Intermec EasyCoder 301 Service Manual Download

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EasyCoder 301

Bar Code Label Printer

P/N 1-960420-02
Edition 3
September 1999

Service Manual

Summary of Contents for EasyCoder 301

Page 1: ...EasyCoder301 BarCodeLabelPrinter P N 1 960420 02 Edition 3 September 1999 Service Manual ...

Page 2: ...ibbon Unwind Unit 20 6 3 Ribbon Rewind Unit 21 6 4 Ribbon Media Sensor 22 6 5 Break Shaft 24 7 Print Unit 7 1 Description 25 7 2 Platen Roller 26 7 3 Stepper Motor 27 7 4 Belts 28 7 5 Ribbon Media Sensor 30 7 6 Printhead 32 7 8 Headlift Mechanism 35 8 Media Take Up 8 1 Media Take Up Unit 37 9 Label Taken Sensor 9 1 Description 38 9 2 Sensor Module 39 9 3 Light Guide 41 10 Electronics Compartment 1...

Page 3: ...eam Inc TrueType is a trademark of Apple Computer Inc Unicode is a trademark of Unicode Inc Windows is a trademark of Microsoft Corporation 12 Paper Cutter 12 1 Description 64 12 2 Controlling the Cutter 65 12 3 Installation 65 12 4 Cleaning 68 13 Troubleshooting 13 1 Diagnosing the Printer 68 13 2 No Reaction at Power Up 69 13 3 Printer Stops Working after Startup 69 13 4 Power Supply Failures 70...

Page 4: ...01 Spare Parts Catalogue1 Intermec EasyCoder 301 Direct Protocol Programmer s Guide Pleasenotethattheoperationsdescribedinthismanualonlyshould be carried out by skilled and authorized personnel with proper training and full understanding of written English The printers contain wires and circuits with 100 240V AC voltage which implies the risk of electrical shock Moving parts may also cause harm if...

Page 5: ...es may be required to correct the interference DOC Notice Canada Canadian Dept of Communication REGULATIONS COMPLIANCE DOC A This digital apparatus does not exceed the class A limits for radio noise emissions from a digital apparatus as set out in the radio interference regulations of the Canadian Department of Communication Ministère des Communications du Canada CONFORMITE DE REGLEMENTS DOC A Le ...

Page 6: ... relates is in conformity with the following standards Electrical Safety EN 60950 EMC Emissions EN 50081 1 92 EN 55022 94 class B EN 61000 3 2 95 EMC Susceptibility EN 50082 1 92 IEC 801 2 84 IEC 801 3 84 IEC 801 4 88 following the provisions of Directives 89 336 EEC and 73 23 EEC Mölndal 1998 02 02 Hans Lindén President 1 Intermec assumes no responsibility as regards fulfilling the CE Directive i...

Page 7: ...ng and a LinerLess model for direct thermalprintingonstandardorlinerlessdirectthermalpaper Both have a printhead density of 8 dots mm 203 2 dots inch The standard model has an internal backing paper rewind unit for peel off operation and can be fitted with an optional paper cutter facilities that har no available for the LinerLess model All printers are delivered from factory preset for either 115...

Page 8: ...sion Level 60 dB A Microprocessor 32 bit Firmware Intermec EasyCoder 301 Direct Protocol 2 00 Label and Ribbon End Sensors Yes Mains Voltage 115 230VAC 10 15 4 2A 60 50Hz Build option PFC Regulation IEC 61000 3 2 Maximum Power Consumption Stand by 30W Typical label 70W Maximum 250W Communications Interface Standard 1 x RS 232C Serial and 1 x Centronics Parallel Print Speed tear off 100 or 150 mm s...

Page 9: ...odels and Options 1 3 Measures 32 2 mm 1 27 174 mm 6 85 235 5 mm 9 27 169 3 mm 6 67 R 2 1 4 5 m m 8 4 5 15 mm 0 59 16 mm 0 62 33 mm 1 30 285 mm 11 22 352 9 mm 13 89 R 177 8 m m 7 00 An optional paper cutter increases the printer s total length to 396 mm 15 6 ...

Page 10: ...es of operation and containing important information on printhead and transfer ribbons1 The user cover is attached to the bottom plate using two moulded hingesandiskeptclosedbyalargecircularreleasebuttonatthetop of the printer Replacement Open the user cover Atonehingeatthetime useyourthumbtofirmlypresstheuser coverupwardssotheshaftinsidethehingedisengagesfromthe bottom plate moulding The composit...

Page 11: ...ideforthelabelstopsensor LSS see chapter 9 The light guide is attached to pins in the front cover moulding by means of locking washers On the LinerLess models there is also a tear off edge that enables the paper to be torn off in an upward direction The front cover is kept in closed position using a snap lock in the centre line wall Replacement Place the printer upside down on some soft material t...

