MUI Maintenance manual cover.

ai 1 05/05/2010 09:28:50

the team to trust maintenance manual

Monochrome user Interface

CM

MY

CY

CMY

Markem-Imaje Limited
Nottingham Science Park
University Boulevard
Nottingham NG7 2QN
www.markem-imaje.com Tel.: +44 (0)115 943 0055
 TABLE OF CONTENTS

1 General Information 1-3

1.1 Uptime™ Total Services 1-4

2 Setup and Timing Issues 2-3

2.1 Introduction 2-3

2.2 Setup Issues 2-4
2.2.1 Air Pressure Settings 2-4
2.2.2 Print Anvil 2-4
2.2.3 Printhead Gap 2-5
2.2.4 Ribbons 2-5
2.3 Important Printer Settings 2-6
2.4 Print Darkness 2-6
2.4.1 Print Speed 2-7
2.5 Print Signal Issues 2-8
2.5.1 Debounce Time 2-8
2.5.2 Debounce Distance 2-8
2.5.3 Print Delay 2-8
2.6 Print Quality Issues 2-9
2.6.1 Head Out Time 2-9
2.6.2 Start Border 2-10
2.6.3 End Border 2-10
2.6.4 Head In Time 2-10
2.6.5 Ribbon Advance Distance 2-10
2.7 Moving the Printed Image 2-11
2.7.1 Registration 2-11
2.7.2 Offset 2-11
2.8 Timing issues 2-12
2.8.1 Print Timings 2-13
2.8.2 SmartDate 5 and SmartDate 5 / 128 - Intermittent Mode 2-15
2.8.3 Printing Time - Intermittent Printers 2-16
2.8.4 Print Cycle Time - Intermittent Printers 2-16
2.8.5 SmartDate 5, SmartDate 5 / 128 - Continuous Mode and SmartDate 5s 2-17
2.8.6 Printing Time - Continuous Printers 2-17
2.8.7 Print Cycle Time - Continuous Printers 2-17
2.8.8 Speed Profile Recorder 2-18
2.9 Distance between prints on the ribbon 2-23
2.10 Distance between prints on the substrate 2-23
2.10.1 Minimum Distance between prints in DRS mode 2-24

SmartDate 5.1 (Rev AG)

TABLE OF CONTENTS

3 Maintenance 3-1

3.1 Introduction 3-1

3.2 Cleaning and Care 3-2
3.3 Maintenance Scheme 3-3
3.3.1 Quick/Regular Checks 3-3
3.3.2 Monthly Checks 3-4
3.4 Care of the Printhead 3-5
3.5 Cleaning the Printhead 3-6
3.6 Replacing the Printhead 3-7
3.6.1 Removing the damaged printhead (SmartDate 5) 3-7
3.6.2 Removing the damaged printhead (SmartDate 5s) 3-8
3.6.3 Removing the damaged printhead (SmartDate 5 / 128) 3-9
3.6.4 Setting the correct Printhead voltage 3-10
3.7 Replacing the Peel Roller 3-12
3.8 Replacing the Ribbon Guide Rollers 3-14
3.9 Replacing the Ribbon Movement Roller 3-15
3.9.1 Replacing the Roller Magnet 3-15
3.9.2 Replacing the Movement Roller 3-16
3.9.3 Replacing the Ribbon Movement Sensor 3-17
3.10 Replacing the Ribbon Tension Roller 3-18
3.11 Replacing the Ribbon Tension Sensor 3-19
3.12 Replacing the Micro Switches 3-20
3.13 Replacing the Solenoid Valves 3-21
3.13.1 SmartDate 5 and SmartDate 5s 3-21
3.13.2 SmartDate 5 / 128 Solenoid Valves 3-24
3.14 Replacing the Drive Belts 3-25
3.14.1 Replacing the Drive Belt - SmartDate 5 3-25
3.15 Replacing the Drive Belt - Shuttle Printer 3-27
3.16 Changing the Printer Hand - SmartDate 5 3-30
3.17 Changing the Printer Hand - SmartDate 5 / 128 3-33
3.18 Changing the Printer Hand - Shuttle Printer 3-36
3.19 Changing the Cassette Hand 3-41
3.20 Replacing the Printer PCBs 3-43
3.21 Replacing the Controller PCB 3-46

SmartDate 5.1 (Rev AG)

 TABLE OF CONTENTS

4 Technical Information 4-1

4.1 Introduction 4-1

4.2 The SmartDate 5 Printers 4-2
4.3 Printer Components 4-3
4.3.1 Linear Slides 4-6
4.3.2 SmartDate 5 and SmartDate 5 / 128 4-7
4.3.3 SmartDate 5s Shuttle Printer 4-8
4.3.4 Intermittent Drive System 4-9
4.3.5 Continuous Drive System - SmartDate 5 Printer 4-10
4.3.6 Continuous Drive System - SmartDate 5s Shuttle Printer 4-11
4.3.7 Ribbon Drive System 4-12
4.4 Printhead Module 4-13
4.5 SmartDate 5 53mm Print Module Components 4-14
4.6 SmartDate 5 / 128 Print Module Components 4-15
4.6.1 SmartDate 5 53mm Printhead Assembly 4-16
4.6.2 SmartDate 5 / 128 mm Printhead Assembly 4-17
4.6.3 SmartDate 5 35 mm Printhead Module Operation 4-18
4.6.4 SmartDate 5 / 128 Printhead Module Operation 4-18
4.6.5 Printhead Type Detection 4-19
4.6.6 Printhead Temperature Control 4-19
4.6.7 Printhead Voltage Control 4-19
4.7 Printer Orientation 4-20
4.7.1 Orientation - SmartDate 5 and SmartDate 5 / 128 4-22
4.7.2 Orientation - SmartDate 5s Shuttle Printer 4-25
4.8 Printer Calibration 4-27
4.8.1 Print Module / Shuttle Carriage Calibration 4-28
4.8.2 Ribbon Calibration 4-31
4.8.3 Printer Cassette 4-33
4.8.4 Cassette Components SmartDate 5 and SmartDate 5 / 128 4-34
4.8.5 Cassette Components SmartDate 5s 4-35
4.8.6 Ribbon Calibration / Movement Roller 4-36
4.8.7 Ribbon Tension Roller 4-37

SmartDate 5.1 (Rev AG)

TABLE OF CONTENTS

4.9 Printer Electrical Components 4-38

4.9.1 Stepper Motors 4-39
4.9.2 Ribbon Movement Sensor 4-40
4.9.3 Ribbon Tension Sensor 4-41
4.9.4 Micro Switches 4-42
4.9.5 Printhead Prime Position 4-45
4.9.6 Printhead Print Position 4-45
4.9.7 Encoder 4-46
4.9.8 Printer PCB 4-47
4.9.9 Printer PCB Components 4-48
4.9.10 Printer PCB Connectors 4-49
4.9.11 Printer PCB Test Points 4-50
4.9.12 Printer PCB Fuse 4-50
4.9.13 Printer PCB LEDs 4-51
4.10 Printer Interconnection PCBs 4-52
4.11 The SmartDate 5 Controller 4-53
4.11.1 Controller Components 4-54
4.11.2 Controller Rear Connectors 4-55
4.11.3 Mains Power Switch 4-55
4.11.4 Power Supply 4-56
4.11.5 Controller PCB 4-57
4.11.6 Controller PCB Micro-processor 4-57
4.11.7 Controller PCB Components 4-58
4.11.8 Controller PCB Connectors 4-59
4.11.9 Controller PCB Test Points 4-60
4.11.10 Controller PCB LEDs 4-61
4.11.11 Controller PCB Links 4-63
4.11.12 Controller PCB Fuses 4-63
4.11.13 SmartDate 5 Interfaces 4-64
4.11.14 Controller to Printer Interface 4-64
4.11.15 Controller PCB to User Interface 4-65
4.11.16 Auxiliary Serial Comms Interface 4-65
4.11.17 Ethernet Interface 4-65
4.11.18 USB - A 4-65
4.11.19 USB - B 4-65
4.11.20 External I/O Interface 4-66

SmartDate 5.1 (Rev AG)

 TABLE OF CONTENTS

5 Troubleshooting 5-1

5.1 Introduction 5-1

5.2 Status LEDs 5-2
5.3 Fault and Warning Messages 5-2
5.3.1 Fault Messages 5-3
5.3.2 Warning Messages 5-14
5.4 Common Issues 5-21
5.4.1 No Power to the Printer 5-21
5.4.2 Printhead Cables 5-21
5.4.3 Encoder 5-21
5.5 No Information Is Printed 5-22
5.6 The Printhead Does Not Move Out 5-22
5.7 Drive System Issues 5-23
5.7.1 Ribbon is not driving 5-23
5.7.2 Ribbon Drive Problems 5-23
5.7.3 Ribbon Creasing 5-23
5.7.4 Ribbon Breaking or Scuffing Prints 5-24
5.7.5 Ribbon Coning (Continuous Printers) 5-24
5.7.6 Peel Roller Problems 5-24
5.7.7 Head not returning to home position 5-25
5.7.8 Shuttle not driving 5-25
5.7.9 Drive Belt Issues 5-25
5.8 Printhead Module / Shuttle Carriage Drive Problems 5-26
5.9 Cassette Problems 5-27
5.9.1 Cassette Release Problems 5-27
5.10 Cassette Insertion Problems 5-27
5.10.1 Cassette Rollers Alignment 5-27
5.11 Display Issues 5-28
5.11.1 Back light only lit 5-28
5.11.2 LCD only, no Back light 5-28
5.11.3 Display is totally blank 5-28

SmartDate 5.1 (Rev AG)

TABLE OF CONTENTS

5.12 Print Quality Problems 5-29

5.12.1 Poor Print Quality (when in DRS Mode) 5-30
5.12.2 Faded print 5-30
5.12.3 Faded on one side 5-31
5.12.4 Blurred edges 5-31
5.12.5 Missing lines perpendicular to printhead 5-31
5.12.6 Text missing at start of print 5-32
5.12.7 Text missing at end of print 5-32
5.12.8 Print rubs off 5-32
5.12.9 First Dots Missing or Ragged 5-33
5.12.10 Last Dots Missing or Ragged 5-33
5.12.11 Elongated or compressed print 5-33
5.12.12 Double printing 5-34
5.12.13 Prints occur on every other product (or less) 5-34
5.12.14 Overlapping prints 5-34
5.12.15 Cropped Prints 5-34
5.13 Job Selection Problems 5-35
5.13.1 Selecting a Job 5-35
5.13.2 Host PC 5-35
5.13.3 Image corruption problems 5-35
5.14 Checking Database Information 5-36
5.14.1 Local 5-36
5.14.2 Host 5-36
5.14.3 Database mode 5-36
5.15 Communication Problems 5-37
5.15.1 Communications Do Not Work 5-37
5.15.2 Selecting RS-232/RS-485 operation 5-38
5.15.3 RS-485 Node Numbers and Network ID 5-38
5.15.4 RS-232 (NGPCL) Communication 5-38
5.15.5 Networking Issues 5-39
5.15.6 Communication ports 5-39
5.15.7 Communications connection 5-39
5.15.8 Broken wires or shorts 5-39
5.16 Disaster Recovery 5-40
5.16.1 Recovery Using CoLOS Create Pro 5-41
5.16.2 Recovery Using CoLOS Control 5-42
5.16.3 Recovery using the PC Tools Application 5-42
5.16.4 Recovery using Compact Flash 5-42

6 Recommended Spares 6-1

6.1 SmartDate 5 53mm Spare Parts 6-1

6.2 SmartDate 5 53 mm Spares Kits 6-2
6.3 SmartDate 5 / 128 Spare Parts 6-4
6.3.1 SmartDate 5 / 128 Spares Kits 6-5

SmartDate 5.1 (Rev AG)

 SECTION 1
GENERAL INFORMATION

SmartDate 5.1

Maintenance Manual
 SECTION 1 - GENERAL INFORMATION

1 General Information
This manual is designed to assist with keeping your SmartDate 5 in good working
order.
Topics covered in the following sections include:
• General maintenance and cleaning.
• Technical information about the SmartDate 5.
• Fault finding and troubleshooting problems.
• Replacement parts and recommended spares.

Additional information regarding mechanical drawings or electrical schematics

can be found on the CD in the relevant folders.

SmartDate 5.1 1-3

SECTION 1 - GENERAL INFORMATION

1.1 Uptime™ Total Services

• Application Specialists
• Installation
• myMARKEM
• Repair Centre
• Training
As part of the Markem-Imaje continuous commitment to helping customers
succeed, Markem-Imaje has introduced the Uptime Total Solutions Program, a
comprehensive array of services to maximize uptime, productivity and customer
satisfaction. These value-added services focus in the following critical areas:
Maximizing the reliability of your coding systems. The Markem-Imaje
Reliability Program supports our customers with resources committed to the
"science of reliability." Our Reliability Engineering team works integrally with the
product development process to deliver best-in-class performance for all Markem-
Imaje products. For real life simulation, the program also incorporates laboratory
application testing as well as ongoing customer field reliability monitoring and
testing. Markem-Imaje customers can register at myMARKEM.com and view real-
time reliability data, including MTB's on our most popular machine products.
Ensuring a dependable supply chain. Markem-Imaje utilizes a fully Integrated
Logistic Management System supported by strategic partnerships with other
world-class companies like UPS Worldwide Logistics. Our regional repair centres
offer a cost-effective solution for modular exchange or repairs of Markem-Imaje
machines to keep your line running. Combining these capabilities with a strong
local presence around the globe and consistent product availability and delivery
performance all help keep you up and running.
Strengthening your relationship with us. Markem-Imaje representatives are
the industry-leading experts in marking and coding solutions. We work with the
vast majority of packaging equipment manufacturers (OEMs) to provide a
seamless integration and deliver you the right solution. Comprehensive support
programs include print samples on your actual packaging materials, on-line trials
or extended long-term trials to reinforce the high level of quality and reliability that
Markem-Imaje can bring to your application.
The program includes, but is not limited to, the following services: sample printing,
training, technical support, logistics support, financing, on-line support, contracts,
and project management. At the core of Uptime is our corporate reliability
program, unrivalled in our industry and the reason products such as the
SmartDate 5, SmartDate® and 5000 Series case coders are the undisputed
industry leaders.

1-4 SmartDate 5.1

 SECTION 2
SETUP AND TIMING ISSUES

SmartDate 5.1

Maintenance Manual
 SECTION 2 - SETUP AND TIMING ISSUES

2 Setup and Timing Issues

2.1 Introduction
The following section provides general advice for ensuring that your SmartDate 5
is working at its most efficient.

Topics covered in this section include:

• Air pressure
• Printhead Gap
• Print Anvils
• Ribbons
• Printer Settings
• Print Signals
• Print Quality Issues
• Moving the printed image
• Timing Issues
• Speed Profiles
• DRS issues

SmartDate 5.1 2-3

SECTION 2 - SETUP AND TIMING ISSUES

2.2 Setup Issues

2.2.1 Air Pressure Settings

Make sure that the air is connected on the side of the printer body.
The setting of the air pressure is critical to the performance of the printhead.
• Check that the air pressure regulator is set to the required pressure (typically
between 3.0 to 4.5 bar.
• The regulator setting required depends upon the printhead gap; the distance
between the printhead, in it’s home position, and the print platen, or print
roller.
• Too little pressure will result in poor quality or no print.
• Too much pressure may result in increased physical wear on the printhead
and platen. The substrate is marked where the printhead has dug in.
• Exceeding the stated pressure will over stress the printhead.
• To get the optimum air pressure for the application, it is recommended that the
printhead to substrate gap is set between 1.0 and 2.0 mm. See below for
exact details.
• The air pressure should then be set to 3 bar and gradually increased until a
good quality print is apparent.
• The operation of the solenoid may be tested by using the Manual functions or
toggling the output on the I/O screen.

2.2.2 Print Anvil

The print roller and print platen are wear parts, and should be checked regularly
for damage.
If the print roller has become damaged this will cause print quality problems. For
example a flat spot on the roller rubber will appear as a repeated blank area on
the Test pattern. A worn area on the print platen rubber may cause the print to be
faded on one side.

2-4 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.2.3 Printhead Gap

This is the distance between the printhead in its prime position and the contact
point on the substrate. This should be measured with the Cassette in its closed
position.
Do not use metal objects to test the gap distance, use only wood, plastic or other
non conductive materials.
Adjustment to the print gap can be made by adding or removing the shims
provided with the mounting bracket. The gap between the printhead and the print
platen or print roller is critical to the performance of the printer.
The following settings are recommended:
SmartDate 5 - 1.00 mm to 2.00 mm
SmartDate 5 / 128 - 1.00 mm to 2.00 mm
SmartDate 5s - 1.00 mm to 2.00 mm
SmartDate 5s - 0.5 mm to 1 mm (High throughput applications)
In situations where it is necessary to increase the printhead gap above 3 mm
(zipper bags) the “Tension adjust” setting should be reduced. See Section 6 -
Menus - Ribbon Setup.

2.2.4 Ribbons
SmartDate 5 uses inside wound ribbon; If this is webbed incorrectly (wound the
wrong way around) no printing can occur. The correct substrate/paper to ribbon
match is also important for print quality.
Different conditions will require different types of ribbon.
Some examples follow:
Wax/Resin, Wax/High Resin and Resin
For full details on ribbon please contact you local Markem-Imaje representative or
visit the Markem-Imaje Web site.

SmartDate 5.1 2-5

SECTION 2 - SETUP AND TIMING ISSUES

2.3 Important Printer Settings

Various Printer Settings will affect the performance of the SmartDate 5
The initial setup of the machine would normally be performed by a qualified
Markem-Imaje Technician, but if not the following information should prove
helpful.

2.4 Print Darkness

The print darkness is adjusted by varying the amount of time heat is applied for
each row of dots printed and altering the amount of cooling time allowed between
rows.
Generally, increasing the Darkness% darkens the printing but can increase
smudging. Conversely, decreasing the Darkness% reduces smudging. Some
ribbon/substrate combinations may require a Darkness% other than the standard
100%.
SmartDate 5 automatically limits the amount of energy transferred to the
Printhead. This prevents the head being damaged by incorrect use of the
darkness value. If the print quality is not good refer to the Troubleshooting Section
for diagnosis.
Print darkness levels should be set in relation to the print speed.
• For example, if the print speed is high, the print darkness may have to be
raised to achieve good print quality.
• If the print speed is lowered the print darkness should be reduced accordingly.
• As a general rule darkness levels should be kept as low as the line speed and
print quality requirements will allow This will ensure that the print-head life will
be used to its optimum.
• Darkness levels that are too high may also contribute to poor print quality or
ribbon breakage (especially when printing bar-codes or horizontal lines.)
• The maximum darkness level for any print speed is 140%. SmartDate 5
automatically compensates for this if the print speed is raised or lowered.
• If a printhead dot has become damaged and no replacement is readily
available, raising the darkness level may be enough to spread the heat to
effectively close the gap. This would allow the printer to be used while a new
printhead arrived.

Note: The darkness level should be reduced when the new printhead is fitted.

