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Ice PegasusHS Service Manual

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PegasusHS

Service Manual

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

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Summary of Contents for Ice PegasusHS

  • Page 1: Service Manual

    PegasusHS Service Manual P/N 361854-21 Revision: AA, November 2006...
  • Page 2 Copyright 2006, Clearmark solutions LLP. (herein referred to as ICE). All rights reserved. This document is the property of Clearmark solutions.and contains confidential and proprietary information owned by ICE Any unauthorized copying, use or disclosure of it without the prior written permission of ICE is strictly prohibited.

  • Page 3: Compliance Information

    Compliance Information For Customers in U.S.A. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) this device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation.

  • Page 4: Pour La Clientèle Du Canada

    ICE Pegasus Service Manual Pour la Clientèle du Canada Le present appareil numerique n’emet pas de bruits radioelectriques depassant les limites applicales aux appareils numerique de las class A prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada.

  • Page 5: Support And Training

    - our customer - the complete service you deserve. The Total Source Commitment The ICE Service Program is an integral part of our business in providing marks, codes, and images where, when, and how often customers specify for packages, products, or printed materials. Our commitment includes: •...

  • Page 6: Customer Training

    ICE. highly recommends that you complete a Customer Training Course on the printer. Note: The manuals are intended to be supplements to (and not replacements for) ICE. Customer Training. For more information on ICE. Customer Training Courses, call 01159 640144. Rev AA...

  • Page 7: Table Of Contents

    Table of Contents Compliance Information For Customers in U.S.A........i For Customers in Canada .
  • Page 8 ICE Pegasus Service Manual Working with Printer Connections ......3–12 Product Sensors/Print Signals ......3–12 Encoder .
  • Page 9 ICE Pegasus Service Manual Updating the CLARiTY Operating Software ....5–23 Chapter 6 — System Events Chapter 7 — Troubleshooting Chapter 8 — Illustrated Parts List How to Read the IPL .

  • Page 10: Chapter 1 - Safety

    Introduction The policy of ICE. is to manufacture printing/coding systems and supplies that meet high standards of performance and reliability. Therefore, we employ strict quality control measures to eliminate the potential for defects and hazards in our products.

  • Page 11: Safety Conventions Used In The Manual

    ICE Pegasus Service Manual Safety Conventions Used in the Manual Specific safety information is listed throughout this manual in the form of Warning statements. Pay close attention to these statements as they contain important information that help in avoiding potential hazards to yourself or to the equipment.

  • Page 12: General Caution Notices

    ICE Pegasus Service Manual Warning PERSONAL INJURY. Keep hands and clothing clear of the printer while it is on. Warning PERSONAL INJURY. To ensure that the connecting cables and pipes do not become a trip hazard or become entangled in any machinery, all connecting cables and pipes must be secured safely during installation.

  • Page 13: Safety Guidelines

    ICE Pegasus Service Manual Caution EQUIPMENT MAINTENANCE. Before and after performing any maintenance or repair on the product, check that the two safety labels are clearly visible. One is on the power supply cover and the other by the potential nip point next to the pulley in the printer body.

  • Page 14: Do Not Remove Warning Labels

    ICE Pegasus Service Manual Do Not Remove Warning Labels Do not, under any circumstances, remove or obstruct any warning or instruction labels on the printer. Placement of the Printer Warning PERSONAL INJURY. Do not place the printer in a hazardous location.

  • Page 15: Chapter 2 - Introduction

    Introduction This chapter contains the following topics: • A description about the intended use of the product • Information about the audience for whom this manual is intended • A description of how the manual is organized • Information about other manuals that are associated with this printer •...

  • Page 16: About This Manual

    ICE Pegasus Service Manual About this Manual This service manual includes information about installing, maintaining, troubleshooting, and servicing the printer. It also contains sections about the theory of operation and component identification, including an illustrated parts breakdown. This document is intended to be used only by trained service personnel. It is intended to be a supplement to (and not a replacement for) formal training.

  • Page 17: Theory Of Printing

    ICE Pegasus Service Manual Theory of Printing The information on how the thermal transfer printer works is as follows (Figure 2-1): • The printhead contains miniature heating elements under a glass coating (300 dpi - 12 dots/min) • A carrier ribbon, with ink bonded to one side is used as the printing media •...

  • Page 18: Continuous Motion Printing

    ICE Pegasus Service Manual • The printhead traverses across the ribbon, causing print to transfer onto substrate. • The printhead presses against a flat platten pad. HEAD OUT HEAD IN PRINT 1. Ribbon Transferred Carbon 2. Substrate 3. Platten Rubber 4.
  • Page 19 ICE Pegasus Service Manual RIBBON FEED MATERIAL FEED 1. Ribbon Transfer Carbon Print 2. Platten Roller 3. Substrate 4. Thermal Printhead Figure 2-3: Continuous Print Motion Theory of Printing Rev AA...