Page 12: ... the power and remove the power cord Disconnect all interface cables at the printer s rear plate Open the front and user covers Remove the Posidrive screw at the rear of the media compart ment RemovethePosidrivescrewintherecessforthebarcodewand interface Pull out the cover starting by angling out the front edge and the pushingthecoverrearwards Takecarenottodamagethewire locks on the Centronics con...

Page 13: ... read Amber steady Bar code wand active lasts max 10 sec s momentarily During power on Red steady Bar code wand inactive Error e g Printhead lifted Out of paper Out of ribbon1 Paper jam in cutter1 single flash Bar code reading failed Feed Button The Feed button can be used for the following purposes To feed out a blank label before any label design has been downloaded to the printer To print a lab...

Page 14: ...donottrytorepairitbutreplace the entire module Turn off the power to the printer and remove the power cord Open the front cover Remove the electrics cover see chapter 2 3 Remove the CPU board see chapter 11 2 Insert a narrow screwdriver or similar into the hole in the centre of the Interface Module pcb and pry it out of the rails Disconnect the connector from J2 Fit the replacement Interface Modul...

Page 15: ...Intermec EasyCoder 301 Service Manual Ed 3 14 Chapter 3 Front and Operator Interface 3 2 Interface Module cont d Components Schematics ...

Page 16: ...centre linewall with the exception of the user and front covers Description The bottom plate holds the centre line wall with all its connected modules the front cover and the user cover It also supports the outer end of the platen roller and the tear off edge On the bottom sideofthebottomplate therearefourrubberfeetandaproductlabel see chapter 1 1 Rubber Feet Replacement Turn the printer upside do...

Page 17: ...mm 3 coreandthelower for 38 1 mm 1 5 core To loosen the hanger turn it about 30 back and forth in any directionandpullitout Insertitinthehangerintheappropriateslot and press it firmly down Its top and bottom ends should match the grooves in the centre line wall Adjust the moveable guide so its position matches the width of the paper roll 38 1 mm 1 5 core 76 mm 3 core 1 When using a full size paper...

Page 18: ...nto the print unit and the rear lower one1 is used for the backing paper in connection with peel off operation Each roller is fitted with two guide rings The inner smaller one should be in flush with the inner end of the roller while the outer largeroneshouldbeadjustedaccordingtothewithofthepaperweb The roller is locked on the shaft using a circlip Refer to the EasyCoder 301 LinerLess Installation...

Page 19: ...intake of the printer Measures should be taken to protect the paper from sand dust grit andotherhardparticleswhichmaydamagetheprintheadorimpair the printout quality Itisalsoimportantthatsuchanexternalsupplyisprotectedagainst any conditions that may harm the paper This is especially impor tant in case of direct thermal paper which may be vulnerable to direct sunlight heat airborne solvents plastici...

Page 20: ...bbon goes from the unwind spool and under the print mechanism where it passes above the ribbon media sensor Then itgoesforwardundertheprinthead whereitisexposedtoheatfrom the printhead resistor elements which melts the ink and leaves the imprint on the receiving face material On its way to the ribbon rewind unit the ribbon passes a break shaft which can be adjusted to prevent ribbon wrinkling Fina...

Page 21: ...aft pressed into the centre line wall The spool contains a spring that serves as a friction brake which gives enough resistance to obtain a proper tension of the ribbon A leaf spring on the spool is used to engage the ribbon core Shaft Spring Tube Inner Spring Holder Outer Spring Holder Unwind Spool Leaf Spring Complete assembly Circlip Avoid dismantling these parts ...

Page 22: ... ribbon unwind unit plus a disc that is pressed against the centre line wall by three small springs fitted in theholeslabelled R inthediskbrake Thesetwobreaksallowthe spool to be rotated manually to facilitate ribbon load and still preventbreakingtheribbonorcausingmotoroverloadiftheribbon should get jammed A leaf spring on the spool is used to engage the ribbon core Note that many parts are identi...

Page 23: ...ter is set up for direct thermal printing an out of ribbon condition must be indicated or an error will occur Note that a faulty or dirty sensor may indicate a ribbon present condition even during direct thermal printing and give a Ribbon fitted error message1 ThesensorisconnectedtoconnectorJ7ontheCPUboardandfitted to the centre line wall by means of two snap locks Replacement Remove the electrics...

Page 24: ...Intermec EasyCoder 301 Service Manual Ed 3 23 Chapter 6 Transfer Ribbon Mechanism 6 4 Ribbon Media Sensor cont d Components Schematics ...