2-6 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.4.1 Print Speed

The Speed that Printhead moves along the linear slide (SmartDate 5 Intermittent
and SmartDate 5 / 128 Intermittent).
The speed the ribbon moves on the print part of the cycle. (SmartDate 5
Continuous, SmartDate 5 / 128 Continuous and SmartDate 5s)
With Intermittent printers the speed is determined by the dwell time when the
substrate has stopped moving.
• If the print speed is set too low the substrate may start to move before printing
has finished.
• If the print speed is too fast the print quality may not be as good as it could be.
With Continuous printers the speed is automatic as an encoder is used to match
the speed of the substrate.
• The ribbon speed has to match the substrate speed before printing can occur.
If the substrate speed is too high or too low this will affect the print quality.

Note: If the Hi-Speed Operation is enabled, the maximum print speed can be
increased to 1000mm/s.(Not available with SmartDate 5 / 128)

SmartDate 5.1 2-7

SECTION 2 - SETUP AND TIMING ISSUES

2.5 Print Signal Issues

2.5.1 Debounce Time

This is an Intermittent printer setting.
This is the time that the PRINT GO signal must be present before it is actioned.
This avoids double triggering of the print signal if the signal is particularly noisy
(e.g ringing on a relay contact)
If the signal used is arriving as a double pulse, set the Debounce time just high
enough to stop the printer double printing.
The print signal is sampled every 5 milliseconds, so if the Debounce Time is set to
10 milliseconds, the Print Signal must be at least 15 milliseconds.

2.5.2 Debounce Distance

This is a Continuous printer setting.
This is the distance that the substrate must travel after receiving a PRINT GO
signal. This is similar to the debounce time for Intermittent printers in that it
ensures that the print signal is valid and not double triggering.
Note: The Debounce Time and Debounce distance increase the overall cycle
time of the printer and should be kept as low as possible. On Continuous
printers, it is advisable, where possible, to set the debounce distance to
zero. Otherwise a time delay is introduced into the cycle which may
produce print drift.

2.5.3 Print Delay

This is an Intermittent printer setting.
With SmartDate 5 Intermittent printers, this sets a delay between a valid PRINT
GO signal and when the Printhead is moved out into position.
If the PRINT GO signal is received before the substrate is stationary, this allows
time for the substrate to settle before printing commences.
Set the print delay setting as low as possible as it increases the overall cycle time
of the printer.
Default - 0 ms

2-8 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.6 Print Quality Issues

The spreadsheet that is available with the CD can be used to assess the best
configuration for the following printer settings. These settings will vary depending
on such things as the printhead gap, air pressure, print speed etc.

2.6.1 Head Out Time

The time delay between moving the head out and starting to print. This ensures
that the printhead is in position before printing starts.
With the SmartDate 5s, successful printing also depends on the ribbon speed
matching the substrate speed.
To save time during the printing cycle, the Printhead can be moved into position
while the ribbon is accelerated. By first calculating how long it takes to accelerate
the ribbon, SmartDate 5 takes into account the Head Out Time and determines
when the head must be moved into position. In this way the printhead is in
position and ready to print at the same time as the ribbon and substrate speed
match.
Note: If there are problems with the start of the print, e.g. the first part of the print
is missing, (cut off), it could be that the Head Out Time is set too short.
(This may be because the air pressure is particularly low and it takes
longer for the Printhead to move).
If there are problems with the ribbon breaking or scuffing prints, it is possible that
the Head Out Time is set too long. The head will move before the ribbon begins
to accelerate, i.e. the ribbon will not be up to speed.
This typically need never be changed, On applications where the dwell time is
maybe not quite enough then you may find that this can be reduced as a last
resort to a value of 15ms.
Default - 25ms

SmartDate 5.1 2-9

SECTION 2 - SETUP AND TIMING ISSUES

2.6.2 Start Border

This setting allows a number of blank lines (steps)(1 line = 0.083mm or 0.0033”)
before printing. This helps to compensate for certain printing applications where it
is difficult to obtain good print quality at the start of the print.
The value should be set to the lowest value possible to ensure good print quality.
Setting this too high will increase the overall cycle time, and limit the throughput.
This setting does not waste ribbon, as the ribbon drive will only wind on the
amount of ribbon actually printed on.
Default - 2.0 mm

2.6.3 End Border

This setting allows a number of blank lines (steps)(1 line = 0.083mm or 0.0033”)
after printing. This helps to compensate for certain printing applications where it is
difficult to obtain good print quality at the end of the print.
The value should be set to the lowest value possible to ensure good print quality.
Setting this too high will increase the overall cycle time, and limit the throughput.
This setting does not waste ribbon, as the ribbon drive will only wind on the
amount of ribbon actually printed on.
Default - 0.5 mm

2.6.4 Head In Time

This typically need never be changed, as it is the time allowed for the Printhead to
move in from the substrate to the normal position.
Default - 5ms

2.6.5 Ribbon Advance Distance

This allows you to set the distance the ribbon advances between prints (in
addition to the length of the print)
Default - 1mm

2-10 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.7 Moving the Printed Image

The position of print within the printing area can be changed. Altering the
Registration and Offset co-ordinates moves the printed information in the head
feeding direction and up and down the Printhead.
On intermittent printers, when the Registration is altered the printhead will move to
its new datum position immediately and will use this new datum until the
Registration is altered again. The ribbon is moved, if necessary such that ribbon is
not wasted by altering the Registration.

2.7.1 Registration
It is possible to move the print image down the print area.
This ability is useful if small movements are required.
CAUTION: If larger position changes are required this method may not be
suitable.
For example, on a SmartDate 5 Intermittent, if you have an image length of 40mm
and you move the image down the printhead by 40mm, then that gives you a total
length of 80mm. The maximum print length is only 74mm, so you will miss the last
6mm of the image.
When selecting the Image, if the amount of registration plus the image is too long,
you will get a warning message. You can press “Hide” to clear this warning, but
you should reduce the offset or the image length before proceeding.

2.7.2 Offset
This allows fine adjustment of the print position across the printhead.
This ability is useful if small movements are required.
CAUTION: If larger position changes are required this method may not be
suitable.
For example, It is possible to move the print image off the side of the ribbon and
printhead.
If you have an image width of 40 mm and you move the image across the
printhead by 20 mm, then that gives you a total width of 60mm. The printhead is
only 53 mm in width so you will only print the first 33 mm of the image, leaving off
7mm.

SmartDate 5.1 2-11

SECTION 2 - SETUP AND TIMING ISSUES

2.8 Timing issues

Many timing issues (speeding up the line/host machine) can arise when setting up
a new application, or when changing the way an existing application works.
Timing issues can be common to the SmartDate 5, SmartDate 5 / 128 and
SmartDate 5s. Since the machines work differently, it is likely that timing issues
will vary with the machine type. The following information address these
differences.
Please note that the actual Timing settings are common for all types of machine.
The last recorded Print Cycle timings can be viewed from the Engineering -
Diagnostics menu.

2-12 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.8.1 Print Timings

This option lists speeds and times for the last print cycle performed.
To access the Print Timings menu:

1. From the Engineering screen menus select Diagnostics.

2. The Diagnostics screen is displayed.

Menu 1. All

2. Printer Configuration

3. Input Status

Back Select

3. From the Diagnostics screen menu select Print Timings.

4. The Print Timings screen is displayed.

Diagnostics

Print Timing Information

Printing Time: 250 ms

Back

SmartDate 5.1 2-13

SECTION 2 - SETUP AND TIMING ISSUES

Table 2– 1: Print Timings

Title Description

Printing Time This is the time taken to print the image

This is the time taken for the printhead to move

Print Cycle Time
out, print and return to the Home position.

Time after selection to image the design in the

Imaging Time
printer memory.

Time taken to update any incremental fields in

Image Update Time
the design.

2-14 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.8.2 SmartDate 5 and SmartDate 5 / 128 - Intermittent Mode

The SmartDate 5 does not accelerate in a linear manner. As an example, it takes
7mm to accelerate to 500mm/s. It is therefore more difficult to give theoretical
timings to the print cycle.
A more exact way of doing this is to try it.

1. Calculate the overall cycle time required for the application.

2. Download the required design to the SmartDate 5.
3. Select the design.
4. Set the required print speed.
5. Do a print.
6. Look at the timings in the Diagnostics menu.

On an Intermittent printer it is not the Cycle Time that is critical, but the Print Time,
because the return stroke can be carried out when the host machine is moving the
substrate onward. It is therefore important, when trying to decide whether or not
the SmartDate 5 can be considered for the application, to find out the Dwell Time
of the host machine. Knowing only the throughput will not be sufficient. Even if the
throughput is slow, you could still have a very small dwell time in which to print.

SmartDate 5.1 2-15

SECTION 2 - SETUP AND TIMING ISSUES

2.8.3 Printing Time - Intermittent Printers

The Printing Time (in the Timing menu) consists of the following:
• Head Out time
• Start Border
• Print (Print speed set in Controller)
• End Border
• Head In time
On a SmartDate 5 Intermittent this time MUST be less than the dwell time for the
application to work.

2.8.4 Print Cycle Time - Intermittent Printers

On receipt of a print signal the whole print cycle is as follows:
• Debounce Time
• Print Delay
• Head Out time
• Start Border
• Print (Print speed set in Controller)
• End Border
• Head In time
• Return Speed

2-16 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.8.5 SmartDate 5, SmartDate 5 / 128 - Continuous Mode and SmartDate 5s

The timing on the continuous printers is slightly different. It is not the Print Time
that is the critical timing but generally the Repeat Time.

2.8.6 Printing Time - Continuous Printers

The Printing Time (in the Timing menu) consists of the following:
• Head Out time
• Start Border
• Print (Print speed set by Encoder)
• End Border
• Head In time

2.8.7 Print Cycle Time - Continuous Printers

On receipt of a print signal the whole print cycle is as follows:
• Debounce Distance
• Print Delay
• Head Out time
• Start Border
• Print (Print speed set by Encoder)
• End Border
• Head In time
• Return Speed

SmartDate 5.1 2-17

SECTION 2 - SETUP AND TIMING ISSUES

2.8.8 Speed Profile Recorder

The Speed Profile Recorder can be used on Continuous printers to determine if
the print is occurring at the most appropriate time.
For example, on certain Form - Fill - Seal machines or Flow Wrappers, the speed
of the moving substrate can ramp up and down.
It is possible during the machine cycle, for the substrate speed to exceed the
maximum printing speed for SmartDate 5.
If the print occurs at this point in the cycle, the print quality will be unacceptable or
the print may be discarded completely.
To ensure that the print is occurring at the correct point in the machine cycle, a
speed profile can be recorded and uploaded to a PC.
This data can then be used to analyse if the print is occurring at the correct point
in the machines cycle.
Note: A PC Tools application is available on the SmartDate 5 CD.

2-18 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

To record a Speed Profile on the SmartDate 5 Continuous, SmartDate 5 / 128

Continuous or SmartDate 5s, the following conditions apply:
• The Printer must be connected to the controller.
• The Encoder must be set to External - Quadrature or External - Pulse Train
• The Controller must be connected to a SmartTouch unit or a PC running the
PC Tools application.
Two other options must be set up;
• The Resolution (how often the substrate speed is recorded)
• The Trigger (The action that will initiate the Speed profile)

To access the first of these options:

1. From the Engineering menu screen select Settings.

Menu 4. Digital I/O Control

5. Settings

6. Diagnostics

Back Select

SmartDate 5.1 2-19

SECTION 2 - SETUP AND TIMING ISSUES

2. The Settings menu screen is displayed.

Menu 1. Machine

2. Image

3. Print Features

Back Select

3. Use the bottom Quad button to scroll to Encoder.

4. Select Encoder by pressing the right button.
5. The Encoder menu screen is displayed.

Menu 1. Encoder Type

2. Encoder Direction

3. Encoder Resolution

Back Select

2-20 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

6. Select Encoder Type by pressing the right button.

Menu 1. Encoder Type

2. Encoder Direction

3. Encoder Resolution

Back Select

7. Ensure that the Encoder type is set to External - Quadrature or External -

Pulse Train
8. Select Back by pressing the left button.

9. Use the bottom Quad button to scroll to Speed Profile Recorder.

10. Select Speed Profile Recorder by pressing the right button.
11. The Speed Profile Recorder screen is displayed.

Menu 1. Resolution

2. Trigger

Back Select

12. Configure the two options to the preferred requirements.

SmartDate 5.1 2-21

SECTION 2 - SETUP AND TIMING ISSUES

Resolution

This sets the period between speed samples in the profile.

The speed profile once initiated records 1500 speed samples.
A low resolution (100 ms) will record over a longer period. (2.5 mins)
A high resolution (1 ms) will record over a shorter period but will provide more
detailed information. (1.5 secs)

Trigger

The Trigger option allows you to set what action initiates the start of the Speed
Profile.
Manual Trigger
This allows you to manually initiate the start of the speed profile. With the
SmartDate 5 set to producing mode, access the speed profile menu. Press
“Select” to initiate the start of the speed profile.
Print Go Trigger will initiate the start of the Speed profile after the SmartDate 5 is
set to producing mode and then receives the first Print Go signal.

Note: Using the manual option allows you to start the profile from the
SmartDate 5, SmartTouch controller or the PC application.

2-22 SmartDate 5.1

 SECTION 2 - SETUP AND TIMING ISSUES

2.9 Distance between prints on the ribbon

Two things can affect the distance between each print on the ribbon.
• If the substrate accelerates or decelerates between the end of the registration
and the start of print, the gap will be affected.
• When the printer adjusts the ribbon tension the gap will be affected.

2.10 Distance between prints on the substrate

With Intermittent printers the distance between the prints is set by the stopping
position of the substrate or labels.
With Continuous printers several things can affect the "minimum" distance
between the prints on the substrate:
• The amount of registration set after the Print Go signal.
• The amount of Start and End border set.
• The Debounce distance.
• The Head down and Head up time.
• The Return speed of the ribbon.

SmartDate 5, SmartDate 5 / 128 and SmartDate 5s continuous printers always

allows the substrate to move a set distance after receiving a Print go signal. This
distance is the same no matter the speed of the substrate.
After this distance the printhead has been lowered ready to print.
This ensures the printed image does not drift from the required position on the
substrate.
The following details list the distance the substrate will travel from the end of the
registration:
SmartDate 5 Combined printer - Standard mode - 26.11 mm + Start border
SmartDate 5 / 128 Combined printer - Standard mode - 22.5 mm + Start border
SmartDate 5s Shuttle printer - Standard mode - 10.91 mm + Start border
SmartDate 5s Shuttle printer - High Speed mode - 15.45 mm + Start border

SmartDate 5.1 2-23

SECTION 2 - SETUP AND TIMING ISSUES

2.10.1 Minimum Distance between prints in DRS mode

When using DRS mode the percentage of ribbon saving will affect the distance
travelled.
Shuttle printer - DRS mode - 10.91 mm + Start border x max ribbon save ratio
The maximum ribbon save ratio will be the ratio the printer uses at 1800mm/s
If the DRS ratio is set at less than 56% the maximum ribbon save ratio will be
2.25:1
If the DRS setting is set above 56% the maximum ribbon save ratio will be derived
from the DRS setting.
Example:
With a DRS setting of 20% the distance from the Print Go signal to the start of
print will be (10.91 + start border) x 2.25) = 29mm
With a DRS setting above 56% the minimum distance between prints will be
larger.

2-24 SmartDate 5.1

SECTION 3
MAINTENANCE

SmartDate 5.1

Maintenance Manual
 SECTION 3 - MAINTENANCE

3 Maintenance
3.1 Introduction
The SmartDate series of Overprinters are extremely successful, however as with
any machine, if it is not set up and maintained correctly, problems can occur.
This section is designed to provide information about how to keep your
SmartDate 5 in good working order.

Topics covered in this section include:

• General cleaning and care.
• Maintenance schemes.
• Care of the printhead.
• Replacing the printhead.
• Replacing the ribbon guide rollers.
• Replacing the peel roller.
• Replacing the ribbon movement roller.
• Replacing the ribbon movement sensor.
• Replacing the ribbon tension roller.
• Replacing the ribbon tension sensor.
• Replacing the Micro switches
• Replacing the Solenoid Valves
• Replacing the drive belt.
• Changing the printer hand.
• Replacing the PCBs

SmartDate 5.1 3-1

SECTION 3 - MAINTENANCE

3.2 Cleaning and Care

To ensure that your SmartDate 5 operates correctly, the entire unit should be
cleaned on a regular basis.

Printer:

Particular attention should be given to the inside of the printer body, especially if
food products are able to fall into the unit.
• Turn off the power to the controller.
• Turn off and isolate the air supply to the printer body.
• Remove the printer cassette and clean inside the printer body. Since there are
electronic components inside this casing, DO NOT use water to clean the unit.
Isopropanol cleaning wipes can be used for this purpose.
• To clean debris from the inside of the printer body, Markem.Imaje recommend
the use of a soft bristle brush.

3-2 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.3 Maintenance Scheme

These recommended actions will ensure consistent high quality from the
Markem.Imaje SmartDate 5 technology for package identification.

3.3.1 Quick/Regular Checks

• Check and clean printhead (daily check). Use Isopropanol wipes.
• Check that the ribbon is tracking through the cassette correctly. Pull the ribbon
through by hand, and visually check to see if the ribbon is creasing across the
width of the ribbon. (See Troubleshooting 5.7.3)
• Check the Peel Roller for any ink build up and clean if necessary. Use
Isopropanol wipes
• Check that Darkness / Speed settings are site standard. This will ensure that
the print remains a good quality, and it may also highlight any potential
problems. For example, if the darkness is unusually high, the printhead may
need cleaning. The darkness has probably been set high to compensate.
• Check Air is set to recommended pressure.
• Check condition of Platen rubber (SmartDate 5 - Intermittent mode). Clean or
replace it if necessary. The platen rubber needs to be smooth, flat and free
from debris. To change the platen rubber, first take the old platen rubber off.
All the adhesive should be removed from the metal platen base. Replace with
a Markem.Imaje platen rubber for best results.
• Check for wear or internal debris.
• The 37 way D-type cable must be fitted in a manner so that a tool is required
to remove it. The unit should not be powered until it is securely attached to
each unit.

SmartDate 5.1 3-3

SECTION 3 - MAINTENANCE

3.3.2 Monthly Checks

• Check condition of peel roller: Remove roller and inspect internally for wear.
Replace if necessary.
• Check condition of the ribbon guide rollers: Check that bearings are smooth.
• Check the condition of the shuttle rollers (SmartDate 5s).
• Check condition of ribbon sensor roller. Inspect the roller coating for wear and
damage. If worn or damaged, replace the roller.
• Ensure all rollers are square to the Cassette or Printer.
• Check the magnet for any damage or non-alignment. This magnet is used for
ribbon detection and ribbon calibration.
• Print a test image to check printhead quality and alignment. See Section 6 -
Menus.
• Check condition of printhead/ shuttle carriage drive belt and associated
components: pulleys, bearings, retainers and shafts.
• Check Air cylinder.
• Check that the tension roller slide is free to move.