  • Page 20: Chapter 3 - Technical Description

    Unpacking the Printer Inspect the kit for any damage carefully. Refer the list of parts in Table 3-1 and Figure 3-1 on page 3-2. If any item is damaged or missing, call ICE., Customer Service Department at 01159 640144. Printer Part Printer...
  • Page 21 ICE Pegasus Service Manual Printer Part CLARiTY Configuration Manager CD 4mm Air Tubing CLARiTY Controller Bracket QA Documentation and CE Certificate Table 3-1: Printer Configuration Parts List (Continued) 1. Air Regulator 6. Printer 2. 4mm Air Tubing 7. I/O Low Profile Cable 3.

  • Page 22: Installing The Printer

    ICE Pegasus Service Manual Installing the Printer Ensure that the following services are available while the printer is being installed: • Power: 90 - 264 VAC, 320 VA, 47 - 63 Hz • Compressed Air: 87 psi (6 bar) max, dry, uncontaminated with a 6 mm pipe fitting •...
  • Page 23 ICE Pegasus Service Manual M6 Tapped Holes Thread Depth 6.00 20.73 mm (2 PLCS) 3 Places (0.82 inches) 70.73 mm (2.78 inches) 159.60 mm 185.30 mm (7.3 inches) (6.23 inches) 167.15 mm 157.80 mm (6.58 inches) 164.00 mm (6.21 inches) (6.46 inches)

  • Page 24: Clarity Controller

    ICE Pegasus Service Manual The print platen rubber (for printers in intermittent mode) or the roller (for printers in continuous mode) should be positioned such that it is at a distance between 6.45 inches and 6.50 inches (164 mm and 165.5 mm) from the back edge of the printer (Figure 3-4).
  • Page 25 ICE Pegasus Service Manual 118.90 mm (4. 68 inches) M6 Female Thread Both Sides. Thread Depth 6.00 69.20 mm (2.72 inches) Figure 3-5: CLARiTY Controller Dimensions The maximum distance of the CLARiTY controller from the printer body is 9.8 ft (3 m).

  • Page 26: Air Regulator

    ICE Pegasus Service Manual Air Regulator The air regulator should be connected to a clean, dry factory air supply using a 6 mm pipe. The 4 mm diameter pipe should be used to connect the air regulator to the printer.

  • Page 27: Installing The Ribbon In The Cassette

    ICE Pegasus Service Manual Installing the Ribbon in the Cassette Caution EQUIPMENT DAMAGE. The use of incompatible ribbon can seriously damage your printer and such a damage is not covered by your printer warranty. Use only the ribbon that is approved by your dealer.
  • Page 28 ICE Pegasus Service Manual 1. Ribbon Roller (x2) 2. Ribbon Spool (x2) Figure 3-7: Cassette Removed Pull the two ribbon spools (one containing the entire used ribbon) from the cassette firmly, as shown in Figure 3-8. The discs that are situated under each spool can be used to lever the spool off the cassette.
  • Page 29 ICE Pegasus Service Manual • The black disc for the new roll of ribbon • The silver disk for the empty roll When the printer is running, the new ribbon unwinds from the black holder and winds onto the silver spool holder.
  • Page 30 ICE Pegasus Service Manual Slide the empty spool completely down onto the holder that has a silver disc (Figure 3-10). Figure 3-10: Ribbon Spool Complete Turn the empty spool by hand to take up any excess ribbon. Stop turning the empty spool when the full spool starts to rotate (Figure 3- 11).

  • Page 31: Adjusting The Air Pressure

    ICE Pegasus Service Manual Note: Ensure the following: • The ribbon runs in between the printhead and the printer's print roller or print pad • The ribbon is not twisted or caught • The ribbon has not become loose while replacing the cassette...
  • Page 32 ICE Pegasus Service Manual 24VDC 1. PNP Sensor 2. 15-pin Male D-type Connector Figure 3-12: PNP Sensor Wiring (Print Sensor) 24VDC 1. Print Signal Relay Contact 2. 15-pin Male D-type Connector Figure 3-13: Mechanical Contact Wiring (Print Sensor) Working with Printer Connections...

  • Page 33: Encoder

    ICE Pegasus Service Manual Encoder For the continuous motion operation of the printer, an encoder is used to track the speed of the packaging material. The encoder is wired into the printer's input/output connector. The printer is configured to use a quadrature mode encoder by default, N.

