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Intermec EasyCoder 501 E, Service Manual

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Intermec EasyCoder 501 – Service Manual Ed. 7

52

Chapter 8    Print Unit

8.6 Label Stop Sensor, 
cont.

To replace a defective sensor, proceed as follows:

•    Disconnect the two cables to the LSS from the CPU board.

•    Using a #T20 Torx screwdriver, remove the three screws that 

hold the lower gable to the print unit. 

     CAUTION!
     Do not loosen the center screw (marked with a shade of grey 

below), or the platen roller alignment will be lost! 

•    Put the ball bearing and its bracket aside, as well as the rear 

guide plate.

•    Pull out the lower gable and the LSS assy.

•    Remove the two #T8 Torx screws that hold the defective 

sensor.

•    Cut the cable clip and remove the defective sensor.

•    Reassemble in reverse order, replacing the cable clip.

•    Connect the cable from the lower sensor to P-600 on the CPU 

board and the cable from the upper sensor to P-601.

#T20 Torx Screws

Rear Guide Plate

LSS assy.

Lower Sensor

Upper Sensor

Lower Gable

IMPORTANT!

Do not loosen this screw!

Bracket

Ball Bearing

Ball Bearing

Washer

#T8 Torx Screws

Note. The liner drive roller with its washer and ball bearing is 
omitted in EasyCoder 501 LinerLess.

Summary of Contents for EasyCoder 501 E

Page 1: ...EasyCoder501 BarCodeLabelPrinter P N 1 960320 06 Edition 7 October 2001 Service Manual ...

Page 2: ...5 1 Internal Supply 26 5 2 External Supply 30 6 Label Slack Absorber 6 1 Description 35 6 2 Dismantling 36 7 Transfer Ribbon Mechanism 7 1 Description 37 7 2 Ribbon Supply Unit 37 7 3 Ribbon Rewind Unit 39 7 4 Ribbon End Sensor 41 8 Print Unit 8 1 Different Models 43 8 2 Main Parts 43 8 3 Platen Roller 46 8 4 Stepper Motor 47 8 5 Tear Bar 49 8 6 Label Stop Sensor LSS 50 8 7 Printhead 53 8 8 Headli...

Page 3: ...119 17 CPU Board 17 1 Access to CPU Board 121 17 2 Overview 122 17 3 Circuits and Straps 124 17 4 Connections 131 17 5 Components Diagram 132 17 6 Circuit Diagrams 1 CG16 Master Processor 133 2 A D and I O Circuits 134 3 Interfaces to Printer Devices 135 4 Data Shiftout to Printhead 136 5 HPC Slave Processor 137 6 Stepper Motor Drives 138 7 ROM Memory 139 8 RAM Memory 140 9 uart1 Interface Circuit...

Page 4: ...der 501 E 501 LL Test Mode Diagram 196 25 6 EasyCoder 501 SA Test Mode Diagram 197 26 Trouble Shooting 26 1 Printer Dead 198 AC power failure 198 Power supply failure 198 Transformer and cabling failure 199 CPU board failure 200 Printhead CPU Board mismatch 201 26 2 Single Function Failure 202 No display function 202 No keyboard reaction 202 Error messages transmitted or displayed 203 No memory ba...

Page 5: ...is subject to change without prior notice and does not represent a commit ment on the part of Intermec Printer AB Copyright Intermec Printer AB 2001 All rights reserved Published in Sweden EasyCoder EasyLAN Fingerprint and LabelShop are registered trademarks of Intermec Technologies Corp The word Intermec the Intermec logo InterDriver and PrintSet are trademarks of Intermec Tech nologies Corp Bits...

Page 6: ...der 501 E Installation Operation manual Intermec EasyCoder 501 SA Installation Operation manual Intermec EasyCoder 501 LL Installation Operation manual Intermec EasyCoder 501 Spare Parts Catalog Intermec EasyCoder 501 Installation Instructions for various options Intermec Direct Protocol v6 13 Programmer s Guide Intermec Fingerprint v6 13 Programmer s Guide Intermec Fingerprint v6 14 Reference Man...

Page 7: ...ense will be required to take whatever measures 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...

Page 8: ...onformity with the following standards EN 60 950 1992 EN 50 081 1 1992 EN 55 022 Class B EN 50 082 2 1995 ENV 50 140 10 V m ENV 50 204 10 V m ENV 50 141 10 V m EN 61 000 4 2 6 kV Con 8 kV Air EN 61000 4 4 2 kV power lines 1 kV signal lines following the provisions of Directives 89 336 EEC and 73 23 EEC Mölndal 1998 09 01 Hans Lindén President 1 Intermec assumes no responsibility regarding the CE D...

Page 9: ...an be identified by their external appearance EasyCoder 501 S Standard has a single Print button on its front panel EasyCoder 501 E Enhanced and 501 LL LinerLess have a setup keyboard with 22 programmable keys EasyCoder 501 SA Stand Alone hasafullQWERTYkeyboardwithadditionalcontrolkeysadapted for the Intermec Stand Alone program 1 Models and Options ...

Page 10: ...09 V D E geprüfte Sicherheit The machine sign on the printer s rear plate provides information on type part number and serial number The voltage switch indicates the mains voltage for which the printer is set up 115 or 230VAC Always check this switch before connecting the printer You can also detect if the printer is fitted with any optional inter face board by means of the additional connectors o...

Page 11: ...ge from the snap lock IM PORTANT PRINTHEAD AND RIBBON INFORMATION The use of any thermal transfer ribbons other than those supplie d by UBI will invalid ate the printhead warranty UBI thermal transfer rib bons are engineered specifically for this printhead The quality of thermal and thermal transfer media supplies in this printer is also of great importance for the quality of printing bar codes an...

Page 12: ... front where the cutter replaces the front hatch see Chap ter 12 The EasyCoder 501 LinerLess has a spcial cutter By opening the front hatch or the optional cutter unit fitted in its place you can check if the printer is fitted with a Memory Card Adapter see Chapter 13 and or a Label Taken Sensor see Chap ter 11 Paper Cutter Unit LabelTaken Sensor Memory Card Adapter inside ...

Page 13: ...sing a T10 Torx screwdriver remove the four screws at the bottom of the cover plate and the four screws along the upper edge hidden under the right hand cover In the electronics compartment you may check for example Type of CPU Board fitted Fingerprint EPROM version Configuration EPROM type Optional ROM expansion EPROMs fitted Correct type of GAL circuits Optional Real Time Clock circuit RTC fitte...

Page 14: ...ter in the immediate mode of Inter mec Fingerprint The instructions FILES rom FILES ram and FILES card1 allows you to check what files the various parts of the printer s memory contains The statements FONTS and IMAGES can be used for the same purpose regarding fonts and images Use theVERSION function to check version of the Inter mec Fingerprint firmware The Intermec Fingerprint utility program PR...

Page 15: ...205 mm 8 0 in Maximum Ribbon Length 450 m 1476 ft 450 m 1476 ft 450 m 1476 ft N A Label Slack Absorber N A Standard Standard Standard Keyboard Built In Print Key Only 22 Programmable Keys QWERTY w control keys 22 Programmable Keys Bitmap Fonts Expandible 4Times Min 1 Std 10 Min 1 Std 10 10 Min 1 Std 10 Bar Code Generators Depends on F W version Depends on F W version 10 Depends on F W version Star...

Page 16: ...5 4 mm 5 33 275 mm 10 83 68 8 mm 2 71 Dot No 0 8 dots mm printhead in right hand position 79 mm 3 11 363 mm 14 29 481 5 mm 18 96 R 1 3 9 m m 5 4 7 20 mm 0 79 20 mm 0 79 30 mm 1 18 186 mm 7 32 13 mm 0 51 38 mm 1 50 Paper slot Paper slot 1 3 Measures An optional paper cutter increases the printer s total length by 28 mm 1 1 inches ...

Page 17: ...ided with holes for mounting a cutter con nector 4 pin female DIN type and a memory card adapter At the top part of the front moulding there is a cavity for the keyboard display assy This assembly is affixed by means of two grub screws which can be loosened using a 2 mm hexagon wrench Keyboard Display assy Front Moulding Provision for Cutter Connector Provision for Memory Card Adapter Grub Screws ...

Page 18: ...ack into the front moulding since it makes it easier to align the brackets with the grub screws The keyboard display assy consists of a plate with two brackets a self adhesive keyboard an interchangeable slide and a keyboard interface pcb with a 2 16 character LCD and three LEDs The keyboard is connected to P 3 on the interface pcb via a semi trans parent cable running through a slot in the plate ...

Page 19: ...e can be replaced by another one for example to adapt the printer for a certain language or a special application There are three different standard slides with English text as shown below Keyboard of EasyCoder 501 S Keyboard of EasyCoder 501 E and 501 LinerLess Keyboard of EasyCoder 501 SA Power Error Ready Print Power Error Ready Print Feed Enter Setup Pause F5 F4 F3 F2 F1 7 4 1 8 5 2 0 9 6 3 C ...