Page 25: ...should not be readjusteduntilanyothermeasureshaveproveninsufficient Refer to chapter 13 12 for measures to be taken to remedy ribbon wrinkling Adjustment Loosen the Posidrive screw slightly so the shaft can be moved with some resistance left If the ribbon wrinkles on the inner side lift the break shaft slightly If the ribbon wrinkles on the outer side lower the break shaft slightly After having ad...

Page 26: ...ensor detects whether the printhead is lifted or lowered Theplatenrollerisfittedinpermanentlylubricatedbronzebearings on walls protruding from the bottom plate The roller shaft runs through the centre line wall and into the electronics compartment where it is driven by the stepper motor via a belt and pulley arrangement In the LinerLess model the platen roller is made of a material that prevents t...

Page 27: ...nthe D plane at the end of the shaft A short tooth belt runs to the pulley of the stepper motor Replacement Open the electrics cover as described in chapter 2 3 Remove the CPU board as described in chapter 11 2 Pull away the tooth belt from the platen roller pulley Insert a flat screwdriver under the outer bearing and pry it loose upwards snap locked Insert a large screwdriver or similar tool betw...

Page 28: ... up pulley1 Loosen the cable running from the stepper motor to J10 on the CPU board Loosen the four Posidrive screws that hold the motor s flange and pull out the motor Reassembleinreverseorder takingspecialnoticeofthefollow ing Place the belts over the pulley of the replacement motor noting that the longer belt1 should run in a loop around the rear upper pillar that holds the motor Put back the b...

Page 29: ...oting that the longer belt1 should run in a loop around the rear upper pillar that holds the motor and be fitted closest to the motor Put back the stepper motor but do not tighten the screws completely Put back the belt s over the pulley s as illustrated above Adjust the tension of the belt s as described below Fit back the ESD plate1 CPU board and the electrics cover in reverse order WARNING Befo...

Page 30: ...e motor will not interfere with the CPU board Tighten the screws completely Check the tension of the long belt as illustrated above1 The belt should flex up or down approximately 1 cm 4 in either direction If not loosen the two Posidrive screws that hold the tension adjuster plate and move it up or down until a proper tension is obtained Fit back the CPU board and the electrics cover in reverse or...

Page 31: ...flectedfromthebacksideofthepaper Ifthereisablackmark no light will be received The printer s setup decides how the signals will be interpreted In case of labels w gap or tickets w gap signals from the upper opticalsensorareusedtodetectwhenagaporslotchangestopaper In case of tickets w mark the lower sensor is used to detect when a black marks starts In case of var length strip and fix length strip ...

Page 32: ...r 301 Service Manual Ed 3 31 Chapter 7 Print Unit 7 5 Ribbon Media Sensor cont d Components Ribbon Media Sensor Black Mark Sensor upper circuit board lower circuit board Schematics Ribbon Media Sensor Black Mark Sensor ...

Page 33: ...t barcodesandimages willbeproduced Itisimportantfortheprintoutqualityandthelife oftheprintheadthatthelineofresistorsisclean thattheenergylead through the resistors matches the characteristics of the ribbon and or paper and that the printhead pressure is correct Since the ribbon paper serves as cooling media for the resistors it isimportantthatnoresistorsoutsidethepaperwebareactivated i e that the ...

Page 34: ...he physical installation it is important that the printerisinstructedtomeasuretheresistanceofthenewprinthead andadjustitselfaccordingly Thisisdoneby sendingthefollowing instruction PRINT HEAD 1 The printer will check all dots in the printhead and determine its mean resistance Provided you have a two way communication it will return 1 if the printhead is OK else 0 The resistance value is saved in t...

Page 35: ...aning card Raise the printhead Wait for approximately 30 seconds Push most of the same cleaning card under the printhead Lower the printhead Pull out the cleaning card Raise the printhead Allowthecleanedprintheadtodryforapproximately2minutes before reloading the paper and transfer ribbon1 Warning The cleaning card contains isopropyl alcohol CO3 2 CHOH CAS 67 63 01 which is a highly flammable moder...

Page 36: ...nts on the printheadsubstratetothetransferribbonordirectthermalpaper forthetransferofmeltedinkfromtheribbontothereceivingface material and for the friction between the back side of the paper web and the platen roller The handle is fitted to the same shaft as the two adjustable knobs The shaft runs through the centre line wall into the electronics compartment and through a hole in the CPU board On ...

Page 37: ...hile too much pressure can cause ribbon wrinkling and unnecessary printhead wear Theprinter sfactorysetupisforfullwidth thermaltransferprinting 2 0 2 5kponeachknob Whenyouchangethemedia tothicker thinner or narrower it may be necessary to adjust the printhead pressure using trial and error Donotuseanymorepressurethanisnecessarytoobtainthedesired print quality 7 7 Headlift Mechanism cont d Full wid...