  • Page 34: Interlocks And Annunciation

    Videojet 6210 Service Manual Interlocks and Annunciation The 15-pin D-type (male) connector, located on the side of the printer unit is available for connecting with a variety of useful interlock and annunciation signals. Table 3-2 summarizes the input and output connections. Purpose +24 V External input #1 PNP 24 V...

  • Page 35: Data Communication

    Videojet 6210 Service Manual Data Communication All external data communication to the printer are connected through the CLARiTY controller. It contains the following communication ports: • RS232 Serial Communications Port (9-pin Male D-type Connector) Table 3-3 lists the connections to the RS232 Serial Communications Port. Connection Receive Data (Rx) Transmit Data (Tx)
  • Page 36 ICE Pegasus Service Manual 15 Way I/O Cable Unterminated Encoder Low Profile Connector PRINTER Mains Power D25 - M D9 - F RS232 Figure 3-15: Videojet 6210 Cable Connections Working with Printer Connections 3-17 Rev AA...

  • Page 37: Switching The Power On

    ICE Pegasus Service Manual Switching the Power On To switch the printer on, turn the power switch on the CLARiTY controller to the I (On) position (Figure 3-16). Power Switch Figure 3-16: Printer Power Switch The boot-up takes approximately 90 seconds. During this a "starting CLARiTY …"...

  • Page 38: Configuring The Printer

    ICE Pegasus Service Manual Figure 3-17: CLARiTY Home Page in the Offline State Configuring the Printer CLARiTY Configuration Manager As coding and labelling equipment have become increasingly versatile and flexible with a wide range of applications, the number of variables that can be configured within a printer, has become very large.
  • Page 39 ICE Pegasus Service Manual Figure 3-18: CLARiTY Configuration Manager The CLARiTY Configuration Manager (Figure 3-18) is a PC software program, that provides the following basic features: • Setting all the printer variables • Saving/retrieving a set of variable values to a PC file for later/ repeated use •...

  • Page 40: Installing The Clarity Configuration Manager

    ICE Pegasus Service Manual access to the printer, while line operators are limited to accessing only the operating variables that are relevant to them. Installing the CLARiTY Configuration Manager To install the CLARiTY Configuration Manager on a PC, insert the CLARiTY Configuration Manager CD-ROM.
  • Page 41 ICE Pegasus Service Manual Run the CLARiTY Configuration Manager on the PC (Figure 3-19). Status Panel Figure 3-19: CLARiTY Configuration Manager Ensure that the printer status panel (at the bottom left of the window) reports the message "Connection Active" and the new printer icon turns green.

  • Page 42: Editing Parameters

    ICE Pegasus Service Manual Editing Parameters Figure 3-20 displays the list of parameters that are available in the printer settings. Parameters List Figure 3-20: Parameter Settings Click the folder required to open or close it or to gain access to the parameters it contains.

  • Page 43: Saving The Changes In The Printer

    ICE Pegasus Service Manual CLARiTY panel. It may be more convenient to make final adjustments at the panel rather than using the CLARiTY Configuration Manager. Saving the Changes in the Printer To make the changes effective, proceed as follows: Click the printer icon in the left-hand pane to open the printer controls at the bottom pane of the window.

  • Page 44: Loading A Saved Archive

    ICE Pegasus Service Manual Loading a Saved Archive To load an archive that was saved previously, proceed as follows: Locate the archive in the left panel and right click on it. Choose Load from the pop-up menu. The archived parameters are displayed on the right-hand pane.

  • Page 53: Chapter 4 - Clarity Operating System

    CLARiTY Operating System This chapter contains the following topics: • Getting started the CLARiTY Operating System • Using the Tools page • Working with Passwords Getting started with the CLARiTY CLARiTY is an icon-based operator control system. It has an easy-to-use touch screen and most areas of the display are "active", that is, touching an area on the screen is like pressing a "button"...

  • Page 54: Using The Tools Page

    ICE Pegasus Service Manual Using the Tools Page Touch the Tools button on the home screen to access the Tools page (Figure 4-2). Figure 4-2: Tools Page The tools page allows you to access the following pages: • Setup page: Permits you to modify a small subset of the printer setup parameters •...