3-4 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.4 Care of the Printhead

Although purpose-built for its application, the printhead is still subject to wear and
tear. Careful consideration at the time of installation and regular preventative
maintenance can significantly help to maximise printhead life.
The most frequent cause of printhead damage is abrasion - either from ingress of
airborne particles or from an abrasive substrate surface. Consequently, printhead
life varies considerably among substrate materials and among applications.
The thermal ribbon protects the printhead against wear. With use of various ribbon
widths and an abrasive substrate, it is possible that the unused, unprotected,
section of the printhead is subjected to wear and damage. Usually, abrasive
substrates have pre-printed inks. Particularly, some red inks may be more
abrasive than other colours.
Procedures for all thermal transfer printers follow:
• Regularly clean the printhead. The frequency of cleaning is entirely
application and environment specific.
• To minimise printhead wear, always use the minimum air pressure that
delivers an acceptable print quality. Never exceed the maximum air pressure
recommended for the particular SmartDate 5 used.
• Use the minimum darkness setting that delivers the required print quality.

SmartDate 5.1 3-5

SECTION 3 - MAINTENANCE

3.5 Cleaning the Printhead

The printhead should be cleaned at regular intervals. These depend on machine
use, operating environment, and choice of thermal ribbon.

1. Turn off the power to the controller and remove the ribbon cassette.
2. Allow the printhead to cool to normal room temperature before proceeding in
order to prevent the possibility of thermal shock damage.
3. Use a cotton swab or a soft cloth soaked in Isopropanol solvent to remove any
residue from the printhead. Take care not to use excessive amounts of
solvent.
The print line is located on the bevelled edge of the printhead.

Use great care not to damage the printhead during cleaning. UNDER NO
CIRCUMSTANCES should abrasive materials, or tools such as screwdrivers, be
used for cleaning the printhead.
Replace the ribbon cassette and check the print quality. If the overall quality is
poor, or some of the dots are not printing, the printhead may need to be adjusted
or changed.

3-6 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.6 Replacing the Printhead

The SmartDate 5 printhead can be changed quickly and easily.
Turn off the power to the controller and isolate the air supply to the printer body.
Remove the ribbon cassette.
Always ensure anti static precautions are used when handling new printheads.

3.6.1 Removing the damaged printhead (SmartDate 5)

1. Push the printhead forward 2. Swing the printhead out from the
towards the peel roller and rotate the print module.
rear of the printhead outwards as
shown above.

3. Disconnect the ribbon cable from 4. Remove the printhead from the
the printer interconnection PCB. print module.

SmartDate 5.1 3-7

SECTION 3 - MAINTENANCE

3.6.2 Removing the damaged printhead (SmartDate 5s)

Covers removed for photographic purposes.

1. Push the printhead forward 2. Swing the printhead out from the
towards the peel roller and rotate print module.
the rear of the printhead outwards
as shown above.

3. Disconnect the ribbon cable from 4. Remove the printhead from the
the printer interconnection PCB. print module.

3-8 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.6.3 Removing the damaged printhead (SmartDate 5 / 128)

1. Release the printhead locking screw by one and a

half turns. Do not remove!

2. Push the printhead cylinders 3. Remove the ribbon connector

forward and use the handle to pull from the printer interface PCB.
the damaged printhead off the
location pin.

4. Remove the power connector 5. Remove the printhead from the

from the printer interface PCB. printer body.

5. Reverse this process to fit a replacement printhead.

SmartDate 5.1 3-9

SECTION 3 - MAINTENANCE

3.6.4 Setting the correct Printhead voltage

Note the resistance value printed on the PCB side of the new Printhead. This
value must be entered into the controller menu structure.
The processor will then adjust the voltage level to suit the particular printhead
resistance level.

Each Printhead has an individual

Resistance level, and the voltage level
setting required for each is different.
A label on the printhead displays the
rating for that particular one.
In this case, R = 1272

The Printhead resistance option can be accessed from the Engineering menus.
To access the Engineering Menus:

1. From the Menus screen select Engineering.

Menu 3. Darkness

4. Engineering

1. Select Job

Back Select

3-10 SmartDate 5.1

 SECTION 3 - MAINTENANCE

2. The Engineering Menus screen is displayed.

Menu 10. File Management

11. Printhead Resistance

12. Speed Profile

Back Select

3. Use the bottom Quad button to scroll to the Printhead Resistance menu.
4. Press the right button to Select the menu.
5. The Printhead Resistance menu screen is displayed.

Printhead Resistance

Currently: 1270

New: 1298

Cancel Accept

6. Use the left and right Quad buttons to move the cursor.
7. Use the top and bottom Quad buttons to change the date or time.
8. When finished press the right button to Accept the changes.

SmartDate 5.1 3-11

SECTION 3 - MAINTENANCE

3.7 Replacing the Peel Roller

The Peel Roller body is a wear part and should be checked for damage and
changed if necessary.
Note: This procedure is the same for the SmartDate 5 / 128 version of the
printer.

1. Remove the retaining screw from 2. Remove the screw and washer
the end of Peel roller. and lift off the roller body.

3. Fit a new Peel roller body over the 4. Clean off any excess fluid and
shaft and secure the screw with ensure the roller is free to rotate.
Loctite 222.

3-12 SmartDate 5.1

 SECTION 3 - MAINTENANCE

5. If the peel roller shaft has been 6. Once the seal has been broken at
damaged, undo the retaining nut at the base of the screw, use an Allen
the base and remove the complete key to unscrew the Peel roller.
assembly.

7. Remove the roller from the printer 8. Fit a new peel roller assembly and
carriage plate. ensure that it is secure and free to
rotate. Secure with Loctite 222.

SmartDate 5.1 3-13

SECTION 3 - MAINTENANCE

3.8 Replacing the Ribbon Guide Rollers

The ribbon guide rollers are vulnerable to damage through misuse and may have
to be changed if they become bent or damaged.
Note: This procedure is the same for the SmartDate 5 / 128 version of the
printer.

1. Remove the damaged roller by 2. Before fitting a replacement roller,

applying a spanner to the two flat apply Loctite to the screw thread at the
surfaces at the base of the roller. base of the roller.

3. Place the new roller in position and 4. Clean off any excess fluid and
tighten. ensure the roller is free to rotate.

3-14 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.9 Replacing the Ribbon Movement Roller

3.9.1 Replacing the Roller Magnet

If the magnet on the movement roller has been damaged it will have to be
replaced.
Note: This procedure is the same for the SmartDate 5 / 128 version of the
printer.

1. Remove the securing screw on the 2. Remove the damaged components.

end of the roller.

3. Fit a new set of components to the 4. Clean off any excess fluid and
end of the roller and secure the ensure the roller is free to rotate.
retaining screw with Loctite 222.

SmartDate 5.1 3-15

SECTION 3 - MAINTENANCE

3.9.2 Replacing the Movement Roller

The procedure for replacing the ribbon movement roller is the same as for the
ribbon guide rollers.
Note: This procedure is the same for the SmartDate 5 / 128 version of the
printer.

1. Remove the damaged roller by 2. Before fitting a replacement roller,

applying a spanner to the two flat apply Loctite 222 to the screw thread
surfaces at the base of the roller. at the base of the roller.

3. Place the new roller in position and 4. Clean off any excess fluid and
tighten. ensure the roller is free to rotate.

3-16 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.9.3 Replacing the Ribbon Movement Sensor

If the sensor has to be replaced, the procedure should be as follows:
Switch off and disconnect the power to the machine.

1. Remove the cover from the printer 2. Remove the retaining screw from
body and disconnect the sensor the printer base plate.
connector.

3. Remove the sensor from the printer 4. When fitting a replacement sensor,
body. ensure that the retaining screw is
secured with Loctite 222.

SmartDate 5.1 3-17

SECTION 3 - MAINTENANCE

3.10 Replacing the Ribbon Tension Roller

If the tension roller becomes damaged the whole assembly will require changing.
Dependant on the hand of the cassette the ribbon supply flange (red) may have to
be removed to gain access to the securing screws.
The procedure is as follows:

1. Remove the four retaining screws 2. Remove the damaged tension roller
from the tension roller carriage. assembly. Be careful not to loose the
spring or damage the linear slide
assembly.

3. Note the spring. 4. Replace with a new assembly and

secure the screws with Loctite 222. Do
not forget the spring.

3-18 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.11 Replacing the Ribbon Tension Sensor

If the tension sensor has to be replaced, the procedure should be as follows:
Switch off and disconnect the power to the machine.

1. Remove the cover from the printer 2. Disconnect the sensor connector.
body.

3. Remove the sensor retaining screws 4. Remove the sensor from the printer
from the printer baseplate. body.

5. When fitting a replacement sensor,

ensure that the retaining screws are
secured with Loctite 222.

After fitting a new Ribbon Tension sensor, the sensor will require calibrating.
Please contact Markem.Imaje for details.

SmartDate 5.1 3-19

SECTION 3 - MAINTENANCE

3.12 Replacing the Micro Switches

If the micro switches have to be replaced, the procedure should be as follows:
Switch off and disconnect the power to the machine.

1. Remove the cover from the printer 2. Remove the micro switch retaining
body and disconnect the appropriate screws from the printer base plate.
micro switch connector.

3. Remove the micro switch from the

printer body.

4. When fitting a replacement sensor,

ensure that the retaining screws are
secured with Loctite 222.

3-20 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.13 Replacing the Solenoid Valves

3.13.1 SmartDate 5 and SmartDate 5s

If the solenoid valves have to be replaced, the procedure should be as follows:
Switch off and disconnect the power to the machine.

1. Remove the cover from the printer 2. Remove the securing nuts from the
body. printer power / control connector.

3. Disconnect the printer wiring from 4. Remove the retaining nuts from
the PCB. the printer PCB.

SmartDate 5.1 3-21

SECTION 3 - MAINTENANCE

5. Loosen the two securing screws on 6. Pull back the plate to allow easier
the baseplate. removal of the printer PCB.

7. Remove the two retaining screws

from the heatsink plate.

3-22 SmartDate 5.1

 SECTION 3 - MAINTENANCE

8. Lift the PCB off the support pillars. 9. Push the PCB back to allow access
to the solenoid valve.

10. Remove the securing screws and lift 11.Remove the small air pipes from the
off the solenoid valves. solenoids.

12. When fitting a replacement valve, ensure that

the retaining screws is secured with Loctite 222.

SmartDate 5.1 3-23

SECTION 3 - MAINTENANCE

3.13.2 SmartDate 5 / 128 Solenoid Valves

This version of the SmartDate 5 uses two solenoid valves.

1. Run position.
2. Print position.

The removal and replacement procedure is as

shown previously.

When replacing the printer PCB ensure that all of the wiring and air
connectors are re-fitted correctly. Ensure that the two connectors
shown above are located and secured correctly.

3-24 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.14 Replacing the Drive Belts

The Combined printer and Shuttle printer drive belts can become worn or
damaged after long periods of running. The belt should be checked at regular
intervals for wear or damage.

3.14.1 Replacing the Drive Belt - SmartDate 5

Note: This procedure is the same for the SmartDate 5 / 128 version of the
printer.

1. Remove the covers and remove 2. Remove the two retaining screws
the printhead as described in 3.6. from the air pipe cover.

3. Remove the air pipes from their 4. Remove the four retaining screws
connectors. from the print module.

SmartDate 5.1 3-25

SECTION 3 - MAINTENANCE

5. Pull the module upwards off the 6. Remove the two retaining screws
key and move it out of the way. form the belt clamp.

7. Loosen off the belt tensioner 8. Use a tool to release the tension
screws. and remove the belt from the end of
the pulley.

9. Remove damaged drive belt. 10. Remove the belt clamp and re-fit
it to a new belt.

3-26 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.15 Replacing the Drive Belt - Shuttle Printer

1. Shuttle printer. 2. Remove the securing screws from

the shuttle carriage.

3. Loosen the belt tensioner screws. 4. Remove the four retaining screws
from the print module.

SmartDate 5.1 3-27

SECTION 3 - MAINTENANCE

5. Pull the module upwards off the key 6. Remove the three retaining screws
and move it out of the way. from the print module adapter plate.

7. Remove the print module adapter 8. Use a tool to release the tension and
plate and place to one side. remove the belt from the end pulley.

3-28 SmartDate 5.1

 SECTION 3 - MAINTENANCE

9. Remove the shuttle carriage and 10. Remove the belt clamp and re-fit it
damaged drive belt. to the new belt.

11. The belt tension is automatically

adjusted before re-tightening the
screws.

SmartDate 5.1 3-29

SECTION 3 - MAINTENANCE

3.16 Changing the Printer Hand - SmartDate 5

Note: We strongly recommend that re-handing of the printers should not be
attempted by anyone who has not received the relevant training from
Markem.Imaje.
Switch off and disconnect the power to the machine.
Disconnect the printer from the controller and remove the side covers.

1. Remove the printhead as 2. Remove the air pipe cover plate.

described in 3.6.

3. Remove the air pipes from the 4. Note the colour coding.
connectors.

3-30 SmartDate 5.1

 SECTION 3 - MAINTENANCE

5. Remove the four retaining 6. Remove the print module and

screws from the print module. place to the side.

7. Remove the peel roller and place 8. Disconnect the air pipe support
to the side. plate from the printer interface PCB.

9. Rotate the plate so that the air 10. Re-fit the print module facing the
pipe are facing the opposite way. opposite way.

SmartDate 5.1 3-31

SECTION 3 - MAINTENANCE

11. Re-connect the air pipes. 12. Re-place the air pipe cover.

13. Re-connect the printhead 14. Replace the printhead and print
ribbon cable. roller as shown.

Note: When replacing the screws use Loctite 222 retaining fluid.

3-32 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.17 Changing the Printer Hand - SmartDate 5 / 128

Switch off and disconnect the power to the machine.
Disconnect the printer from the controller and remove the side covers.
Remove the printhead as shown previously in 3.6.3.

1. Remove the covers from the 2. Disconnect the air pipes from the
printer body. print module.

3. Loosen the locking nut at the 4. Use an Allen key to remove the
base of the peel roller. peel roller and place to one side.

SmartDate 5.1 3-33

SECTION 3 - MAINTENANCE

5. Undo the four retaining screws 6. Remove the print module from
from the print module. the printer.

7. Remove the printhead power 8. Re-connect the power cable to

cable. the connector on the opposite side.

9.Loosen the screws on the rear of 10. Re-tighten the screws and move
the PCB and move the air pipes to the print module carriage to the
the opposite side. opposite side.

3-34 SmartDate 5.1

 SECTION 3 - MAINTENANCE

11. Replace the print module facing 12. Re-connect the air pipes.
the opposite way.

13. Replace the printhead. 14. Reconnect the printhead power

cable and ribbon cable.

15. Replace the peel roller.

SmartDate 5.1 3-35

SECTION 3 - MAINTENANCE

3.18 Changing the Printer Hand - Shuttle Printer

Note: We strongly recommend that re-handing of the printers should not be
attempted by anyone who has not received the relevant training from
Markem.Imaje.
Switch off and disconnect the power to the machine.
Disconnect the printer from the controller and remove the side covers.

1. Remove the print roller and place 2. Remove the finger guard and
to the side. place to the side.

3. Push the printhead forward 4. Swing the printhead out from the
towards the peel roller and rotate print module.
the rear of the printhead outwards
as shown above.

3-36 SmartDate 5.1

 SECTION 3 - MAINTENANCE

5. Disconnect the ribbon cable from 6. Remove the three retaining

the printer interconnection PCB. screws from the ribbon cable cover.

7. Remove the cover and place to 8. Remove the two retaining screws
the side. that secure the ribbon end cover
from the print module.

9.Move the ribbon cable out of the 10.Remove the air pipe cover
way. screws.

SmartDate 5.1 3-37

SECTION 3 - MAINTENANCE

11.Remove the air pipe cover and 12.Disconnect the air pipes.
place to the side.

13.Remove the remaining print 14.Remove the print module and

module securing screws. place to the side.

15.Move the printhead ribbon and 16.Remove the securing screws

air pipes out of the way. from the print module carriage.

3-38 SmartDate 5.1

 SECTION 3 - MAINTENANCE

17. Move the print module to the 18. Push down on the Cassette lock
new position and secure. mechanism and rotate to the closed
position.

19.Move the shuttle carriage to the 20. Re-position the ribbon cable
opposite side. and air pipes on the print module
carriage plate. (air pipes on top)

21. Replace the print module facing 22. Replace two of the securing
the opposite direction. Ensure that screws as shown above.
the ribbon and air pipes are not
trapped.

SmartDate 5.1 3-39

SECTION 3 - MAINTENANCE

23. Re-connect the air pipes noting 24. Re-fit the air pipe cover.
the colour coding.

25.Re-position the ribbon end plate 26. Re-connect the ribbon cover
cover and secure with the remaining plate.
two screws.

27.Re-connect the printhead. 28. Re-fit the peel roller.

3-40 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.19 Changing the Cassette Hand

If the printer hand is changed the handing of the associated cassette must also be
changed.
Below is an example of how to re-hand the shuttle cassette, the procedure for the
combined cassette is the same.

1. Use a 11 mm spanner to loosen the 2. Rotate the take up reel until a small
nut under the ribbon take up reel. allen key or screwdriver can be fitted
through the hole in the body of the take
up reel.

3.With this in place rotate the take up 4.Remove the take up reel from the
reel body until it is free. cassette.

SmartDate 5.1 3-41

SECTION 3 - MAINTENANCE

1. Repeat the operation for the ribbon 2. Remove the ribbon supply reel from
supply reel. the cassette.

3.Re - fit the take up and supply reels

on the opposite sides of the cassete
body.

3-42 SmartDate 5.1

 SECTION 3 - MAINTENANCE

3.20 Replacing the Printer PCBs

If the printer PCB has to be replaced the procedure should be as follows:
Switch off and disconnect the power to the printer.
Remove the printer base cover.

1. Remove the covers from the printer 2. Remove the securing nuts from the
body. printer power / control connector.

3. Disconnect the printer wiring from 4. Remove the retaining nuts from
the PCB. the printer PCB.

SmartDate 5.1 3-43

SECTION 3 - MAINTENANCE

5. Loosen the two securing screws on 6. Pull back the plate to allow easier
the baseplate. removal of the printer PCB.

7. Remove the two retaining screws

from the heat-sink plate.

3-44 SmartDate 5.1

 SECTION 3 - MAINTENANCE

8. Lift the PCB off the support pillars. 9. Push the PCB back to allow access
to the solenoid valve.

After fitting a new printer PCB the Ribbon Tension sensor will require calibrating.
Please contact Markem.Imaje for details.

Note: When a Printer PCB is replaced, the Printhead resistance has to be re-
entered and the Tension Sensor has to be re-calibrated.

SmartDate 5.1 3-45

SECTION 3 - MAINTENANCE

3.21 Replacing the Controller PCB

If the Controller PCB has to be replaced, the procedure should be as follows:
Switch off and disconnect the power to the printer.