Page 20: ... Diagram 040701 01 P2 P1 P4 C1 C3 RN2 C4 R7 R4 R5 R6 R9 IC1 C2 IC2 RN1 P3 R3 R2 R1 LED1 LED2 LED3 Keyboard Interface Board 1 040701 26 Components Diagram Connections P 1 Permanently attached cable to P 2 on CPU Board P 2 LCD Display soldered P 3 Keyboard P 4 Provision for separate print key for special applications ...

Page 21: ...0 18 A6 10 7 COL1 PB1 19 A5 9 6 COL2 PB2 AD0 20 34 DB0 8 5 COL3 PB3 AD1 21 33 DB1 7 4 COL4 PB4 AD2 22 32 DB2 6 3 COL5 PB5 AD3 23 31 DB3 5 2 COL6 PB6 AD4 24 30 DB4 4 1 SHIFT PB7 AD5 25 29 DB5 3 P3 AD6 A5 74HC04 28 DB6 2 PC0 14 AD7 27 DB7 1 2 3 4 5 6 7 8 9 10 PC1 15 1 P1 12 13 PC2 16 IC2F PC3 74HC04 17 1 RN1 74HC04 PC4 READY 13 1 PC5 6 5 ERROR 12 1 5V 10 11 PC6 LED1 LED2 LED3 IC2C RS 11 IC2E PC7 74H...

Page 22: ...ear hinge disengages At the inside of the door there is a label showing how to load the media and the transfer ribbon The standard door can be replaced by an optional door provided with a clear panel for easier view of the ribbon and media sup plies The hinges can be adjusted by means of the two pairs of T10 Torx screws visible on the outside Possibly the other parts of the hinges which are fitted...

Page 23: ...ns of two hinges of the same type as those of the right hand door The front hatch is kept shut by a snap lock and can be swung down almost to a vertical position The hatch can be removed from its hinges by pushing it to the left until the snap lock on the right hand hinge disengages The front hatch can be replaced by an optional paper cutter unit Alignment is performed in the same way as the right...

Page 24: ...itted to the printer s frame by means of a total of eight T10 Torx screws four along the lower edge and another four along the top WARNING The electronic compartment contains wires and components with dangerous voltage 115 230 VAC Switch off the printer and disconnect the power cord before removing the left hand cover After having disconnected the power cord open the right hand door Using a T10 To...

Page 25: ...enter section and the transformer unit by two similar screws A bracket is affixed to the inside of the rear plate by a screw see illustration below The upper rear corner of the CPU board is inserted into a slot in this bracket so as to provide increased stabil ity Any installed interface board will have to be disconnected before the rear plate can be removed CPU Board Bracket ...

Page 26: ...a from external supplies These slots can be provided with optional edge guides as described in Chapter 5 The mchine label with the signs of approval is fitted on the rear plate 4 2 Devices on Rear Plate 0 230V MADE IN SWEDEN Thermal Printer 501 Model 1 501011 14 Serial 115 230V 2 6 1 3A 50 60Hz INTERMEC PRINTER AB MADE IN SWEDEN 25016 This equipment complies with the requirements for a Class A com...

Page 27: ...er roll cores with an inner diameter between 38 and 40 mm 1 5 to 1 6 inches A large crescent shaped plate keeps the media roll aligned with the print mechanism In the EasyCoder 501 LinerLess the crescent shaped plate is replaced by a circular plate fitted inside the inner most bobbin module Maximum diameter of an internal media roll is 205 mm 8 inches and maximum width is 120 mm 4 7 inches except ...

Page 28: ...a roll might cause excessive media to be unwound when the printing is stopped The brake torque should be 50 20 Nmm1 The printer is prepared for the fitting of a media low sensor in having a code disc fitted as standard at the innermost part of the bobbin package Be careful to fit the studs of the innermost bobbin into the holes in the code disk when the package is assembled 5 1 Internal Supply con...

Page 29: ...d prevent jerks The brake torque should be 50 20 Nmm1 The printer is prepared for the fitting of a media low sensor in having a code disc fitted as standard at the innermost part of the bobbin package Be careful to fit the studs of the innermost bobbin into the holes in the code disk when the package is assembled 5 1 Internal Supply cont 1 Refer to Appendix 2 for a descrip tion of how to check the...

Page 30: ... 3 inches cores The adapter is locked by means of a screw Be careful not to let the screw hit the leaf springs or the cams of the bobbins An optional media roll retainer can be fitted on the bobbins but not on the adapter to hold large media rolls It is not used in connec tion with EasyCoder 501 LinerLess 5 1 Internal Supply cont 76 mm 3 inch Adapter Media Roll Retainer ...

Page 31: ...ferent media widths The kit also contains two shafts and two sets of guide rolls that can be fitted to the rear of the print unit The kit can be used in many different ways as explained later in this chapter This illustration shows a full installation on an EasyCoder 501 E IM PORTANT PRINTHEAD AND RIBBON INFORMATION The use of any thermal transfer ribbons other than those supplie d by UBI will inv...

Page 32: ...edia supply is located in relation to the printer Insert the complete unit through the slot from the outside and attach it to the rear plate by means of two T20 Torx screws In case of the upper position use the screws included in the kit and in case of the lower position use the two existing screws that hold the rear plate to the bottom plate Adjust the position of the outer guide to fit the width...

Page 33: ...ottom plate before you can fit the inner guide roll If there is no rear guide shaft already fitted in the printer use one of the shafts included in the kit and attach it to the printer s centre line wall using a T20 Torx screw included inserted from the electronics compartment as illustrated below Before removing the left hand cover read the instructions in Chap ter 1 1 Adjust the inner guide roll...

Page 34: ...g read the safety instruc tions in Chapter 1 1 If the printer is fitted with a Liner Batch Takeup Kit its stepper motor must be removed see Chapter 9 Remove the guide shaft EasyCoder 501 S or label slack absorber EasyCoder 501 E SA using a T20 Torx screw driver Fit a guide shaft with two guide rolls in the lowest of the holes on the printer s center section using a T20 Torx screw All parts are inc...

Page 35: ...ply should be protected from dust sand grit and other particles that may damage the printhead or impair the printout quality Note that if the printer is to be permanently used with an external media supply only the internal media supply spool together with the large crescent shaped guide plate could easily be removed see Chapter 5 1 5 2 External Supply cont ...

Page 36: ...absorber will flutter back and forth compensating for the variations in tension Since the label slack absorber only is required at high speed print ing 100 mm sec 4 inches sec it is has been omitted from the EasyCoder 501 S model where it is replaced with a simple shaft with two green guide washers see below To facilitate media load the label slack absorber can be rotated 180 clockwise to a locked...

Page 37: ...label slack absorber unit is fitted to the center section using two T20 Torx screws inserted from the electronics compartment The shaft should be screwed into the flange with a tightening torque of 5 Nm T20Torx Screw 2x T10Torx Screw Torsion Spring Shaft Flange T10Torx Screw Spacer Grip Edge Guide ...

Page 38: ...t consists of a shaft on which a spool is fitted The spool can pivot 1 3º on the shaft and the spool can be moved sideways It is most important that the pivoting point of the spool is centered in relation to the ribbon width Therefore the shaft is provided with six grooves which correspond to the standard widths of Intermec transfer ribbons see table to the left By compressing the spool its snap l...

Page 39: ...lfa turn the diameter of the spring has been compressed enough to allow the sleeve to slip The brake torque should be 55 5 Nmm1 The sleeve is filled with ball bearing grease If the brake torque deviates from the rec ommended value replace the grease We recommend Castrol Sin plex 2 When the rotating force ceases the spring tends to pull back the ribbon keeping it tight The shaft rotates in bearings...

Page 40: ...e The unit is driven via a belt by the same stepper motor that drives the platen roller The rewind unit is provided with a friction brake and a ratchet gear wheel in order to keep the ribbon tight The ribbon rewind unit is fitted to the center section using two T20 Torx screws inserted from the electronics compartment One of the screws runs in a crescent shaped slot to allow adjustment or removal ...

Page 41: ...Then you can inspect the friction felt No further dismantling is normally required Reassemble in reverse order making sure that the one way clutch in the gear wheel works in the correct direction Finally fit the belt over the gear wheel adjust the tension of the belt as described in Chapter 8 4 and tighten the screws that hold the flange The braking torque can be adjusted by adding or removing was...

Page 42: ...mirror to a receiver in the sensor The firmware compares the signal from the sensor with the printer s setup in regard of media type in order to avoid printing on the wrong type of media Set up Detection Error Thermal transfer media Ribbon OK Thermal transfer media No ribbon Error 1027 Out of transfer ribbon Direct thermal media No ribbon OK Direct thermal media Ribbon Error 1058 Transfer ribbon f...

Page 43: ...PROGRAM BY TYPING X 30 BREAK 1 88 BREAK 1 ON 40 ON BREAK 1 GOSUB 1000 50 IF PRSTAT AND 8 THEN SOUND 100 50 ELSE BEEP 60 GOTO 50 70 END 1000 BREAK 1 OFF 1010 GOTO 70 RUN Remove the transfer ribbon from the sensor s beam of light for example by pulling out a loop and run the program The printer should emit a low sound Put back the ribbon into the beam and the printer should start to beep with a high...