  • Page 55: Working With Setup Page

    ICE Pegasus Service Manual Working with Setup Page Touch Setup button on the tools page to access the setup page (Figure 4-3). Figure 4-3: Setup Page The Setup page allows you to access the following parameters: • Printhead and printing operations •...
  • Page 56 ICE Pegasus Service Manual Printhead Setting in Intermittent Mode Touch the Printhead button on the setup page to access the printhead parameters. Figure 4-4: Printhead Parameters in Intermittent Mode The Printhead page in intermittent mode allows you to access the following parameters: •...
  • Page 57 ICE Pegasus Service Manual • Print Darkness: The amount of energy being transferred into the printhead. It should be set to the lowest value that provides acceptable quality of print at the required throughput. • Interleaved Images: Enables a lower quality draft mode of printing with a 50% saving in ribbon consumption •...
  • Page 58 ICE Pegasus Service Manual Working with the Consumables Setup Page Touch Consumables button on the setup page to access the consumables parameters (Figure 4-6). Figure 4-6: Consumables Page The consumables page allows you to set the following parameters: • Ribbon Width: Sets the ribbon tension to the optimum value...
  • Page 59 ICE Pegasus Service Manual Working with the Control Setup Page Touch the control button on the setup page to access the control page (Figure 4-7). Figure 4-7: Control Page The control page allows you to set the following parameters: • Internationalisation: Sets the language of the CLARiTY screen and the...

  • Page 60: Working With Diagnostics

    ICE Pegasus Service Manual Working with the Options Setup Page There are no options available at this time, it may be introduced in the next versions of the CLARiTY. Working with Diagnostics Touch diagnostics button on the tools page to access the diagnostics page (Figure 4-8).
  • Page 61 ICE Pegasus Service Manual Working with Printhead Diagnostics Touch Printhead button on the Diagnostics page to access the printhead diagnostics page (Figure 4-9). Figure 4-9: Printhead Diagnostics Page The printhead diagnostics page allows you to access the following parameters: • Inputs •...
  • Page 62 ICE Pegasus Service Manual Touch Inputs on the Printhead diagnostics page to access the input parameters (Figure 4-10). Figure 4-10: Printhead Inputs Diagnostics Page The input diagnostics page allows you access the following parameters: • Encoder: Touch the encoder button to access the encoder diagnostics page.
  • Page 63 ICE Pegasus Service Manual - Encoder Speed: Shows the actual real-time speed of the film being measured by the encoder - Encoder Scaling: A parameter set to run the printing ribbon at a slightly lower speed to the packaging film. This can improve printing quality at very high packaging film speeds.
  • Page 64 ICE Pegasus Service Manual Touch Outputs on the Printhead Diagnostics page to access the output parameters (Figure 4-12). Figure 4-12: Printhead Outputs Diagnostics Page Each button shows the status of a physical output on the printer. Touching the Toggle button allows you to force the state of an output, high or low which is useful for diagnostic purposes.
  • Page 65 ICE Pegasus Service Manual Touch the Optics button on the Printhead Diagnostics page to access the ribbon calibration system page. Figure 4-13: Printhead Ribbon Calibration Page The ribbon calibration systems works on a shadowgraph principle. A pair or LED's are mounted inside the printer and a receiver is mounted onto the back of the printhead carriage.
  • Page 66 ICE Pegasus Service Manual Touch the General button on the Printhead Diagnostics page access to the general diagnostic parameters. Figure 4-14: Printhead General Diagnostics Page The printhead general diagnostics page allows you access the following parameters: • Printer Mode: Indicates if the printer is configured as intermittent or continuous motion •...
  • Page 67 ICE Pegasus Service Manual Figure 4-15 shows a typical screen display of an encoder profile. Figure 4-15: Encoder Profiles Graph The graph displayed on the CLARiTY Operator Interface takes into account, settings for 'Maximum Print Speed', current 'Registration' settings and the image size printed.
  • Page 68 ICE Pegasus Service Manual To capture the Encoder profiling on the CLARiTY screen, proceed as follows: Touch the Encoder Profiles button on the Printhead Diagnostics page access to the Encoder Profiles parameters (Figure 4-16). Figure 4-16: Encoder Profiles Page To set up the options for the profile you are want to capture, touch the following buttons: •...
  • Page 69 ICE Pegasus Service Manual In addition, if CLARiTY Configuration Manager is communicating with the printer, the encoder profile may be uploaded to a PC for analysis. To upload encoder profile to a PC, proceed as follows: Click on the new coder icon and navigate through devices and select Capture Encoder Profile from the list as shown in Figure 4-17.
  • Page 70 ICE Pegasus Service Manual To access this file, select Log Files folder from new coder as shown in Figure 4-18. Figure 4-18: Encoder Profiles - Log Files This file can be used for diagnostic purposes by the Development Team for advanced diagnostics purposes.
  • Page 71 ICE Pegasus Service Manual Working with Printhead Timings Touch the Timings button on the Printhead Diagnostics page access to the timings page (Figure 4-19). This diagnostic page provides information about the last print or print job selection that was made. It is useful in high throughput applications to understand what the printer is trying to do, especially in continuous motion applications.
  • Page 72 ICE Pegasus Service Manual • Job Data Update Time (ms): Indicates the total time taken to update all the dynamic variables in the image (time, date, counters) • Counter Update Time (ms): Indicates the time taken to update all the counter fields in the image •...
  • Page 73 ICE Pegasus Service Manual Working with Control Diagnostics Touch Control button on the Diagnostics page to access the system Control page. Figure 4-21: Control Parameters The following parameters can be accessed in this page: • Versions: Displays the software versions of the various software components installed in the printer.
  • Page 74 ICE Pegasus Service Manual Working with Options There are no diagnostics for the Options menu. Working with Database Touch Database button on the Diagnostics page to access the Database page. Figure 4-22: Database Page The following parameters can be access in this page.
  • Page 75 ICE Pegasus Service Manual Connecting the USB Database Instead of connecting a PC/laptop to the printer via a null modem cable in order to download jobs, the USB device can be connected directly into the USB port on the CLARiTY Operator Interface (Figure 4-23).
  • Page 76 ICE Pegasus Service Manual The database page displays the External Database (Figure 4-24). Figure 4-24: External Database Touch External Database button to view all the jobs in the USB device (Figure 4-25). Figure 4-25: Jobs List on USB Device 4-24...

