  • Page 100 Disassembly / Assembly Procedures 4. Use the 42-110-54 Drive Belt Tension Tool. Position the tool between the two pulleys as shown, so that the point presses on the Drive Belt [D]. Note: In place of the Drive Belt Tension Tool, you can use your finger to deflect the belt 1-2mm (3/64-5/64”) 5.

  • Page 101: Replacing Belt Drive Gear Pulleys

    Disassembly / Assembly Procedures Replacing Belt Drive Gear Pulleys There are three Belt Drive Gear Pulleys. One is mounted on the Exit Grit Roller Shaft, one is located behind the Encoder Assembly on another Grit Roller Shaft, and one is mounted on the Entry Grit Roller Shaft.
  • Page 102 Disassembly / Assembly Procedures 2. Remove the washer, tension spring, thin washer, washer, and plastic washer from the end of the Grit Roller Shaft (note order for reassembly) [B]. 3. Remove the Pulley from the shaft [C]. To reinstall, repeat the above procedure in the reverse order. Note: Align the slot on the pulley with the pin in shaft before installing.

  • Page 103: Replacing The Lifter Motor Assembly Or Lifter Gear

    Disassembly / Assembly Procedures Replacing the Lifter Motor Assembly or Lifter Gear Remove Lifter Motor Assembly Only 1. Unplug the wire harness from the Lifter Motor Assembly [A]. 2. Remove the two screws holding the Motor Assembly to the Motor Assembly Bracket [B]. 3.
  • Page 104 Disassembly / Assembly Procedures 3. Remove the C-clip located on the end of the shaft [C]. 4. Unplug the pegs and turn the two plastic bayonet bearings to release the Motor Bracket [D]. 5. Remove the two C-clips (one on either side) on the Lifter Gear [E]. 6.

  • Page 105: Replacing The Stepper Motor

    Disassembly / Assembly Procedures Replacing the Stepper Motor 1. Remove the two screws [A]. 2. Unplug the wire harness from the Stepper Motor Printed Circuit Board [B]. 3. Note the position of the Motor Gears to ensure that the gears will mesh with the Service Station gear (if the Service Station is installed) [C].

  • Page 106: Lubricating Grit Roller Round Clips

    Disassembly / Assembly Procedures Lubricating Grit Roller Round Clips Three Ground Clips are located on the right side of the Print Engine, at the ends of the Grit Roller Shafts. To access the, remove the Lifter Motor and the Stepper Motor. See “Replacing the Lifter Motor Assembly or Lifter Gear”...

  • Page 107: Removing The Clamshell Assembly

    Disassembly / Assembly Procedures Removing the Clamshell Assembly Removing the Clamshell Assembly provides access to parts underneath the Clamshell Assembly. Removing Clamshell Assembly 1. Remove the four screws attaching the Clamshell to the chassis (one on each corner). 2. Gently lift the Clamshell from the chassis. Take care not to pinch or damage any wires or ink hoses.

  • Page 108: Replacing Exit Sensor

    Disassembly / Assembly Procedures Replacing Exit Sensor 1. Unlatch the Exit Sensor Cover [A]. 2. Carefully pull the Sensor off of the locating pin [B]. 3. Turn the Sensor over and unplug the wiring harness. To reinstall, repeat the above procedure in the reverse order. Replacing Label Web Sensor The Label Web Sensor consists of an Emitter (located in the upper Clamshell) and a Receiver (located in the lower clamshell).

  • Page 109: Replacing Service Station Sled Printed Circuit Boards

    Disassembly / Assembly Procedures Receiver (Under Lower Clamshell) 1. Remove the screw [A]. 2. Carefully pull the Receiver off of the locating pins [B]. 3. Turn the Receiver over and unplug the wiring harness [C]. To reinstall, repeat the above procedure in the reverse order. Replacing Service Station Sled Printed Circuit Boards 1.