Page 44: ...other whereas the liner drive roller is idle unless a liner batch takeup kit is fitted see Chapter 9 The tear bar makes it easier to tear off continuous or preperforated stock It is also used for peel off operation The label stop sensor LSS controls the media feed and checks for out of media conditions The printhead produces the heat that melts the ink on the ribbon or blackens the direct thermal ...

Page 45: ...Intermec EasyCoder 501 Service Manual Ed 7 44 Chapter 8 Print Unit 8 2 Main Parts cont Liner Drive Roller Stepper Motor Platen Roller Tear Bar Printhead Headlift Mechanism EasyCoder 501 S E and SA ...

Page 46: ...r 8 Print Unit Load Load Print Print Load Print 8 2 Main Parts cont Stepper Motor Non stick Platen Roller Plasma coated Tear Bar Plasma coated Surface Headlift Mechanism EasyCoder 501 LinerLess Printhead NoThermalTransfer Mechanism No Liner Drive Roller ...

Page 47: ...the single grub screw that hold the pulley on the shaft Using a T20 Torx screwdriver remove the bracket that holds the bearing at the outer end of the shaft Pull out the roller and the two ball bearings Reassemble in reverse order using a fresh set of roller and ball bearings The distance between the pulley of the pressing roller and the inner gable of the print unit should be 5 mm 2 inches Check ...

Page 48: ...ted by means of two T20 Torx screws to a bracket which in its turn is attached to the print unit gable by three T20 Torx screws When fitting the stepper motor to the bracket check the tension of the belt to the platen roller before the screws are tightened The bracket does not need to be dismantled for replacing the stepper motor or the belt The pulleys of the stepper motor are glued to the motor ...

Page 49: ...of ribbon rewinder belt not EasyCoder 501 LL The belt should be adjusted so it neither jump the cogs nor becomes subjected to unnecessary wear Slightly loosen the two T20 Torx screws that hold the flange of the ribbon rewind unit Turn the ribbon rewind unit so the belt becomes tight yet will flex slightly when you press it with a finger Tighten the screws Check that the parts can rotate freely and...

Page 50: ... to stick to the bar When media is to be rewound internally see Chapter 9 the tear bar must be replaced by an optional takeup guide using the same screws as illustrated below When not used the takeup guide can be stored at the rear of the media compartment as illustrated in Chapter 1 1 There is no such device in the EasyCoder 501 LinerLess When the tear bar is fitted back after batch takeup operat...

Page 51: ...transparent liner backing paper between labels will let some of the light through Absence of media lets the light pass uninterrupted The Intermec Fingerprint firmware detects the start of each label that is when the condition switches from semi transparent liner to opaque label If the light passes without any interruption for more than 61 mm 2 4 inches of media feed an out of paper condition is as...

Page 52: ...t has not been interrupted within 61 mm 2 4 inches of media feed The LSS may require adjustment when the user changes to another brand or sometimes even batch of media and when a defective sensor has been replaced Before starting the adjustment check that both the upper and lower sensor are clean and free from obstructions Also check that the LSS is laterally positioned as to detect the gaps or bl...

Page 53: ...d its bracket aside as well as the rear guide plate Pull out the lower gable and the LSS assy Remove the two T8 Torx screws that hold the defective sensor Cut the cable clip and remove the defective sensor Reassemble in reverse order replacing the cable clip Connect the cable from the lower sensor to P 600 on the CPU board and the cable from the upper sensor to P 601 T20Torx Screws Rear Guide Plat...

Page 54: ...nk melts and sticks to the receiving face material where the ink immediately becomes solid again producing a black spot The transfer ribbon does not smear neither before nor after printing Nor do the printed labels smear even if the printout may be smudged by extensive rubbing if an unfortunate combination of ribbon and face material is used The thermal transfer method makes it possible to use a m...

Page 55: ...ng the media feed direction represents a shorter distance than the same number of dots across the media feed direction see table below The reason is that the 8 dots mm density printhead and the media feed mechanism are designed according to metric standards whereas the 11 81 dots mm print head is designed to be exactly 300 dots inch which is not compen sated for by a similar media feed For most pr...

Page 56: ...ng the Intermec Fingerprint function HEAD The printhead is fitted to an adapter plate by means of a single screw A locking mechanism operated by a lever holds the adapter plate to the headlift bracket A guide screw can be fitted either to the left or right at the top of the adapter plate in order to select the printhead s lateral position in relation to the headlift bracket see later in this chapt...

Page 57: ...bbon if any Turn the lock handle counter clockwise to open position see illustration The printhead adapter assembly will now be free and can be carefully removed as far as the cables allow Disconnect the two printhead cables Pull at the connectors rather than the cables Printhead fitted in right hand position Note the position of the guide screw 8 7 Printhead cont Guide Screw Locked Position Lug L...

Page 58: ...art of the adapter is held by the two lugs on the bracket You can switch between printheads with different densities at will except in EasyCoder 501 LinerLess that only uses an 8 dots mm printhead Turn the locking handle clockwise to locked position Put back the transfer ribbon if any Check that the printhead cables do not interfere with the ribbon Lower the printhead Switch on the power At power ...

Page 59: ...ft hand position see illustra tion dot No 0 is aligned with the inner edge of the media Since the maximum print width is 104 mm 4 1 inches and the maxi mum media width is 120 mm 4 7 inches this leaves a margin of at least 16 mm 0 6 inches along the outer edge of the media where no printing can be performed FEED DIRECTION Dot 0 Dot line on printhead X start Width Origin Length From media supply Dot...

Page 60: ... inches inside the inner edge of the media Since the maximum print width is 104 mm 4 1 inches and the maximum web width is 120 mm 4 7 inches this leaves a margin of at least 13 mm 0 51 inches along the outer edge of the web If an 110 mm 4 33 inches wide web is used the printhead will be centered with a 3 mm 0 12 inches margin on each side Dot 0 X start Width Origin Length Dot 831 PRINT WINDOW PRIN...

Page 61: ... mm 0 03 inches inwards of the inner edge of the media Since the maxi mum print width is 108 3 mm 4 26 inches and the maximum media width is 120 mm 4 7 inches this leaves a margin of at least 10 9 mm 0 43 inches along the outer edge of the media where no printing can be performed Dot 0 X start Width Origin Length Dot 1279 PRINT WINDOW PRINT WINDOW FEED DIRECTION Dot line on printhead From media su...

Page 62: ...d position see illustra tion dot No 0 is aligned with the inner edge of the media Since the maximum print width is 104 mm 4 1 inches and the maxi mum media width is 114 mm 4 49 inches this leaves a margin of at least 10 mm 0 39 inches along the outer edge of the media where no printing can be performed FEED DIRECTION Dot 0 Dot line on printhead X start Width Origin Length From media supply Dot 831...

Page 63: ...hes inside the inner edge of the media Since the maximum print width is 104 mm 4 1 inches and the maximum web width is 114 mm 4 49 inches this leaves a margin of at least 7 mm 0 28 inches along the outer edge of the web If an 110 mm 4 33 inches wide web is used the printhead will be centered with a 3 mm 0 12 inches margin on each side Dot 0 X start Width Origin Length Dot 831 PRINT WINDOW PRINT WI...

Page 64: ...ft bracket The bracket itself is designed as a torsion spring The headlift shaft ends with a handle at one side and a code disk at the other The position of the code disk is read by the headlift sensor so the software can determine whether the printhead is lifted or lowered The sensor is connected to P 608 on the CPU board Code Disk Headlift Sensor Printhead Bracket Upper Gable Handle Adjustable S...

Page 65: ...shaft by means of three screws which allow the angle between the gable and the front edge the printhead to be factory adjusted The bracket is fitted with a locking mechanism for the printhead assy 8 8 Headlift Mecha nism cont Thermal Printhead Bracket Locking Mechanism Shaft Do not loosen these screws Factory adjusted ...

Page 66: ...obs of both adjusters are rotated clockwise as far as they go On the inside the knobs are designed as ratchet wheels An increased resistance and clicking sound occurs at each quarter of a turn When assembling an adjuster unit the pawls of the stop unit must be pressed inwards so they fit inside the knob Else they are liable to be broken For information on how to adjust the printhead pressure for v...

Page 67: ...ves the liner drive roller roller in the print unit and the takeup unit The rewind roller is fitted as stan dard even when no rewind kit is installed A rewind unit that takes up the spent liner or the printed media to be rewound for later use A guide plate that replaces the tear bar when labels or other types of printed media are wound up internally also see Chap ter 8 5 When not used the rewind g...

Page 68: ...ommodate the liner from a full roll of labels BatchTakeup Operation The takeup unit can accommodate approx 1 4 to 1 3 of a full label roll 9 1 Description cont Tear bar retained IM PO The use of an the printhead The quality of for the qualit paper we only UB TEAR OFF Tear bar replaced by guide plate Front hatch kept open ...