  • Page 77: Working With Passwords

    ICE Pegasus Service Manual Using the buttons in the bottom of the page (Figure 4-25 on page 4-24) you can either view the job, or send a file to the local database, or delete the job from the USB device.

  • Page 78: Password Protection Set-Up

    ICE Pegasus Service Manual • Set-up • Diagnostics • Databases This is can be easily explained by means of an example (Table 4-1): Registration Set-up Diagnostics Databases Level 1 (Operator) Level 2 (Line Super- visor) Level 3 (Mainte- nance) Table 4-1: Password Protection - Example...
  • Page 79 ICE Pegasus Service Manual The menu tree to reach password protection set-up is shown in the CLARiTY screen in Figure 4-27. Figure 4-27: Password Set - up In addition to the global enable/disable of passwords there are three parameters for each of the three user levels available: •...

  • Page 80: Chapter 5 - Maintenance

    Maintenance This chapter contains the following topics: • Maintaining the Power Supply • Maintaining the CLARiTY Controller • Maintaining the Printer • Maintaining the Cassette • Updating the CLARiTY Operating Software Warning PERSONAL INJURY. Before attempting any maintenance or repair on any part of the product, disconnect the printer from the main power supply and isolate the printer from any external energy sources including other connected equipment.

  • Page 81: Maintaining The Power Supply

    ICE Pegasus Service Manual Maintaining the Power Supply This section contains the information on how to replace the fuse. Replacing the Mains Fuse The fuses are the only user-serviceable parts in the power supply unit. To replace the mains fuse, proceed as follows: Using a small screwdriver, press and turn the fuseholder anticlockwise, and remove the fuseholder (Figure 5-1).

  • Page 82: Maintaining The Clarity Controller

    ICE Pegasus Service Manual Refit the fuseholder in its original position. Maintaining the CLARiTY Controller Replacing the Power Supply Unit To open and replace the Power Supply Unit, proceed as follows: Remove the top cover from the base of the CLARiTY Unit by unscrewing the 5 screws shown in Figure 5-3.
  • Page 83 ICE Pegasus Service Manual Disconnect the white power connectors from the front and back of the PSU and from the main PCB as shown in Figure 5-4. Connectors Figure 5-4: Power Connections Removal Maintaining the CLARiTY Controller Rev AA...

  • Page 84: Replacing The Clarity Processor Pcb And Lcd Touchscreen

    ICE Pegasus Service Manual Next turn the base over and undo the four screws from the base plate. The PSU can now be separated from the base plate. Screws Figure 5-5: Base Screw Removal To re-assemble reverse the above procedure ensuring that all electrical connectors are securely pushed into place.
  • Page 85 ICE Pegasus Service Manual Remove the six securing screws from the D-type connectors on the bottom of the CLARiTY unit (Figure 5-6). D-Type Securing Screws Figure 5-6: Top Case Detail Carefully remove the three connectors from the PCB taking care not to bend or twist the cables (Figure 5-6).
  • Page 86 ICE Pegasus Service Manual Remove and retain the two screws securing the PCB (Figure 5-7). Screws Figure 5-7: PCB Connections Gently slide and lift the PCB away from the LCD and touch screen assembly taking care not to damage the three cables coming from the LCD/Touchscreen module.
  • Page 87 ICE Pegasus Service Manual case aperture (Figure 5-8). Figure 5-8: PCB Removal Disconnect the backlight power cable (white/pink) connection. Remove and retain the four screws holding the LCD/touchscreen assembly to the metal support plate. Maintaining the CLARiTY Controller Rev AA...
  • Page 88 ICE Pegasus Service Manual Remove and retain the white ribbon cable from the now separated LCD/touchscreen assembly (Figure 5-9). Figure 5-9: Separated LCD Assembly Place the new LCD/touchscreen assembly face down on a clean, soft surface and fit the support plate using the four screws removed earlier.
  • Page 89 ICE Pegasus Service Manual Replace the white ribbon cable ensuring that the right angle is as shown (Figure 5-11). Figure 5-11: LCD Ribbon Cable Detail Slide/lower this assembly back into the top case, being careful not to damage the seal or to trap the backlight power cable and re-fit the three securing screws and the anti-vibration washers.