Page 38: ...deofthecentre linewallisaspringbrakeplusadisc that is pressed against the centre line wall by three small springs fitted in the holes labelled M in the disk brake These two breaks allow the spool to be rotated manually to allow the operator to manually wind up some of the backing paper and still prevent causing motor overload if the paper should get jammed The U shaped media take up pin on the spo...

Page 39: ...detected by an optical sensor in the sensor module Obviously ifthereisnolabelprotrudingfromtheprintunit nolight will be reflected back Thisway theprinter sfirmwarecandetermineifaprintedlabelhas beenremovedornot Ifthelabelhasnotbeenremoved theprinting ofthenextlabelinabatchprintjobwillbeheldpendingtheremoval of the label The LTS is enabled disabled by the commands LTS ON and LTS OFF The status of t...

Page 40: ...ule donottrytorepairitbutreplacethe entire module Turn off the power to the printer and remove the power cord Open the front cover Remove the electrics cover see chapter 2 3 Disconnect the connector from J4 Jerk the LTS casing up and down to disengage the snap locks Fit the replacement LTS module in reverse order Components 9 2 Sensor Module Casing Sensor pcb Connect to J4 on CPU board Snap locks ...

Page 41: ...Intermec EasyCoder 301 Service Manual Ed 3 40 Chapter 9 Label Taken Sensor 9 2 Sensor Module cont d Schematics ...

Page 42: ...rotherthingsthatmayblockordimthelight Use isopropyl alcohol or a cleaning card to remove adhesive residue The LTS will only work when the front cover is in closed position Replacement Open the front cover With a pair of small sharp cutting pliers cut off the locking washers that hold the light guide Be careful not to damage the plastic pins Replace the light guide with a new one Press the new lock...

Page 43: ...vers Remove the Posidrive screw at the rear of the media compart ment RemovethePosidrivescrewintherecessforthebarcodewand interface Pull out the cover taking care not to damage the wire locks on the Centronics connector on the printer s rear plate 10 2 Main Parts CPU board Memory Card Adapter Main Switch Mains Inlet Stepper Motor Wand Interface Cutter Interface Operator Interface WARNING Before re...

Page 44: ...take precautions to prevent electrostatic discharges and use non conductive tools to avoid short circuits Do not replace a blown fuse If a fuse blows a serious fault has occurred and the entire CPU board should be replaced Static EC000 Core System Integration Module SIM In Circuit Emulation Parallel Port DMA Clock MA0 MA9 MD0 MD15 A0 A18 Video CMD CMD Centronics U19 U9 Output UART 16C550 RS 232 PI...

Page 45: ...Circuit 1 1 2 3 2 3 Input 115 230V 50 60 Hz Rectifier Circuit Switching Circuit Start Up Drive T1 T2 Over Voltage Protection Pulse Width Modulator 24V Output Control Printhead Power U36 U33 AC DC AC DC AC DC REG REG Block diagram of the power supply part of the CPU board Refer to chapter 11 8 for detailed schematics 11 1 Description cont d ...

Page 46: ...PU board proceed as follows Checkthatthemainsvoltagestrapisfittedcorrectly seechapter 11 3 Check that all cables are free and will not become inaccessible when the CPU board is fitted PlacetheCPUboardunitlooselyinsidetheelectronicscompart ment so the hole in the rear plate becomes aligned with the pin on the bottom plate Connect the printhead cable to J9 on the CPU board Pull at the cable from the...

Page 47: ...oltage Strap Left side 115V AC Right side 230 V AC J10 Stepper Motor J9 Printhead J7 Ribbon Media Sensor J4 Label Taken Sensor J1 Boot Sector Straps normal position both on left side J2 Operator Interface Serial Port Parallel Port Real Time Clock RTC Screw Screw Screw Screw Wand Connector Cutter Connector ...

Page 48: ...ilureoccursduring upgrading the boot sector will be lost and the printer will refuse to work Thesamemayhappenwheninstallinganuninitiatedreplace ment CPU board There is a simply remedy for this condition Turn off the power Opentheelectronicscompartmentasdescribedinchapter10 1 Move both straps fitted on J1 from left and centre pins to the centre and right pins Insertabootrestorecardinthecard1slot i ...

Page 49: ... incoming data In the Direct Protocol it is possible to specify one of the ports as standard IN and or OUT channel see SETSTDIO instruction in the EasyCoder 301 Direct Protocol Programmer s Guide Use the parallel port with the Windows Driver because it is faster than the serial interface Use the serial port with the Direct Protocol because you can receiveerrormessagesandotherdatafromtheprinter Thi...

