operation guide

To the best of our knowledge, the information contained in this guide was correct at the time
of printing. However, continual enhancement of our products can result in some differences
between the instructions represented in this guide and your coder.

MARKEM, Touch Dry, and CimControl are registered trademarks of MARKEM Corporation.

CoLOS and Composer are trademarks of MARKEM Corporation.

This guide was written by:

Markem-Imaje
150 Congress Street
Keene, New Hampshire 03431 U.S.A.

Copyright © 2008. All Rights Reserved.

REFERENCE LIST

The information on your packing slips can be written below for reference. When contacting
Markem-Imaje, please give your Model Number, Serial Number, and Customer Account Number.

Model:__________________________________________________________________

Serial Number: ___________________________________________________________

Customer Account Number: _________________________________________________

Date Installed: ____________________________________________________________

Other Information: _________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

0855849enf 6/08 iii

iv 0855849enf 6/08
 TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Information
1.0 Welcome to the Model 5200/5400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 What’s in this Guide?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0 Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.0 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Certification ...............................................9
4.2 Automatic Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Location of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 Foreseen Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.6 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.7 Training Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.0 Label and Symbol Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.0 Removal from Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Basic Operation
1.0 Basic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.0 The Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Powering On the Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Powering Off the Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.0 The User Interface Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.1 Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.2 Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.3 ENTER and EXIT Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.4 START and STOP Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.5 Directional Arrow Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.6 Select Characters Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.7 Using the Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.0 The Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Jet Test and Purge Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Printhead Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

0855849enf 6/08 v
 TABLE OF CONTENTS
SECTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Printing
1.0 Powering on the Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.0 The Top Level Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 Selecting a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Previewing a Job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.0 Production Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.0 Adding Ink .............................................. 41
4.1 Adding an Ink Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2 Adding an Ink Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.0 Making Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Setting the LCD Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Setting the Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.0 Database Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning and Care
1.0 Daily Cleaning of the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 Purging .............................................. 52
1.2 Jet Testing .............................................. 53
1.3 Wiping .............................................. 54
2.0 Cleanup .............................................. 54

SECTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Troubleshooting
1.0 Troubleshooting Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.0 Signal Lights .............................................. 57
2.1 LED Indicators on the Print Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2 Signal Tower Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3 LED Indicator on the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.0 Unreadable Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.0 Beep Due to Open Ink Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.0 The Purge Button Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

vi 0855849enf 6/08
 SECTION 1

General Information

Model 5200/5400
Operation Guide
 SECTION 1 GENERAL INFORMATION
1.0 Welcome to the Model 5200/5400

The Model 5200 and 5400 are part of the 5000 Series of case coders,
which use MARKEM Touch Dry® ink technology, and provide
flexibility and quality in coding cases directly on your packaging line.

Depending on the ink delivery module of your coder, ink blocks or ink
bottles are used.

The Model 5200 can be configured with up to two printheads and the
Model 5400 can be configured with up to four printheads.

Images are designed and prepared for printing from a computer using
MARKEM Composer™ or CoLOS™ Create image design software,
which allow for input of variable data and multiple languages.
Composer or CoLOS Create job files are downloaded to the coder for
printing images on your product or package. The coder can be
connected to a dedicated computer or networked with a host
computer for connection to multiple Markem-Imaje coders.

Operation is controlled through a user interface module, which is

mounted to the top of the enclosure. Some operations may also be
controlled through networking.

1.1 What’s in this Guide?

• Introductory information
• Glossary of terms
• Safety information
• Using the user interface module (keypad and display)
• Selecting jobs
• Operating the coder
• Cleaning and caring for the coder
• Troubleshooting basic problems

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SECTION 1 GENERAL INFORMATION
1.2 Related Documentation

This guide is part of a documentation set. Below is a list of

documents in the Model 5200/5400 documentation set and their
respective part numbers.

• Model 5200/5400 Documentation Set . . . . . . . . . . . . . . 0855847

• Model 5200/5400 Installation and Setup Guide . . . . . . . 0855848
• Model 5200/5400 Operation Guide . . . . . . . . . . . . . . . . 0855849
• Model 5200/5400 Menu Tree Diagram. . . . . . . . . . . . . 10020356
• Model 5200/5400 Service Guide . . . . . . . . . . . . . . . . . . 0855855
• Model 5200/5400 Operator Quick Reference Card . . . . 0855856
• Model 5200/5400 Fault Messages . . . . . . . . . . . . . . . . 10019996
• Model 5200/5400 Preventive Maintenance Instructions . 0840813
• Model 5200/5400 Printhead Soak Kit Instructions . . . . . 0840546
• Model 5200/5400 Customer Setup Parameters. . . . . . . 0855903

4 0855849enf 6/08
 SECTION 1 GENERAL INFORMATION
2.0 Before You Begin

This guide makes a few assumptions. Before you can begin printing,
make sure:

• The coder is completely and correctly installed and integrated with

your packaging line. If you do not know whether installation is
complete, ask your company's setup technician.
• Machine setup parameters and software settings have been
configured. If you do not know whether the coder is completely
configured, ask your company's setup technician.
• Two job files have been designed, saved, and downloaded into the
flash memory of the coder. If you do not know the name of the job
you want to print, you may use one of the two downloaded job files
or ask your company's setup technician for assistance.

Images to be printed are designed on a computer using Composer or

CoLOS Create image design software. The set of job parameters,
including the image data, is called a “job file.” The images for all
printheads in the job file are called the “label.”

The job file must be downloaded from the computer to the coder.
Then the job file must be selected before printing on your product or
package.

• The Composer or CoLOS Create software manuals describe how

to design, name, and save job files.
• The “Database Management” section of the Model 5200/5400
Installation and Setup Guide describes how to download, view,
back up, and delete job files.
• The Model 5200/5400 Operation Guide describes how to select
and print job files. If you need help with job files, ask your
company’s setup technician.

Note that the Model 5200 and 5400 coders are almost identical
electrically, mechanically, and in terms of software. The major
difference between the two models is the maximum number of
printheads that can be configured, and design changes necessary to
accommodate the printheads.

Procedures and pictures throughout this guide depict the Model 5200.
Adapt the instructions as needed for the Model 5400.