Page 69: ...tepper motor and or support plate before the screws are tightened The takeup unit is fitted with a brace that holds the liner or media The unit is fitted to the printer s center section using two T20Torx screws that can be accessed through holes in the CPU board A break shaft in front of the rewind unit guides the liner or media under the slack absorber The stepper motor is connected to P 400 on t...

Page 70: ... sudden jerks A bobbin plate helps to hold possible rewind cores The assembly is held together by a T20 Torx screw at the end of the shaft If the rewind unit does not have enough strength to wind up the media or to peel off the labels it may depend on a too dry friction felt Dismantle the unit and soak the felt pad in fresh motor oil Remove excessive oil with a piece of tissue and reassemble the u...

Page 71: ...y reducing the cost of thermal transfer printing and increasing the time between ribbon reloads The Ribbon Save Device works automatically but can be switched off if so desired see Chapter 10 2 When the firmware deter mines that no printing is to be performed within the next 20 mm 0 8 inches or more of media feed the printhead is lifted by a motor and the transfer ribbon is stopped The operation o...

Page 72: ...threaded between the rear drive roller and the pressing roller By default the Ribbon Save Device is automatically switched on whenever such a device is fitted However ribbon save operation can be switched off on at will by means of RIBBON SAVE OFF and RIBBON SAVE ON statements RIBBON SAVE OFF ON affects both the immediate and the programming modes There are no adjustments available to the operator...

Page 73: ...anism Therefore the Ribbon Save Device is a factory installed option only The Ribbon Save Device consists of the following main parts each described in a separate subsection The print unit differs in some important respects from the standard direct thermal thermal transfer print unit described in Chapter 8 See Chapter 10 6 The headlift mechanism consists of a DC motor and an elec tronics board fit...

Page 74: ...ing ribbon save operation At the rear part of the print unit there is an additional drive roller that pushes the media forward when the printhead is lifted A spring loaded set of pressing rollers provides the nec essary friction between media and drive roller A linkage lifts the pressing rollers when the printhead is lifted manually using the green knob for example at media and ribbon load The rea...

Page 75: ...a when being pushed forward by the rear drive roller The guide plates can be dismantled without any tools to make it easy to remove possible stuck labels The lateral position of the label stop black mark sensor is adjusted using a screw instead of a handle The LSS can be removed without dismantling the lower outer gable There are no provisions for retaining the platen roller alignment when the low...

Page 76: ...ear drive roller is driven by the same belt and stepper motor as the fplaten roller and fitted to the gables of the print unit in a fashion similar to the platen roller Rear Drive Roller Replacement To replace the rear drive roller you must remove the stepper motor belt and pulley as well as the lower plastic guide plate When fitting back the pulley make sure that the distance between the side of ...

Page 77: ...ooking head on into the print unit when the printhead is lifted Align the centerpoint of theV shaped upper sensor with the center of the gaps to be detected The linear markings on the lower guide plate can also be used for positioning of the LSS as they are spaced with an interval of exactly 1 cm 0 39 inches from the edge that guides the media This method is especially useful for black marks measu...

Page 78: ...wdriver and lift the outer end free before carefully pulling out the guide plate Guide Plates Cleaning The rectangular areas with a smooth surfaces on each guide plate are actually windows which are transparent to the light emitted by the LSS These areas must be kept free from dust stuck labels and adhesive residue Only use isopropyl alcohol for cleaning Snap Lock Upper Guide Plate LSS Unit Lower ...

Page 79: ...he print unit Label Stop Black Mark Sensor Replacement To remove the LSS bracket from the carriage for example when cleaning or replacing a sensor proceed as follows see illustration on the next page Remove the upper and lower plastic guide plates Remove the printhead Adjust the LSS to approximately center position Disconnect the cables from P 600 and P 601 on the CPU board Disengage the snap lock...

Page 80: ...he outer end and push it inwards so the inner notch in the bracket engages the carriage Press down the outer end of the bracket so the snap lock engages the outer notch Press the bracket inwards as far as it goes and check that the bracket is secured by the snap lock Connect the cable from the lower sensor to P 600 and the cable from the upper sensor to P 601 on the CPU board Put back the guide pl...

Page 81: ...head bracket are connected using two screws that can move in holes in the bridge Adjustment is done by means of two nuts Printhead Bridge Adjustment To adjust the relation between the bridge and the printhead bracket proceed as follows Turn the headlift knob as to release the spring pressure from the printhead bracket Measure the distance between the nuts and the lifting bridge using a feeler gaug...

Page 82: ...g sleeve by means of two spring loaded arms in order to be self aligning A linkage connects the turning sleeve to the headlift shaft so the pressing roller is lifted when the printed is lifted manually using the headlift knob for example at media load but not when the printhead is lifted by the headlift motor during ribbon save opera tion E Ring Shaft Tubular Spacers Excenter E Ring Tubular Pin Tu...

Page 83: ...er motor fitted on a bracket that also holds the connection board which controls the headlift motor and the ribbon rewind motor The headlift motor is fitted with an excenter that engages a lever fitted on the headlift shaft The lever is provided with a steel spacer to protect it from wear Printhead assy Lever Spacer Headlift Mechanism and Connection Board ...

Page 84: ... of the motor a cam is fitted A photoelectric sensor connected to P 4 on the connection board detects the position of the cam printhead lifted or lowered The outer end of the motor s shaft is supported by a ball bearing inserted in the bracket The cam is provided with an eccentrically fitted ball bearing that engages the printhead lift lever see the previous page 10 7 Headlift Mecha nism cont Conn...

Page 85: ... nism cont Adjustment The whole unit is fitted to oblong holes in the chassis which allow the mechanism to be slightly adjusted in relation to the headlift lever The distance can be measured with a feeler gauge when the printhead is lowered and should be 0 3 mm 0 01 inch Insert feeler gauge here ...

Page 86: ...the belt to be adjusted The lower leg of the stepper motor assy runs through a bracket at the top of the headlift mechanism to give the latter addi tional support Replacement To replace the belt the stepper motor unit must be removed After fitting a new belt adjust as described below Adjustment Loosen the three T20 Torx screws and rotate the stepper motor assy until the belt becomes tight but stil...

Page 87: ...ual Ed 7 86 Chapter 10 Ribbon Save Device 10 9 Connection Board Connection Board 1 040702 28 Components Diagram Connections P 1 Permanently attached cable to P 8 on CPU Board P 2 Ribbon Rewind Motor P 3 Lifting Motor P 4 Optical Switch ...

Page 88: ...ST1 ST2 ST3 ST4 ST5 ST6 GND EN_ENG2 74HC573 11 CLK 1 OE 2 19 ST6_ENG2 D 3 18 ST5_ENG2 D 4 17 ST4_ENG2 D 5 16 ST3_ENG2 D 6 15 ST2_ENG2 D 7 14 ST1_ENG2 D 8 13 D 9 12 D IC1 5V R4 P4 2 4 LIFT_HEAD 1 POSITION 3 R3 74HC86 5V 2 NOT_RUN 3 1 1 IC4A IC4B 4 1 6 5 R5 74HC86 Q1 R7 Q3 Q2 R6 V40 DC MOTOR P3 2 1 R9 C14 5V ST4_ENG2 ST5_ENG2 ST6_ENG2 R8 C13 5V ST1_ENG2 ST2_ENG2 ST3_ENG2 PBL3717 15 AOUT 8 PHASE 1 BO...

Page 89: ...the sensor by any label ticket tag piece of strip or liner that has not been removed from the outfeed area A prerequisite is that the media is fed out along the center section of the printer The LTS is connected to P 606 on the CPU board The sensitivity of the receiver can be adjusted by means of the potentiometer WR 602 and the intensity of the emitter by a strap on P 607 on the CPU board 11 1 De...

Page 90: ... function as otherwise the printer will not react on the LTS signal Make a simple program that checks the printer s status for example 10 BREAK 1 88 20 BREAK 1 ON 30 ON BREAK 1 GOSUB 1000 40 FORMFEED 50 IF PRSTAT AND 2 THEN BEEP 60 GOTO 50 70 END 1000 BREAK 1 OFF 1010 GOTO 70 RUN You can break this program by transmitting the character X ASCII 88 decimal on the standard serial interface uart1 Swit...

Page 91: ...it as shown by the two illustrations below Fit the cable underneath the top part of the bracket as illustrated in the lowermost picture T10Torx Screw LTS assy Fit LTS here Cable held by bracket The illustrations show the print unit of an EasyCoder 501 E The EasyCoder 501 LL has a slightly different type of print unit see Chapter 8 2 which however does not affect the installation of the LTS ...

Page 92: ...el in the outfeed slot to create a label not taken condition The printer should start to beep continuously If not turn the potentiometer back and forth until the beeping starts Adjust the potentiometer so the beeping does not stop when the screw is turned a quarter of a turn in either direction If necessary fit or remove a jumper on P 607 to change the intensity of the LTS emitter Strap fitted Hig...

Page 93: ... EasyCoder 501 LL Both cutter units are fitted on the same hinges as the front door which they replace and is connected by a single cable to the DIN connector on the printer s front The paper cutters are available both as a factory installed options and as a field installable upgrading kit 12 1 Description WARNING In the standard cutter the cutting edge will rotate to home position when the power ...