Page 50: ...XD 2 2 TXD 2 3 RXD TXD 3 3 RXD 3 2 TXD DTR 4 4 4 20 DTR GND 5 5 GND 5 7 GND DSR 6 6 RDY 6 6 DSR RTS 7 7 CTS 7 4 RTS CTS 8 8 RTS 8 5 CTS 9 9 11 6 Communication Ports cont d Parallel Port Standard IEEE 1284 I compliant Centronics Interface Cable Computer end Depends on type of host computer IBM PC DB25 male connector Printer end 36 pin female Centronics connector Pin Function Transmitter 1 Strobe Ho...

Page 51: ...R74 R111 R153 R114 R115 R113 C12 R42 RV3 U29 U30 Q1 R68 R105 R64 R125 C64 R135 R122 R121 C54 R120 C53 R119 R118 C61 R130 R131 C62 R134 R133 C63 R132 C65 R124 R136 R63 R62 R102 R43 R44 R45 C39 R67 R66 R65 C46 R104 R103 C22 C23 R71 R72 R106 C47 D5 D6 U15 U16 R73 R51 R75 F7 F4 F1 F2 F3 F5 F6 F8 J1 U4 U5 U6 R12 C5 C3 R9 R8 R7 C2 R6 R5 R4 R3 R2 R1 R16 C14 C21 C13 C20 C38 C36 R100 R99 R98 R97 R96 R129 R...

Page 52: ...RAS5 _RESET CLOCK DQ0 2 0 91 1 2 3 4 5 6 7 0 8 1 14 7 2 3 1 1 2 3 4 5 6 10 11 12 13 14 15 7 8 9 R7 10K R8 0R R9 0R VCC R69 0R Use 470R for debugging DQ1 3 1 DQ2 4 2 DQ3 5 3 DQ4 7 4 DQ5 8 5 DQ6 9 6 DQ7 10 7 DQ8 31 8 DQ9 32 9 A0 16 0 A1 17 1 A2 18 2 A3 19 3 A4 22 4 A5 23 5 A6 24 6 A7 25 7 A8 26 RAS 14 8 DQ10 33 10 DQ11 34 11 DQ12 36 12 DQ13 37 13 DQ14 38 14 DQ15 39 15 CAS0 29 CAS1 28 WR 13 OE 27 U21...

Page 53: ...0 1 2 3 4 5 6 10 11 12 13 14 15 7 8 9 20 22 23 24 160 2 3 4 5 6 8 9 10 11 15 17 18 0 1 2 VCC 7 14 29 40 48 60 71 88 93 102 112 123 134 144 153 GND 1 12 21 35 36 45 54 66 78 90 96 107 119 129 138 149 159 U12 MC68322 right side VCC VCC R1 10K R2 0R INTEL Fit for INTEL FLASH only R16 OR F800 Fit for F800 FLASH only R17 10K R26 0R A0 A1 U2 29F400 FLASH 256Kx16 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A...

Page 54: ...rface D0 D1 D2 D3 D4 D5 D6 D7 OP1 OP2 TXD RXD RTS DTR CTS DSR CD RI 2 RESET 39 IOR2 25 IOR1 24 IOW2 21 IOW1 20 CS2 16 3 CS1 15 CS0 VCC 14 A2 29 A1 30 A0 31 3 2 1 AS 28 RCLK 10 X2 19 X1 C10 100n C35 100n 18 C1 C1 1 3 3 4 5 6 7 8 9 38 11 13 35 36 37 NC0 NC1 NC2 NC3 1 12 VCC GND 44 DDIS 26 RXRDY 32 TXRDY 27 INT 33 BAUD UART VCC U17 MAX202 L1 4u7 RS232 DRIVER 17 22 23 34 40 41 42 43 0 1 2 3 4 5 6 7 U3...

Page 55: ...B _WAIT _PC_WE _LABEL_TAKEN_TX _LABEL_DRIVE_0 _LABEL_DRIVE_1 _LABEL_DRIVE_2 _LABEL_DRIVE_3 _LABEL_DRIVE_4 PC_REG_A PC_CE1_A PC_CE2_A PC_CE1_B PV_CE2_B MEM_A _MEM _IO MEM_B PC_REG_B _PC_MEMEN_A _PC_MEMEN_B PC_BYTE_A PC_BYTE_B _PIC_RESET _FSYNC_EN 1 2 3 0 1 2 3 1 2 3 14 13 0 15 74HCT02 1 U11 VCC 11 12 13 74HCT04 1 U25 3 4 9 13 5 74HCT02 1 U11 8 9 10 74HCT02 1 U11 2 3 1 74HCT04 1 U25 6 74HCT02 1 U11 ...