1. Remove the four retaining screws 2. Lift off the Controller cover.
from the Controller cover.

3. Remove the six retaining screws from 4. Disconnect the various connectors
the D type connectors. from the PCB.

Caution: Anti static precautions should be adhered to when

handling PCBs

3-46 SmartDate 5.1

 SECTION 3 - MAINTENANCE

5. Remove the two PCB securing 6. Carefully remove the PCB from the
screws. controller unit.

Fitting a new controller PCB is the reversal of this process.

SmartDate 5.1 3-47

SECTION 3 - MAINTENANCE

3-48 SmartDate 5.1

 SECTION 4
TECHNICAL INFORMATION

SmartDate 5.1

Maintenance Manual
 SECTION 4 - TECHNICAL INFORMATION

4 Technical Information
4.1 Introduction
This section is designed to provide quick access to Technical information about
the SmartDate 5 machines.

Topics covered in this section include:

• Printer Components
• Printhead Module
• Printer Orientation
• Printer Cassette
• Printer Electrical Components
• Controller
• Interfaces

SmartDate 5.1 4-1

SECTION 4 - TECHNICAL INFORMATION

4.2 The SmartDate 5 Printers

The SmartDate 5 printer is the unit that contains all the printer mechanics together
with an intelligent control board. The mechanical components vary between
printer types within the SmartDate 5 family.
Three distinct versions of the printer are available:
SmartDate 5 - Intermittent / Continuous Printer.
SmartDate 5 / 128 - Intermittent / Continuous Printer.
SmartDate 5s - Shuttle Continuous Printer.

Figure 4–1: SmartDate 5 - Combined Intermittent / Continuous

Figure 4–2: SmartDate 5 / 128 - Intermittent

Figure 4–3: SmartDate 5s - Shuttle Continuous

4-2 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.3 Printer Components

The image below shows the main components of the printers:

SmartDate 5

1 2
3 3

4
5
6
7
8

10

Figure 4–4: SmartDate 5 Printer Components

1. Ribbon Tension Sensor.

2. Ribbon Movement Sensor.
3. Ribbon Motor Drive Couplings.
4. Cassette Lock.
5. Carriage Drive Belt.
6. Micro Switch.
7. Printhead Interconnection PCB.
8. Linear Slide.
9. Printhead Module.
10. Peel Roller.

SmartDate 5.1 4-3

SECTION 4 - TECHNICAL INFORMATION

SmartDate 5 / 128

1 2
3 3

4
5
6
7

8
9

10

Figure 4–5: SmartDate 5 / 128 Printer Components

1. Ribbon Tension Sensor.

2. Ribbon Movement Sensor.
3. Ribbon Motor Drive Couplings.
4. Cassette Lock.
5. Carriage Drive Belt.
6. Micro Switch.
7. Printhead Interconnection PCB.
8. Linear Slide.
9. Printhead Module.
10. Peel Roller.

4-4 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

SmartDate 5s

1 2

3 3

4
5 6

7 8

10

Figure 4–6: SmartDate 5s Printer Components

1. Ribbon Tension Sensor.

2. Ribbon Movement Sensor.
3. Ribbon Motor Drive Couplings.
4. Cassette Lock.
5. Carriage Drive Belt.
6. Micro Switch.
7. Shuttle Carriage.
8. Linear Slide.
9. Printhead Module.
10. Peel Roller.

SmartDate 5.1 4-5

SECTION 4 - TECHNICAL INFORMATION

4.3.1 Linear Slides

Two linear slides are used on the SmartDate 5 machines, one for transportation of
the Print module carriage and one for the Shuttle carriage.
The linear slides are supplied with a linear ball bearing carriage which provides a
smooth motion for the assemblies.
When the Combined printer is used as an Intermittent motion printer, the linear
slide is used to move the Print Module.
When the Combined printer is used as a Continuous motion printer, the linear
slide is used only to position the Print module if an “offset” is required.
Under normal circumstances the print module would be moved to the datum
position and the Printer body position would be adjusted to align the printhead
with the centre line of the print roller.
With the Shuttle version of the SmartDate 5s printer, the print module position is
fixed and no movement is possible.
In this case the printer body has to be positioned to align the printhead with the
centre line of the print roller.
In both cases the Print module mounting plate or the Shuttle carriage plate are
connected to the drive belt by means of a clamp plate.
This enables the Stepper motor to drive the Print module/Shuttle carriage in both
directions.

4-6 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.3.2 SmartDate 5 and SmartDate 5 / 128

The SmartDate 5 and SmartDate 5 / 128 printers have the print module carriage
plate mounted onto the bearing carriage.
This slide is positioned near the edge of the printer plate.

3
1
2

1. Print Module Carriage Plate.

2. Linear Slide.
3. Micro Switch.
4. Linear Bearing Carriage

SmartDate 5.1 4-7

SECTION 4 - TECHNICAL INFORMATION

4.3.3 SmartDate 5s Shuttle Printer

The SmartDate 5s printers have the shuttle carriage plate mounted onto the
bearing carriage.
This slide is positioned in between the carriage drive belts.

4
1

1. Print Module Mounting Plate.

2. Linear Slide.
3. Micro Switch.
4. Shuttle Carriage.

1 4
3

4-8 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.3.4 Intermittent Drive System

SmartDate 5 and SmartDate 5 / 128

The intermittent version of this printer requires the printhead to move over the
substrate while printing occurs.
When this model is used as an Intermittent printer, the printhead module is driven
backward and forward along a linear slide by means of a printhead carriage that is
connected to the drive belt.
A stepper motor is used to drive a toothed drive belt around two geared pulley's,
one of which is used to tension the belt.
Printing occurs while the substrate is stationary.
II

Figure 4–7: SmartDate 5 LH - Intermittent Mode

1. Carriage Drive Belt.

2. Clamp Plate.

The printhead module is mounted on this carriage and is secured by four screws.

SmartDate 5.1 4-9

SECTION 4 - TECHNICAL INFORMATION

4.3.5 Continuous Drive System - SmartDate 5 Printer

The Continuous version of this printer does not require the printhead to move over
the substrate while printing occurs.
When this model is used as a continuous printer the printhead module is held in a
fixed position and has no motion on the linear slide.
The stepper drive is used for positioning the print module only, and has no
function during the print process.
Printing occurs when the substrate is in motion.
The Ribbon drive system is responsible for accelerating the ribbon up to the same
speed as the substrate so that printing can occur.
The print module is mounted onto the print module carriage the same way as for
the Intermittent version of this printer.
I

Figure 4–8: SmartDate 5 LH - Continuous Mode

1. Carriage Drive Belt.

2. Clamp Plate

4-10 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.3.6 Continuous Drive System - SmartDate 5s Shuttle Printer

The Continuous shuttle version of this printer does not require the printhead to
move over the substrate while printing occurs.
With this model the printhead module is held in a fixed position and is independent
of the linear slide.
The linear slide in this machine is used for the shuttle carriage.

Figure 4–9: SmartDate 5s Shuttle LH

1. Carriage Drive Belt.

2. Shuttle Carriage.
3. Clamp Plate

A stepper motor is used to drive a toothed drive belt around two geared pulley's,
one of which is used to tension the belt.
This drive belt is connected to the shuttle carriage.
When the ribbon cassette is inserted into the printer body, the drive shafts of the
shuttle are engaged into the two bushed holes in the shuttle carriage.
The ribbon shuttle is then driven backward and forward along the linear slide.
During printing the ribbon is required to accelerate up to the same speed as the
moving substrate before printing can take place.
Printing occurs when the substrate is in motion.
The unique Markem-Imaje shuttle drive system allows the SmartDate 5s to
achieve very high operating speeds on continuous running substrates.

SmartDate 5.1 4-11

SECTION 4 - TECHNICAL INFORMATION

4.3.7 Ribbon Drive System

The ribbon drive system is responsible for control of the ribbon tension, ribbon
movement and ribbon operating speed.

1 1

1. Ribbon Stepper Motor Drive Dogs

The ribbon drive is a direct drive system and does not require the use of a clutch.
This is achieved by the use of two stepper motors.
The stepper motors are connected to the ribbon supply and waste take up spools
via dog clutches.
This gives the printer the ability to drive the ribbon accurately in both directions.
The drive system requires no setting up and therefore alleviates the possibility of
incorrect torque being used.
The ribbon is routed around a movement roller which then supplies data to a
microprocessor in the printer via a hall effect sensor.
The SmartDate 5 firmware uses an algorithm to calculate the amount of tension
required for the ribbon and adjusts the stepper motors accordingly.

4-12 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.4 Printhead Module

The SmartDate 5 Print Module is designed to be used on all versions of the
SmartDate 5 series printers.
The modular design means that it can be used for both Combined and Shuttle
versions of the printer.
The print module can also be easily changed from a right hand to a left hand
module.
The module houses the mechanism for printhead movement and the printhead
assembly.

Figure 4–10: SmartDate 5-Print Module with Combined Printhead Assembly

Figure 4–11: SmartDate 5 / 128 Print Module with 128-mm-Printhead

Assembly

SmartDate 5.1 4-13

SECTION 4 - TECHNICAL INFORMATION

4.5 SmartDate 5 53mm Print Module Components

The print module consists of a housing unit, an actuator block assembly, three
solenoid operated air cylinders, a linear slide, a printhead mounting block and
printhead.
All three cylinders are mounted into an actuator block assembly.
The actuator block also provides connection points for the cylinder air supplies.
The actuator block and printhead mounting block are connected to a linear slide.
Two of the cylinders are used to move the actuator block to the “Prime position”
ready to print.
The third cylinder is used to move the printhead mounting block and printhead to
the printing position.
The solenoid operated print cylinder is used during this process and is activated
by an external print signal.

2
5 4

Figure 4–12: SmartDate 5 53mm Print module

1. Housing unit
2. Printhead mounting block
3. Linear slide
4. Actuator block
5. Cylinder air supply connectors

4-14 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.6 SmartDate 5 / 128 Print Module Components

This print module consists of a housing unit, a linear slide and carriage and four
air operated cylinders.
The outermost solenoid operated cylinders are used to move the printhead to the
prime position.
The remaining two solenoid operated print cylinders are used during the print
process and are activated by an external print signal.

Figure 4–13: Printhead Module

1. Housing unit
2. Printhead guide bracket
3. Linear Slide
4. Prime Position Solenoid Operated Air Cylinder (2)
5. Print Position Solenoid Operated Air Cylinder (2)

SmartDate 5.1 4-15

SECTION 4 - TECHNICAL INFORMATION

4.6.1 SmartDate 5 53mm Printhead Assembly

The printhead assembly is designed for easy removal and replacement.
The assembly plate is attached to the printhead by two 3 mm dowel pins and two
3 mm cap head screws.
The complete assembly can be detached from the print module easily by pushing
against the retaining spring and pulling the assembly away from the print module.

Figure 4–14: SmartDate 5 53 mm Printhead Assembly

Figure 4–15: SmartDate 5s 53 mm Printhead Assembly

Note: Take care not to damage the flexible ribbon cable.

4-16 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.6.2 SmartDate 5 / 128 mm Printhead Assembly

The printhead assembly is designed for easy removal and replacement.
The printhead assembly is attached to the printhead guide bracket by means of
two spring loaded ball bearings.
These grip onto a grooved shaft on the guide bracket.
The complete assembly can be detached from the print module by pulling the
assembly away fro the print module.

Figure 4–16: SmartDate 5 / 128 mm Printhead Assembly

SmartDate 5.1 4-17

SECTION 4 - TECHNICAL INFORMATION

4.6.3 SmartDate 5 35 mm Printhead Module Operation

When the ribbon cassette is interlocked with the printer body, the prime position
solenoid is activated and the printhead is moved to its prime position ready print.
(1)
The solenoid operated print cylinder is activated when the printer receives a valid
print signal.
This moves the printhead into contact with the substrate ready to print. (2)
.

1 2

4.6.4 SmartDate 5 / 128 Printhead Module Operation

When the ribbon cassette is interlocked with the printer body, the prime position
solenoids are activated and the printhead is moved to its prime position ready
print. (1)
The solenoid operated print cylinders are activated when the printer receives a
valid print signal.
This moves the printhead into contact with the substrate ready to print. (2)

1 2

4-18 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.6.5 Printhead Type Detection

The SmartDate 5 printer can support two different widths of printhead a 53 mm
wide printhead and a 128mm wide printhead.
Both printhead types have thermistors and these have separate inputs to the
printer board.
On power up the micro-controller samples the two printhead temperature sensors.
One will be reporting a temperature; the other will be at full-scale (maximum).
The micro-controller can use this information to determine the type of printhead
fitted.
If both sensors report full-scale, or if neither reports full-scale the micro-controller
must report a fault.

4.6.6 Printhead Temperature Control

The printheads are fitted with thermistors and the temperature is constantly
monitored.
The Strobe and Cont pulse widths are adjusted by the firmware to compensate,
ensuring a consistent print darkness at varying temperatures.

4.6.7 Printhead Voltage Control

The printhead voltage is electronically adjusted under processor control.
A lookup table based on an spreadsheet based off the electrical data sheets
provides a means of determining the required voltage setting for a given printhead
resistance.
The table also provides a calculated value for the digital potentiometer used to set
the printhead voltage.
The printhead resistance level, which can be adjusted by the controller, is stored
in the printer.
To adjust the voltage the algorithm used first uses the lookup table to set the
potentiometer to the calculated setting.
Due to component tolerances this setting will not always provide the correct
voltage.
The algorithm then uses the ADC connected to the printhead voltage to fine adjust
the potentiometer.

SmartDate 5.1 4-19

SECTION 4 - TECHNICAL INFORMATION

4.7 Printer Orientation

It is critical to the success of the printer that all parties understand the orientation
of the printer.
Orientation is common to both Intermittent and Continuous printers.
Both Combined and Shuttle versions of the SmartDate 5 printers can be Left or
Right hand orientated.
The decision to select a right or left hand printer will depend on the direction of the
substrate and access to remove the ribbon cassette.
With Continuous printers the print-head angle must always be in the direction of
travel of the substrate.
With Intermittent printers, the substrate is stationary when being printed onto and
the only issue here is access to the printer cassette.
The rule for determining the printer hand is as follows:

4-20 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

Left Hand Printer showing: Right Hand Printer showing:

Angle of the Printhead. Angle of the Printhead.
Direction of the Substrate Direction of the Substrate travel.
travel.

If the SmartDate 5 is to print from the underside of the substrate, and the Cassette
is to face in the same direction the opposite hand would be required.
Alternatively the same hand could be used but access to the Cassette would have
to be from the opposite side.

Right Hand Printer showing: Left Hand Printer showing:

Angle of the Printhead. Angle of the Printhead.
Direction of the Substrate travel. Direction of the Substrate travel.

SmartDate 5.1 4-21

SECTION 4 - TECHNICAL INFORMATION

4.7.1 Orientation - SmartDate 5 and SmartDate 5 / 128

The printer hand is determined by the configuration of the connectors on the
printer Interface PCB.
The SmartDate 5 and SmartDate 5 / 128 printers calibrate the printer carriage on
power up to establish the Home position.
The print module is always moved towards the limit switch.
Based on the printer hand, the print module will either remain in the left hand
datum position or move to the right hand datum position.
The Datum positions for the Combined printers are shown below.
The actual print positions of the print module will depend upon any offset that may
have been set in the printer settings.
This is particularly so with SmartDate 5 when used as a Continuous printer, where
the printhead must be directly in line with the centre of the Print roller.

4-22 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

Direction of Substrate Travel

Figure 4–17: SmartDate 5 Left Hand - Intermittent Mode

Direction of Substrate Travel

Figure 4–18: SmartDate 5 Right Hand - Intermittent Mode

SmartDate 5.1 4-23

SECTION 4 - TECHNICAL INFORMATION

Below are examples of the print module in offset positions.

Direction of Substrate Travel

Figure 4–19: SmartDate 5 Left Hand - Continuous Mode

Direction of Substrate Travel

Figure 4–20: SmartDate 5 Right Hand - Continuous Mode

4-24 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.7.2 Orientation - SmartDate 5s Shuttle Printer

The print module on the shuttle version of the SmartDate 5 printer does not move.
It is held in a fixed position on the printer plate.
A micro-switch determines if the printer is a left hand or a right hand.
The switch is situated under the position for the left hand module and is only
activated when the module is a left hand.
If the switch is not activated the printer is assumed to be a right hand machine.

SmartDate 5.1 4-25

SECTION 4 - TECHNICAL INFORMATION

Direction of Substrate Travel

Figure 4–21: SmartDate 5s Shuttle LH

Direction of Substrate Travel

Figure 4–22: SmartDate 5s Shuttle RH

4-26 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.8 Printer Calibration

The SmartDate 5 printer calibrates on power up or if the ribbon cassette has been
removed and replaced.

SmartDate 5 Combined printer

The style of the printer (Intermittent or Continuous) is determined by a printer

parameter setting.

Power up

On power up the printer establishes the following information:

• The printer hand.
• The datum position of the print module.
• The diameter of the ribbon reels.
• The tension of the ribbon.

Cassette Removal

If the cassette is removed and replaced the printer establishes the following:
• The datum position of the print module.
• The diameter and tension of the ribbon.

SmartDate 5s Shuttle printer

The position of the print module on the SmartDate 5s shuttle version is fixed and a
micro-switch is used to determine the hand of the printer.
The shuttle is moved to the appropriate position for a left or right hand machine.

Power up

On power up the printer establishes the following information:

• The printer hand.
• The diameter of the ribbon reels.
• The tension of the ribbon.
• The required position for the shuttle.

Cassette Removal

If the cassette is removed and replaced the printer establishes the following:
• The datum position of the shuttle.
• The diameter and tension of the ribbon.

SmartDate 5.1 4-27

SECTION 4 - TECHNICAL INFORMATION

4.8.1 Print Module / Shuttle Carriage Calibration

SmartDate 5 requires that the print module / shuttle carriage is calibrated.
On power up the printer will initiate the calibration sequence to determine if the
printer is a left or right hand version.
A stepper motor is used to drive a toothed drive belt around two geared pulley's,
one of which is used to tension the belt.

Printhead Module

The drive belt is connected to a print module carriage plate that is mounted on the
Linear Slide carriage.
The Printhead module is mounted on the carriage plate and is secured by four
screws.

Shuttle Carriage

The drive belt is connected to a Shuttle carriage that is mounted directly onto the
Linear Slide carriage.

4-28 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

Print Module Calibration - SmartDate 5 and SmartDate 5 / 128

The printer hand is determined by the configuration of the connectors on the

printer Interface PCB.

Print Module

Datum Switch
Left Hand
Position

Figure 4–23: Combined Printer LH - Continuous

During calibration the print module is always moved towards the limit switch.
The print module is then held at the left hand datum position or driven to the right
hand datum position based on the printer hand.
The datum position of the print module can be adjusted if required by accessing a
setting on the User Interface screen.
Intermittent - Offset setting
Continuous - Carriage Position setting

SmartDate 5.1 4-29

SECTION 4 - TECHNICAL INFORMATION

Shuttle Calibration - SmartDate 5s

A Handing micro-switch determines if the printer is a left hand or a right hand

printer.
The switch is situated under the position for the left hand module and is only
activated when the module is a left hand.
Once this is established the printer will move the shuttle carriage to the
appropriate datum position.