Page 94: ...nt from the standard cutter The most important differences from the standard cutter are Plasma coated shears and guides to prevent labels from sticking to the cutter mechanism Better access to the anvil blade for cleaning Permanent silicon lubrication of the shears A three fingered guide plate that holds the cut off labels A safety switch the prevents the cutter from rotating when the anvil blade ...

Page 95: ...ld be adjusted accordingly The following values are recommended for cutting between labels and for variable length strip In both cases the start adjustment is calculated to allow the media be pulled back after cutting so print ing can start directly at the forward edge of next copy Density 8 dots mm 203 2 dpi 11 81 dots mm 300 dpi Labels Start adjust 294 441 Stop adjust 180 270 Var length strip St...

Page 96: ...blade is in open position Soak a cotton swab with WD 40 multi spray or similar 1 and rub it against the cutting edge of the anvil blade to dissolve any adhesive residue Inspect the interior of the cutter for possible shreds of labels adhesive residue and similar If necessary clean using a clean ing card or a cotton swab soaked with WD 40 Close the anvil blade and lock the arm with the brace Fold u...

Page 97: ...s fitted with a label taken sensor LTS it has to be removed before the cutter can be fitted see Chapter 11 Fit the cutter unit to the vacant hinges Make sure that the lock ing plate snaps into the groove of the right hand hinge and that the angled plate at the bottom of the cutter is inserted under the printer s bottom plate Fit the cable from the cutter unit into the DIN connector above the memor...

Page 98: ...power cord and switch on power The cutter will perform an idle cycle in order to occupy its home position Switch off the power Tilt down the cutter and route the media through the cutter unit between the guide plates see illustra tion above Then tilt up the cutter again and lock it in closed position Check that the printhead is lowered and switch on the power Now the printer is ready for operation...

Page 99: ...he other cable from the cutter interface connector is fitted on P 6 on the CPU board see Chapter 17 4 Disconnect any jumper on P 607 on the CPU board1 see Chapter 17 3 Fit the cutter unit to the vacant hinges Make sure that the lock ing plate snaps into the groove of the right hand hinge and that the angled plate at the bottom of the cutter is inserted under the printer s bottom plate 12 4 Install...

Page 100: ...ccupy its home position Use for example the Terminal Setup in Intermec Shell or setup strings to change the startadjust value to 294 and the stopadjust value to 250 Setup strings should be composed like this SETUP DETECTION FEEDADJ STARTADJ 294 SETUP DETECTION FEEDADJ STOPADJ 250 Switch off the power Tilt down the cutter and route the media through the cutter unit between the guide plates see illu...

Page 101: ...ommend to fit it unless some other means of taking care of the label are provided such as an applicator The guide plate has a special plasma coating that prevents labels from getting stuck To prevent damage during transportation the guide plate is not fitted at delivery but is easy to fit using an T10 Torx key Loosen the two T10 Torx screws that hold the plate beneath the cutter s outfeed slot a f...

Page 102: ... or replacing a CPU board The LTS fitted inside the cutter on an EasyCoder 501 LL can be used for detecting paper jams This function does not interfere with the normal LTS function Just write a few lines in a Fingerprint program as illustrated by the following example IMMEDIATE OFF Init QJAMWAIT 150 see note OPTIMIZE BATCH ON MAIN LOOP W TICKS QJAMWAIT PF WHILE TICKS W AND NOT PRSTAT AND 2 WEND IF...

Page 103: ... the washers LinerLess Cutter The following parts are available as spares The guide plate see Chapter 12 4 The spring that holds the anvil blade Replace this spring if the pulling force becomes less than 1 75 N The cutter home position microswitch The safety microswitch anvil shear open closed The label taken sensor The latter three parts requires some dismantling of the cutter unit before they ca...

Page 104: ...nism to the cutter s front cover Lift out the mechanism and you have full access to the label taken sensor and the home position microswitch Reassemble in reverse order To replace the safety microswitch proceed as follows Disconnect the spring loaded brace and open the anvil blade Remove the plate over the upper rear parts of the cutting mecha nism held by two Torx T20 screws Now you have full acc...

Page 105: ... present on the buffers IC 3 to IC 5 data from the card is subsequently received through the bidirectional buffers IC 1and IC 2 see circuit diagram 1 971706 26 later in this chapter The purpose of signal ENIO is to address the immediate data while signal RD transfers the same data on D0 D15 from the memory card to the multiplexed address data bus AD0 AD15 of the CPU board It is possible to read a ...

Page 106: ...13 1 Description cont Memory Card Adapter Board Components Diagrams Memory Card Adapter Board 1 971706 26 Soldering Side Memory Card Adapter Board 1 971706 26 Component Side P 2 P 1 IC 7 D 1 C 7 RN 1 RN 2 F 1 C 5 C 3 R 2 R 5 R 1 C 2 IC 6 C 1 C 4 C 6 GNDC IC 1 IC 4 IC 5 IC 2 IC 3 ...

Page 107: ...NMI 16 DREG1 17 A23 18 A22 19 A21 20 A20 21 A19 22 A18 23 A17 24 A16 25 AD15 26 AD14 27 AD13 28 AD12 29 AD11 30 AD10 31 AD9 32 AD8 33 AD7 34 AD6 35 AD5 36 AD4 37 AD3 38 AD2 39 AD1 40 AD0 1 AN1 5V 1 AN2 5V CSLOW 2 D7 3 D13 4 D6 5 D12 6 D5 7 D11 8 D4 9 D3 10 10k D14 2 D15 3 CSHIGH 4 D8 5 D0 6 D9 7 D1 8 D10 9 D2 10 10k GND D3 D4 D5 D6 D7 CSLOW A10 RD A11 A9 A8 A13 A14 WR 5V Memory Card P2 CPU Connect...

Page 108: ... Chapter 13 Memory Card Adapter 13 1 Description cont Bus Driver Board Components Diagrams Bus Driver Board as fitted on the CPU Board Bus Driver Board 1 971712 25 Components P1 P1 MOUNTED ON SOLDERING SIDE P2 D1 971712 ØØ C3 IC3 IC4 IC2 IC1 C2 C1 ...

Page 109: ...AD4 AD2 AD0 1 19 2 3 4 5 6 7 8 9 17 AD14 18 16 15 14 13 12 11 5 3V 5 3V GND GND CSMEM RD WR HBE GND GND GND GND NADS GND NMI GND A23 A22 A21 A20 A19 A18 A17 A16 AD15 AD14 AD13 AD12 AD11 AD10 AD9 AD8 AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3EN1 3EN2 G3 BUSDIR GND AD15 AD13 AD11 AD9 AD7 AD5 AD3 AD1...

Page 110: ... Screws RTK ST 2 9 x 16 FZB One installation instructions booklet Switch off the power For double security pull the power cord out of the power cord receptacle at the rear plate of the printer Open the right hand door and remove the left hand cover Open the front hatch or cutter unit Using the three short T10 Torx screws in the kit attach the bracket onto the adapter s circuit board Also fit the l...

Page 111: ...ory card adapter to the free connector P 2 on the Bus Driver board Check that the cable cannot be damaged by movable mechanical parts Put back the left hand cover as initially mounted Check that a memory card can easily be inserted and pulled out from the adapter Close the front hatch and right hand door and insert the mains cable Switch on power The printer is now ready for use 13 2 Installation ...

Page 112: ...ation program Once programmed they cannot reprogrammed SRAM cards may be used the same way as OTPROM cards The files in such a card are regarded as an integrated part of the printer s ROM memory and can be listed using the statement FILES rom DOS formatted memory cards are always of SRAM type and can both be read from and written to that is they will work almost like a floppy disk Files in a DOS f...

Page 113: ...trated below Make sure that the manufacturer s logotype on the memory card is facing upwards Press firmly inwards so the pins in the adapter engage the cor responding slots in the memory card Switch on the power again and close the front hatch Before removing the memory card switch off the power Open the front hatch and pull the card straight out Close the front hatch and switch on the power again...

Page 114: ...be read and used for indicate paper low and ribbon low conditions as opposed to out of paper and out of ribbon conditions which are supported by the standard error han dling See SYSVAR system array in Intermec Fingerprint v6 14 Reference Manual The sensors require no regular cleaning However should any mal function be detected you may try to blow the sensor clear from dust or media residue before ...

Page 115: ... 17 4 Continue by fitting the media low sensor Media Low Sensor Remove the three T20 Torx screws holding the large crescent shaped guide plate that surrounds the media supply unit see Chapter 5 1 Remove the guide plate Fit the sensor under the code disc of the upper supply unit using the same method as when fitting the ribbon low sensor Connect the cable to P 602 on the CPU board see Chapter 17 4 ...

Page 116: ...from Intermec at a low cost The fonts come as files in PC format and can be downloaded to the printer via the Kermit communication protocol or be copied to a memory card which is inserted in the printer s optional memory card adapter The Intermec Fingerprint statement FONT converts the selected outline font according to the specified characteristics to Finger print s internal bitmap font format af...