  • Page 110: Replacing Wiper Motor Flex Cable Pca

    Disassembly / Assembly Procedures 3. Swing the Sled away from the Clamshell and turn it over. Carefully unclip the two Printed Circuit Boards [C]. To reinstall, repeat the above procedure in the reverse order. Note: Make sure that the wire harnesses are plugged into the correct printed circuit board. Replacing Wiper Motor Flex Cable PCA 1.
  • Page 111 Disassembly / Assembly Procedures 3. Disconnect the Wiring Harnesses. To reinstall, repeat the above procedure in the reverse order. Note: Make sure that the Ribbon Cable and the Wiring Harnesses are plugged in correctly. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 112: Removing Upper Main Platen Assembly

    Disassembly / Assembly Procedures Removing Upper Main Platen Assembly The Upper Main Platen Assembly is located in the Upper Clamshell [A]. Open the Print Engine Clamshell to access the Assembly. 1. Remove the two screws located on both sides of the Upper Clamshell (two screws on each side) [B].
  • Page 113 Disassembly / Assembly Procedures 2. Remove the Upper Main Platen Assembly. To reinstall, repeat the above procedure in the reverse order. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 114: Replacing Printhead Locator Assembly

    Disassembly / Assembly Procedures Replacing Printhead Locator Assembly Follow the steps below to replace the Printhead Locator Assembly. Assembly is pre-assembled and includes: • Printhead Lever Latch • Lever Latch Solenoid and Printhead Open/Closed Sensor and wire harness • Pump side and Valve side Ink Revolvers with ink hoses attached. •...
  • Page 115 Disassembly / Assembly Procedures 4. Remove the Printhead Cartridge by tilting it towards the ink lines, and carefully lifting it out of the printer. 5. Place the Printhead Cartridge in its protective packaging cap. 6. Remove the Operator Side Covers. QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 116 Disassembly / Assembly Procedures 7. Remove the MPCA Cover. 8. Disconnect the red/black wire from the Label Web Sensor Receiver PCA (located on the underside of the Upper Clamshell) [A]. Note: You may have to remove the PCA (two screws) to disconnect the wire. Carefully pull the wire back through the Print Engine Frame.
  • Page 117 Disassembly / Assembly Procedures 9. Carefully cut the wire ties securing the wire harness [B] to the Print Engine Frame as needed. 10. Disconnect the J2001 wire harness from the MPCA [C]. Carefully pull the wire harness through the Print Engine Assembly. Important: Before pulling out the wire harness, note how it is routed through the Print Engine.
  • Page 118 Disassembly / Assembly Procedures 11. Disconnect the Ink Hoses from the Dual Pinch Valve that go through the Valve Revolver [D] (Operator Side). Note: These hoses attach to the underside of the Dual Pinch Valve. You may have to remove the Dual Pinch Valve Assembly to access the hoses.

  • Page 119: Replacing The Printhead Lever Latch

    Disassembly / Assembly Procedures 15. Lift the Assembly out of the Print Engine. Important: Watch for drip - make sure that the wiring and the hoses do not get pinched or snagged. To reinstall, repeat the above procedure in the reverse order. Replacing the Printhead Lever Latch The Printhead Lever Latch is easily broken if forced open manually.
  • Page 120 Disassembly / Assembly Procedures 6. Lift the latch manually to access the two Latch Springs. 7. Remove the Printhead Cartridge by tilting it toward the ink lines, then carefully lifting it out of the Printhead Compartment. 8. Once removed, place the printhead in a protective packaging cap. 9.
  • Page 121 Disassembly / Assembly Procedures 10. Gently insert a small, flathead screwdriver between the blue Printhead Latch Pin and the black plastic hinge [A]. Rotate to pop the Printhead Latch out of the hinge without damaging either piece. Caution: Be careful - the Black Plastic Hinge breaks easily. Use only gentle pressure when removing / installing the Printhead Latch Pin.
  • Page 122 Disassembly / Assembly Procedures 3. Use needle-nose pliers to position the other end of the spring into the notch in the Printhead Latch. 4. Repeat these steps on the left side. 5. Remove the printhead from its protective cap. 6. Wipe the printhead surface according to standard installation procedure, then install. 7.