Shuttle Printer LH Shuttle Printer RH

Datum Micro Switches

4-30 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.8.2 Ribbon Calibration

Both Combined and Shuttle versions of the SmartDate 5 printer require the ribbon
drive to be calibrated.
Ribbon Calibration - SmartDate 5 and SmartDate 5s
Ribbon calibration is performed by running the two ribbon drive stepper motors.
This in turn drives the ribbon round a movement roller which has a 16 pole
magnet on the end of it.
The ribbon sensor input is connected to a Hall-effect sensor mounted in the
printer base plate.
The sensor detects the rotation of the multi pole magnet and outputs an analogue
signal through one of the control units ADC inputs.
This signal is then analysed by the firmware to establish the diameters of the
ribbon supply and take up reels.
Ribbon tension is then adjusted by stepping the two ribbon drive motors
independently at the required ratio.

SmartDate 5.1 4-31

SECTION 4 - TECHNICAL INFORMATION

Hall Effect Sensor Movement Roller

Combined Printer LH Intermittent Combined Printer LH Cassette

Hall Effect Sensor Movement Roller

Shuttle Printer LH Shuttle Printer LH Cassette

4-32 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.8.3 Printer Cassette

The Printer Cassette is used to house the ribbon for the SmartDate 5 printers.
Three styles of cassette are available:
• SmartDate 5 cassette
• SmartDate 5 / 128 cassette
• SmartDate 5s Shuttle cassette

The cassettes comprise of a ribbon supply reel and waste take up reel, ribbon
guide rollers, ribbon movement and tension rollers and a brake mechanism.
The SmartDate 5s also has a ribbon shuttle mechanism.
A location pin and cassette latch mechanism are used to interlock the cassette
with the printer body.
The ribbon supply and waste take up reels have dog clutches which are used to
connect to the printer ribbon drive motors.
When the Cassette is inserted into the printer body, the drive dogs are pushed
backwards into the ribbon supply and take up spool shafts. This action releases
the brake mechanism on the shafts and allows the ribbon to rotate freely.
The outer wall of the ribbon supply and rewind shafts are fitted with leaf springs to
secure the ribbon cores and prevent slipping during printing.
The ribbon supply / take up assemblies and guide rollers are screw fitted to the
cassette body to enable easy removal.
The SmartDate 5 Cassette can accept a 900m ribbon supply roll.
The SmartDate 5 / 128 Cassette can accept a 600m ribbon supply roll.

SmartDate 5.1 4-33

SECTION 4 - TECHNICAL INFORMATION

4.8.4 Cassette Components SmartDate 5 and SmartDate 5 / 128

1 2 3

5 6

Figure 4–24: SmartDate 5 Cassette

1. Ribbon Movement Roller.

2. Location Pin.
3. Ribbon Tension Roller.
4. Brake Assembly
5. Ribbon Waste Take up.
6. Ribbon Supply.
7. Cassette Locking Mechanism.
8. Ribbon Guide Rollers and Cassette location Pins.

Note: The SmartDate 5 / 128 version components are the same design but
longer.

4-34 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.8.5 Cassette Components SmartDate 5s

1 2 3

5 6

8
10
8

Figure 4–25: SmartDate 5s Shuttle Cassette

1. Ribbon Movement Roller.

2. Location Pin.
3. Ribbon Tension Roller.
4. Brake Assembly.
5. Ribbon Waste Take up.
6. Ribbon Supply.
7. Cassette Locking Mechanism.
8. Ribbon Guide Rollers.
9. Ribbon Guide Rollers and Cassette location Pins.
10. Shuttle.

This cassette is similar to the SmartDate 5 cassette but it also houses the shuttle
mechanism used for the SmartDate 5s printer.
The shuttle is a carriage with two ribbon rollers and is mounted on a linear bearing
slide on the cassette. When the cassette is engaged with the printer body, the
location pins on the end of the roller shafts locate into the shuttle carriage in the
SmartDate 5s printer body.

SmartDate 5.1 4-35

SECTION 4 - TECHNICAL INFORMATION

4.8.6 Ribbon Calibration / Movement Roller

The ribbon movement roller houses a 16 pole magnet which is located into a Hall
effect sensor when the cassette is interlocked with the printer body.
As the roller and magnet rotate, the magnetic field strength varies.
Data is gathered by the Hall effect sensor and analysed by the processor.
This used to control the ribbon drive.
Information such as ribbon breaks or remaining length of ribbon are controlled
from this data.

4-36 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.8.7 Ribbon Tension Roller

The ribbon tension roller is used to help maintain a constant tension on the ribbon.
The roller is mounted on a linear slide on the cassette, the end of the shaft is
dome shaped and does not rotate.
When the cassette is interlocked with the printer body the end of the shaft comes
into contact with the tension sensor.
As the ribbon tension increases the pressure that is applied to the sensor also
increases. The data from this sensor is then analysed by the processor and the
stepper motors are adjusted accordingly.

SmartDate 5.1 4-37

SECTION 4 - TECHNICAL INFORMATION

4.9 Printer Electrical Components

The image below show the main electrical components of the printers:

Motor and Sensor Connectors

Printer
PCB

Stepper
Motors

Printer Power and Signals Connector

Encoder
Connector
Solenoid
Valves

Printhead

4-38 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.9.1 Stepper Motors

SmartDate 5 uses three stepper motors, one to drive the carriage for the
printhead module/shuttle and two for control of the ribbon.
The position of the stepper motors is the same for all models of the SmartDate 5
printer.
The stepper motors are six wire motors connected in a unipolar configuration.
The motors are connected to the printer board via 6-way 2.54 mm Molex KK
connectors.

Connection points:
• X2 - Carriage Motor
• X4 - Ribbon motor 1
• X7 - Ribbon motor 2

When the Combined printer is in Intermittent mode the printhead carriage motor
steps are in direct relationship to the linear movement of the printhead.
With Continuous versions of the printer the printhead carriage has no linear
motion during printing.
The ribbon motors steps are configured according to data from the Ribbon roller
sensor, Ribbon tension sensor and Encoder if being used.

SmartDate 5.1 4-39

SECTION 4 - TECHNICAL INFORMATION

4.9.2 Ribbon Movement Sensor

The ribbon sensor is monitored to determine the ribbon supply and waste take up
reel diameters, and to enable ribbon break detection.
The ribbon sensor input is connected to a Hall-effect sensor mounted on the
printer base plate.

The sensor detects the magnetic field of a multi-pole magnet mounted on the
ribbon movement roller as it rotates.
This signal from the sensor is analysed by the Micro-control unit.
The analogue signal from this sensor is analysed by the processor during printing
and the stepper motors are adjusted accordingly.
The Micro-control unit will then determine how much ribbon tension is required
and adjust the ribbon stepper motors accordingly.

4-40 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.9.3 Ribbon Tension Sensor

The ribbon tension sensor is a pressure type sensor (transducer)
The sensor is mounted into the base plate of the printer.

When the cassette is interlocked with the printer body, the end of the ribbon
tension roller shaft comes into contact with the ribbon tension sensor.
As the ribbon is driven the amount of tension applied to the roller varies and
therefore the amount of pressure applied to the sensor
The Micro-control unit will then determine how much ribbon tension is required
and adjust the ribbon stepper motors accordingly.

Cassette

Linear Slide

Ribbon Tension Roller

Roller moves as the ribbon tension

increases

Ribbon Tension Sensor

Printer Body

Note: The end of the ribbon roller shaft does not rotate.

SmartDate 5.1 4-41

SECTION 4 - TECHNICAL INFORMATION

4.9.4 Micro Switches

The SmartDate 5 printer uses two micro switches.
There is a “Home” switch.
There is one “Cassette Open/Closed” switch.
The position of these switches is different for the SmartDate 5 printer and the
SmartDate 5s Shuttle printer.

4-42 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

Handing Detection

SmartDate 5 - SmartDate 5 / 128

The printer hand is determined by the position of the printhead ribbon cable.
Depending on the position of the printhead module, the ribbon cable is connected
into one of the connectors on the printhead Interface PCB.
If the module is moved to the alternative position the other connector is then used.

SmartDate 5s - Shuttle Continuous Printer

The switch is fitted below the mounting holes for the Left Hand shuttled printer
carriage plate.
The switch is operated when the printer is configured as a Left Hand printer.
If the printer is configured as a Right hand printer, the switch is not active.

SmartDate 5.1 4-43

SECTION 4 - TECHNICAL INFORMATION

Carriage Direction

SmartDate 5 Printer

The (Printhead) carriage is attached to the “lower edge” of the drive belt.
To drive the carriage towards the Home switch the motor must rotate anti-
clockwise.

SmartDate 5s - Shuttle Continuous Printer

The (Shuttle) carriage is attached to the “upper edge” of the drive belt.
To drive the carriage towards theHome switch the motor must rotate clockwise.

Cassette Open/Closed Detection

This micro switch is located on the underside of the printer plate.

The cassette latch shaft has a flange with a notch cut into it and when rotated to
the closed position this used to activate the micro switch.

4-44 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.9.5 Printhead Prime Position

SmartDate 5 and SmartDate 5 / 128 use a solenoid valve with 2 cylinders to move
the printhead to the prime position.

4.9.6 Printhead Print Position

All models use solenoid operated air valves to move the printhead to the print
position.
The solenoids are activated by a Print GO signal and cause the print cylinder/
cylinders to move the printhead to the print position.
SmartDate 5 uses one solenoid and one air cylinder, SmartDate 5 / 128 uses one
solenoid valve and two cylinders.

SmartDate 5.1 4-45

SECTION 4 - TECHNICAL INFORMATION

4.9.7 Encoder
The Encoder is used in conjunction with Continuous printers.
The Encoder is used to calculate the current Substrate speed and adjust the
ribbon speed to match.
The recommended Encoder used with SmartDate 5 is a Quadrature style
encoder. (Bi-directional)

Clockwise or Anti clockwise directions are determined by facing the Encoder

wheel with the motor behind the wheel.
The four wires from the Encoder connect into the printer through a 9 way D type
connector on the printer body.

4-46 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.9.8 Printer PCB

The SmartDate 5 printer PCB is located in the printer unit.
The printer PCB controls the printhead signals, motor movement and solenoid
actuation inputs and outputs.
The Continuous shuttle version of the printer interfaces with a speed encoder for
matching of print speed.
It is connected to, receives power from and communicates with the Controller unit
via a single multi-core cable.
The printer board has its own Micro-controller which communicates with the Main
Controller unit and a PLD (Programmable Logic Device).

SmartDate 5.1 4-47

SECTION 4 - TECHNICAL INFORMATION

4.9.9 Printer PCB Components

The main components of the printer PCB are shown below:

X20 X11 X9 X6

X30

X15

X29

X14

X22

X1

X27 X3 X26 X25

TP16 TP17 TP4

TP14 TP15 TP5 V6
TP26 TP9 V45 V44 V46

TP8
TP48
TP10 TP49
TP2

V49
V50
V47
V48

TP1
TP29

V35
V34
V33
TP11
TP12
TP13

TP3

4-48 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.9.10 Printer PCB Connectors

The printer PCB connectors are listed below:

Table 4– 1: Printer PCB Connectors

Number Connector Function

X1 37W-D-PLG Controller to Printer Interface

X3 2W-Molex Cassette Interlock Switch

X6 2W-Molex Ribbon Roller Hall Effect Sensor

X11 3W-Molex Printhead Prime Position Solenoid

X14 Header 5 x 2 Debug Port

X15 Header 14 x 2 Debug Port

X25 6 W-Molex Carriage Stepper Motor 3

X26 6 W-Molex Ribbon Wind Stepper Motor 1

X27 6 W-Molex Ribbon Wind Stepper Motor 2

X28 30W Card Edge Printhead Interconnection

Quadrature Encoder Input,

X29 Header 5 x 2
Status Output

X30 6 W-JST Ribbon Tension Sensor

SmartDate 5.1 4-49

SECTION 4 - TECHNICAL INFORMATION

4.9.11 Printer PCB Test Points

The printer PCB Test points are listed below:

Table 4– 2: Printer PCB Test Points

Test Point Function

TP1 +45VCP (Controller to Printer)

TP2 +5V (Logic)

TP3 0VCP

TP4 +VPH (Printhead “Variable” Voltage)

TP5 0VPH

TP8 0V (Logic)

TP9 0V (Logic)

TP10 0V (Logic)

TP29 +24V (Encoder)

TP48 +3,3 V (Logic)

TP49 +2,5 V (Logic)

4.9.12 Printer PCB Fuse

The printer PCB has two thermal resettable fuse F1 F2 and F3.

4-50 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.9.13 Printer PCB LEDs

The printer PCB LEDs are listed below:

Table 4– 3: Printer PCB LEDs

LED Description Function

On when Printhead is in Print

V6 Head Print Solenoid (Yellow)
position.

On when Printhead is in Prime or

V11 Head Prime Solenoid (Yellow)
Print position.

V33 CPU (Yellow) Flashes during CPU activity.

V34 Spare (Yellow)

V35 PLD (Yellow) Flashes during PLD activity

V44 Print Go (Green) On when Print Go signal is active.

Power on.
Status
V45 This flashes off during the print
(Front Panel - Blue)
cycle.

Green = Producing
Amber = Warning (Substrate over
Status
V46 speed or under speed)
(Front Panel - Tri-Colour.)
Red = Ready (Printing disabled)
Red = Fault (Flashes)

On when Encoder channel A is

V47 Encoder Channel A (Green)
active.

On when Encoder channel B is

V48 Encoder Channel B (Green)
active.

User configurable Output

V49 Status 1 Encoder (Yellow)
On when activated.

User configurable Output

V50 Status 2 Encoder (Yellow)
On when activated.

SmartDate 5.1 4-51

SECTION 4 - TECHNICAL INFORMATION

4.10 Printer Interconnection PCBs

The SmartDate 5, SmartDate 5 / 128 and SmartDate 5s shuttled printers use
interconnection PCBs to interface between the main printer PCB and the
printhead.
The styles are different but the function is the same for all.
Examples are shown below:

Figure 4–26: SmartDate 5 - Figure 4–25: SmartDate 5s -

Interconnection PCB Interconnection PCB

Abb. 4–27: SmartDate 5 / 128 - Interconnection PCB

4-52 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.11 The SmartDate 5 Controller

The SmartDate 5 Controller contains the system power supplies, the controller
board, the user interface panel and various external connection points.
The User Interface panel uses a monochrome (1 bit) 240 x 64 pixel screen with a
six button membrane keypad.

The Controller is responsible for:

• Power regulation and distribution.

• Power and control for the printer.
• Local User Interface control.
• Serial communications.
• Ethernet
• User configurable I/O.
• I/O expansion.
• Image data storage.
• Image data transfer.

SmartDate 5.1 4-53

SECTION 4 - TECHNICAL INFORMATION

4.11.1 Controller Components

The main components of the Controller are shown below:

2 3 4

6 7 8 9

1) Battery 6) Power Supply

2) LCD Data Connector 7) Mains Power Connector

3) Front Panel Hot key Connector 8) Main PCB DC Power Connector

4) LCD Backlight Connector 9) Fan Connector

5) Main PCB

4-54 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.11.2 Controller Rear Connectors

1 2 3 4 5 6

1. USB-B Connector
2. Ethernet Connector.
3. USB-A Connector
4. RS-232 Comms Connector.
5. External I/O Connector.
6. Printer Power / Control Connector.
7. Mains Connector, Fuse and Power Switch.

4.11.3 Mains Power Switch

The power supply connector comprises of an On/Off switch, a IEC320 socket and
a 250V Fuse holder.

On / Off Switch

Fuse Holder

Power Connection

No voltage configuration is required as the unit uses a universal input power

supply.

SmartDate 5.1 4-55

SECTION 4 - TECHNICAL INFORMATION

4.11.4 Power Supply

The SmartDate 5 power supply unit has a Universal input and 45V DC output.
The unit can deal with AC input voltages from 90 to 264V AC Input frequency of
47 to 63 Hz
The unit provides power for the Controller and for the Printer and is convection
cooled.

+45V Stepper Motor Supply

The +45V for the stepper motors is routed via the Cassette closed switch for
safety reasons.

+24V I/O Supply

The +24V supply powers the I/O interfaces.

Logic Supplies

The logic supply is split into four power rails: +5V, +3.3V, +2.5V and +3.3VI / 0VI.
(Isolated)

Printhead Supply

The printhead supply is based around an adjustable regulator that converts the
45V input to a software-controlled voltage output.
The output voltage is adjusted to suit the resistance of the printhead fitted by
means of a digital potentiometer.
The values are entered at the user interface.

4-56 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.11.5 Controller PCB

The SmartDate 5 Controller PCB is located in the SmartDate 5 Controller unit and
provides connection points for Communication signals, External I/O and the
SmartTouch user Interface.
The Controller PCB also provides power and control signals for the printer.

4.11.6 Controller PCB Micro-processor

The Micro-processor is responsible for the following:
• Image manipulation.
• Image data transfer to the Printer.
• Communication signals
• Control of External Inputs and Outputs

SmartDate 5.1 4-57

SECTION 4 - TECHNICAL INFORMATION

4.11.7 Controller PCB Components

X15 X10 X13 X14 X5 X4

X8

X7
F3

F2 F1 F4 X6

X20

X23 X9 X22 X3 X2 X1

Figure 4–28: Controller PCB Connectors and Fuses

TP21 TP18 TP15 TP16

TP23

TP22

TP11 TP10 V26 V28 V23 V22 V21 V20 V24 TP19 TP2 TP1

Figure 4–29: Controller PCB Test Points and LEDs

4-58 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.11.8 Controller PCB Connectors

The Controller PCB connectors are listed below:

Table 4– 4: Controller PCB Connectors

Number Connector Function

X1 37W D Type SKT Printer Power and Signals

X2 15W D Type PLG External I/O

X3 9W D Type PLG Auxiliary Communications

X4 20W Molex Expansion I/O

X6 6W Molex Power Supply

X7 Header 5 x 2 JTAG Port

X8 Header 5 x 2 Power PC Debug Port

X9 8W - RJ45 SKT Ethernet 10/100 Base - T

X13 Header 8 Keypad

X14 3W Molex LCD Back light

X15 Header 10 x 2 Graphical LCD

SmartDate 5.1 4-59

SECTION 4 - TECHNICAL INFORMATION

4.11.9 Controller PCB Test Points

The Controller PCB Test points are listed below:

Table 4– 5: Controller PCB Test Points

Test Point Function

TP1 Printhead Data Clock

TP2 Printhead Data 1 - 53mm/128mm

TP3 Printhead Data 2 - 128mm

TP4 Line Link

TP10 +3.3VI (Isolated Comms Supply)

TP11 0VI (Isolated)

TP14 +45V Main PCB Supply

TP15 +5VL (Logic)

TP16 +3.3V Main PCB Logic Supply

TP18 0V (Logic)

TP19 0V (Logic)

TP20 0V (Logic)

TP21 +2.5V PLD Logic Supply

TP22 +24V I/O Supply

TP23 0VP (Power)

TP 24 0V(Logic)

4-60 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.11.10 Controller PCB LEDs

The main Controller PCB LED’s are listed below:

Table 4– 6: Controller PCB LEDs

LED Description Function

Permanently Illuminated when +3.3V

V2 PWR - Power On
power supply is on.