Page 117: ...Remove the existing GAL circuit on IC 700 on the CPU board and replace it with the smallest of the circuits included in the kit The small semicircular mark must face upward Fit the EPROM package marked 5 in socket IC 104 and the EPROM package marked 6 in socket IC 105 In both cases the semicircular mark must face upward Inspect the circuits you have fitted for bent legs If necessary remove the cir...

Page 118: ...tch and the voltage selector are accessible through slots in the rear plate The transformer unit is connected to P 300 on the CPU board via a single cable The cables of the transformer unit are permanently affixed to either the transformer unit or theAC power cord receptacle WARNING The transformer unit contains wires and components with dangerous voltage 115 230 VAC Always remove the power cord b...

Page 119: ...acket that holds the CPU board to the rear plate Remove the two T20 Torx screws that hold the transformer unit to the rear plate and the single T20 Torx screw that con nects it to the center section Slide the unit slightly forward and remove it The ring core transformer and the AC power cord receptacle are fitted to the mounting plate by means of posidrive screws whereas the on off switch and the ...

Page 120: ...lack Black Black Yellow 16 4 Wiring Diagram AC Power Cord Receptacle w Filter On Off Switch Transformer Voltage Select Switch shows 115V selected To P 300 on CPU Board AC Voltage Black Black Ye Gr Yellow Black 4 Red 3 Red 2 Blue 1 Blue Black P1 P2 Black Black Brown Brown Brown Brown Red Red Orange Orange Yellow Ye Gr Built in overheating protection S1 S2 0 V 0 V 0 V 115 V 115 V 115 V 115 V 115 C o...

Page 121: ...ce Manual Ed 7 120 Chapter 16 Transformer Unit 1 4 BLUE BLUE RED RED YELLOW GREEN BLACK BLACK ORANGE RED BROWN BROWN YELLOW To P 300 on CPU Board To On Off Switch and Voltage Selector Ring Core Transformer 16 4 Wiring Diagram cont ...

Page 122: ...charge see note Keep in mind that the RAMs and the clock circuit are battery backed up Therefore there is a risk of short circuit if any con ductive tools are used on the CPU board When adding or replacing any socket mounted circuits make sure that their front markings are heading in the direction indicated by the components diagram in Chapter 17 5 17 1 Access to CPU Board 17 CPU Board 4 T10Torx S...

Page 123: ...ad Data measurements for example printhead temperature and voltage PROM for program formats and character generators RAM for formats and images Inputs outputs and communication The CPU board is equipped with two processors IC 07 and IC 402 the former of which is a 32CG16 that has an overall con trol of printer activities whereas the latter is an HPC 16083M that operates as a slave processor CPU 32...

Page 124: ...board are illustrated by the following diagram For a detailed circuits diagram refer to Chapter 17 6 13 AC DC CONVERTER VOLTAGE WATCH DOG DC DC CONVERTER 33 V DC DC CONVERTER 24 V DC DC CONVERTER 5 V RESET Battery Battery charge circuit P 300 P 302 D 308 P 303 4 3 2 1 1 2 V24 V40 5V RESET RESET V24 EN AD VIN VIN OK THRESH VEE AD CHARGE DC DC CONVERTER 40 V ...

Page 125: ...ration EPROMs or Flash Memory IC 106 to 109 SRAM packages IC 200 RS 232 driver circuit IC 402 HPC slave processor IC 508 DMA circuit IC 700 Program GAL STD or EHC FY 300 Fuse 6 3A 5x20 FST IEC Optional Circuits IC 20 Clock Circuit RTC IC 104 to 105 Memory expansion EPROMs or FLASH IC 205 to 206 Optocouplers for 20 mA CL on uart1 IC 207 RS 422 circuit for RS 422 on uart1 17 3 Circuits and Straps Ha...

Page 126: ...Fingerprint v6 14 Reference Manual IC 100 to IC 105 General Information These sockets can use either EPROMs or Flash Memory pack ages EPROMs must be fitted in pairs for example IC 100 stores the even byte portion and IC 101 stores the odd byte portion of a 16 bit word Each pair of EPROMs must have the same size EPROMs should be CMOS type with a max access time of 120 ns IC 100 to IC 101 can use EP...

Page 127: ...max 120 ns and be fitted in couples first couple on IC 106 and IC 107 second on IC 108 and IC 109 All SRAM packages must be of the same type and size 2 128K 2 1 Mbit Total of 256K 2 Mbit 4 128K 4 1 Mbit Total of 512K 4 Mbit 2 512K 2 4 Mbit Total of 1 024K 8 Mbit 4 512K 4 4 Mbit Total of 2 048K 16 Mbit The size of the SRAMs is automatically defined by the printer The RAM memory is battery backed up...

Page 128: ...ich means that it has a program of its own burnt into an internal ROM memory This circuit controls machine related functions like Thermal printheads The slave processor generates the strobe time signals which continuously control the energy supplied to each thermal element of the printhead Thus each element receives at all times the exact amount of electrical energy in order to develop the necessa...

Page 129: ...AL circuits for IC 700 one for Easy Coder 501 S another for EasyCoder 501E and EasyCoder 501 SA and a third for EasyCoder 501 LinerLess It is most important the correct type of GAL is fitted PrinterType GAL Part No EasyCoder 501 S 1 971803 xx EasyCoder 501 E SA 1 971804 xx EasyCoder 501 LL 1 971810 xx FY 300 Fuse The same type of fuse 6 3A 5 20 FST IEC is used on all Easy Coder 501 printers regard...

Page 130: ... for any size of EPROMs but are required if the size is 512K 4 Mbit P 200 DTR RTS Select This strap selects DTR or RTS signal for RS 232 on uart1 pin 20 also see Chapter 18 2 Pin 1 2 DTR indicates printer turned on Pin 2 3 A copy of RTS signal is produced Default Jumper on pin 1 2 P 202 Interface Select This strap selects one of three types of interface on uart1 Upper position RS 232 Middle positi...

Page 131: ...bled Jumper removed 5V disabled Default Jumper fitted P 604 Emitter Level for Ribbon End Sensor Two levels can be selected for the light intensity of the sensor s emitter Jumper fitted High Intensity Jumper removed Low Intensity Default N A P 607 Emitter Level for LabelTaken Sensor optional Two levels can be selected for the light intensity of the sensor s emitter Jumper fitted High Intensity Jump...

Page 132: ...pter P 4 Interface Expansion P 300 Power from Transformer P 303 24V P 8 Ribbon Save Optional Connections P 1 Memory Expansion memory card adapter P 4 Interface Expansion extra interface board P 6 Paper Cutter P 8 Ribbon Save Device P 303 24V P 400 Stepper Motor 2 paper rewind P 602 Media Low Sensor P 605 Ribbon Low Sensor P 606 Label Taken Sensor Standard Connections P 2 Panel Interconnection Boar...

Page 133: ...00 R14 R15 C7 R16 C8 R18 C9 IC204 C4 R10 R423 C605 R422 IC02 IC700 F702 R425 R22 C413 IC03 IC702 C702 R721 IC06 R503 R502 P602 R642 R627 2 1 IC512 IC502 IC510 IC503 IC509 IC511 040700 10 C505 C507 C506 C22 C508 C21 C20 C16 IC16 IC09 IC12 IC13 IC19 C37 C17 C35 C34 C13 C12 IC04 IC17 C30 IC18 R5 IC404 P3 BEEP C412 R415 IC21 P303 Q4 RESET Q303 Y400 R416 R400 C410 R26 R300 R316 R312 R308 R314 R322 R330...

Page 134: ...E 15 11 WAIT2 16 10 WAIT1 17 9 CSMEM 18 8 CS4 19 7 CS3 20 6 CS2 21 5 CS1 22 4 CS0 23 3 2 1 RESETB RESETB MEMTYPE A18 74HC32M 2 A18 CS 3 1 IC03A 1 74HC32M 5 CS4B 6 4 IC01B 74HC32M 2 CS3B 3 1 IC01A IO9 IO8 IO7 IO6 IO5 IO4 IO3 IO2 IO1 IO0 I9 I8 I7 I6 I5 I4 I3 I2 I1 I0 1 1 1 DMAHLDA 74HC541M 9 A23 8 A22 7 A21 6 A20 5 A19 4 A18 3 A17 2 A16 19 A16 A17 A18 A19 A20 A21 A22 A23 OE2 11 18 17 16 15 14 13 12 ...

Page 135: ... GND A1 A2 9 A0 A1 10 PC7 11 NC 12 PC6 13 PC5 14 PC4 15 PC0 16 PC1 17 CGDATA CGSTROB CGLATCH PPWREN CGCLK CGENABLE CGSTART OR ON 5V AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0 RESET RN3 WR IN2 IN1 ERROR DATAIN RS IDENT DI IDENT NC WR PA1 PA2 PA3 PA4 PA5 PA6 PA7 8255AM IC23 PB0 PB1 PB2 NC PB3 PB4 PB5 PB6 PB7 19 20 21 22 23 24 25 26 27 28 OUT1 OUT2 OUT3 OUT4 18 PC3 PC2 PC1 PC0 PC4 PC5 PC6 NC PC7 A0 A1 GND CS PA...