0855849enf 6/08 5
SECTION 1 GENERAL INFORMATION
3.0 Glossary
allocation The maximum number of labels that the selected job will be allowed to
print before the user is prompted to reset the allocation count or a new job
is selected.

array See jet array.

backplane board Printed circuit board for I/O connections.

bar code reader A laser-equipped device that reads identification codes by scanning a strip
of parallel bars of varying widths, groups of which represent alphanumeric
characters.

BBE Best Before End; denotes the recommended date by which a product
should be used.

carton A container, usually made of cardboard, onto which the coder prints. Also
called case. See product.

case A container, usually made of cardboard, onto which the coder prints. Also
called carton. See product.

caution A potentially hazardous situation which, if not avoided, could result in

personal injury.

chamber A receptacle in the ink delivery module that stores ink.

CimControl® MARKEM proprietary software for networking multiple coders.

coder A machine such as the Model 5200 or 5400 that is primarily used to print
codes on the customer’s product.

Composer™ MARKEM proprietary software for designing images for the coder.

CoLOS™ Control MARKEM proprietary network software, for data transfer, remote operation
and machine monitor / data logging operations; released in 2006.
CoLOS™ Create MARKEM proprietary software for designing images for the coder;
released in 2006.

download To retrieve a copy of a file from a computer and transfer it to the coder.

dynamic field Information in a job file that changes, such as a serial number or date.

enclosure The cabinet that houses the electrical components, VPC module, and ink
delivery module.

error A fault that generates a message on the display, and stops printing.

fault A problem with the coder that will generate an error or warning message
on the display, and will turn on an indicator LED on the user interface
module.
6 0855849enf 6/08
 SECTION 1 GENERAL INFORMATION
field A specific manipulatable area within the job file.

flash The process of writing the control software to nonvolatile memory.

holding chamber The lower portion of the ink delivery module where ink is heated and stored.

host computer The computer that contains the data that is downloaded to the coder. This
computer may contain software such as CimControl and CoLOS Create.

ILS Ink Level Sensor. An electrical device used to monitor ink levels. Formerly
called LOIS (Low On Ink Sensor).

image The displayed or printed representation of the information, composed of one

or more fields, from one printhead. The images for all printheads connected
to the coder are called the label.

ink bottle Container of solid ink that the operator inserts through the ink door.

ink delivery module The assembly that stores, heats, and pumps the ink.

jet array The area on the front of the printhead that ejects droplets of ink onto the
customer’s product.

jet test The process of printing a pattern used to confirm the proper operation of all
jets.

job See job file.

job file A set of parameters that determines what, how, where, and when images
will print. Before printing, the image data must be downloaded to the coder
from the host computer.

label The displayed or printed images from all printheads connected to the coder.

local The storage of job files on the coder, after having been downloaded from the
host computer.

LOIS Low On Ink Sensor. See ILS.

melting chamber The upper portion of the ink delivery module that melts the ink from the ink
bottle.

OCU Optional Control Unit.

offline The state of the coder when not printing.

online The state of the coder when printing.

optional control unit An optional control device that can be connected to the coder, which allows
up to two bar code readers and one product ID reader to be connected.

PH Printhead. Specific printheads are abbreviated as PH1, PH2, PH3, and PH4.

0855849enf 6/08 7
SECTION 1 GENERAL INFORMATION
package See product.

print station The complete assembly consisting of the enclosure, electrical

components, user interface module, and ink delivery module.

product The material or item onto which the coder prints. Also called carton, case,
package, or packaging.

product ID reader A bar code reader that scans product information to determine which job
file to print.

purge The forcing of trapped air and hot ink through the jet array for a few
seconds.

reader See bar code reader.

registration The location of the printed image on the package, based on whether the
print trigger is determined by a sensor or fixed spacing setting.

reservoir A receptacle inside the printhead that stores ink.

SC The Model 5200 SC and 5400 SC have an ink delivery module that uses
ink blocks instead of ink bottles.

SICK A manufacturer of bar code readers which interface with the coder.

signal tower An optional device consisting of a set of lamps to indicate coder status.
Formerly called fault beacon.

SSCC Serialized Shipping Container Code.

umbilical The assembly including the ink line, electrical line, and vacuum line that
connects the printhead to the enclosure.

user interface module The keypad and display mounted to the top of the enclosure for the user to
enter and receive information about the coder.

VPC Vacuum Pressure Controller.

warning A fault that generates a message on the display, but does not stop printing.

8 0855849enf 6/08
 SECTION 1 GENERAL INFORMATION
4.0 Safety Information

The Model 5200/5400 has been designed to meet various safety

standards. To alert you to potentially hazardous situations, labels and
messages appear on the coder and throughout the guides.

CAUTION refers to a potentially hazardous situation which, if not

avoided, could result in personal injury.

4.1 Certification

The Model 5200/5400 has been designed to meet the following

standards and specifications.

CE Marked

• 98/37/EC Machinery Directive

• 73/23/EEC Low Voltage Directive
Laws for electrical equipment within certain
voltage limits.
• 89/336/EEC EMC Directive
Laws relating to electrical magnetic
compatibility
• EN 60204-1 Electrical Safety
• EN 61000-6-4 Generic Emission
• EN 61000-6-2 Generic Immunity

ETL Listed

• Conforms to ANSI/UL Standard 60950, 3rd Edition (2000)

• Certified to Canada/CSA C22.2 Standard 60950, 3rd Edition
(2000)

0855849enf 6/08 9
SECTION 1 GENERAL INFORMATION
4.2 Automatic Startup

CAUTION

Do not allow an automatic packaging machine startup after a

Model 5200/5400 reset.

Install the Model 5200/5400 Status Output Signal Option for a

manual packaging machine reset. Automatic startup of a
packaging machine could kill or seriously maim an operator.

TECHNICAL ISSUE: The Model 5200/5400 has an optional feature

which enables it to stop or prevent packaging machine operation
when coder conditions prevent marking the packages. These
conditions include, but are not limited to, FAULTS, WARMUP
PERIODS, and PRINT DISABLED STATUS. Some of these coder
conditions are cleared manually by the operator, and some are
cleared automatically. In either case, if the Model 5200/5400 has
NOT been properly connected, the packaging machine can begin
cycling when the condition is cleared. Failure to observe this may
result in personal injury.