Page 56: ...VCC Microcontroller 17 14 15 RA1 RA2 RA3 RB0 RB1 RB2 RB3 RB4 RB5 RB6 RB7 18 1 2 6 7 8 9 10 11 12 13 VSS CLKOUT 5 9 10 11 12 13 8 OSC1 16 RTCC 3 MCLR 4 VCC _LABEL_THROUGH _LABEL_REFLECT _CS_PIC CLOCK _PIC_RESET _HEAD_OPEN _RESET S C1 1D R U23 74F74 5 4 3 2 1 6 VCC S C1 1D R U24 74F74 5 11 12 13 4 3 2 1 6 VCC VCC VCC S C1 10 R U24 74F74 9 10 11 12 13 8 VCC S C1 10 R CLK4 VCLK _PH_VLCK _LSYNC _PH_STR...

Page 57: ... 36V VCC U32 R74 1K R51 1R0 R75 1R0 R76 58K C27 820p C43 820p C40 100n PHASE 1 8 7 9 6 11 2 10 16 15 3 14 4 5 12 13 MB MA VM1 VM2 GND1 GND2 GND3 GND4 I0 I1 VCC VR T C E 3717 1 2 3 4 PHASE_B I0_B I1_B 36V 36V VCC U31 R47 1K R40 1R0 R73 1R0 R48 58K C26 820p C25 820p C41 100n PHASE 1 8 7 9 6 11 2 10 16 15 3 14 4 5 12 13 MB MA VM1 VM2 GND1 GND2 GND3 GND4 I0 I1 VCC VR T C E 3717 ...

Page 58: ...ERATURE PRINTHEADTEMPERATURE MOTOR SUPPLY PRINTHEAD RESISTANCE COMP_40V COMP_RESISTANCE _PH_STROBE1 PH_VIDEO _PH_LATCH _PH_STROBE2 _PH_STROBE0 _PH_CONT0 PH_BEO _PH_VCLK 1 R153 10K VCC 3 2 12 4 5 U28 LM339 R62 10K 24V 24V 24V_PH VCC GND VCC 3 1 12 6 7 U28 LM339 24V GND VCC 3 14 12 8 9 U28 LM339 24V GND VCC t 3 13 12 10 11 U28 LM339 24V GND R103 6K8 R104 10K 36V R66 10K R65 22K 24V 24V C39 100n R67 ...

Page 59: ...WP_A 25 1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 0 1 2 3 4 5 6 7 5 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 A56 Note Byte order swapped VCC R57 10K R100 10K R15 10K R61 10K R60 10K _PC_CE1_B _PC_CE2_B _CE1 _CE2 A0 A25 D0 D15 R98 10K _OE _WE RESERVED _IORD RESERVED _IOWR _REG RESET READY _IREQ _WAIT _CD1 _CD2 BVD1 _STSCHG BVD2 _SPKR WP _IOIS16 RESERVED _INPACK _VS1 _VS2 VCC VCC VCC VPP1 VPP2 ...

Page 60: ...0n C23 100n C20 100n C14 100n C7 100n C28 100n C12 100n C16 100n C6 100n 24V C59 4n7 R146 4K7 R149 150K R128 27K L5 2700u C72 470u C60 470u C69 100n C68 470n D18 ES1B C52 120u C51 100n RV1 V250LA20A RV2 SG 220 R127 4K7 L5 2700u D8 2KBP10 t 2 3 1 1 anode 2 1 8 4 5 3 6 7 VFB C67 100n R132 1K COMP Vref RT CT Isense OUT P1 P2 W1 100 TURNS VCC GND base catode collector NC emitter 6 2 5 3 4 6 7 12 J8 R1...

Page 61: ...470u C57 10000U R125 2K7 6 7 8 anode base catode collector NC emitter 1 1 k ref a 2 8 5 2 4 3 U36 SFH600 1opt7 GND1 GND11 GND8 GND2 GND13 GND6 GND17 GND10 GND12 GND15 GND14 GND4 GND9 GND3 GND5 GND7 VCC TP_VCC TP_PH 5V_AUX 24V 24V_PH 36V U30 IMD2 C66 47u C55 10u D6 BZX84C20 D5 BZX84C20 C73 100n U34 ZR78LO5G C56 3300u D22 UF4003 UF4003 UF4003 UF4003 D25 D23 D24 C77 4n7 U38 D10LC20U 6 9 5 10 4 11 3 1...