Normally Off
V3 HR - Hard Reset Flashes once on Power up or
Software Reset

CPU - Central Processor

V4 Flashes during normal operation.
Unit

Illuminates only when a Flash Device

V5 Flash Busy
is being programmed.

V6 FPGA Flashes when FPGA is active

SPD - Ethernet 10/100 Base Off = 10 Base - T

V8
T Speed On = 100 Base - T

V9 USB-B Active On when active

V10 Graphic Controller Flashes when active

SmartDate 5.1 4-61

SECTION 4 - TECHNICAL INFORMATION

Table 4– 7: Controller PCB I/O LEDs

LED Description Function

UC1 - User Configurable On when the configured Output is

V20
Output 1 activated

UC2 - User Configurable On when the configured Output is

V21
Output 2 activated

Normally Open Relay

V22 FLT - Fault Output
Closes on Fault

Normally Open Relay

V23 WRN - Warning Output
Close on Warning

V26 PG - Print Go Input PNP Input

IN1 - User Configurable

V28 PNP Input
Input

4-62 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.11.11 Controller PCB Links

The Controller PCB use various links to configure functions on the board.
The Controller PCB links are listed below:

Table 4– 8: Controller PCB Links

Link Description Function

PNP Input
X11 PG - Print Go Input
Position A - PNP B - NPN

IN1 - User Configurable PNP Input

X12
Input Position A - PNP B - NPN

Position A - Default
X16 Run Bootstrap
Position B - Forced program refresh

Position A - Linked
X21 Battery
Position B - Not Linked

4.11.12 Controller PCB Fuses

The Controller PCB is fitted with thermal resettable fuses.
The Controller PCB fuses are listed below:

Table 4– 9: Controller PCB Fuses

Fuse Description

F1 Fault Output

F2 Warning Output

F3 24V Supply

F4 24V Auxilliary

SmartDate 5.1 4-63

SECTION 4 - TECHNICAL INFORMATION

4.11.13 SmartDate 5 Interfaces

The controller PCB uses various interfaces to communicate with the printer and
the outside world.
A description of these follows:

4.11.14 Controller to Printer Interface

The Interface between the Controller and Printer is a single multi-core cable that
carries the following:

• Power supplies.
• Serial channels for transferring printhead data.
• Full Duplex serial data link to pass all control and monitoring information.
• High speed control signals.

To ensure robust signal integrity the printer to controller link is via a twisted-pair
RS-422 interface.
The cable is terminated at each end with Male and Female 37 pin D type
connectors.
The cable length can be up to 10 metres in length.

4-64 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

4.11.15 Controller PCB to User Interface

The Interface between the Controller and User Interface is a combination of three
cables.
The function of these connections follows:
The User Interface Keypad connects via a 8-way single in line connector to X13
on the Controller PCB.
The Back light connects via two wires to 3-way 2.54mm Molex connector X14 on
the Controller PCB.
The LCD connects via a 20-way IDC ribbon cable to X15 on the Controller PCB.

4.11.16 Auxiliary Serial Comms Interface

A 9 way D type connector provides RS-232 comms.
This enables the SmartDate 5 printers to be communicated with on a point to
point basis (RS-232)

4.11.17 Ethernet Interface

An Ethernet connection is provided as standard on the SmartDate 5 controller.
This connection can be used for Networking the SmartDate 5 printers.

For connection and setup information see the Operation manual Section 3 -
Installation.

4.11.18 USB - A
This connection is provided for use with a USB memory stick to download or
upload data from or to the SmartDate 5 controller.

4.11.19 USB - B
This connection is to be used for future Network connectivity. E.G. CoLOS

SmartDate 5.1 4-65

SECTION 4 - TECHNICAL INFORMATION

4.11.20 External I/O Interface

A 15 way D type connector provides for customer I/O signals.
All the external inputs and outputs are made available to the customer on
connector X2.

Inputs

All customer inputs can be individually set to suit either PNP or NPN style devices.
Selection is made via jumper links X11 and X12 where position A is PNP (default)
and B is NPN.

The green LED’s on the Controller board indicate that the respective input is
active.

Outputs

All outputs are 24V PNP.

The yellow LED’s indicate the status of each output.
Fault and Warning are volt-free style outputs (30 V dc, 1 amp maximum rating)
with PTC fuse protection.

4-66 SmartDate 5.1

 SECTION 4 - TECHNICAL INFORMATION

The table below shows the Default configuration for the X2 pin numbers.

Table 4– 10: X2 Default Configuration

Pin Number Function

1 +24V - IO

2 Print Go

3 0V - IO

4 User Configurable Input 1

5 X

6 X

7 Fault - C

8 Fault - N/O

9 Warning - C

10 Warning - N/O

11 User Configurable Output 1

12 0V - IO

13 User Configurable Output 2

14 X

15 X

SmartDate 5.1 4-67

SECTION 4 - TECHNICAL INFORMATION

4-68 SmartDate 5.1

 SECTION 5
TROUBLESHOOTING

SmartDate 5.1

Maintenance Manual
 SECTION 5 - TROUBLESHOOTING

5 Troubleshooting
5.1 Introduction
This section is designed to provide information that will help you quickly solve
problems which may stop your SmartDate 5 working efficiently.

Topics covered in this section include:

• Status LEDs
• Fault messages
• Warning messages
• Common Issues
• Drive System Issues
• Print Module / Shuttle Carriage Drive Problems
• Cassette Problems
• Display Problems
• Print Quality Problems
• Job Selection Problems
• Communication Problems
• Disaster Recovery

SmartDate 5.1 5-1

SECTION 5 - TROUBLESHOOTING

5.2 Status LEDs

Status LED indicators on the printer will indicate if the machine is in Producing
mode or Ready mode. LEDs will also indicate if the printer is in a Fault condition.
The SmartDate 5 user Interface will also display any Warning or Error messages.
Some basic guidelines for troubleshooting follow:

5.3 Fault and Warning Messages

The messages are listed below along with potential causes and remedial actions.

5-2 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.3.1 Fault Messages

In the event of a fault, a message is displayed on the Home screen or Menu
screen being accessed at the time. Some fault messages can be temporarily
hidden by pressing the “Hide” option button. This allows the action being
performed in a particular menu to be completed. Other faults will require
immediate attention.

Table 5– 1: Fault Messages

Fault Message 1000 - No Printer Connected

Description The Controller can not detect a printer connection.

Printer cable loose.

Possible Faulty printer cable.
Causes Printer PCB Fault.
Controller PCB Fault.

Power off the SmartDate 5 check that the connecting cable

is secure and then re-power.
Remedial
Try a different printer cable.
Action
Try a different printer unit.
Try a different Controller unit.

Fault Message 1001 - Printer Power Supply Fault

Description Printer fails to function.

Possible
The power supply to the printer is faulty. (low voltage)
Causes

Remedial Return the controller and printer to the Markem.Imaje

Action service centre.

Fault Message 1002 - Printer Hardware Fault

Description Printer will not function.

Possible
A problem has occurred with the printer hardware.
Causes

Remedial
Return the printer to the Markem.Imaje service centre.
Action

SmartDate 5.1 5-3

SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1003 - Controller Hardware Fault

Description Controller will not function.

Possible
A problem has occurred with the controller hardware.
Causes

Remedial
Return the controller to the Markem.Imaje service centre.
Action

Fault Message 1004 - Printhead Detect Failure

Description The printer can not detect the printhead.

The printhead cable is loose.

Possible
The printhead cable is damaged
Causes
The printhead is damaged.

Remove the cassette, check printhead and printhead cable

Remedial for damage.
Action Try a different printhead.
Try a different printhead cable.

Fault Message 1005 - Software Fault

Description A system fault has occurred.

Possible
The software has experienced an error condition.
Causes

Remedial
Re-power the SmartDate 5
Action

Fault Message 1006 - Software Assert

Description A system fault has occurred.

Possible
The software has experienced an error condition.
Causes

Remedial
Re-power the SmartDate 5
Action

5-4 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1007 - Printhead Resistance Not Set

Description The printhead resistance requires setting.

Possible
A new printer PCB has been fitted.
Causes

Remedial
Set the printhead resistance level.
Action

Fault Message 1008 - Tension Not Calibrated

Description The Tension sensor requires calibration.

Possible
A new printer PCB has been fitted.
Causes

Remedial
Calibrate the Tension sensor.
Action

SmartDate 5.1 5-5

SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1100 - Bootstrap Failure

Description Printer fails to program.

Possible
Faulty printer.
Causes

Remedial
Return printer to Markem.Imaje for repair.
Action

Fault Message 1101 - Carriage Failed to Home

The print module / shuttle carriage is not reaching the home

Description
position limit switch.

The carriage is being stopped from moving by a blockage.

Possible
The drive belt is damaged.
Causes
The Home position limit switch is faulty.

Remove the cassette and check for blockages.

Check the drive belt for damage.
Remedial
Check the limit switches for damage.
Action
Use the diagnostics screen to check the limit switch input
signals.

Fault Message 1104 - Calibration Failed initial Tension

Description The printer will not calibrate.

No ribbon fitted.
The ribbon is not webbed up correctly.
Possible Wrong ribbon width selected.
Causes The supply spool is slipping.
The take up spool is slipping.
The printer is set to the wrong printer type.

Open the cassette and check the ribbon.

Remedial Check the take up spool.
Action Check the printer type in the Settings - Machine options
Use the diagnostic screen to check the calibration values.

Fault Message 1105 - Calibration Ribbon Sensor Failed

Description The printer will not calibrate.

Possible The ribbon movement sensor is damaged.

Causes The ribbon movement roller magnet is damaged.

Remedial Remove the cassette, check the sensor and magnet for
Action damage.

5-6 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1106 - Calibration Diameter Out of Range

Description The ribbon reel diameter is out of range.

Incorrect ribbon fitted.

Possible
The ribbon is wound directly onto the take up spool without a
Causes
ribbon core.

Remedial Fit the correct ribbon

Action Wind the ribbon onto a ribbon core.

Fault Message 1107 - Calibration Unable to Tension

Description Unable to obtain the correct ribbon tension

The ribbon tension sensor is damaged.

Possible
The ribbon tension roller is damaged.
Causes
The ribbon tension sensor requires calibrating.

Remove the cassette and check the ribbon sensor and roller
for damage.
Remedial
Use the diagnostic screen to check the tension sensor input
Action
signal.
Re-calibrate the tension sensor.

Fault Message 1108 - Tension Offset Out of Range

Description Unable to obtain the correct ribbon tension

The ribbon tension sensor is damaged.

Possible
The ribbon tension roller is damaged.
Causes
The ribbon tension sensor requires calibrating.

Remove the cassette and check the ribbon sensor and roller
for damage.
Remedial
Use the diagnostic screen to check the tension sensor input
Action
signal.
Re-calibrate the tension sensor.

SmartDate 5.1 5-7

SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1200- Ribbon Fault

Description The printer will stop functioning.

The ribbon has broken during calibration.

Possible
The ribbon has broken during printing.
Causes
The ribbon movement sensor is faulty.

Remove the cassette and re- web the ribbon.

Remedial
Use the diagnostic screen to check the ribbon movement
Action
sensor input signal.

Fault Message 1201- Ribbon Fault

Description The printer will stop functioning.

The ribbon has broken during calibration.

Possible
The ribbon has broken during printing.
Causes
The ribbon tension sensor is faulty.

Remove the cassette and re- web the ribbon.

Remedial
Use the diagnostic screen to check the ribbon tension
Action
sensor input signal.

Fault Message 1202 - Solenoid Fault

Description One of the print module solenoid valves is not activating.

The connector to the solenoid has become loose.

Possible
The connector or wiring is damaged.
Causes
The solenoid is damaged.

Check the solenoid by using the Manual control function to

operate it.
Remedial Check the Diagnostics screen solenoid output to see if it
Action toggles on/off
Power off the printer, remove the rear cover and manually
activate the valve by pressing the orange button.

Fault Message 1203- Carriage Overrun

The print module / shuttle carriage has hit a limit switch

Description
during the print cycle.

Possible
Broken belt.
Causes

Remedial
Remove the cassette, and check the belt.
Action

5-8 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1204 - Printhead Voltage Fault

Description The Printhead voltage is out of range.

Faulty printhead.
Possible
Faulty printhead ribbon cable.
Causes
Faulty printer PCB

Check the printhead and ribbon cable for damage.

Remedial
Try fitting a different printhead or ribbon cable.
Action
Replace the printer PCB

Fault Message 1205 - Ribbon Fault (unexpected movement)

Description

Possible
Ribbon not fitted correctly in the cassette.
Causes

Remedial Remove the cassette, re-fit the ribbon. Re-insert the

Action cassette to clear the fault.

Fault Message 1206 - Low Air Pressure

Description

Possible
The air pressure has dropped.
Causes

Remedial
Check the air pressure and increase if required.
Action

Fault Message 1207 - Multiple Missed Prints

Description

Possible
Print trigger sensor is detecting multiple signals.
Causes

Remedial
Check that the sensor is correctly fitted.
Action

Fault Message 1208 - End of Ribbon

Description

Possible
The ribbon has run out.
Causes

Remedial
Fit a new ribbon.
Action

SmartDate 5.1 5-9

SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1209 - Print Go Expected While Substrate Moving

Description

Possible The print trigger sensor has been triggered before the
Causes substrate has stopped moving. (Intermittent printer)

Remedial
Check the sensor.
Action

Fault Message 1210 - Encoder Failed

Description

Possible The Encoder signal is not being received when Print Go

Causes signals are active.

Remedial
Check the Encoder.
Action

Fault Message 1211 - Printhead Prime Failure

Description

Possible
Printer hardware fault.
Causes

Remedial
Notify Markem.Imaje
Action

5-10 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1300- Cassette Open

Description The printer will not calibrate.

Possible The Printer Cassette is not closed correctly.

Causes The cassette closed micro switch is faulty.

Ensure that the cassette is engaged with the printer body

Remedial and close the cassette locking lever.
Action Use the diagnostics screen to check the cassette closed
micro switch input.

Fault Message 1301 - 1305 User Defined Faults

Description User Defined Faults

Possible
These faults are raised via the Flex I/O inputs
Causes

Remedial
Action

Fault Message 1306- Print Go while Allocation Complete

Description The printer has stopped printing.

The allocation limit for the number of prints has been

Possible
reached. The number of prints required is set when the job is
Causes
selected.

Remedial Clear the allocation. Select a new job or update the current
Action job.

SmartDate 5.1 5-11

SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message 1400- Corrupt File system

Description The job file can not be selected.

Possible
The database has become corrupted.
Causes

Remedial Use the “Restore to Factory” defaults function and re-

Action download the jobs.

Fault Message 1401 - Failed to Restore Job

Description Job failed to restore a following a power cycle

Possible
Job / Image / Font file missing
Causes

Remedial Re- download the job

Action Select another job

Fault Message 1402 - Failed to Update Job Data

Description Image field data will not update

Possible
NGPCL communications fault
Causes

Remedial
Check the communications connection and configuration.
Action

Fault Message 1403- Log File Full

Printing may be stopped, depending on the option set for

Description
logging.

Possible
The system Log file has become full up.
Causes

Remedial Retrieve the log file or disable the variable data logging to
Action continue printing.

Fault Message 1404 - Calendar File Exhausted

Description Unable to complete Job selection.

Possible The Calendar file which is used for BBE date configuration
Causes has become full up.

Remedial Download a new calendar file or select a job which does not
Action use a calendar file.

5-12 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 1: Fault Messages

Fault Message - 1500 Printer Overheat

Description The printer temperature has reached an unacceptable level.

Possible High ambient temperature

Causes The pack rate is too high.

Remedial Switch off the SmartDate 5 and allow to cool down.

Action Reduce the line speed.

Fault Message - 1501 Controller Overheat

The controller temperature has reached an unacceptable

Description
level.

Possible
High ambient temperature
Causes

Remedial
Switch off the SmartDate 5 and allow to cool down.
Action

Fault Message 1502 - Printhead Over Temperature

Description The printhead temperature is too high.

The print darkness level is too high.

Possible
The printhead is damaged.
Causes
The printhead thermistor is damaged.

Remedial Reduce the darkness level.

Action Replace the printhead.

SmartDate 5.1 5-13

SECTION 5 - TROUBLESHOOTING

5.3.2 Warning Messages

In the event of a warning, a message is displayed on the Home screen or Menu
screen being accessed at the time. Home screen warnings can be hidden by
pressing the “Hide” option button. If the same warning re-occurs the message will
be displayed again. Menu screen warnings can also be hidden so that the action
being performed in a particular menu can be completed. In this case if the warning
re-occurs the message will not be displayed a second time, instead the Status
symbol will change to the warning symbol. This allows manual operation of the
printer without having to continually clear the warning message. e.g. missed print
warnings.

Table 5– 2: Warning Messages

Warning Message 2000 - Printhead Clean Required

Possible The printhead has performed a specified number of prints and

Causes requires cleaning.

Remedial Remove the cassette, clean the printhead then replace the
Action cassette.

Warning Message 2001 Clock Problem

Possible
The system clock has been reset to the default value.
Causes

Remedial
Re-configure the system date and time.
Action

Warning Message 2002 Printer processor Step Too Low

Possible
Causes

Remedial
Contact Markem.Imaje
Action

Warning Message 2003 Printer Command Failed

Possible
Incorrect Sequence of Manual Control Actions.
Causes

Remedial
Action

5-14 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 2: Warning Messages

Warning Message 2100 - Image Not Ready

Possible The SmartDate 5 was unable to locate the image due to a

Causes timing issue

Remedial Reduce the pack rate speed or reduce the number of updating
Action fields on the image.

Warning Message 2101 - Missed print

Possible The SmartDate 5 was unable to print the image due to a speed
Causes or timing issue. (Continuous printers)

Remedial Run a Speed profile to see if the print is occurring at the

Action correct point of the packaging machine cycle.

Warning Message 2102 - Truncated Print

The length of the image plus the amount of registration

Possible
(Intermittent printer) exceeds the distance that the print
Causes
module can travel.

Remedial
Reduce the amount of registration.
Action

Warning Message 2103 - Cropped Print

Possible The image has been designed with fields which are off the
Causes printable area.

Remedial
Re-design the image.
Action

Warning Message 2104 - Max Print Width Exceeded

Possible
The image width exceeds the maximum print width setting.
Causes

Remedial Reduce the width of the image or adjust the image width
Action setting.

SmartDate 5.1 5-15

SECTION 5 - TROUBLESHOOTING

Table 5– 2: Warning Messages

Warning Message 2105 - Discarded Print

Possible The printer has auto-aborted a print in Low speed reprint

Causes mode.

Increase the substrate speed.

Remedial
Run a Speed profile to establish if the print is occurring at the
Action
correct point of the packaging machine cycle.