  • Page 90: Maintaining The Printer

    ICE Pegasus Service Manual Maintaining the Printer This section contains the information on how to replace: • The Compact Flash Card • The Main PCB of the printer • The Peel Roller • The Printhead • The Cassette Rollers Replacing the Compact Flash Card To replace the compact flash card, proceed as follows: Remove the cassette and place the printer face down on a flat surface.

  • Page 91: Replacing The Main Pcb

    ICE Pegasus Service Manual The Compact Flash card is located on the side with the mounting plate (the opposite side to the printhead). Using a pair of long nosed pliers, gently grip the Compact Flash Card and pull to extract (Figure 5-13).
  • Page 92 ICE Pegasus Service Manual Locate and remove the 2 screws (Figure 5-14). Screws Figure 5-14: Cassette Screws Removal Remove the rear cover as detailed above in the section “Replacing the Compact Flash Card” on page 5-11. Next remove the nuts securing the D-Type connectors to the side plate still secured to the unit (Figure 5-15).
  • Page 93 ICE Pegasus Service Manual Disconnect the 8 electrical connectors located around the edge of the PCB. Undo the 2 screws securing the PCB to the supports and carefully withdraw the PCB including the 15way D-Type connector for the I/O connections (Figure 5-16).

  • Page 94: Replacing The Peel Roller

    ICE Pegasus Service Manual Then connect the I/O ribbon cable to the PCB and slide it into place. Ensure that the connector X9 is threaded through the access hole in the heat sink (Figure 5-18). Figure 5-18: X9 Connector Access Secure the PCB using the 2 screws and then reverse the procedure from 5 to 1 above.
  • Page 95 ICE Pegasus Service Manual Remove the screw on the top of the peel roller as shown in Figure 5- 1. Peel Roller 2. Screw Figure 5-19: Peel Roller Screw Removal Remove the peel roller. Peel Roller Figure 5-20: Peel Roller Removal Replace the peel roller and secure it using the screw removed in step Refit the cassette to the printer.

  • Page 96: Replacing The Printhead

    ICE Pegasus Service Manual Replacing the Printhead To replace the printhead proceed as follows. Remove the printhead retaining screw as shown in Figure 5-21. Printhead Screw Figure 5-21: Printhead Screw Removal Move the printhead from the parked position. Disconnect the printhead and remove.

  • Page 97: Setting The Printhead Resistance

    ICE Pegasus Service Manual Reconnect the printhead connector to the new printhead. Place the printhead in the parked position and secure it with the printhead screw. Set the printhead resistance. Setting the Printhead Resistance Printheads are manufactured with variations in their resistance. The printhead resistance is pre-set in the factory.

  • Page 98: Maintaining The Cassette

    ICE Pegasus Service Manual Touch the Printhead button to open the Printhead Setup Page. Select the Printhead Resistance parameter and enter the resistance value that was displayed on the printhead label (Figure 5-24). ICE Pegasus Service Manual Figure 5-24: Printhead Resistance Setting Use the arrows or the keypad to set the settings and touch OK to save the settings.
  • Page 99 ICE Pegasus Service Manual Loosen and remove the ribbon guide, with a 12 mm spanner from the cassette, as shown in Figure 5-25. Figure 5-25: Roller Guide Removal Remove the roller from the ribbon guide, as shown in Figure 5-26.
  • Page 100 ICE Pegasus Service Manual Adjusting the Cassette Latch The latch components on the printer are set at the factory and normally do not require adjustment. If it is necessary to adjust the latch, proceed as follows. Remove the cassette from the printer.
  • Page 101 ICE Pegasus Service Manual Adjust the latch screw (4 mm hex socket) and hold it in place while tightening the lock nut, as shown in Figure 5-28. Figure 5-28: Latch Screw Adjustment Note: A correctly adjusted latch should not allow the movement of the cassette when in the printer, but should allow the cassette to be pulled from the printer under any circumstances when the release button is pressed.