Page 62: ... B1 220R R35 VCC VCC 220R _SWITCH_PANEL VCC 2 3 4 J6 CUTTER CUT_START CUT_DONE 1 2 3 F5 F6 F4 4 VCC 24V R52 10K VCC D7 GL480 R116 220R Q3 PT481F R110 1K _HEAD_OPEN J11 BARCODE 6 5 4 3 2 1 IRQ_BARCODE PC_READY_A _DEBUG_RST F8 F7 VCC R109 R108 OR DEBUG OR DEBUG VCC R107 10K Debugging only CPU Board 1 301700 04 Cutter Connection CPU Board 1 301700 04 Headlift Sensor CPU Board 1 301700 04 Bar Code Wan...

Page 63: ..._PRESENT 1 2 3 4 5 6 7 8 _LABEL_DRIVE_1 U6 IMB10 C1 B2 4 5 6 3 2 1 E1 E2 C2 B1 VCC VCC R112 22K R20 1K2 _LABEL_DRIVE_2 R12 150R _LABEL_DRIVE_3 U5 IMB10 C1 B2 4 5 6 3 2 1 E1 E2 C2 B1 VCC VCC R11 330R _LABEL_DRIVE_4 _LABEL_TAKEN_TX U4 IMB10 C1 B2 4 5 6 3 2 1 E1 E2 C2 B1 VCC VCC 24V R39 100R R40 82R VCC R13 82R R111 4K7 R115 82R R113 47K VCC F12 F13 F11 F10 F9 1 F3 2 F2 3 4 F1 R41 18K R38 68K R37 10K...

Page 64: ...C8 U7 R36 R35 C43 R108 R109 R110 R52 R41 R39 R48 C25 C26 R47 R38 R37 R40 C6 C4 R107 R78 C28 R50 C29 C27 R74 R111 R153 R114 R115 R113 C12 R42 RV3 U29 U30 Q1 R68 R105 R64 R125 C64 R135 R122 R121 C54 R120 C53 R119 R118 C61 R130 R131 C62 R134 R133 C63 R132 C65 R124 R136 R63 R62 R102 R43 R44 R45 C39 R67 R66 R65 C46 R104 R103 C22 C23 R71 R72 R106 C47 D5 D6 U15 U16 R73 R51 R75 F7 F4 F1 F2 F3 F5 F6 F8 J1 ...

Page 65: ...render the cutter inoperable which may damage the electric motor Maximum paper thickness is 250 µm 250 grammes m2 for normal paper based materials Minimum practical copy length is 38 1 mm 1 5 The Paper Cutter increases the printer s total weight to approx 5 6 kgs 15 lbs and its length to 396 mm 15 6 ThePaperCuttercanbetiltedforwardinordertofacilitatecleaning and paper load A microswitch prevents u...

Page 66: ...alculated to allow the paper web be pulled back after cutting so printing can start directly at the forward edge Labels Start adjust 250 Stop adjust 100 Strip Start adjust 250 Stop adjust 180 Turn off the main switch and remove the power cord and interface cable Open the printer s front cover Turntheprinterupsidedownanduseapiercertopryoutthetwo L shaped hinge pins that hold the front cover Remove ...

Page 67: ...at the bottom of the cutter unit should be aligned with the hinges on the bottom moulding Insert the hinge pins as shown above Connect the cable from the cutter to the upper circular one of the two connectors on the printer s front Thread the paper through the slot in the cutter Closethecutter connecttheinterfacecableandpowercordand finally turn on the power 12 3 Installation cont d ...

Page 68: ...ar basis is required for trouble free operation Should the cutter inadvertently have been used to cut through any adhesive you should clean the cutter immediately Tiltdownthecutteranduseacottonswabmoistenedwithisopropyl alcohol or a similar solvent to wipe clean cutting parts 12 4 Cleaning ...

Page 69: ... the presently loaded paper The printhead resistance is measured and stored in memory After a short delay a test label is printed and the printer enters the Dump Mode firware version 2 00 or later Use this short list to find the symptom that applies to the printer No reaction at power up 13 2 Printer stops working after startup 13 3 Power supply failures 13 4 Interface Module errors 13 5 Error mes...

Page 70: ...ter 13 5 Boot sector lost Refer to chapter 11 5 Description The Power LED is lit The Print key works properly Possible Causes and Suggested Remedies Communication problems Refer to chapters 13 7 13 9 Printer malfunction Check if the printer can print test labels see chapter 13 1 Description The Power LED is lit amber There is no reaction on software commands There is no reaction when the Feed key ...

Page 71: ...d see chapter 11 9 Check the cabling between the mains supply and the CPU board If the cable is OK replace the CPU board Blown fuse on the CPU board Replace the CPU board WARNING The CPU board the mains receptacle and the main switch contain wires and circuits with dangerous voltages Description The complete console is dead LED control lamp is not lit and the Feed key does not work TheVCCvoltageon...