Page 136: ...16 4 A6 18 2 A5 EN 1 CSPANEL 74HC241M IC05 AD8 AD9 AD10 AD11 AD12 AD13 AD14 18 AD15 RD PANEL INTERFACE 5V WR1 1 2 3 AD4 AD3 AD5 AD2 AD6 AD1 AD7 AD0 CSX0 CSX1 XINT WR RD X0 X1 NMIHPC 5 3V GND RESET A4 A2 A3 A1 GND 26 25 24 23 22 21 I O INTERFACE 5V DI IDENT VDISP ECLK RESET BRD BWR CSPANEL GND GND A6 A5 DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 GND 20 19 18 17 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P4 16 15 EN GND...

Page 137: ... DMAHLDA 6 SHIFT 4 WR 3 RD 2 IOW 1 IOR IC508 21 AD15 D7 22 AD14 D6 23 AD13 D5 26 AD12 D4 27 AD11 D3 28 AD10 D2 29 AD9 D1 30 AD8 D0 40 A8 A7 39 A7 A6 38 A6 A5 37 A5 A4 35 A4 A3 34 A3 A2 33 A2 A1 32 A1 A0 R510 EOP DACK0 DREQ0 DACK1 DREQ1 DACK2 DREQ2 DACK3 DREQ3 RESET CLK CS HREQ AEN ADSTB HLDA READY MEMW MEMR IOW IOR 3D 3D 2D R M1 1 1C3 1C2 1 SRG8 3D 3D 2D R M1 1C3 1C2 1 SRG8 IC504 D D D D D D D D O...

Page 138: ...5 I4 I3 I2 VCC EXUI B0 B1 B2 B3 B4 B5 B6 B7 WO GND CKI 9 8 7 6 4 3 2 1 68 67 66 65 64 63 61 NMIHPC RESET AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7 GND IC19C IC502A 1 74HC04M 74HC074M D D D D D D D D 9 8 7 6 5 4 3 2 A1 A2 A3 A4 A5 A6 A7 A8 OE CLK STRBCLK C403 C402 Y400 19 18 17 16 15 14 13 12 IC408 74HC573M D D D D D D D D 2 3 4 5 6 7 8 9 OE CLK R410 GND ST1 ENG1 ST2 ENG1 ST3 ENG1 ST4 ENG1 ST5 ENG1 ST6 ENG1 ...

Page 139: ... I0 VR TIMING CURRENT GND D403 8 9 7 11 2 10 ST6 ENG1 ST4 ENG1 ST5 ENG1 5V IC401 PBL3770 GND C405 R405 R406 R408 C404 15 1 16 14 V40 3 V40 13 12 5 4 P401 1 2 3 4 5 6 7 8 D404 AOUT BOUT EMITTER VM VM GND GND GND GND PHASE I1 I0 VR TIMING CURRENT GND D405 8 9 7 11 2 10 ST3 ENG1 ST1 ENG1 ST2 ENG1 5V IC403 PBL3770 GND C407 R411 R412 R414 C406 15 1 16 14 V40 3 V40 13 12 5 4 D406 AOUT BOUT EMITTER VM VM...

Page 140: ...R A19 OE CS A18 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A1920 WRL19 RD CS1 AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7 27C080 IC104 30 12 11 10 9 8 7 6 5 27 26 23 25 4 28 29 3 2 1 31 24 22 D0 D1 D2 D3 D4 D5 D6 D7 13 14 15 17 18 19 20 21 A17 A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A19 A20 WR A19 OE CS A18 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A1920 WRL1...

Page 141: ... A10 A11 A12 A13 A14 A15 A16 A18 WR RD CS A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A19 WRH RD CS3B 628512 A18 CS 30 AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7 13 14 15 17 18 19 20 21 IC108 12 11 10 9 8 7 6 5 27 26 23 25 4 28 3 2 1 31 29 24 22 D0 D1 D2 D3 D4 D5 D6 D7 A17 A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A18 WR RD CS A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 ...

Page 142: ...S 9 DSR 12 DSR 14 CTS 16 RXDRS TXD RTS RESET MC145407 CEXT CEXT C209 17 10V C202 4 10V 10 TXD 8 RTS 6 DTR R201 R200 P200 1 2 3 C200 C201 15 RESET 13 RTS 11 TXD 18 20 3 1 IC207 8 2 7 3 6 5 DS8921 R213 R214 DTR 20 TXD RTS RXD CTS DCR 5VEXT GNDI 20M1 20M1 20M2 20M2 TXD TXD RXD RXD RS422I RS422I RS422O RS422O F201 F202 F203 F204 F205 F206 F207 F208 F210 F212 F213 F214 F215 F216 F217 F218 F219 26 27 1 ...

Page 143: ...VCC 5V NC 1 D7 AD15 2 D6 AD14 3 D5 AD13 4 TONE DECODER OUTPUT TONE OUT TIME CAP TONE IN IN FILTER OUT FILTER GND R644 R641 P607 2 C612 R633 R632 Q602 1 5V 8 5 R630 IC604 6 3 2 1 LM567CM 5V R624 C606 C608 2 C610 GND 3 4 2 1 P603 3 WR601 1 TONE DECODER OUTPUT TONE OUT TIME CAP TONE IN IN FILTER OUT FILTER GND R631 R629 P604 2 C607 3 4 2 1 P601 GND 3 Q601 2 1 1 GND 3 2 1 P600 LSS Lower 3 4 2 1 5V C60...

Page 144: ...16 17 18 19 20 STARTD 21 LOAD 22 DATA 23 F700 TPHCLK ERROR DATAIN AD TEMP PRINTHEAD P24 R704 R717 LM358M 1 3 R715 2 8 IC703A V24 R708 R706 IC701 C700 1 LM317LZ 2 3 R705 C701 R711 AD RES R718 R703 R701 V24 Q701 R714 R702 R700 P24 Q700 9 F701 GND GND 3 IC204B 1 4 7406M 3 1 2 U 1 25V GND AD TEMP GND OR ON STARTD LOAD DATA TPHCLK ERROR STROB1 GND INC 5V 5V GND P700 1 2 3 4 5 6 7 8 17 9 11 12 14 13 10 ...

Page 145: ... 7 144 Chapter 17 CPU Board 17 6 12 Power to Printhead PPWREN IC702B 4 R712 6 5 74HC08M 2 R709 R707 V40 1 Q702 3 R713 R716 3 Z700 2 R302 AD P24 R306 P301 P24 Q704 GND 1 2 Q703 3 GND GND 2 3 4 5 6 7 8 9 V24 HEADLIFT R721 GND GND 10 1 GND C704 ...

Page 146: ...301 Q302 R328 R325 4 5 2 1 9 6 7 R334 R335 R336 R338 C312 C317 C313 C316 GND GND R323 R321 C314 C315 GND D309 5V C311 D308 VEE Q303 R322 1 2 3 R330 R327 RESET RESETB Q304 1 2 3 GND GND R327 R333 R332 5V R331 4 3 2 7 8 TL7709M VCC 6 SENSE RESET 5 RESIN RESET CT REF 1 GND IC302 GND C319 C318 C322 Z300 R329 R326 10 11 IC600C LM339M COMP 13 R343 R307 GND R308 R310 GND GND C320 R341 TRESH R340 5V VIN O...

Page 147: ...at can be used to check various signals or voltages using an oscilloscope or a volt age meter ADS Address strobe Controls address latches NHOLD Hold request from DMA active low VEE Battery voltage Min 3 0V at power up Nominal 3 6V RESET Reset active low during power up High at normal operation P24 Printhead voltage 24V 1V during print cycle and cutter operation 40V Stepper motor voltage 40V 2V V24...

Page 148: ... OK do the setup Contrast setup Print contrast is set Serial comm setup All uarts are initiated Service setup Label limits are set Paper type is set Image buffer size is set Head resistance is measured1 Sizes of receive and transmit buffers are set Detection setup Start and stop adjust are set If any part of the setup is lost the message Setup lost Press any key will be displayed and the program w...

Page 149: ...RS 422 In RXD RS 422 Out DTR out RS 422 Out RXD CAUTION A shielded communication cable is required in order to comply with the FCC DOC approval and to avoid the risk of interference to radio communications All EasyCoder 501 printers are fitted with a DB 25pin male inter face connector on their rear plates communication port uart1 This connector can be used for an RS 232 an RS 422 or a 20 mA curren...

Page 150: ...33 to 49 ft and the maximum transmission speed is 19 200 baud 38 400 on optional interface boards RS 232 circuit must be fitted on IC 200 fitted as standard Jumper must be fitted on uppermost position of P 202 RS 422 circuit on IC 207 optocouplers on IC 205 and IC 206 optional and straps on P 204 to P 209 are of no consequence The following hardware straps can be fitted P 200 DTR signal Pin 1 2DTR...