ACTION: There are various ways for an installer to use the Model
5200/5400 Status Output Signal Option to control a packaging
machine. Only someone familiar with the packaging machine can
determine the best way to signal it with an external device like the
Model 5200/5400. If in doubt, consult the manufacturer of the
packaging machine.

THE MODEL 5200/5400 INSTALLER IS RESPONSIBLE FOR

CONFIGURING THE SOFTWARE AND INSTALLING THE
STATUS OUTPUT SIGNAL OPTION IN A WAY THAT REQUIRES
THE OPERATOR TO MANUALLY RESTART THE PACKAGING
MACHINE AFTER A MODEL 5200/5400 CONDITION HAS BEEN
CLEARED. Any deviation from this method is unsafe and is not
approved by Markem-Imaje or applicable regulatory agencies.

Ratings Each set of dry contacts in the two status relays is

rated for a maximum of 30 VDC at 1 Amp.

10 0855849enf 6/08
 SECTION 1 GENERAL INFORMATION
4.3 Safety Labels

High Voltage

To prevent injury from electrical shock, remove the power cord from
the electrical outlet before performing troubleshooting or repair.
Electronic troubleshooting must be performed by personnel trained to
troubleshoot electrical circuits.

Hot Surfaces

To prevent injury from burns, be careful not to touch the jet array
surface or hot ink directly. Wear protective eyeglasses when working
with hot ink.

Protective Earth

This label identifies a protective earth point.

Earth

This label identifies an earth point.

4.4 Location of Safety Labels

FRONT REAR

0855849enf 6/08 11
SECTION 1 GENERAL INFORMATION

FRONT

REAR

12 0855849enf 6/08
 SECTION 1 GENERAL INFORMATION
4.5 Foreseen Use

The Model 5200/5400 is an industrial case coder, designed for

printing on substrates used in case and carton packaging, including
coated and uncoated corrugated cardboard, glossy surfaces, rigid
plastics, flexible films, and shrinkwrap.

This coder was designed for or adapted by Markem-Imaje to a

specific application at the time of sale. This application is the
intended use.

4.6 Misuse

Using this coder for anything other than the specific application can be
a misuse. Contact Markem-Imaje before attempting to use this coder
for anything other than the intended use.

Misuses include but are not limited to:

• Failing to observe instructions or directives pertaining to the

installation, use, and repair of this coder, including the use and
disposal of related chemicals.
• Operating an unserviceable, incomplete, or modified coder.
• Not observing safety messages and labels.
• Permitting an unqualified person to operate or repair this coder.
See “Training Programs.”
• Combining or interfacing other equipment with this coder for
anything other than the intended use.
• Using supplies or materials that are not recommended for use with
this coder, which may produce unsatisfactory or unexpected
results.

4.7 Training Programs

Operators, maintenance personnel, and service technicians are

considered qualified when they have gained, through training and
experience, an understanding of safe and correct methods of
operation, maintenance, or repair.

Markem-Imaje conducts training programs. In addition to ongoing

courses about current machine models, customers are invited to
inquire about any training need.

0855849enf 6/08 13
SECTION 1 GENERAL INFORMATION
5.0 Label and Symbol Identification
Serial/I.D./Rating Label

This label is located on the rear of the enclosure and indicates the
following:

Model number
Information about the coder
Information about Markem-Imaje
Patents covered
Serial number
CE mark
Electrical specifications
Attention symbol
Electrical diagram number
AC voltage configuration ~
Circuit breaker overcurrent protection

Voltage Configuration Labels

Spare voltage configuration labels are provided. If the AC voltage

configuration of your coder changes, affix the appropriate voltage
configuration label to the Serial/I.D./Rating label on the rear panel of
the enclosure, so it covers the old voltage configuration rating.

Earth Label for Printheads

This label is located above the I/O panel and indicates the earth
points for the four printheads.

Consult Installation Instructions

This label advises the installer in both English and French to consult
the installation instructions before connecting to the power source.

Attention: Consult Accompanying Documents

This symbol indicates that information is available in accompanying

documents and appears in locations such as the Serial/I.D./Rating
label, near the FAULT LED on the user interface module, and near
the 3.6V lithium battery on the control board.

14 0855849enf 6/08
 SECTION 1 GENERAL INFORMATION
CE Mark

This symbol indicates that the coder meets safety and environmental
requirements as defined in the European Directives.

ETL Listed

This label indicates that the coder conforms to ANSI/UL Standard

60950 and is certified to Canada/CSA C22.2 Standard 60950.

Status

This symbol is located near the STATUS LED on the user interface
module, and indicates whether or not the coder is ready to print.

Ink Supply

This symbol is located near the INK LED on the user interface
module, and indicates whether or not the ink supply is sufficient.

Start

This symbol is located on the START key on the keypad, and is used
to start printing.

Stop

This symbol is located on the STOP key on the keypad, and is used to
stop printing.

Enter

This symbol is located on the ENTER key on the keypad, and is used
to open the selected menu or accept information.

Exit

This symbol is located on the EXIT key on the keypad, and is used to
exit from a menu or cancel information.

Jet Test/Purge

The symbol on the left is located next to the Jet Test button.
The symbol on the right is located next to the Purge button.

0855849enf 6/08 15
SECTION 1 GENERAL INFORMATION
Optional Control Unit (OCU)

This symbol indicates the interface device port that is used for bar
code readers or a product ID reader.

Serial Port

This symbol indicates the serial ports.

I0I0I (1) - Host (RS232, RS422, and RS485)
I0I0I (2) - ASCII Comms (RS232)
I0I0I (3) - Not Used (RS232)

Printhead

This symbol indicates a printhead connection. The printheads are

abbreviated as PH1, PH2, PH3, and PH4.

Keyboard

This symbol indicates the keyboard port.

Encoder

This symbol indicates the external encoder port.

Product Sensor

This symbol indicates the product (or carton) sensor port.

Signal Tower

This symbol indicates the signal tower port.

Use Only MARKEM Touch Dry® Ink

This label is located both on the top of the printhead and near the ink
chamber on the top of the enclosure, visible when the ink door is
open. Failure to use Markem-Imaje ink can cause system
performance issues and can void the machine warranty.