  • Page 123: Replacing The Printhead Lever Latch Solenoid

    Disassembly / Assembly Procedures Replacing the Printhead Lever Latch Solenoid Remove the Printhead Latch Solenoid 1. Open the Printer Toolbox. 2. Open the Service drop-down menu. 3. Select System Deprime. 4. Lift the latch manually to access the Solenoid and Printhead Locator Assembly 5.
  • Page 124 Disassembly / Assembly Procedures 7. Remove the five screws securing the Printhead Locator Assembly to the Print Engine Frame. 8. Remove the two screws securing the Solenoid to the Printhead Locator Assembly. 9. Cut two cable ties [A]. QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 125 Disassembly / Assembly Procedures 10. Unplug the Solenoid Connector from wiring harnesses [B]. 11. Carefully lift the Base Assembly just enough to remove the Solenoid Assembly from under the Printhead Locator Assembly. 12. Install the new Solenoid. To reinstall, repeat the above procedure in the reverse order. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 126: Uw-250 Unwinder

    Disassembly / Assembly Procedures UW-250 Unwinder Remove Top Cover 1. Carefully pull up and remove the Speed Control Knob [A]. 2. Remove the three screws holding the top cover in place [B]. 3. Remove the top cover. Rear Cover Access Points 1.

  • Page 127: Front Panel Cover

    Disassembly / Assembly Procedures Front Panel Cover 1. Remove the Spindle Lock from the Label Roll Spindle [A]. 2. Remove the four screws holding the panel to the Unwinder body [B]. 3. Remove the panel. Main Drive Belt 1. Remove the top cover, 2.

  • Page 128: Main Drive Motor

    Disassembly / Assembly Procedures 3. Slide the Drive Belt off of the Shaft Pulley and Motor Pulley [C]. Note: You may have to remove the two motor mounting screws and push the Motor Assembly back through the bracket to get enough clearance to move / replace the Drive Belt.

  • Page 129: Printed Circuit Board

    Disassembly / Assembly Procedures 3. Push the Motor and the Pulley back through the bracket and lift out of the unit. Note: To remove the Pulley, remove the set screw and slide the Pulley off of the Motor Shaft. To reinstall, complete the above steps in the reverse order. Note: Loop the Drive Belt around the Motor Pulley Spindle as you push the Motor and the Pulley through the Bracket.

  • Page 130: Large Gear

    Disassembly / Assembly Procedures Large Gear 1. Remove the Phillips head screw securing the Tension Arm Wire to the Tension Arm Shaft using the Rear Cover Access Port [A]. 2. Remove the C-Clips (one on each side of the bracket) [B]. 3.

  • Page 131: Recalibrate Unwinder

    Disassembly / Assembly Procedures Recalibrate Unwinder Tools Needed: • Phillips head screwdriver • 5/32 Allen wrench • Handheld tachometer (optional) When replacing the Potentiometer or other parts on the Unwinder, it may be necessary to recalibrate the Unwinder to maintain optimum performance. The following procedure sets the point at which the Unwinder switches between running clockwise or counterclockwise depending on the tension that media exerts on the Tension Arm Assembly.
  • Page 132 Disassembly / Assembly Procedures 4. Loosen the set screw [A] on the small gear on the Potentiometer shaft. Remove the small gear. 5. With the power ON and the Reel Shaft moving in its normal operating direction (clockwise), slowly turn the potentiometer [B] counterclockwise until rotation stops. Important: Make sure that the Shaft is rotating in its operating direction (clockwise).

  • Page 133: Rw-250 Winder

    Disassembly / Assembly Procedures c. Raise and lower the Tension Arm to get its uppermost and lowermost positions to get clockwise and counterclockwise rotation. d. For the arm in the upper position, speed should be at or near 150 rpm. e.

  • Page 134: Rear Cover Access Points

    Disassembly / Assembly Procedures Rear Cover Access Points 1. Spindle Shaft Bearing Cover [A]. 2. Tension Arm Shaft screw access [B]. 3. Motor Mounting Screw access [C]. Note: DO NOT remove the rear cover due to increased possibility of damaging internal parts. Front Panel Cover 1.

  • Page 135: Main Drive Belt

    Disassembly / Assembly Procedures 5. Slide the front panel away from the Winder body. Main Drive Belt 1. Remove the top cover. 2. Remove the C-Clip holding the Spindle Shaft in place [B]. 3. Slide the Shaft Assembly forward. 4. Slide the Drive Belt off of the Shaft Pulley and Motor Pulley [C]. Note: You may have to remove two motor mounting screws and push the Motor Assembly back through the Bracket to get enough clearance to remove / replace the belt.

  • Page 136: Printed Circuit Board

    Disassembly / Assembly Procedures 2. Remove the two Allen head motor mounting screws from the Bracket Assembly using the two motor mounting screw access ports in the rear cover [B]. 3. Push the Motor and the Pulley back through the bracket and lift out of the unit. Note: To remove the Pulley, remove the set screw and slide the Pulley off of the motor shaft.