  • Page 102: Updating The Clarity Operating Software

    ICE Pegasus Service Manual Updating the CLARiTY Operating Software The operating software of the printer can be upgraded by a process called a CLARiTY Update. The current version of the software is displayed at the page TOOLS > DIAGNOSTICS > CONTROL > VERSIONS where the software part number can be read.
  • Page 103 ICE Pegasus Service Manual Connect the printer to the PC and when the coder icon is green, right click on the icon. Figure 5-29: CLARiTY Update Window Click on CLARiTY Update and navigate to the CAB file stored on the PC disc.
  • Page 104 ICE Pegasus Service Manual Copy the CLARiTY software onto an USB memory stick. Note: The software must be stored in a root directory called \CLARiTY update. Connect the stick to the CLARiTY Operator Interface via the USB port as shown in Figure 5-30.
  • Page 105 ICE Pegasus Service Manual If the parameter is set to No, navigate to TOOLS>SETUP>CONTROL and touch the CLARiTY Update button. Select 'Yes' to proceed to the next stage of the update or 'No' to return to the 'Home' screen. If 'Yes' is selected, the CLARiTY update screen is displayed.
  • Page 106 ICE Pegasus Service Manual Touch OK, a confirmation page appears (Figure 5-33). Figure 5-33: CLARiTY Confirmation Page Touch Yes and the printer starts to update the software. Note: It is very important to ensure that the power to the printer is not removed during the update process or the flash card in the printer may get corrupted.

  • Page 107: Chapter 6 - System Events

    System Events This chapter contains the following topic: • List of faults and warnings Table 6-1 lists the faults and warnings Error Report on CLARiTY Operator Interface Status E1001 ‘Count Limit Reached’ - One or more of the counters Fault in the image has reached the end value set in the image design.
  • Page 108 ICE Pegasus Service Manual Error Report on CLARiTY Operator Interface Status E3001 ‘Perform Motor Calibration’ - Motors have not been Fault calibrated. Calibrate via CLARiTY Config E3002 ‘Printhead Resistance Not Set’ - Set the printhead Fault resistance on CLARiTY - Tools>Setup>Print- head>Printhead resistance...
  • Page 109 ICE Pegasus Service Manual Error Report on CLARiTY Operator Interface Status E3019 ‘Unprinted Pack’ - Substrate speed fell below 40mm/s Fault for too long to print last pack. E3020 ‘Incorrect Reel Size’ Fault E3021 ‘Print Cycle Error’ - Note the values in Tools>diagnos- Fault tics>printhead>states>captured states and report.

  • Page 110: Chapter 7 - Troubleshooting

    Troubleshooting This chapter contains the following topic: • Information on error messages, its possible causes and the remedies Table 7-1 lists the error messages, its possible causes and the remedies Error Possible Causes Remedies Message Cassette not fully seated Push the cassette in until you hear it “click”...
  • Page 111 ICE Pegasus Service Manual Error Possible Causes Remedies Message Broken ribbon Reinstall the ribbon Excess of slack in ribbon Reinstall the ribbon when the cassette is loaded Damaged cassette Check for the damaged cassette base plate, giving misaligned drive or ribbon...
  • Page 112 ICE Pegasus Service Manual Error Possible Causes Remedies Message Dirt or obstruction Clean the emitter and between the emitter and detector gently with a soft detector cloth Faulty emitter assembly Replace the emitter Optical assembly Calibration Sensor Dirty Faulty detector assembly...
  • Page 113 ICE Pegasus Service Manual Error Possible Causes Remedies Message Power supply voltage Check the power supply varies too much output Faulty printer PCB Replace the main printer Motor Volts Error Faulty Motor Check the motor and replace if necessary Power supply voltage...
  • Page 114 ICE Pegasus Service Manual Error Possible Causes Remedies Message Power plug not fully Check and correct seated in the socket Power not turned on at Check and correct the source or at the power supply Power cable not properly Check and correct...
  • Page 115 ICE Pegasus Service Manual Error Possible Causes Remedies Message Condition of the belt drive Check and correct and pulleys Printhead stepper motor Check and correct not plugged in securely Linear slide carriage Turn the power off. Try to Printhead does jammed move the linear slide.
  • Page 116 ICE Pegasus Service Manual Error Possible Causes Remedies Message Insufficient or no air Check and set the air pressure pressure to 3 bar No Print Signal Go to: Tools/Diagnostics/ Printhead/Inputs and check the presence of incoming print signal. Low Darkness level...
  • Page 117 ICE Pegasus Service Manual Error Possible Causes Remedies Message Invalid or no image Select a valid image selected Printer will not go on-line Fault message not Clear the fault message cleared Incorrect air pressure Check and set the air pressure to 3 bar...
  • Page 118 ICE Pegasus Service Manual Error Possible Causes Remedies Message Start border too short Increase the start border Intermittent Mode Only: Print signal timing is Substrate is moving while incorrect. If necessary, delay attempting to print the print until the film stops...