Warning Message 2106 - Truncated Offset

The “Offset” amount has caused the image to exceed the

Possible
available ribbon / printhead width. The Offset has been
Causes
reduced to prevent cropping of the image.

Remedial
Reduce the amount of Offset.
Action

Warning Message 2107 - Substrate Over speed

Possible The substrate is travelling faster than the maximum print

Causes speed of the SmartDate 5.

Remedial
Reduce the substrate speed.
Action

Warning Message 2108 - Substrate Under speed

Possible The substrate is travelling slower than the minimum print

Causes speed of the SmartDate 5.

Remedial
Increase the substrate speed.
Action

Warning Message 2109 - Low Ribbon

Possible
The ribbon is nearing the end of the roll.
Causes

Remedial
Prepare a new roll of ribbon ready to replace the existing one.
Action

5-16 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 2: Warning Messages

Warning Message 2110 - Low Ribbon Tension Corrected During Print

Possible Adjustments were made to correct the ribbon tension during a

Causes print.

Remedial
Warning message cleared by operator action.
Action

Warning Message 2111 - End of Ribbon Detected

Possible
The end of ribbon sensor has detected the end of the ribbon.
Causes

Remedial
Warning message cleared by operator action.
Action

Warning Message 2112 - End of Ribbon Sensor

Possible
The End of Ribbon sensor requires calibrating.
Causes

Remedial
Warning message cleared by operator action.
Action

Warning Message 2113 - Relative Motion Missed Print

Possible The substrate was moving when the Print Go signal was
Causes received.

Remedial
Warning message cleared by operator action.
Action

Warning Message 2114 - Relative Motion Spoiled Print

Possible The printer failed to complete the print. The substrate moved
Causes during print.

Remedial
Warning message cleared by operator action.
Action

Warning Message 2115 - Missing Lines from Print

Possible Loss of print quality due to the substrate speed slowing during
Causes printing.

Remedial
Warning message cleared by operator action.
Action

SmartDate 5.1 5-17

SECTION 5 - TROUBLESHOOTING

Table 5– 2: Warning Messages

Warning Message 2200 - Corrupt File

Possible
The image file being selected has been corrupted
Causes

Remedial
Re-download the image.
Action

Warning Message 2201 - Settings Corrupt

Possible
The printer settings have become corrupted.
Causes

Remedial By clearing this message the settings will be set to default

Action values.

Warning Message 2202 Logging Stopped

Possible The log file has reached full capacity and data logging has
Causes been stopped.

Remedial
Retrieve the log file or disable image field update data logging.
Action

Warning Message 2203 - Log File Wrap Round

Possible
The log file has reached full capacity and is re-starting the log.
Causes

Remedial
If this is unacceptable re configure the Logging options.
Action

Warning Message 2204 - Log File Nearly Full

Possible
The system log file is almost at full capacity.
Causes

Remedial
Retrieve the log file or disable image field update data logging.
Action

Warning Message 2205 - Calendar file Nearly Exhausted

Possible
The calendar file associated with the Job is almost full up
Causes

Remedial Load a new Calendar file or select a Job which does not
Action require a calendar file.

Warning Message 2206 - Job Database Not Available

Possible
The communication link is not connected (CoLOS Control)
Causes

Remedial
Re-connect the communication link.
Action

5-18 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

Table 5– 2: Warning Messages

Warning Message 2207 - File System Nearly Full

Possible
The file system is almost full.
Causes

Remedial
Delete unnecessary files from the system.
Action

Warning Message 2208 - File System is Full

Possible
The file system is full.
Causes

Remedial
Delete unnecessary files from the system.
Action

Warning Message 2209 - Firmware Upgraded - Settings Lost

Possible The Firmware has been upgraded and the machine settings
Causes have been returned to the factory default values.

Remedial
Action

Warning Message 2210 - Firmware Upgrade Failed

Possible
The attempted Firmware upgrade failed.
Causes

Remedial
Retry.
Action

SmartDate 5.1 5-19

SECTION 5 - TROUBLESHOOTING

Table 5– 2: Warning Messages

Warning Message 2300 - Printer High Temperature

Possible
The printer temperature is reaching an unacceptable level.
Causes

Remedial Turn off the power to the SmartDate 5 and allow the printer to
Action cool down.

Warning Message 2301 - Controller High Temperature

Possible
The controller temperature is reaching an unacceptable level.
Causes

Remedial Turn off the power to the SmartDate 5 and allow the controller
Action to cool down.

Warning Message 2302 - Printhead Under Temperature

Possible The printhead temperature has not yet reached an acceptable

Causes working level.

Remedial The SmartDate 5 will automatically initiate a pre-heat cycle

Action before printing can commence.

5-20 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.4 Common Issues

Listed below are a number of possible faults and suggestions for possible
corrective actions.

5.4.1 No Power to the Printer

• Power switch must be in the ON position. This switch is located at the rear of
the controller.
• Check that the mains cable is correctly inserted into the mains connector
below the switch.
• Check that the mains fuse on the fuse selector is OK and replace it if
necessary.
• Check the mains supply to the SmartDate 5. There may be another fuse or
MCB installed to protect the Mains Cable at source.

5.4.2 Printhead Cables

• Check that the printer to controller cable is tightly screwed in to the connector.
Connectors may vibrate loose under normal operation if not correctly
installed. Loose connections may be the cause of many problems such as
poor print, no print, or no power to the printhead.
• Check that there are no kinks in the printhead data flexible ribbon cable.
• Check that the wires in the printhead power cable are securely fastened to the
connectors.

5.4.3 Encoder
• Check that the encoder is rotating freely. The SmartDate 5 in continuous
mode or SmartDate 5s will not print unless the encoder is moving.
• Check that the encoder is sending a signal back to the SmartDate 5. Use the
diagnostics screen to check the encoder input signals.
• Check that the Encoder is calibrated correctly.
• Check that the Encoder is configured correctly for Clockwise or Anti clockwise
direction. Direction is determined by facing the Encoder wheel with the motor
behind the wheel as shown previously.
• For best results the Encoder wheel should be positioned on the moving
substrate over the print roller.
• Mismatched substrate speed and ribbon speed will lead to tension faults.

SmartDate 5.1 5-21

SECTION 5 - TROUBLESHOOTING

5.5 No Information Is Printed

If the printer appears to be operating correctly but no data is printed, check the
following:
• Is a valid design selected?
• Check that the print speed and contrast values are at appropriate levels for
the thermal ribbon and substrate.
• Is the printhead coming into full contact with the print platen / roller across its
full width?
• Is the correct ribbon loaded with the inked surface away from the printhead. Is
it driving correctly?
• Check that the air supply is at the appropriate pressure.
• On continuous printers, the encoder signal may not be providing the correct
speed information.
• The printhead may be faulty.

5.6 The Printhead Does Not Move Out

The Printhead in / out motion is driven by a small pneumatic solenoid. If the head
does not move out, use Manual mode to test the operation of the solenoid. Check
the following:
• Check the air supply pressure and the pipe work between the components.
• Check that the head is free to rotate in its mounting.
• Check the solenoid wiring.
• Replace the solenoid and / or the air cylinder as required.
• If the fault persists, replace the Printer PCB.

5-22 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.7 Drive System Issues

5.7.1 Ribbon is not driving

• Check that the ribbon cores on the supply and take up spools are not slipping.
You can see this by taking the ribbon core off and looking on the inside.
• Check that the drive couplings for the ribbon drive have not come loose. This
can easily be checked by trying the coupling by hand.

5.7.2 Ribbon Drive Problems

• If the print darkness is too high or the print speed too low, the ribbon can be
weakened and break. This can be eliminated by reducing the darkness or
increasing the speed.
• The ribbon take up is not winding the waste ribbon correctly.
• Check that there is no interference between the accumulated wasted ribbon
and any other part of the printer body. Ensure that the waste ribbon spool is
gripping the core firmly.

5.7.3 Ribbon Creasing

Ribbon creasing is generally due to the ribbon attempting to ‘track’ across the
Printhead.
The most common causes are:
• Bent ribbon guide pins. This may occur if the cassette is dropped. It is not
usually possible to bend a pin back into position. Remove and replace the
guide pin.
• A bent peel bar. Remove and replace the peel bar.
• Poor print platen / roller alignment can in some cases cause ribbon creasing
as the substrate tries to pull the ribbon across the printhead.

SmartDate 5.1 5-23

SECTION 5 - TROUBLESHOOTING

5.7.4 Ribbon Breaking or Scuffing Prints

(Continuous printers)

If there are problems with ribbon breaking or scuffing prints, it is possible that the
Head Out Time is set too long. The printhead will move out as the ribbon begins to
accelerate.The printhead will then make contact with the ribbon before it is up to
speed.
• Try reducing the Head Out Time

(Intermittent printers)

The printhead may be starting to print before the substrate / labels have stopped
moving. The target material must be stationary before printing occurs.
• Try increasing the print delay.
• With the SD5s printer, high deceleration speeds (above 10m/s2) should be
avoided if the temperature is below 5deg C.

5.7.5 Ribbon Coning (Continuous Printers)

If there is a problem with the waste ribbon coning on the take up reel, check the
following:
• Ensure that the printhead is aligned correctly with the print roller. (See
Installation) If incorrectly aligned this will cause tracking problems.
• Ensure that the ribbon is tracking parallel on the cassette rollers and is
positioned correctly.
• Ensure that none of the rollers have been bent or damaged.
• Ensure that the Printhead and Peel roller are clean. Ink deposits can also
contribute to ribbon coning.

5.7.6 Peel Roller Problems

• If a peel roller is difficult to spin due to a build up of material debris between
the inner roller body and shaft, change the roller.
• If the peel roller is very worn and running loose on the shaft, change the roller.
• Ensure adhesive used to secure the retaining screw has not run between the
roller shaft.

5-24 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.7.7 Head not returning to home position

(SmartDate 5 - Intermittent mode only)
This problem only relates to the Intermittent printer. If the head feeds satisfactorily,
but does not return to the correct home position, check the amount of registration
that has been set. The printhead module will only return to the default start
position if the registration is set to 0.

5.7.8 Shuttle not driving

(SmartDate 5s only)
Check that the shuttle drive belt is not damaged or broken.

5.7.9 Drive Belt Issues

The drive belts are tensioned by adjusting the position of the idler pulley. If any of
the belts are slipping, this will cause carriage feed or print quality problems.The
drive pulley on the stepper motor drive shaft should also be secure.
When the belt is tensioned correctly, about 5 mm of movement should be present.
The motor drive can be tested by operating the Head / Shuttle Home Head /
Shuttle feed function in Manual mode.
Excessive tension on the belts may cause the motors to stall.

SmartDate 5.1 5-25

SECTION 5 - TROUBLESHOOTING

5.8 Printhead Module / Shuttle Carriage Drive Problems

A stepper motor, drive belt and linear slide are used to move the Printhead
module / Shuttle carriage.
The carriage drive may stall when the SmartDate 5 is under excessive load.
If the carriage does not drive, check the following:
• Is the ribbon is loaded correctly?
• Is there any mechanical interference stopping the carriage moving?
• Check the condition of the drive belt and drive pulleys.
• Check the condition of the linear slide.
• With the power to the unit turned off, is the Printhead module free to move
along the slide?
• Are the stepper motor connections correct and secure.
• If the fault persists, replace the Printer PCB.

5-26 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.9 Cassette Problems

5.9.1 Cassette Release Problems

(SmartDate 5s only)
It is likely that the printer is in the middle of a print, or you have an error message
that has stopped the machine in the middle of the print cycle. The print light on the
front of the printer may or may not be on, depending at what stage of the print
cycle it is at.
You can press the DISCARD PRINT key then remove the cassette to reset the
printer or, do it automatically (see printer settings)
Alternatively you can use the Manual menu functions to move the carriage to the
home position.
Note: The printer will start printing again upon receipt of a print signal. The
current product will not be printed.

5.10 Cassette Insertion Problems

If the cassette will not insert into the printer body, check the following:
(SmartDate 5)
• Check that there is no mechanical interference.
• Check that the cassette rollers are not bent.
• (SmartDate 5s)
• Check that the Shuttle mechanism is set to the home position before insertion.
• Check that the Shuttle rollers are not bent or damaged.
• Replace shuttle rollers if required

5.10.1 Cassette Rollers Alignment

• Pick up the cassette and rotate the ribbon by hand by winding on the take up
spool.
• Look at the ribbon as it goes around the rollers and visually note whether the
ribbon is pulling to one side. If this is the case it is probably the cassette rollers
that are out of alignment.
• If alignment is only slightly out, you may be able to gently knock the roller back
into alignment. Otherwise the cassette roller will have to be replaced.

SmartDate 5.1 5-27

SECTION 5 - TROUBLESHOOTING

5.11 Display Issues

5.11.1 Back light only lit

If the Controller LCD screen is lit, but the text or icons are just visible check the
following:
• Has the LCD contrast been set too high or low?
• Adjust the contrast by pressing the left quad and right quad buttons
simultaneously. This displays the Adjust Contrast screen.
• If no text or icons are visible check that the LCD connector to the Controller
PCB has not become loose.
• If necessary replace the Controller LCD module.
• If necessary replace the Controller PCB

5.11.2 LCD only, no Back light

If the LCD text is visible but the back light is not on check the following:
• Has the back light connector to the controller PCB become loose?
• Is the wiring damaged?
• If necessary replace the Controller LCD module.
• If necessary replace the Controller PCB.

5.11.3 Display is totally blank

Check the status light on the front of the SmartDate 5 printer.
• If it is not lit, then check the power to the SmartDate 5.
• If it is lit, check that the LCD and Back light connectors to the Controller PCB
have not become loose.
• If necessary replace the Controller LCD module.
• If necessary replace the Controller PCB.

5-28 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.12 Print Quality Problems

The most common causes of poor print quality are:
• Dirty printhead: Clean the printhead with the Markem.Imaje Isopropanol wipes
and try again. Take care not to damage the printhead during cleaning. Always
allow the printhead to cool prior to cleaning.
• Dirty, worn or badly misaligned print platen / roller: Produce a full-size test
print to establish the quality of the print.
• Ribbon is not driving correctly: Clean the ribbon rollers and check that the
ribbon is loaded correctly.
• Excessive vibration of the packaging machine: Improve the mounting of the
SmartDate 5. If possible, increase the print delay so that vibration has reduced
by the time printing starts.
• On intermittent printers, the substrate is still moving when printing starts:
Increase the print delay.
• On continuous printers, the speed encoder is not providing an accurate
measurement of the speed of the substrate: Adjust encoder.
• Matching of the ribbon to the substrate is very important. An improper match
will not produce good print quality: Contact your local Markem.Imaje Business
Centre for further details.
• Check the air supply setting for appropriate pressure.
• Lines of dots are not printing. If cleaning the printhead and platen / roller does
not resolve the problem: Replace the printhead.

SmartDate 5.1 5-29

SECTION 5 - TROUBLESHOOTING

5.12.1 Poor Print Quality (when in DRS Mode)

If in Ribbon Save mode reduce the ratio gradually until an acceptable print is
achieved. Note that other parameters such as print darkness and / or air pressure
may require adjustment when altering the ratio.

5.12.2 Faded print

Print quality is dependent on the following:
• Quality of the substrate and ribbon being used,
• Print Darkness
• Air pressure and print speed combination
• Condition of the machine being used to print
The age and storage conditions of the ribbon can also affect the print quality. The
printhead should be kept clean by using Isopropanol wipes. It should never be
touched with any abrasive material or metallic objects.
The Test Pattern function is the best way of setting the machine print standards,
such as evenness of the print; positioning of the image; and checking for damage
to the dots.

Recommendations:

• Clean the printhead and platen

• Increase the air pressure
• Increase the darkness or
• Reduce the print speed
• Reduce print ratio.
• Review ribbon.

5-30 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.12.3 Faded on one side

This is generally due to a misalignment of the printer to the platen roller/ pad. The
printhead will move down to print on the substrate, and will hit one side of the
roller/ pad first.
Recommendations:
• Check that the printer is not loose, especially if it has just been replaced.
• Align the printer correctly. You can use the HEAD DOWN key in the
Engineering Mode/ Manual Control menu to move the head out. Doing this
whilst increasing the air pressure from zero upwards will enable you to see
whether the alignment is correct. If the printhead is misaligned loosen the
screws on the mounting bracket and align the printhead along the roller.
• Tighten the screws and try a test print.

5.12.4 Blurred edges

This is generally due to the darkness setting being too great, however, it could
also be compromised if DRS is enabled.
Recommendations:
• Reduce the darkness or increase the print speed

5.12.5 Missing lines perpendicular to printhead

This is generally due to either a dirty printhead or a damaged printhead. Dirt can
build up on the printhead after a period of time causing dots to be missing. If a
printhead becomes damaged by physical or element damage, it can cause
missing dots, see section Printhead Care.
Recommendations:
• Clean the printhead.
• Use the Offset to move the image away from the damaged dots, or replace
the printhead.

SmartDate 5.1 5-31

SECTION 5 - TROUBLESHOOTING

5.12.6 Text missing at start of print

This can usually be resolved by increasing the Start Border setting. This will allow
the printhead to run along the ribbon before it starts printing.

5.12.7 Text missing at end of print

This can usually be resolved by increasing the End Border setting. This will allow
the printhead to run along the ribbon after the print.

5.12.8 Print rubs off

This can be for a number of reasons:
• There is not enough energy going to the head. This is more apparent in cold
environments. Increasing the Darkness and in extreme conditions, the
background energy levels of the head can make a difference to the
permeability. Putting the SmartDate 5 in High Speed Mode will also make a
difference.
• In environments of high temperature and humidity, the applied ribbon may still
be warm and could rub off. Trying a different ribbon grade could be the
solution.
• Mismatch in ribbon/ substrate. Some substrates have coatings that make it
very difficult to adhere to. The coatings may be, for example, a wax/ resin mix
similar to the actual ribbon. If this is the case, then trying another ribbon grade
is the best recommendation. If you are using a Markem.Imaje Grade 3810,
then try a Grade 3910. This may resolve the problem, but remember this is a
resin-based ribbon that needs more energy to print, so may be limited in
speed (typically to <350mm/s on polypropylene).

5-32 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.12.9 First Dots Missing or Ragged

Increase the Start Border if you experience print quality problems such as the first
dots of the print are missing. The printhead will move X Lines (Set in Start Border)
on the ribbon before starting to print.
If there are problems with the start of the print, in that the first part of the print is
missing (cut off), it could be that the Head Out Time is set too short. This may be
because the air pressure is particularly low and it takes longer for the printhead to
move

5.12.10 Last Dots Missing or Ragged

Increase the End Border if you experience print quality problems, such as the last
dots of the print are missing or ragged. The printhead will move X lines (Set in End
Border) on the ribbon when the print is complete.

5.12.11 Elongated or compressed print

(Intermittent printers)

The printhead is printing on the substrate when it is still moving. Modify the Print
Delay Parameter.
Depending on whether the application is printing in the same direction of the
substrate or against the direction of substrate movement depends on whether you
will need to increase the Print Delay or reduce it.