16 0855849enf 6/08
 SECTION 1 GENERAL INFORMATION
1.0 Removal from Service

Follow these instructions to remove the coder from service. These

instructions also pertain to transporting or storing the coder.

1. Use the Shutdown menu to cool down and power off the coder.
2. Disconnect the AC power cord from the electrical source.
3. Disconnect cables and connections, accessed from the I/O door.
4. Disconnect the umbilical lines from the printhead and the
enclosure.
5. Remove the signal tower, carton sensor, and encoder, if
applicable.
6. Remove each printhead from its mounting assembly.
7. Move the enclosure to the desired location, and package the
enclosure, printhead(s), and cables in the original shipping
container.

0855849enf 6/08 17
SECTION 2

Basic Operation

Model 5200/5400
Operation Guide
 SECTION 2 BASIC OPERATION
1.0 Basic Components

The coder consists of the print station (1), umbilical (2), printhead
(3), and any options installed.

The print station consists of the user interface module (4) and
enclosure (5). The enclosure is the cabinet that houses the electrical
components, vacuum pressure controller, and ink delivery module.

Mounted to the top of the enclosure is the user interface module,

consisting of a keypad and display, which are used to operate,
program, and monitor the coder.

3
1

2
5

0855849enf 6/08 21
SECTION 2 BASIC OPERATION
An umbilical (1), which consists of an ink line, vacuum line, and
electrical line, connects each printhead to the print station.

The operator inserts an ink bottle through the ink door (2). The ink
is melted and transported to the printhead through the ink line. The
printhead ejects droplets of ink onto your product or package.

22 0855849enf 6/08
 SECTION 2 BASIC OPERATION
2.0 The Power Switch

The power switch (1) is located on the rear of the print station, and is
used to turn the coder on and off.

The I position is ON. The 0 position is OFF.

2.1 Powering On the Coder

Turning the power switch to the I position powers on the coder and
initializes the coder.

• The green STATUS LED will blink.

• The Version menu will appear briefly.
• The Top Level menu will appear.
• The status message will say Warming up or Shut Down.
If the status message indicates the coder is shut down, the start up
process can be initiated by pressing F3 (Start Up).
A prompt will ask you to confirm that you want to start up.
Select YES.
• The amber LED on the printhead will begin to blink.

After about 60 minutes, the blinking green STATUS LED will begin to
blink slowly, indicating that the coder is ready for printing.

0855849enf 6/08 23
SECTION 2 BASIC OPERATION
2.2 Powering Off the Coder

If the printhead is at operating temperature, the coder must be

cooled down before turning the power switch off, or hot ink will weep
from the jet array. The Shutdown feature is used to cool down the
coder.

1. To stop printing, press STOP.

2. From the Top Level menu, press F3 (Shutdown). A message

on the display will ask for confirmation.

3. Press Fl (Yes) to confirm that you want to shut down.

Press F2 (No) to cancel the shutdown.

Job: Chocolate

Shutdown

Are you sure?

Yes No

4. Wait for the coder to cool and the “Shutdown Done” message
to appear, which may take three or four hours.

5. Turn the power switch to the 0 position to remove power from

the coder.

24 0855849enf 6/08
 SECTION 2 BASIC OPERATION
3.0 The User Interface Module

The display (1), keypad (2), and LED Indicators (3) are used to
operate, program, and monitor the coder. Various menus will appear
on the display. The Top Level menu is shown below.

Job: Chocolate
1 25 June 2006 15:17:49

Status
Machine: Ready PH1: On
State: Printing PH2: On
3
Ink: OK

Counts:
Batch : 999
Total : 53796
- Press ENTER to preview image -

Job Reg. Shutdown Main

Select +/- Menu

0855849enf 6/08 25
SECTION 2 BASIC OPERATION
3.1 LED Indicators

LED indicators on the user interface module are used to monitor the
coder. The Top Level menu provides messages to indicate the
nature of the printing status, ink supply, and fault condition.

The green STATUS LED indicates whether conditions are met for
printing.

On Online
Off Power is off
Blinking Warming up/cooling down (fast blinking) or
Ready (slow blinking)

The blue INK LED indicates when the coder needs ink

Off Bottle of ink is present

On Add ink bottle
Blinking Add ink bottle immediately

The amber FAULT LED indicates when the coder needs attention.

Off No error or warning

On Warning
Blinking Error (printing will stop)

26 0855849enf 6/08
 SECTION 2 BASIC OPERATION
3.2 Navigation

Various menus will appear on the display. The user navigates through
the menus using the keypad.

• Function keys (F1, F2, F3, F4)

• ENTER and EXIT keys
• START and STOP keys
• Directional arrow keys

On some menus, text must be entered into a text field. A Select

Character dialog box will appear, allowing you to enter one character
at a time.

3.2.1 Menu Functions

The pointer is the triangle on the display that indicates which field is
selected. To move the pointer, use the directional arrow keys.

A selection is a highlighted field or parameter on the display. The

selection will be affected by pressing a key.

When the list of options is too long to fit on the display, an Up-Arrow or
Down-Arrow will appear on the display. The symbols are intended to
inform the user that additional options are listed above or below.

When Page Up and Page Down buttons appear on the display, the
corresponding function key will display the previous or next portion of
the menu or list.

The Modify button appears on the display when the selected

parameter has a value that can be changed. A box will open that will
allow the user to enter a numerical value.

Press the Modify button when a value that can be modified is active.

Increase (+) and Decrease (–): On menus that have + (plus) and -
(minus) signs, F1 and F2 are used to scroll through options or to
decrease or increase values.

Insertion Point: On menus where text is entered, a blinking line ( I )

indicates where the next character selected will be inserted.

For certain parameters or selections, dialog boxes will appear on the

display, providing information to you or asking you for information.

0855849enf 6/08 27
SECTION 2 BASIC OPERATION
3.2.2 Function Keys

The F1, F2, F3, and F4 keys are function keys. Pressing one of
these keys selects the button described above it on the display.
Depending on the menu, the available functions will vary. Function
keys often open new menus.