  • Page 137: Large Gear

    Disassembly / Assembly Procedures 2. Remove the four Phillips head screws from the Printed Circuit Board [B]. 3. Remove the Printed Circuit Board. To reinstall, complete the above steps in the reverse order. Note: When reconnecting wiring, make sure to connect the correct J3 marked wire. One connects the Interface Cable used with the QL-250 printer while the other connects the External Power Connector for use with an external power source.

  • Page 138: Potentiometer Assembly

    Disassembly / Assembly Procedures Potentiometer Assembly 1. Disconnect the Potentiometer from the Printed Circuit Board (J1-B). 2. Remove the Phillips head screw from the end of the gear shaft [B]. 3. Loosen the set screw on the small gear and slide the gear off of the shaft [C]. 4.

  • Page 139: Recalibrate Winder

    Disassembly / Assembly Procedures Recalibrate Winder Tools Needed: • Phillips Screwdriver • 5/32 Allen Wrench • Handheld Tachometer (optional) When replacing the Potentiometer or other parts on the Winder, it may be necessary to recalibrate the Winder to maintain optimum performance. The following procedure sets the point at which the Winder switches between running clockwise or counterclockwise, depending on the tension that media exerts on the Tension Arm Assembly.
  • Page 140 Disassembly / Assembly Procedures 4. Loosen the set screw [A] on the small gear on the Potentiometer shaft. Remove the gear. 5. With the unit power ON and the Reel Shaft moving in its normal operating position (clockwise), slowly turn the Potentiometer [B] counterclockwise until rotation stops. Important: Make sure that the shaft is rotating in its normal operating direction (clockwise).

  • Page 141: Maintenance

    Maintenance Chapter 5: Maintenance General, periodic maintenance is needed to keep the printer in good working order. Many tasks can be performed by operators with basic supplies, as no special tools are needed. Other tasks should only be performed by trained service personnel. Note: High volume usage may require more frequent maintenance.

  • Page 142: Maintenance Schedule

    Maintenance Maintenance Schedule Part Action AS NEEDED MAINTENANCE (Depending on printer usage) Media Path, Service Station (Wiper, Roller, Clean to remove media fibers and ink Platen). residue. Ink Revolver Couplings Inspect and clean after every printhead removal. Printhead Wipe as needed to maintain print quality Printhead Pen Driver PCA Clean contacts after every printhead removal.
  • Page 143 Maintenance Part Action Ink Tubing, Connections, Peristaltic Pump, Inspect for leaks, kinks, pinches, and proper Pinch Valve and Vents, Buffer Boxes, Ink location. Revolver Couplings Ink Waste Tray Inspect for excessive ink saturation or leakage. Lift Motor Gear Inspect for proper operation, debris, and wear.

  • Page 144: Replacing Ink Tanks

    Maintenance Replacing Ink Tanks Replace the Ink Tanks when ink runs out. 1. Open the Printer Toolbox. System Status information appears on the right side of the System Status Window. 2. Navigate to the Ink Cartridge Status Boxes on the left side of the System Status Window. The Ink Cartridge Status Boxes (“C, K2, Y, M, K1”) may present as low or empty.
  • Page 145 Maintenance 5. Once the Confirm screen displays, it is safe to remove the ink tanks. Important: DO NOT press Continue until AFTER you have removed and replaced the Ink tanks and closed the ink tank latches. 6. Open the front cover (hinged at the bottom). 7.
  • Page 146 Maintenance 12. From the Service drop-down menu, select Refresh Ink Levels. The ink colors fill in as the ink tanks are installed. If the ink colors do not fill in after a few seconds, select Replace Ink Tanks again and reinstall the ink tanks. Note: If the ink tank is installed but the ink tank indicator still does not refresh, See Cleaning Ink Tank Contacts 13.

  • Page 147: Cleaning Ink Tank Contacts

    Maintenance Cleaning Ink Tank Contacts When reinstalling or replacing ink tanks, the Ink Level Indicator in the Toolbox may not refresh. This may be due to a dirty Ink Tank Level Prism and/or QA Chip Contacts on that Ink Tank(s). Cleaning Contacts 1.
  • Page 148 Maintenance 5. Release the ink tank latches [A]. 6. Remove the ink tanks with the levels that did not refresh [B]. 7. Clean the Ink Level Prism [A] and the QA Chip Contacts [B] with a clean, dry, lint-free cloth. Note: Dampen a cloth with distilled water to wipe the prism but DO NOT get the QA Chip Contacts wet.