(Continuous printers)

Check that the encoder is not slipping on the roller.

If the Encoder setting is configured as Internal, the (Film speed) Substrate speed
set must match the actual substrate speed.

SmartDate 5.1 5-33

SECTION 5 - TROUBLESHOOTING

5.12.12 Double printing

Check the sensor/ signal source to make sure that it is not triggering twice per
product. If the input is a relay, and you find that it is bouncing, then increase the
Debounce Time or Debounce distance to filter out the bounce.

5.12.13 Prints occur on every other product (or less)

The likely causes for this are timing issue (refer to Timing Issues, Section 3, for
further details).
The print cycle may be too long:
• The overall print cycle is longer than the product to product time. The
SmartDate 5 must complete its cycle before it can process the next print
signal.
Either reduce the throughput of the host machine or increase the cycle time on the
SmartDate 5. On an Intermittent printer this can be done by increasing the print
speed, or possibly the return speed, depending on the particular application. On a
Continuous printer this can be done by increasing the return speed only. Also
check the Debounce and Delay Time.
• Registration setting is too long (Continuous only)
• This can increase the Cycle time to be greater than the product to product
time, thus only printing every other product.

5.12.14 Overlapping prints

When using DRS mode to print larger images at high substrate speeds, it is
possible for the gap between prints on the ribbon to overlap. If this occurs the
Ribbon Advance setting should be increased to allow bigger gaps between the
prints on the ribbon.

5.12.15 Cropped Prints

With Combined machines if the printer is changed from an Intermittent to a
Continuous printer it is necessary to re-power the printer. If this is not done and an
image length longer than 75 mm is selected, the image will be cropped to 75 mm.

5-34 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.13 Job Selection Problems

5.13.1 Selecting a Job

A valid Job or test pattern must be present in the printer memory for SmartDate 5
to able to print something. This can be done by selecting a test pattern in
Engineer mode or selecting a Job by using select Job in Producing or Ready
mode.
If selecting a Job, all the information must be present in the database or host PC.
Any relevant Image files, Settings files, Font or Logo files must be present.

5.13.2 Host PC
If a host PC is being used, it is important that the communication parameters are
set correctly, both at the PC and the SmartDate 5.

5.13.3 Image corruption problems

Images can occasionally become corrupted. This would be noticed in the form of
missing text fields on the image or not being able to select a Job.
To ensure that the images are as they should be, it is best to clear the problem
image out of the SmartDate 5 and re- download the design. To ensure that no
remnants of the corrupt image are left in the printer memory, select a Test Print
before re-selecting the image.
If there are no obvious image corruption problems, check the printhead data
flexible ribbon cable for damage.

SmartDate 5.1 5-35

SECTION 5 - TROUBLESHOOTING

5.14 Checking Database Information

5.14.1 Local
You can check whether the Job is present in the local memory by scrolling through
the database using SELECT JOB. If the Job is not visible then it is not present.

5.14.2 Host
You can check whether the Job is present on the PC by looking in the Job
Manager in the CoLOS Create Pro Software or Selecting a Job in CoLOS Control.

5.14.3 Database mode

You must have the correct mode selected on the SmartDate 5 for Job selection to
be possible.
If it is a stand-alone SmartDate 5, you should be in Local mode. If you are part of
a network of SmartDates connected to a PC, then you could be using Local mode
or you could be in Host mode, depending on the particular application.
To determine whether you are in Local mode or Host mode, select a product using
the SELECT JOB command. The selection screen will indicate which mode you
are in.
If a list of Jobs is displayed, then the SmartDate 5 Local Database is being used.
If the Job name has to be entered manually then the SmartDate 5 is set to use a
Host PC.

5-36 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.15 Communication Problems

5.15.1 Communications Do Not Work

If DCP communication fails between SmartDate 5 and CoLOS Control, check the
following:

Ethernet Communications

• Is the correct IP address configured?

• Is the correct IP Subnet mask configured?
• Is the DCP Actor name (Device Network ID) on the SmartDate 5 the same as
Device Network ID on CoLOS Control?
• Are the Ethernet cable or connectors faulty?

RS-485 Communications

• Is the SmartDate 5 serial Port 1configured correctly? (DCP RS-485)

• Is Serial Port 1 Baud Rate configured correctly? This must be the same as the
setting on CoLOS Control.
• Is Serial Port 1 CimComms Node configured correctly? This must be the same
as the Device setting on CoLOS Control.
• Is the DCP Actor name (Device Network ID) on the SmartDate 5 the same as
Device Network ID on CoLOS Control?
• Is the correct communications cable connected between the SmartDate 5
Serial port and the CimLan Communications card?

SmartDate 5.1 5-37

SECTION 5 - TROUBLESHOOTING

5.15.2 Selecting RS-232/RS-485 operation

SmartDate 5 is capable of RS-232 and networked RS-485 operation. The mode of
operation is selected in software using the Comms - Serial Port 1 options.
RS-232 is used only for NGPCL communication. This for external devices to
communicate with the SmartDate 5.
RS-485 is used for DCP communication. This can be use to communicate with
CoLOS Control but will be much slower than Ethernet communication.

5.15.3 RS-485 Node Numbers and Network ID

In CoLOS Control networked applications, each SmartDate 5 must have its own
unique actor name and node number.
This should be set to individual numbers for RS-485 operation.
When using DCP over a RS-485 network the Machine Network ID (Actor name)
must also be the same on the SmartDate 5 as it is for the Device in CoLOS
Control.
Node number Range: 1 to 31
Device Network ID: variable up to 16 characters
The effects of having more than one machine with the same node number or
Device Network ID are unpredictable.

5.15.4 RS-232 (NGPCL) Communication

This is used for communication between an external device and SmartDate 5. An
example of this might be for an external device to provide image field data for the
Job being printed. This information can be in ASCII form or Unicode, dependant
on customer requirements.
As with RS-485 communication the Baud Rate must be the same as the external
device.

5-38 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.15.5 Networking Issues

The most common problems with down loading data are incompatibility between
the PC baud rate settings or wrong RS232/RS485 settings.

5.15.6 Communication ports

Check that the cable is installed on the correct communication port on your PC.

RS232

If you are connected to the RS232 port on your External device, confirm that the
Communications configuration is correct.
Baud Rate: 9600, 19200, 32400, 57600 or 115000
Data bits: 8
Parity: None
Stop Bits: 1

RS485

You should make sure that the RS485 port selected in CoLOS Control, is the
actual Comm port connected on your PC. Typically Com1 on the network card is
Com3 on the PC. Com2 on the network card is Com4 on the PC.

5.15.7 Communications connection

For details of the pin connections please refer to Section 3 - Installation and
Section 12 Electrical Schematics.

5.15.8 Broken wires or shorts

• Check the resistance of the wires to make sure that they are connected
correctly.
• Check all connections for short circuits. This is one of the most common
reasons for the communications to be failing, especially on a network.

SmartDate 5.1 5-39

SECTION 5 - TROUBLESHOOTING

5.16 Disaster Recovery

Data Backup For SmartDate 5

With all electronic memory systems, it is still possible to lose the contents if
something extra-ordinary happens. It is therefore recommended that you have
some means of backing up the data located in that memory. Your SmartDate 5
printer is no exception. There are two areas of memory that should be backed up:
• Printer Settings
• Job information.
There are two methods of backing up the contents of the SmartDate 5 memory,
depending on whether you have purchased certain options. If you can say Yes to
one of the questions below, go to the SmartDate 5 ‘General Operation’ section of
the manual and follow the instructions given.

Questions

Do you have CoLOS Create Pro Design Software?

Do you have CoLOS Control networking software?
Do you have a copy of the Markem.Imaje PC Tools application?.
Do you have a Compact Flash card fitted to your SmartDate 5?
If you cannot say Yes to any one of the questions, please telephone your local
Markem.Imaje Business Centre for advice.

5-40 SmartDate 5.1

 SECTION 5 - TROUBLESHOOTING

5.16.1 Recovery Using CoLOS Create Pro

Job Files

The Markem.Imaje CoLOS Create Pro image design software can be used
transfer your Job files to the selected SmartDate 5. Back up copies of your images
can be kept in CoLOS Create Pro. See your CoLOS Create Pro Help files for
details on how to download Jobs.

Settings Files

CoLOS Create Pro does not support the uploading / downloading of printer
settings files. Settings files are created using Markem.Imaje CoLOS Control
software. The Markem.Imaje service engineer should, if requested, leave you with
a copy of the settings file for the particular application. This file can also be printed
out as a reference. You may use this to check the settings on the SmartDate 5
controller.

SmartDate 5.1 5-41

SECTION 5 - TROUBLESHOOTING

5.16.2 Recovery Using CoLOS Control

Job Files

If your SmartDate 5 is linked to CoLOS Control via an Ethernet (multi-link) you can
re-download all your Jobs by selecting the previously designed images and
sending them to the required SmartDate 5. See your CoLOS Control help files for
details on how to select and download Jobs.

Settings Files

If your SmartDate 5 is linked to CoLOS Control via an Ethernet or RS-485 (multi-

link) you can upload all the printer settings from the SmartDate 5 and save it as a
file on your PC. This file can also be printed out as a reference. To keep a record
of your printer settings follow the steps below, using CoLOS Control:
• Enter CoLOS Control, and go into Supervisor Mode
• Select CoLOS Control, My Devices and select the required Device.
• Select Device Settings, the last recorded settings file details is displayed.
• Select Upload Settings to refresh the details.
• Select Save Settings, name the file and save the *.settings file to an
appropriate place on your PC.
• This file can then be attached to a Job file or used to re-install your specific
printer setting to your SmartDate 5.
• To download the settings file to the SmartDate 5 or a different SmartDate 5
select the Download Settings option for the appropriate Device.

5.16.3 Recovery using the PC Tools Application

The PC Tools application is provided on the CD which comes with your SmartDate
5. This can be used to upload / download Job detail information and Printer
settings information to your machine.

5.16.4 Recovery using Compact Flash

This option is limited in that it does not allow you to upload information to a PC.
The card is used as a replacement for the local database. Machine printer
settings, database information and other machine specific details are stored on
the card.
If your SmartDate 5 stops functioning for any reason, the card can be removed
and inserted into a replacement machine.
All of the information stored on the card will be transferred to the replacement
SmartDate 5.

5-42 SmartDate 5.1

 SECTION 6
RECOMMENDED SPARES

SmartDate 5.1

Maintenance Manual
 SECTION 6 - RECOMMENDED SPARES

6 Recommended Spares
Note: Fasteners may be sold in economic pre-packed quantities.

6.1 SmartDate 5 53mm Spare Parts

Table 6– 1: Consumables

Part Number Description Quantity

35688BA Anvil rubber 98mm x 98mm 1

B03285AA Head cleaning kit 1

B03286AA Cleaning kit top up 1

5824648 Cleaning wipes (Pack 100) 1

5825525 Printhead - 53mm wide (Shuttled) 1

10042449 Printhead - 53mm wide (Non Shuttled) 1

SmartDate 5.1 6-1

SECTION 6 - RECOMMENDED SPARES

6.2 SmartDate 5 53 mm Spares Kits

Table 6– 2: 53 mm Basic Spares Kit Assembly (10034964)

Part Number Description Quantity

5825546 Peel Roller Assembly 1

5825294 Idler Pulley Assembly 1

10035404 S100 Tension Sensor 1

B04297AA Fuse - T5AH250V 2

Table 6– 3: 53 mm Non Shuttled Kit Assembly (10034965)

Part Number Description Quantity

5630381 Drive Belt 1

5210986 Guide Rail (linear slide) 1

10041551 Print Action Solenoid Assembly 1

5825050 Carriage Home Micro-switch 1

10042026 Interface Board Assembly (Non Shuttled) 1

10041170 Printhead Module Assembly 1

Table 6– 4: 53 mm Shuttled Configuration Kit Assembly (10034966)

Part Number Description Quantity

5630381 Drive Belt 1

5210982 Guide Rail (linear slide) 1

10041551 Print Action Solenoid Assembly 1

10029690 Shuttle Plate Assembly 1

5825050 Carriage Home Micro-switch 1

10025606 Interface PCB Assembly (Shuttled) 1

10041170 Printhead Module Assembly 1

6-2 SmartDate 5.1

 SECTION 6 - RECOMMENDED SPARES

Table 6– 5: 53mm Cassette Base Kit Assembly (10031734)

Part Number Description Quantity

10029510 Locating Roller Assembly 2

10029511 Tension Sensor Roller Assembly 1

10029512 Movement Roller Assembly 1

10020781 Supply Foil Reel Assembly 1

10028671 Take-up Foil Reel Assembly 1

5943525 Cassette Locating Pin 1

Hardware Spring 1

10017897 Foil Spring Kit 1

5825286 Movement Roller Magnet Kit 1

5210989 Linear Guide Rail & Carriage 1

Hardware Brake Grommet 4

Table 6– 6: Printer Hardware Kit

Part Number Description Quantity

10051572 Printer Hardware Kit 1

SmartDate 5.1 6-3

SECTION 6 - RECOMMENDED SPARES

6.3 SmartDate 5 / 128 Spare Parts

Table 6– 7: Consumables

Part Number Description Quantity

10051396 Anvil rubber 150mm x 170mm 1

10051401 Anvil rubber 150mm x 210mm

B03285AA Head cleaning kit 1

B03286AA Cleaning kit top up 1

5824648 Cleaning wipes (Pack 100) 1

10029219 Printhead Assembly 128mm 1

6-4 SmartDate 5.1

 SECTION 6 - RECOMMENDED SPARES

6.3.1 SmartDate 5 / 128 Spares Kits

Table 6– 8: 128mm Basic Spares Kit Assembly (10046653)

Part Number Description Quantity

10029211 Peel Roller Assembly 1

5825294 Idler Pulley Assembly 1

10035404 S100 Tension Sensor 1

B04297AA Fuse - T5AH250V 2

Table 6– 9: 128mm Spares Kit Assembly (10046654)

Part Number Description Quantity

5630381 Drive Belt 1

5210986 Guide Rail (linear slide) 1

10027145 Print Action Solenoid Assembly 1

5825065 Printhead Power Cable Assembly 1

5825050 Micro-Switch Assembly 1

10051026 Interface Board Assembly 1

10047991 Cassette Latch Safety Switch Assembly 1

10029216 Printhead Module Assembly 1

SmartDate 5.1 6-5

SECTION 6 - RECOMMENDED SPARES

Table 6– 10: 128mm Cassette Base Kit Assembly (10051829)

Part Number Description Quantity

10029281 Locating Roller Assembly 2

10028300 Tension Sensor Roller Assembly 1

10028303 Movement Roller Assembly 1

10028291 Supply Foil Reel Assembly 1

10031259 Take-up Foil Reel Assembly 1

10029270 Cassette Locating Pin 1

Hardware Spring 1

10017897 Foil Spring Kit 1

10035090 Movement Roller Magnet Kit 1

Hardware Brake Grommet 4

Table 6– 11: Printer Hardware Kit

Part Number Description Quantity

10042811 Printer Hardware Kit 1

6-6 SmartDate 5.1

 SECTION 6 - RECOMMENDED SPARES

Table 6– 12: Spare Controller

Part Number Description Quantity

10050071 Controller 1

Table 6– 13: SmartDate 5 53mm Non Shuttled Spare Printer only

Part Number Description

10030244 SmartDate 5 53mm printer (Right Hand)

10030242 SmartDate 5 53 mm printer (Left Hand)

Table 6– 14: SmartDate 5 53mm Non Shuttled Spare Cassette

Part Number Description

10030245 SmartDate 5 53mm cassette (Right Hand)

10030243 SmartDate 5 53mm cassette (Left Hand)

Table 6– 15: SmartDate 5 53mm Non Shuttled Spare Printer + Cassette

Part Number Description

10038064 SmartDate 5 53mm printer + cassette (Right Hand)

10038063 SmartDate 5 53mm printer + cassette (Left Hand)

SmartDate 5.1 6-7

SECTION 6 - RECOMMENDED SPARES

Table 6– 16: SmartDate 5s 53 mm Shuttled Spare Printer only

Part Number Description

10030248 SmartDate 5s 53 mm printer (Right Hand)

10030246 SmartDate 5s 53 mm printer (Left Hand)

Table 6– 17: SmartDate 5s 53 mm Shuttled Spare Cassette

Part Number Description

10030249 SmartDate 5s 53 mm cassette (Right Hand)

10030247 SmartDate 5s 53 mm cassette (Left Hand)

Table 6– 18: SmartDate 5s 53 mm Shuttled Spare Printer + Cassette

Part Number Description

10038066 SmartDate 5s 53 mm printer + cassette (Right Hand)

10030865 SmartDate 5s 53 mm printer + cassette (Left Hand)

6-8 SmartDate 5.1

 SECTION 6 - RECOMMENDED SPARES

Table 6– 19: SmartDate 5 / 128 Spare Printer only

Part Number Description

10029229 SmartDate 5 / 128 printer (Right Hand)

10029230 SmartDate 5 / 128 printer (Left Hand)

Table 6– 20: SmartDate 5 / 128 Spare Cassette

Part Number Description

10028307 SmartDate 5 / 128 cassette (Right Hand)

10029235 SmartDate 5 / 128 cassette (Left Hand)

Table 6– 21: SmartDate 5 / 128 Spare Printer + Cassette

Part Number Description

10043851 SmartDate 5 / 128 printer + cassette (Right Hand)

10043852 SmartDate 5 / 128 printer + cassette (Left Hand)

SmartDate 5 08/09 6-9

SECTION 6 - RECOMMENDED SPARES

Table 6– 22: Recommended Cable Spares (Plastic Moulded) (MET

Approved)

Part
Description Qty
Number

Low Profile
5686420 Printer power and signals cable 1.0 m. 1
37 way D type connector - UL approved

Low Profile
5686412 Printer power and signals cable 3.0 m. 1
37 way D type connector - UL approved

Low Profile
5686423 Printer power and signals cable 10.0 m.
37 way D type connector - UL approved

Standard Profile
5686441 Printer power and signals cable 1.0 m. 1
37 way D type connector - UL approved

Standard Profile
5686443 Printer power and signals cable 3.0 m. 1
37 way D type connector - UL approved

Standard Profile
5686445 Printer power and signals cable 10.0 m. 1
37 way D type connector - UL approved

6-10 SmartDate 5 08/09

 SECTION 6 - RECOMMENDED SPARES

Table 6– 23: Recommended Communication Cable Spares

Part
Description Qty
Number

Local area network cable (LAN)

5686405 1
Ethernet - RJ45 connector

PC cross over cable

5686406 1
Ethernet - RJ45 connector

Communication 232 Cable assembly

5824644 1
9 way D type connector - UL approved

Table 6– 24: Recommended Power Cable Spares

Part
Description Qty
Number

5686230 IEC320 Mains Lead, European Colour, 5.0 m, Euro 1

IEC320 Mains Lead, N. America Colour, 5.0m UL

5686229 1
approved

SmartDate 5 08/09 6-11

SECTION 6 - RECOMMENDED SPARES

6-12 SmartDate 5 08/09