Job: Chocolate
25 Jun 2006 15:17:49

Status
Machine: Ready PH1: On
State: Printing PH2: On
Ink: OK

Counts:
Batch : 999
Total : 53796

- Press ENTER to preview image -

Job Reg. Shutdown Main

Select +/- Menu

3.2.3 ENTER and EXIT Keys

The ENTER key (1) is used to open the selected menu. Changes
that were made to the current menu will be saved when the ENTER
key is pressed.

The EXIT key (2) is used to return to the previous menu.

4 3

2 1

28 0855849enf 6/08
 SECTION 2 BASIC OPERATION
3.2.4 START and STOP Keys

The green START key (3) is used to start printing. When printing, the
coder is online.

The red STOP key (4) is used to stop printing. When not printing, the
coder is offline.

3.2.5 Directional Arrow Keys

The directional arrow keys (5) are used to move the arrow on the
display or the insertion point within a field. Arrow keys can also be
used to navigate from one field to the next.

3.2.6 Select Characters Dialog Box

When asked to enter text, a Select Character dialog box will appear.
The keypad is used to select one character at a time. Each character
selected will be inserted at the insertion point (1).

*I

• Use the arrow keys or F3 (Back) and F4 (Forward) to highlight a

character.
• When the desired character is highlighted, press F1 (Select
Character). The selected character will appear at the insertion
point.
• Use F2 (Delete) to delete the character to the left of the insertion
point.
• When the desired characters are displayed, press ENTER.

NOTE: If the optional keyboard is installed, the keyboard may instead

be used to enter text.

0855849enf 6/08 29
SECTION 2 BASIC OPERATION
3.2.7 Using the Keyboard

An optional keyboard may be used to navigate through menus and

enter alphanumeric characters.

NOTE: The keyboard layout varies, depending on the manufacturer

and style. Your keyboard may differ from the one depicted below.

Esc F1 F2 F3 F4 Backspace Page Up Page Down

Enter Arrow Numeric

Keys Keypad

• Characters typed from the keyboard are equivalent to the

respective characters on the keypad on the coder.
• The F1, F2, F3, and F4 keys on the keyboard are equivalent to
the respective F1, F2, F3, and F4 keys on the keypad.
• The Esc key on the keyboard is equivalent to the EXIT key on
the keypad.
• The Enter key on the keyboard is equivalent to the ENTER key
on the keypad.
• The Backspace key on the keyboard deletes the character to
the left of the insertion point, and is equivalent to the Delete
button on the Select Character dialog box on the display.
• The directional arrow keys on the keyboard are equivalent to the
respective directional arrow key on the keypad.
• The numeric keypad on the keyboard is supported.

NOTE: Extended characters are not supported by the coder.

30 0855849enf 6/08
 SECTION 2 BASIC OPERATION
4.0 The Printhead

Located on the front of the printhead is the jet array (1), where hot
droplets of ink are ejected onto your carton or package.

Located on the rear of the printhead are the umbilical ports, where the
vacuum lines (2), electrical line (3), and ink line (4) and are
connected.

7
5
2 6

FRONT REAR 3 4

4.1 Jet Test and Purge Buttons

The Jet Test button (5) is located next to the jet test symbol on the
rear of the printhead. It is used to print a pattern to confirm the proper
operation of all jets.

The Purge button (6) is located next to the purge symbol on the rear
of the printhead. It is used to force trapped air and hot ink through the
jet array for a few seconds.

4.2 Printhead Status

The Top Level menu reports the status of each printhead. The amber
LED (7) on the rear of the printhead is also used to monitor the status
of the printhead.

The LED is on when the printhead is enabled, ready to print, and there
are no fault conditions.

The LED is off when the printhead power is disconnected, the

printhead is disabled, or the printhead is purging.

The LED blinks when the printhead is warming up or cooling down.

0855849enf 6/08 31
SECTION 3

Printing

Model 5200/5400
Operation Guide
 SECTION 3 PRINTING
1.0 Powering on the Coder
1. Turn the power switch (1) to the I position to power on the coder.

2 1

• The green STATUS LED (2) begins blinking.

• The amber LED on the printhead begins blinking.
• The Version Menu appears briefly.
• The Top Level menu appears.

Job: Chocolate

25 Jun 2006 15:17:49

Status
Machine: Ready PH1:On
State: Offline PH2:On
Ink: OK

Counts:
Batch : 999
Total : 53796

- Press ENTER to preview image -

Job Reg. Shutdown Main

Select +/- Menu

2. The status message will say Warming up or Shut Down.

If the status message indicates the coder is shut down, the start
up process can be initiated by pressing F3 (Start Up).
A prompt will ask you to confirm that you want to start up.
Select YES.
3. Wait for the blinking green STATUS LED to begin to blink slowly.
It takes about 60 minutes for the ink delivery module and ink
lines to warm up and for the coder to be ready for printing. It
could take longer in colder environments or if the supplied
voltage is low.

0855849enf 6/08 35
SECTION 3 PRINTING
2.0 The Top Level Menu

The Top Level menu displays the following information.

• The name of the selected job

• The current date and time
• The status of the machine
• The printing state
• The status of the ink supply
• The status of each printhead
• Batch count and total count
• Instructions to preview the image (or to go online)
• The Job Select button (F1)
• The Registration button (F2)
• The Shutdown button (F3)
• The Main Menu button (F4)

Job: Chocolate

25 Jun 2006 15:17:49

Status
Machine: Ready PH1:On
State: Offline PH2:On
Ink: OK

Counts:
Batch : 999
Total : 53796

- Press ENTER to preview image -

Job Reg. Shutdown Main

Select +/- Menu

36 0855849enf 6/08
 SECTION 3 PRINTING
2.1 Selecting a Job
1. From the Top Level menu, press F1 (Job Select). The Select
Job Menu will display.
Select Job

Chocolate
Strawberry
Vanilla
TestLabel

- Press ENTER to select job -

Preview Find Page
Job Down

2. To view an image before selecting a job, press the Down-Arrow

key until the pointer is beside the name of the job that you
want to view. Press F1 (Preview Job).

The representation of the printhead 1 image will be displayed.

To preview the represented images of other printheads, press
the appropriate key.

If the job has fields that can be changed by the user, a menu
listing the dynamic fields will open. Use the arrow keys and
function keys to change field data.

Press ENTER to select the job. Follow the prompts.