  • Page 149: Storage

    Maintenance 9. Click Continue on the Confirm Screen. 10. From the Service drop-down menu, select Refresh Ink Levels. 11. Close the front cover. Storage New ink tanks should be stored in their original packaging and kept away from the heat to avoid damage.

  • Page 150: Cleaning / Replacing The Printhead Cartridge

    Maintenance Cleaning / Replacing the Printhead Cartridge Cleaning the Printhead Cartridge The printhead in the QL-250 is cleaned automatically each time the printer is turned on, or when the Quick Clean Printhead routine is performed*. Normal Clean Printhead and Full Clean Printhead are used to more thoroughly clean or clear the printhead.

  • Page 151: Replacing The Printhead Cartridge

    Maintenance Replacing the Printhead Cartridge 1. Open the Toolbox. On the System Status screen, System Status information appears on the right side. 2. Open the Printhead Latch [1] using the Printhead Release button in the Printer Toolbox. The printer pumps any ink in its system back into the ink tanks, then the Printhead Latch pops open.
  • Page 152 Maintenance 6. Remove the protective plastic cover from the printhead. Hold the printhead by its handle and un-clip the cover from the printhead. 7. Remove the protective strip from the printhead electrical contacts. Once removed, do not allow the strip to touch the electrical contacts. 8.
  • Page 153 Maintenance 9. Carefully insert the Printhead Cartridge into the compartment at an angle [1] with the printhead surface facing down and the ink nozzles facing the ink hoses. 10. Once seated, gently tilt the cartridge back until it snaps into an upright position [2]. DO NOT force the cartridge into position.
  • Page 154 Maintenance 12. Release and lift up the two latches at the same time to raise the Printhead Clamshell. 13. Moisten the printhead nozzles using distilled water and a damp, lint-free cloth, wiping end to end (wipe the gray strip located below the orange strip). 14.
  • Page 155 Maintenance 16. Watch the System Status screen. Notice that some of the information is in red. As the printer circulates ink and primes the system, these fields should all turn black. 17. Check that the Printhead Icon [7] in the printer image is primed (solid color). 18.

  • Page 156: Printhead Service Life

    Maintenance Printhead Service Life Projected: 50,000,000 ejections per nozzle. The printhead has a total of 70,400 nozzles (14,080 per color channel. Since printing does not use the entire length of the printhead, some nozzles do not fire as often. The most used nozzles will degrade more quickly. Noticing the effects of failed nozzles depends partly on the relative position of those nozzles to each other.

  • Page 157: Replacing Ink Revolvers

    Maintenance 4. Use a new swab for each remaining ink channel until all 10 openings are clean (5 on each side). Replacing Ink Revolvers 1. Route the hose leads from the new Revolver through the same frame cutout as the existing hoses.
  • Page 158 Maintenance 4. Remove the hinge pin. 5. Slide the old Ink Revolver forward in its track and remove. 6. Slide the new Ink Revolver back into its track and align the yoke on the rear with the hinge bracket. Ensure that the new revolver is turned on correctly. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 159: Cleaning The Pen Driver Printed Circuit Board Contacts

    Maintenance 7. Reinstall the pin and the C-Clip. 8. Reinstall the Ink Revolver Cover. Cleaning the Pen Driver Printed Circuit Board Contacts The following procedure outlines how to clean the Printed Circuit Board contact pins that connect with the Printhead Cartridge. 1.

  • Page 160: Cleaning / Replacing The Service Station

    Maintenance 4. Use a very gentle up and down motion to clean the Contact Pins. Note: Hold down the plastic cover to keep moisture away from the rest of the circuit board. Caution: Contact pins are easily bent or damaged! Use only a very gentle up and down motion for cleaning.
  • Page 161 Maintenance 4. From the Service drop-down menu, select Eject Service Station. 5. Once the printer pushes the Service Station out, turn the printer OFF. Caution: Whenever powering down the unit, always press the power button on the Control Panel, wait for the printer to stop processing, then press the Main Power Switch on the rear panel.
  • Page 162 Maintenance 6. Slide the Service Station out of the Service Station port. Note: DO NOT pull the Service Station all the way out until you have disconnected the Ribbon Cable. Note: Place an absorbent towel under the Service Station before removing it to catch any drips or leaks.