  • Page 119: Illustrations

    Illustrated Parts List The Illustrated Part List (IPL) contains the illustrations and the parts lists for the different assemblies in the printer. The parts lists give the part numbers, description and quantity of all the items and the modules in the printer.

  • Page 120: Alphabets

    ICE Pegasus Service Manual Alphabets • An alphabet is assigned to the main assemblies of a printer and each subassembly under the main assembly. See Figure 8-1. For example: If A, B, C and D identify the main assemblies of a printer, then the alphabets E,F, and so on identify the subassemblies below each main assembly in a sequence.

  • Page 121: Tables

    ICE Pegasus Service Manual Tables Table 8-2 describes the styles used to show the explosion of the main assemblies in the parts lists. Item Number Description Main Assembly Main Assembly Subassembly 1 Main Assembly Table 8-2: Representation of the different Subassemblies and parts in the Table...

  • Page 122: Controller Assembly

    Controller Assembly Figure 8-2: Controller Assembly Table 8-3 lists the parts of the controller assembly. Item Number Description Controller Assembly (Refer to Figure 8-2) 400885 Thermal Coder Fuse Kit Set of 10 403348 Power Supply Unit 403345 Processor PCB 403344 LCD Touchscreen 403183 Controller Mounting Yoke Kit...

  • Page 123: Printer Assembly

    Videojet 6210 Service Manual Printer Assembly Printer Assembly with PCB Printer Assembly without PCB Figure 8-3: Printer Assembly Printhead Assembly Figure 8-4: Printhead Assembly Printer Assembly Rev AA...
  • Page 124 Videojet 6210 Service Manual Table 8-4 lists the parts of the printer assembly. Item Number Description Printer Assembly (Refer to Figure 8-3 on page 8-5) 403332 Videojet 6210 Thermal Printer PCB 403339 Thermal Printer 128mb Flash Card Printhead Assembly (Refer to Figure 8-4 on page 8-5) 403325 Thermal Printhead 403324...

  • Page 125: Cassette Assembly

    Videojet 6210 Service Manual Cassette Assembly Figure 8-5: Cassette Assembly Table 8-5 lists the parts of the cassette assembly. Item Number Description Cassette Assembly (Refer to Figure 8-5) 403327 Silver Disc - Pack 5 off 403323 53mm Cassette Roller Set of 6 Print Ribbon (Refer to Table 8-7 on page 8-9 for details)

  • Page 126: Accessories

    Videojet 6210 Service Manual Accessories Figure 8-6: Accessories Table 8-6 lists the accessories of the printer. Item Number Description 403357 Spare 32T Bracket Platen Rubber Pack of 10 (Continuous) 403357 Spare 32T Bracket Platen Rubber Pack of 10 (Intermittent) 401339 Spare Encoder O-ring Pack of 10 403318...

  • Page 127: Printer Ribbons

    Videojet 6210 Service Manual Printer Ribbons Table 8-7 lists the ribbons of the printer. Serial Number Part Number Description 702305 Standard Black 20mm x 600m 702304 Standard Black 35mm x 600m Standard White 20mm x 450m Standard White 35mm x 450m Premium Black 20mm x 550m Premium Black 35mm x 550m Premium White 20mm x 550m...

  • Page 128: Chapter 9 - Drawings

    Drawings Printer Dimensions Figure 9-1 shows the dimensions of the Videojet 6210 (RH) printer. M6 Tapped Holes Thread Depth 6.00 20.73 mm (2 PLCS) 3 Places (0.82 inches) 70.73 mm (2.78 inches) 159.60 mm 185.30 mm (7.3 inches) (6.23 inches) 167.15 mm 157.80 mm (6.58 inches)
  • Page 129 Videojet 6210 Service Manual Figure 9-2 shows the dimensions of the Videojet 6210 (LH) printer. M6 Tapped Holes 20.73 mm 2 PLCS Thread Depth 6.00 (0.82 inches) 3 Places 70.73 mm (2.78 inches) 185.30 mm 159.60 mm (7.29 inches) (6.28 inches) 167.15 mm (6.58 inches) 157.80 mm...
  • Page 130 Videojet 6210 Service Manual Figure 9-3 shows the dimensions of the CLARiTY controller. 118.90 mm (4. 68 inches) M6 Female Thread Both Sides. Thread Depth 6.00 69.20 mm (2.72 inches) Figure 9-3: CLARiTY Controller Dimensions Printer Dimensions Rev AA...

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