To select the job, press F4 (Select This Job).

NOTE: To return to the Select Job Menu, press EXIT.

3. If the name of the desired job is displayed, press the Down-

Arrow key until the pointer is beside the name of the job that
you want to select.
Press ENTER. The job becomes the selected job.

4. If the name of the desired job is not displayed, use the arrow
keys to scroll down the list. The F3 (Page Down) key can also
be used to display the continued listing of file names.
When the pointer is beside the name of the job that you want
to select, press ENTER. The job becomes the selected job.

0855849enf 6/08 37
SECTION 3 PRINTING
5. If you know the name of the desired job, press F2 (Find) to
open the Select Character dialog box.

6. The keypad is used to select one character at a time. Each

character selected will be inserted at the insertion point (1).

Enter Label Name

I
1

Use the arrow keys to highlight a character. When the desired

character is highlighted, press F1 (Select Character). The
selected character will appear at the insertion point.

Use F3 (Back) or F4 (Forward) to move the insertion point left

or right. Use F2 (Delete) to delete the character to the left of the
insertion point.

When the name of the desired label is displayed, press ENTER.

7. If the selected job has fields that can be changed by the user, a
menu listing the dynamic fields will open. Use the arrow keys
and function keys to change field data.

Press ENTER to select the job. Follow the prompts.

8. If the desired job cannot be found, the job file needs to be

downloaded from the computer running Composer or CoLOS
Create software. Refer to the “Database Management” section
of the Model 5200/5400 Installation and Setup Guide or ask
your company's setup technician for assistance.

38 0855849enf 6/08
 SECTION 3 PRINTING
2.2 Previewing a Job
1. From the Top Level menu, press the ENTER key to preview the
selected job.
Job: Test Label

25 Jun 2006 15:17:49

Status
Machine: Ready PH1: On
State: Offline PH2: On
Ink: OK

Counts:
Batch : 999
Total : 53796

- Press ENTER to preview image -

Job Reg. Shutdown Main

Select +/- Menu

NOTE: Pressing the ENTER key will display the printhead image
even if the “Press ENTER to preview image” message does not
appear near the bottom of the Top Level menu.
2. A new menu will display the printhead image.

The directional keys can be used to better view the image:

Press the Up Arrow key to increase magnification.

Press the Down Arrow key to decrease image magnification.

Press the Left Arrow key to slide the image right.

Press the Right Arrow key to slide the image left.

Job: Test Label PH1

- Press ENTER to preview next PH -

Dynamic Preview Preview Preview

Fields PH2 PH3 PH4

0855849enf 6/08 39
SECTION 3 PRINTING
3. If the selected job has dynamic fields, press F1 (Dynamic
Fields) to view a list of dynamic fields

4. A new menu will appear. If the list is too long to be displayed at

one time, the Page Up or Page Down buttons will appear.

Press EXIT to return to the Preview Menu.

NOTE: Dynamic Fields cannot be changed from the Preview

Menu. To change dynamic fields, see “Selecting a Job.”

5. To display the images for printheads 2, 3, or 4, press the

appropriate function key (F2, F3, or F4).

6. Press EXIT to return to the Top Level menu.

3.0 Production Printing

Ensure that the following conditions are met.

• The green STATUS LED is blinking slowly.

• The blue INK LED is OFF. If the LED is blinking or
continuously on, add a bottle of ink. See “Adding Ink” in this
section.
• The amber FAULT LED is OFF.
• The amber LED on the rear of the printhead is ON.
• The desired job has been selected.
• The Top Level menu is displayed.

1. Perform a Jet Test and Purge. See Section 4 of this guide for
instructions.

2. Press START to begin printing. The coder will be online until

STOP is pressed or an error occurs.

40 0855849enf 6/08
 SECTION 3 PRINTING
4.0 Adding Ink

Depending on whether the ink delivery module of your coder uses ink
bottles or ink blocks, follow the appropriate instructions for adding ink.

CAUTION: Hot surfaces.

When the coder is at operating temperature, a bottle of ink or an ink
block can be added only when INK LED is on or blinking. The ink door
will remain locked until the coder is ready to accept another bottle or
block of ink.

WARNING: Use only MARKEM TouchDry® ink.

Markem-Imaje ink is specially formulated and tested for use with the
Model 5200/5400 or Model 5200/5400 SC coder. Failure to use
Markem-Imaje ink can result in machine damage and void the
machine warranty.

NOTE: Close the ink door after adding ink.

When the ink door is left open for an extended period of time, a beep
will sound. When the beep becomes continuous, the coder will pause
until manually reset.

4.1 Adding an Ink Bottle

1. Open the ink door.
2. Remove the empty bottle from the chamber.
3. Remove the cap from the new ink bottle. Insert the ink bottle
upside-down into the chamber.
4. Close the ink door.
The ink door will lock in 60 seconds.

0855849enf 6/08 41
SECTION 3 PRINTING
4.2 Adding an Ink Block
1. Open the ink door.

2. Remove the two ink blocks from their wrappers.

3. Insert one ink block into each slot.

4. Close the ink door.

The ink door will lock in 60 seconds.

42 0855849enf 6/08
 SECTION 3 PRINTING
5.0 Making Adjustments

5.1 Setting the LCD Contrast

NOTE: A quick method of changing the LCD contrast from any menu,
hold down the STOP key and press the Up Arrow or Down Arrow to
change the contrast in 5% increments.

The LCD contrast can be adjusted from the Machine Setup Menu.

1. From the Top Level menu, press F4 (Main Menu).

Job: Chocolate

25 Jun 2006 15:17:49

Status
Machine:Ready PH1: On
State: Offline PH2: On
Ink: OK

Counts:
Batch : 999
Total : 53796

- Press ENTER to preview image -

Job Reg. Shutdown Main

Select + / - Menu

2. From the Main Menu, press F4 (Machine Setup).

If required, enter a password.
The Machine Setup menu will appear.

3. Use the Down-Arrow key until the pointer is beside User

Interface.
Machine Setup

Access Level : Level 3

User Interface...
Printhead 1 Settings...
Printhead 2 Settings...
Printhead Vacuum Settings...
Printhead Mapping...
Print Station Settings...
Shutdown Settings...
Password Settings...
Communications...