  • Page 163: Removing The Service Station When The Printer Is Off And/Or The Printer Is Not Connected To A Computer

    Maintenance 7. Slide the latch open on the Service Station Circuit Board to release the Ribbon Cable. 8. Fully remove the Service Station. Removing the Service Station when the Printer is OFF and/or the Printer is Not Connected to a Computer 1.
  • Page 164 Maintenance 3. Release the two latches and open the Print Engine Clamshell. The Service Station will not fully eject with the Clamshell closed. 4. Insert a small Allen wrench into the end of the worm gear on the Stepper Motor [A]. QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 165 Maintenance 5. Turn the gear until the Capping Station retracts to its lowest point. 6. Place an absorbent towel under the Service Station before removing it to catch any drips or leaks. 7. Gently pull the Service Station while turning the large gear on the right side of the Print Engine counterclockwise.

  • Page 166: Cleaning The Service Station

    Maintenance Cleaning the Service Station Cleaning the Wiper Roller 1. Lift up the Wiper Roller Assembly. 2. Carefully loosen the two small screws retaining the Wiper Roller Latches. DO NOT fully remove the screws. 3. Release the two latches holding the roller. 4.

  • Page 167: Replacing The Wiper Motor Assembly

    Maintenance Replacing the Wiper Motor Assembly The following procedure assumes that the Service Station has been removed. See “Cleaning / Replacing the Service Station” on page 160. 1. Disconnect the Wiper Module Cable from the Service Station Printed Circuit Board. 2.

  • Page 168: Cleaning The Wiper Motor Assembly

    Maintenance 4. Remove the Wiper Roller. To reinstall, complete the above steps in the reverse order. Use a foam swab to lightly lubricate the Wiper Gears with synthetic PTFE grease (Super Lube 21030 or equivalent). Note: Make sure that the Wiper Roller Latch Screws are fully tightened and that the Latches are fully closed before installing the Service Station in the Printer.

  • Page 169: Replacing The Service Station Lifting Arms

    Maintenance Replacing the Service Station Lifting Arms The Replacement Kit includes two Lifting Arms and two C-Clips, one each for both the Operator and the Non-Operator Side Installation. The following procedure assumes that the Service Station has already been removed. See “Cleaning / Replacing the Service Station”...

  • Page 170: Lubricating The Service Station

    Maintenance 2. Slip on the new Lifting Arm and Spring Assembly. Secure with the C-Clips. 3. Apply a standard silicone or Teflon-based grease or lubricant to the Lifting Arm Pivot (Super Lube 21030 or equivalent). Lubricating the Service Station Friction points on the Service Station should be lubricated to ensure optimum performance and reduce wear.
  • Page 171 Maintenance 2. Apply lubricant to the Lifting Arm Cam through the opening (as shown). Repeat on the other side. Lubricate the Service Station Tracks Apply lubricant along the full length of the tracks the Service Station moves on (as shown). Repeat on both sides.
  • Page 172 Maintenance Lubricate Service Station Guide If your printer is equipped with a Service Station Guide, apply lubricant to the Service Station Guide as shown below. Lubricate Lifting Arm Pivot Points Apply lubricant to the Lifting Arm Pivot points as shown. Repeat on both sides. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 173: Reinstalling / Replacing The Service Station

    Maintenance Reinstalling / Replacing the Service Station 1. Carefully unwrap the new Service Station (or reuse the cleaned Service Station). Note: Loose parts may fall out. Keep the roller-side of the Service Station facing up when removing packaging. Caution: Make sure that the latches on the wiper roller are fully locked before installing the Service Station.
  • Page 174 Maintenance 3. Plug the Ribbon Connector (blue-side-up) into the space under the latch. 4. Close the latch. 5. Slide the Service Station into the Service Station port until it touches the bar. Align it with the tracks along the sides and the Guide on the Service Station Dock floor. QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 175 Maintenance 6. Look through the top cover to ensure that the Service Station is aligned with the bar. Important: The Service Station must be perfectly aligned with the bar in order to prevent misalignment and operating problems. 7. Gently push the Service Station while turning the large gear on the right side of the Print Engine clockwise.
  • Page 176 Maintenance 11. From the Service drop-down menu, select Install Service Station to pull the Service Station Note: Make sure that the wick hanging below the Service Station is inside of the plastic trough (inside the Ink Tank Station) to prevent ink seepage. Note: The Service Station should operate smoothly.