Page 72: ...cted Note that verbosity is on in the Direct Protocol by default Error 1005 Out of paper Error 1022 Head lifted Error 1027 Out of transfer ribbon 1 Error 1058 Transfer Ribbon fitted 1 Error 1059 Cutter does not respond 1 Error 37 Cutter device not found 1 TheDirectProtocolisprovidedwithanerror handlerthatcanbe designed to work according to the customer s requirements Refer to the Intermec EasyCode...

Page 73: ...stMode checkthattheprinterandhostaresetforthe same communication parameters such as baudrate parity character length stopbits new line and handshaking Some kindofhandshaking e g XON XOFForRTS CTSisstrongly recommended Damaged RS 232 driver circuit With the aid of an oscilloscope or some kind of line analyser break outbox verifythattheinterfacesignalstoandfrom the CPU board are correct The RS 232 d...

Page 74: ...oard Wrong std IN channel selected in custom made program Verify that the Centronics communication port is selected as standard IN channel Description Label ticket gap or black mark not detected by the media sensor Possible Causes and Suggested Remedies Lost or obsolete paper feed data for example after a headlift or change of media Perform a testfeed operation using a TESTFEED instruction or by p...

Page 75: ...rinter is not set up for thermal transfer printing ChecktheMedia PaperTypesetup e g byprintingatestlabel Ribbon Media Sensor malfunction Check the sensor for paper dust or foreign objects Check that the sensor s cable is undamaged and properly connected to J7 on the CPU board Replace the sensor Description The label taken sensor LTS is not working properly Possible Causes and Suggested Remedies Se...

Page 76: ...nprintheadandJ9ontheCPUboardfitted correctly and not broken or otherwise damaged Dirty printhead Is the printhead clean Residue from label adhesive or burnt transfer ribbon on the printhead prevents it from functioning correctly Clean as described in the Installation Operation manual Wrong type of receiving media Incaseofdirectthermalprinting verifythatthestockofpaper is intended for direct therma...

Page 77: ...ntout on either inner or outer part of label Possible Causes and Suggested Remedies Bad printhead pressure alignment Adjust as described in chapter 7 7 Description Overall too dark printout bleeding Too dark a printout is particularlytroublesomewhenprintingcompactbarcodes in whichcasespacesbetweenthebarsbecomelessdistinctive and consequently less readable Possible Causes and Suggested Remedies Wro...

Page 78: ...become worn from the outer paper edge This will show up when reverting to wider labels Change the pressing roller and possibly also the printhead Preprinted ink has got stuck to the dot line Avoid preprinted labels with ink that has a low melting point less than 225 C Many dots or a block of dots are missing The internal IC circuit of the printhead is probably damaged Replace the printhead Descrip...

Page 79: ...t or adhesive residue can deteriorate the paper feed function or make the paper slip Worn platen roll bearings Check the platen roll bearings for excessive play Check for abnormal noise when manually rotating the platen roller Wrong belt tension Check the tension of toothed belt that drives the platen roller and adjust as explained in chapter 7 4 Faulty stepper motor Connect a working stepper moto...

Page 80: ...bon break shaft adjustment Check the adjustment of the ribbon break shaft see chapter 6 5 Donotchangetheadjustmentbeforeyouhaveperformed all other checks mentioned above Description Transfer ribbon breaks Possible Causes and Suggested Remedies Wrong brand of ribbon Check if the transfer ribbon is an approved brand If not recommend the customer to use approved brands only Incorrect ribbon load Chec...

Page 81: ... or PCMCIA standards DOS formatted SRAM card does not work CheckthatthewriteprotectswitchontheSRAMmemorycard is enabled Check the internal battery of the card missing or no power Flash memory cards cannot be DOS formatted No card inserted at startup The card must be inserted before the power is switched on or the printer is rebooted Bad connection Pull out and insert the card a few times to remove...

Page 82: ...ter disconnect it and disassemble the cutting mechanism from the housing Check connectors X1 and X2 Check soldering points and connections for the microswitch Checkforburningmarksoncomponentsonthecutter scircuit board Description The cutter keeps cycling all the time Possible Causes and Suggested Remedies Electrical fault in cutter Open the cutter disconnect it and disassemble the cutting mechanis...

Page 83: ...ual Ed 3 82 Chapter 13 Troubleshooting Description The motor runs but the blade does not move Possible Causes and Suggested Remedies The gear is broken Replace the cutter mechanism or the entire cutter 13 15 Paper Cutter Troubles cont d ...

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