Page Page
Down Up

0855849enf 6/08 43
SECTION 3 PRINTING
4. Press the ENTER key. The User Interface Settings menu will
appear.
User Interface Settings
Units : Metric (mm)
Language : English
Key Beeper : Disable
LCD Contrast : 70 %
Clock Settings : 18 Sep 2006 15:37:37

+ - Page Modify
Down

5. Press the Down Arrow until the pointer is beside LCD

Contrast.
6. Press F1 (+) to increase the display contrast.
Press F2 (-) to decrease the display contrast.
The minimum value is 0% and the maximum value is 100%.
The default value is 70%.
7. When the desired contrast is set, press EXIT until the Top
Level menu appears.

44 0855849enf 6/08
 SECTION 3 PRINTING
5.2 Setting the Registration
Registration is the location of the printed image on the package. The
registration value is based on whether the print trigger is determined
by a sensor or a fixed spacing setting.
Registration menus can be accessed from the Top Level Menu by
pressing the F2 (Reg. + / -) key. Registration menus allow the user to
increase or decrease registration values.
The Registration Offset value is global and applies to all printheads.
The PH Reg value applies to a specific printhead.
If the print is located in front of the desired location (printing too
early), increase the registration.
If the print is located behind the desired location (printing too
late), decrease the registration.

When the Print Trigger is set to Sensor 1 or Sensor 2, the registration

parameter appears in the Machine Setup Menu. Registration is the
distance before printing after the product passes by the selected
sensor.
When the Print Trigger is set to Fixed Spacing, the Fixed Spacing
parameter appears in the Machine Setup Menu. Fixed Spacing is the
distance from the end of one print to the beginning of the next print.
For additional information on Print Trigger settings, refer to the
“Machine Setup Menu” section of the Model 5200/5400 Installation
and Setup Guide or see your company’s setup technician.

0855849enf 6/08 45
SECTION 3 PRINTING
1. To access the registration menus, press F2 (Reg. + / -) from
the Top Level Menu.

Job: Chocolate

25 Aug 2006 15:17:49

Status
Machine: Ready PH1: On
State: Offline PH2: On
Ink: OK

Counts:
Batch : 999
Total : 53796

- Press ENTER to preview image -

Job Reg. Shutdown Main

Select +/- Menu

The Registration Offset Menu will appear.

Registration Offset

Reg Offset : 1 mm

PH Total Trigger PH Reg

PH1 1 Sensor 1 0
PH2 1 Sensor 1 0
PH3 1 Sensor 1 0
PH4 1 Sensor 1 0

+ - Modify

F1 (+) is used to increase the offset registration. When the total

value is above zero, F2 (-) will be available to decrease the
registration.

The minimum value is -1000mm (-

2. 39.37”) and the maximum value is 1000 (39.37”). The default
value is 0 mm.

NOTE: The sum of the offset and printhead registration values

cannot be less than 0.

46 0855849enf 6/08
 SECTION 3 PRINTING
3. To change the registration offset for all printheads, press F4
(Modify). The Registration Offset dialog box will appear.

Registration Offset

Reg Offset

Enter Reg Offset

0I mm
PH1: 1 2 3
PH2: 4 5 6
PH3: 7 8 9
PH4: 0 -

Select Delete Back Forward

Character

Use the arrow keys to highlight a number. When the desired

number is highlighted, press F1 (Select Character). The
selected number will appear at the insertion point.

Use F3 (Back) and F4 (Forward) to move the insertion point left

or right. Use F2 (Delete) to delete the number to the left of the
insertion point.

When the desired registration offset value is displayed, press

ENTER to return to the Registration Offset Menu.

4. To change the PH Reg for a specific printhead, press the Down-

Arrow until the pointer is beside the desired printhead.

5. Press the Right-Arrow until the desired field is selected.

6. To change the registration value for the selected printhead,

press F1 (+) or F2 (-). Or press F4 (Modify) to open a dialog box
to modify the registration value.

7. When the desired registration values are set, press EXIT to

return to the Top Level Menu.

0855849enf 6/08 47
SECTION 3 PRINTING
6.0 Database Management

Database management allows the Model 5200/5400 user to

manage the files that were created in Composer or CoLOS Create
which reside on the host computer until they are downloaded
(“retrieved”) to the Model 5200/5400.

The Database Management Menu is accessed from the Top Level

menu, by pressing F4 (Main Menu) and then pressing F2
(Database Management) from the Main Menu. Refer to “Database
Management” in the Model 5200/5400 Installation and Setup Guide
for instructions.

The Database Management menu includes the following features:

• Retrieving files
• Viewing files
• Backing up files
• Deleting files
• Clearing the database

Information about the local database size and free space

48 0855849enf 6/08
SECTION 4

Cleaning and Care

Model 5200/5400
Operation Guide
 SECTION 4 CLEANING AND CARE
1.0 Daily Cleaning of the Printhead

To ensure that the printhead operates reliably and to maintain print

quality, it is necessary to clean ink and contaminants from the jet
array daily, using the following procedures:

• Purging
• Jet Testing
• Wiping (only if necessary)
when several attempts at purging are unsuccessful
or in the down jetting position, after each purge

Perform these procedures at least once daily or:

• At the start of each shift

• After each cold startup
• If the coder has been idle for more than 4 hours
• If the jets are not printing properly

NOTE: Use only Markem-Imaje Printhead Wipes (PN 0712075) to

remove ink from the jet array surface. These Printhead Wipes were
specially designed and tested for use with the coder, and prevent lint
particles from getting into the jet array surface. Use of non-Markem-
Imaje Printhead Wipes will cause jet array blockage and will void the
printhead warranty.

NOTE: DO NOT MOVE A HOT PRINTHEAD. Movement will cause

ink to flow into the low vacuum line, and the printhead may require
servicing. It takes approximately 40 minutes for the printhead to
adequately cool down and three to four hours for the coder to fully
cool down and the “Shut down” message to appear.

0855849enf 6/08 51
SECTION 4 CLEANING AND CARE
1.1 Purging
CAUTION. Hot Surfaces. To prevent injury from burns, be
careful not to touch the jet array surface or hot ink directly.
Wear protective eyeglasses when working with hot ink.