  • Page 177: Replacing The Cover Assembly

    Maintenance Replacing the Cover Assembly 1. Open the top cover. 2. Disconnect the Cutter Assembly Wiring Bundle at the connector. 3. Remove the four Torx mounting screws. QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 178: Replacing Ink Waste Tray

    Maintenance Replacing Ink Waste Tray The Ink Waste Tray soaks up any excess ink that may drip from the Print Engine during operation. After a period of time, it may become saturated and need replacement. 1. Open the ink tank door. 2.

  • Page 179: Print Engine Cleaning

    Maintenance Print Engine Cleaning Areas in the Print Engine can become glazed with a buildup of dust, paper lint, and accumulated ink and have to be cleaned regularly. 1. Open the top cover. 2. Open the Clamshell Assembly by releasing the two latches. 3.

  • Page 180: Printing Platen

    Maintenance Capping Station Seal and Squeegee Clean the Capping Station Seal and Squeegee [C] as needed with distilled water on a damp, lint-free cloth. Be careful not to splash or drip on other parts of the printer. Printing Platen Clean the Printing Platen [D] by wiping it with distilled water on a damp, lint-free cloth. Pat dry with a lint-free cloth.

  • Page 181: Appendix A: Safety Precautions

    In addition, follow any specific occupational safety and health standards for your workplace or area. This manual is intended solely for the use and information of AstroNova, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards.

  • Page 182: Appendix B: Borderless Printing

    Borderless Printing Appendix B: Borderless Printing The QL-250 Print Driver (under Printing Preferences) offers two ways for printing to the edge of media, sometimes called Borderless or Full-Bleed printing. Each option adjusts the relationship between the target image, selected media size, and the actual media on which it is printed, but in different ways.
  • Page 183 Borderless Printing Impact of Using Borderless Print Selecting the Borderlesss Print checkbox scales the target image beyond the size of the selected media by adding the Borderless Default Resolution Value set in the Drive. The image is then set to print larger than the actual size of the media. For example, if the Borderless Default setting is 21 (dots) then the resulting Borderless Print selection will have a resolution of 821 dpi (when printing with a normal resolution of 800 dpi).

  • Page 184: Oversize Settings

    Borderless Printing Oversize Settings The Oversize checkbox is located in the Custom Sizes dialog box, in the Printing Preferences tab under the General tab. 1. Select the Oversize checkbox 2. Enter the measurements of physical media in Width and Height fields, selecting units (inches or millimeters).
  • Page 185 Borderless Printing Impact of Using Oversize Selecting Oversize extends the Custom Sizes dimensions beyond that of the actual media being printed on. Since this size extension is equal to both X- and Y- axes, there is no distortion of the target image.

  • Page 186: Additional Considerations And Tips

    Borderless Printing Additional Considerations and Tips Some additional considerations apply to both Borderless Print and Oversize in certain circumstances. Minimum Label Gap and Maximum Width For both Borderless Print and Oversize, additional consideration and testing are required when approaching limitations for the minimum label gap and maximum label width. The Minimum Label Gap is 3mm.

  • Page 187: Appendix C: Ink Flow Diagrams

    Ink Flow Diagrams Appendix C: Ink Flow Diagrams QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 188 Ink Flow Diagrams QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 189 Ink Flow Diagrams QL-250 Service Guide Confidential, Not for Redistribution...

  • Page 190: Appendix D: Adjusting Sensor Readings For Various Types Of Media

    Adjusting Sensor Readings for Various Types of Media Appendix D: Adjusting Sensor Readings for Various Types of Media The QL-250 Print Engine can be used for Label Gap, Blackmark, Continuous (No Mark), and Cut Sheet media. The print engine uses its transmissive sensor to detect media edge and gap. It uses the reflective sensor to detect the Blackmark of media.