Purging is the forcing of trapped air and hot ink through the jet array
for a few seconds and is done periodically to clear the jet array.

This purging procedure cannot be used on printheads in the down

jetting position.

NOTE: In the DOWN JETTING POSITION, an alternative purge

procedure is required.
• Fold three Printhead Wipes together and hold them on the array.
• Press and release the Purge button once, holding the folded
Printhead Wipes on the array during the purge.
• Remove the Printhead Wipes without wiping.

1. For printheads in any position except the down jetting position,

use the drip tray to collect liquid ink and contaminants from the
array face. The drip tray shown below is in the tray bracket.

Tray Bracket
Drip Tray

2. Press and release the Purge button once.

3. After purging is complete, remove the ink drip tray if it is not kept
in the tray bracket.

4. If the drip tray is kept in the tray bracket, remove it periodically to

empty and clean it. Replace it if it becomes worn out or
damaged.

52 0855849enf 6/08
 SECTION 4 CLEANING AND CARE
1.2 Jet Testing
CAUTION. Hot Surfaces. To prevent injury from burns, be careful
not to touch the jet array surface or hot ink directly. Wear
protective eyeglasses when working with hot ink.

1. Press and hold the Jet Test button while moving a piece of paper
approximately 6mm (1/4") from the front of the jet array.

2. Examine the test pattern to confirm proper jet operation.

3. If any jets are not working properly, repeat the Purge and Jet
Test procedures. DO NOT WIPE the jet array unless several
attempts at purging are unsuccessful in recovering jets.

0855849enf 6/08 53
SECTION 4 CLEANING AND CARE
1.3 Wiping
CAUTION. Hot Surfaces. To prevent injury from burns, be
careful not to touch the jet array surface or hot ink directly.
Wear protective eyeglasses when working with hot ink.
The jet array should be wiped ONLY:
• If several attempts at purging are unsuccessful in recovering jets.
• Or in the down jetting position, after each purge.
1. Using a Markem-Imaje Printhead Wipe, wipe the jet array from
the center out.
DO NOT scrub the jet array.
DO NOT drag contaminants across the jet array.
Wipe outward from the center.
2. Clean any ink buildup around the jet array area and in the
corners of the enclosure near the jets.

2.0 Cleanup
The coder meets the following International Protection / Ingress
Protection (IP) international standards:
Enclosure: IP45 (with doors latched)
Printhead: not rated
Carton Sensor: IP65
Encoder: IP65
When washing down the packaging line, take special care to protect
the coder. If dust, water, or other debris collects on the printhead,
failure can result.
1. Allow the printhead to cool down at least 40 minutes.
NOTE: DO NOT SPRAY a hot printhead with water or air. A hot
printhead is sensitive to severe temperature changes. Directly
spraying the printhead may destroy it.
2. Remove any excess supplies and Printhead Wipes from the
areas to be cleaned.
3. Use mild soap and water to wipe dust, dirt, or other debris from
the outer surface of the print station.

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SECTION 5

Troubleshooting

Model 5200/5400
Operation Guide
 SECTION 5 TROUBLESHOOTING
1.0 Troubleshooting Guidelines

The LED indicators on the user interface module will indicate when
the coder is not ready for printing. Further details will be displayed on
the Top Level Menu.

If you encounter a problem that is not covered in this guide, ask your
company's setup technician for assistance.

Diagnostic information can be found in Section 4 of the

Model 5200/5400 Service Guide (P/N 0855855).

Information about error and warning messages can be found in the

document, Model 5200/5400 Fault Messages P/N 10019996.

2.0 Signal Lights

LED indicators on the print station and on each printhead are used to
monitor the coder. The Top Level Menu provides additional
information.

The optional signal tower is also used to monitor the coder.

2.1 LED Indicators on the Print Station

LED indicators are located on the user interface module. The Top
Level Menu provides messages to indicate the nature of the printing
status, ink supply, and fault condition.

The green STATUS LED indicates whether conditions are met for
printing.

The blue INK LED indicates when the coder needs ink.

The amber FAULT LED indicates when the coder needs attention.

STATUS LED
On Online
Off Power is off
Blinking Warming up or cooling down (fast blinking) or
Printhead is offline (slow blinking)

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SECTION 5 TROUBLESHOOTING
INK LED

On Add ink bottle

Blinking Add ink bottle immediately

NOTE: After adding an ink bottle, it might be necessary to

press the ENTER key to resume printing.

FAULT LED

On Warning

Blinking Error

If the coder detects a warning condition, a warning message will

appear on the display, but the coder will continue printing. If the
coder detects an error condition, printing will typically stop.

2.2 Signal Tower Lights

If your coder is equipped with the optional signal tower, the lights on
the signal tower correspond to the LED indicators on the user
interface module as follows:

The top lamp STATUS LED

The middle lamp INK LED

The bottom lamp FAULT LED

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 SECTION 5 TROUBLESHOOTING
2.3 LED Indicator on the Printhead

The printhead LED is located on the rear of the printhead.

Off Printhead power is disconnected or

Printhead is disabled or
Printhead is purging

Blinking Printhead is not ready

Printhead is warming up or cooling down

3.0 Unreadable Display

If the display is too dark or too light, there is a quick method to change
the LCD contrast from any menu. The LCD contrast settings range
from 0% (lightness) to 100% (darkness), with a default of 55%.

If the display is too dark, hold down the STOP key (1) and press the
Down Arrow (2) to change the contrast in 5% increments.

If the display is too light, hold down the STOP key (1) and press the
Up Arrow (3) to change the contrast in 5% increments.

3
1

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SECTION 5 TROUBLESHOOTING
4.0 Beep Due to Open Ink Door

When the ink door is left open for an extended period of time, a beep
will sound. When the beep becomes continuous, the coder will
pause until manually reset.

• Close the ink door.

• Follow the prompts on the display to reset the coder.

5.0 The Purge Button Does Not Function

After five consecutive purges, pressing the Purge button will have no
effect. Another purge will not be allowed until the printhead is refilled
with ink. The LED indicator on the printhead will remain on while the
printhead is being refilled.

Wait a few minutes, and another purge will be allowed.

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User Documentation Department