  • Page 191: Finding The Right Reading Levels For Your Gaps / Markers

    Adjusting Sensor Readings for Various Types of Media Finding the Right Reading Levels for your Gaps / Markers 1. Install the latest firmware version and driver for your Print Engine / printer. 2. Get a strip of four or more labels with their gap / Blackmark. 3.
  • Page 192 Adjusting Sensor Readings for Various Types of Media 11. Check Comma and Finish. 12. Select column C (“pos”) and F (“a2d_st”) for Label Gap Media For Blackmark Media, select column C (“pos”), and G (“a2d_refl”). QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 193 Adjusting Sensor Readings for Various Types of Media 13. From the Insert tab, select Scatter with Straight Lines (left bottom side of drop-down). This will give you a graph. 14. Adjust the X and Y coordinates for your convenience. 15. On column K, copy and paste the following equation: a.
  • Page 194 Adjusting Sensor Readings for Various Types of Media 18. Select column C (“pos”) and K, the new column, and follow STEPS 12 and 13 above. This will give you the second graph. Explanation of the settings: pp_bm_msa_refsignal pp_bm_msa_threshold pp_lg_msa_refsignal pp_lg_msa_threshold The values above are the default values.

  • Page 195: Refsignal

    Adjusting Sensor Readings for Various Types of Media REFSIGNAL REFSIGNAL is the change in a2d reading levels over time calculated to detect gaps / marks. Simply put, when there is a sudden change in the a2d signal, the unit assumes it to be the gaps / marks.

  • Page 196: Special Case Example

    Adjusting Sensor Readings for Various Types of Media Special Case Example See the Blackmark Label below. Note that the Blackmarks are placed between each label, and that the labels are circular. The chart below shows the a2d reading levels for the circular blocks above. Note that in the graph, the sensor is detecting 1) paper 2) circular label 3) Blackmark.
  • Page 197 Adjusting Sensor Readings for Various Types of Media You can adjust the THRESHOLD settings to ignore parts of the readings. If the Threshold is set at 100, anything reading above 100 in the chart will be ignored. Since Blackmarks are flagged for REFSIGNAL levels above 50 in the default setting, then the circular label is not considered is not considered as Blackmarks by the unit.

  • Page 198: Batch Code Variables

    Adjusting Sensor Readings for Various Types of Media Batch Code Variables @echo off REM ------------------------------------------------------------- REM Print Zone Servo Data Collector REM ------------------------------------------------------------- REM load media REM ECHO Loading media REM USBcmd.exe -c pp_pinch_media REM pause SET speed="12" SET distance="48" SET serial="000"...
  • Page 199 Adjusting Sensor Readings for Various Types of Media GOTO collectData :collectData REM make sure the print platen is up USBcmd.exe -c ss_goto print > nul REM clear print zone servo history USBcmd.exe -c servo_history_store 0 > nul USBcmd.exe -c servo_history_reset > nul REM power on sensor USBcmd.exe -c _mech_sensor_pwr_a + >...

  • Page 200: Appendix E: Print Engine Wiring Diagram

    Print Engine Wiring Diagram Appendix E: Print Engine Wiring Diagram QL-250 Service Guide Confidential, Not for Redistribution...
  • Page 201 Index Index a2d Reading Levels ..........195 Electrical Maintenance Precautions ......10 a2d_st ..............195 EOR .................31 Air in the Ink Lines ...........25 As-Needed Maintenance ........142 Fanfold Printing ............32 Feeding Problems ..........13 Batch Code Variables ..........198 Bi-Weekly Maintenance .........142 Borderless Print Checkbox ........182 Gap Reading Levels ..........191 Borderless Print Default Resolution Value .....183 General Safety Precautions - Clothing .......9...
  • Page 202 Index Main Power Connection ...........29 Page Sizing and Handling ........186 Maintenance - Cleaning Ink Tank Contacts ...147 Paper Jam ..............18 Maintenance - Replace Ink Tanks ......144 Paperpath End of Roll ..........20 Maintenance Busy ...........21 Paperpath feed timeout ..........20 Maintenance Supplies and Equipment ....141 PC Capture ..............33 Marker Reading Levels ..........191 Power Problems ............13...
  • Page 203 Index THRESHOLD ............195 VARS_GETSET .............190 Tilt Error ..............22 Toolbox System Status Messages ......19 Wiper Error ...............25 Wiper Overtemp ............25 Unauthorized Printhead ...........19 USB Connection ............29 Yearly Maintenance ..........143 QL-250 Service Guide Confidential, Not for Redistribution...

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