Page 151: ...male connector cable DB9 female connector Housing Housing Cable shield 1 1 not used TXD out 2 2 RXD in RXD in 3 3 TXD out RTS out 4 4 not used CTS1 in 5 5 Signal GND DSR in 6 6 DSR in Signal GND 7 7 RTS out not used 8 15 8 CTS in 5V 16 9 not used not used 17 19 DTR out 20 Printer IBM XT IBM PS2 Part No 1 975580 05 Length 3 metres 9 8 ft 1 If the communication cable is not configuredtotransmitanyCT...

Page 152: ... computer over a distance of up to 1 200 metres 4 000 ft by use of a four wire cable The transmission is full duplex that is reception and transmission can take place simulta neously RS 422 requires an additional circuit and a number of straps to be fitted on the CPU board 18 3 RS 422 232 CL 422 UART1 P202 IC 207 P203 P208 P206 P209 P207 P204 P205 IC 207 RS 422 circuit P 203 external 5V P 202 inte...

Page 153: ... on IC 207 Jumper must be fitted on the lowest position of P 202 to select RS 422 Jumper must be fitted on some of P 204 to P 209 according to diagram below RS 232 circuit on IC 200 standard jumper on P 200 and optcouplers on IC 205 and IC 206 optional are of no conse quence P 203 External 5 Volt1 Jumper fitted connects 5V to pin 16 Caution Max 200 mA Note that 5V requires an additional wire in th...

Page 154: ...e internal logics of the printer and the host computer Therefore this interface is suitable where electrical interference may occur and for transmission over longer distances up to 500 metres or 1 500 ft Depending on the configuration of the connection cable between printer and host computer the printer can work either active that is supplying the current or passive A transmission speed between 30...

Page 155: ... on P 200 are of no consequence P 203 External 5 Volt Jumper fitted connects 5V to pin 16 Caution Max 200 mA Be careful not to enable the external 5V unintentionally which may cause harm to the terminal PC or other device connected to this port Cable Configuration The printer end of the connection cable should have a DB25 female connector The computer end of the cable depends on your type of compu...

Page 156: ...tive transmitter or receiver that is being the supplier of the current to the loop PRINTER CABLE COMPUTER Transmitter Receiver 47 ohm 270 ohm Pin 9 Pin 11 Pin 12 Pin 10 Pin 13 Pin 18 Pin 25 Pin 14 TXD TXD RXD RXD Transmitter Receiver 47 ohm 270 ohm Pin 9 Pin 11 Pin 12 Pin 10 Pin 18 Pin 25 TXD TXD RXD RXD Printer active transmitter active receiver Printer active transmitter passive receiver ...

Page 157: ...ion ports on the rear plate indicate alternatives Serial interface board 2 RS 232 1 RS 232 1 20 mA current loop RS 422 485 interface board 1 RS 422 1 RS 232 1 RS 485 1 RS 232 Please refer to Chapter 1 2 for information on which interface boards are available for each of the various models Parallel interface board 1 Centronics Industrial interface board 1 RS 232 1 connector with 4 IN and 4 OUT port...

Page 158: ...ired straps on the interface board to be installed Connect the cable from the interface board to connector P 4 marked EXT INTERFACE at the lower rear corner of the CPU board Keep interface board and CPU board apart to avoid damage or short circuits Remove the plate that covers the slot for additional interface boards on the printer s rear plate Fit the interface board assembly to the printer s rea...

Page 159: ...t uart1 The Serial Interface Board may either be bought separately as a kit complete with installation instructions or be factory installed With the Serial Interface Board installed the following types of interfaces can be selected uart1 Fitted on printer s CPU pcb RS 232 Standard RS 422 or 20 mA CL Option Additional circuits required uart2 Fitted on serial interface pcb RS 232 uart3 Fitted on ser...

Page 160: ...rap fitted on P 3 between pin 1 2 right and middle pins selects RS 232 20 mA Current Loop Strap fitted on P 3 between pin 2 and 3 middle and left pins selects 20 mA current loop External 5V External 5V max 200 mA can be made available on pin 16 by fitting a strap on P 6 Be careful not to enable this option unintentionally which may cause harm to the connected terminal computer or other device 1 P3...

Page 161: ...eived data to printer 4 RTSA RTSB RS 232 RS 232 RTS from printer 5 CTSA CTSB RS 232 RS 232 CTS to printer 6 DSRA DSRB RS 232 RS 232 DSR to printer 7 GNDI GNDI RS 232 RS 232 Signal ground 8 not used 9 20M1 Current loop 20 mA 10 20M1 Current loop 20 mA 11 TXD Current loop TXD 12 TXD Current loop TXD 13 20M2 Current loop 20 mA 14 20M2 Current loop 20 mA 15 not used 16 5VEXT RS 232 CL 5V max 200 mA if...

Page 162: ...rial Interface Board 1 971703 40 P5 P2 F24 F12 F13 F14 F15 F25 F16 F17 F26 F19 F20 F21 F22 F23 F28 F29 F9 F6 F5 F4 F3 F2 F1 IC4 IC2 IC5 IC3 IC6 IC4 RN1 RN2 C9 C12 C11 C10 C5 C8 C7 C6 Z1 R1 R2 R10 Z2 R3 R4 D2 R12 R16 R17 C2 R5 Q2 R9 C3 R13 R11 C4 R7 Q1 C1 R8 C17 C16 Y1 P3 P6 5V EXT 971 703 02 C21 C28 D3 D1 P4 ...

Page 163: ...D 3 6864 MHz 1 X1 AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7 47k 10 2 5 3 6 4 7 9 8 RN2 RN1 CSX1 WR RD DTRA A4 A3 A2 A1 47k 8 9 10 5 3 7 6 4 2 1 X1 CLK X2 RESET CS WR RD INT A3 A2 A1 A0 D7 D6 D5 D4 D3 D2 D1 D0 RXDA TXDA RXDB TXDB I 6 I 5 I 4 I 3 I 2 I 1 I 0 07 06 05 04 03 02 01 00 IC2 RXDA CTSA DSRA MC145407 CEXT CEXT 10V 10V TXDA RTSA DTRA 1 1 3 20 18 11 13 15 16 14 12 17 4 10 8 6 5 7 9 RXDA CTSA DSRA TXDA ...

Page 164: ...19 20 21 22 23 24 25 GNDC TXDB RXDB RTSB CTSB DSRB GNDI 20M1 20M1 TXD TXD 20M2 20M2 5VEXT RXD DTRB RXD TXDB RXDB RTSB CTSB DSRB GND 20M1 20M1 TXD TXD 20M2 20M2 5VEXT RXD DTRB RXD F12 F13 F14 F15 F16 F17 F19 F20 F21 F22 F23 F24 F29 F25 F26 F28 GNDC 1 2 Z2 R3 12VA 12VA 1 2 Z1 R1 12VB 12VB R2 R4 5 6N139 2 IC6 6 8 3 7 R13 GND GND RXDCL R11 R10 D2 R12 RXD RXD 5 TXD 6N139 2 IC5 6 TXD 8 3 7 R9 R5 74AC14 ...

Page 165: ...ard may either be bought separately as a kit complete with installation instructions or be factory installed With the RS 422 485 Interface Board installed the following types of interfaces can be selected uart1 Fitted on printer s CPU board RS 232 Standard RS 422 or 20 mA CL Option Additional circuits required uart2 Fitted on RS 422 485 interface pcb RS 422 RS 485 Type selected by straps and cable...

Page 166: ...ansmission is half duplex that is transmission and reception cannot take place simultane ously Simplified example of an RS 485 connection A transmission of data can be addressed to a certain unit in an RS 485 multi drop loop provided the Prot addr setup option is enabled Each printer must be given an address by means of straps on the interface board See Intermec Fingerprint v6 13 Program mer s Gui...

Page 167: ...85 P 8 and P 9 should be strapped on master unit Usually the host computer is master P 10 100 terminating resistor Should be strapped on the first and last units regardless of RS 422 or RS 485 P 11 100 terminating resistor Should be strapped on both units in an RS 422 line Communication Port uart3 RS 232 P 6 Connects 5V to pin 16 on uart3 Max 200 mA Caution Be careful not to enable the external 5V...

Page 168: ...INTER 100 ohm P 10 P 8 P 2 P 9 VEE GNDE PRINTER PRINTER PRINTER master RS 485 MULTIDROP LOOP w printer as master unit Screened twisted 2 line cable approx 50 pf m P 8 and P 9 strapped on master unit P 10 strapped on first unit Connection P 2 pin 7 to Chassis GND for example P 2 pin 1 on one unit only No straps No straps P 10 strapped on last unit 100 ohm 100 ohm P 10 P 11 P 8 P 9 VEE GNDE 100 ohm ...

Page 169: ...20 X X Address 21 X X X Address 22 X X X Address 23 X X X X Address 24 X X Address 25 X X X Address 26 X X X Address 27 X X X X Address 28 X X X Address 29 X X X X Address 30 X X X X Address 31 X X X X X X Strap no strap Address 0 is normally used for the host Address Straps P 7 Pin uart3 Remarks 1 GNDC Chassis ground 2 TXDB Transmitted data from printer 3 RXDB Received data to printer 4 RTSB RTS ...

Page 170: ... 422 485 Interface Board 1 971708 40 P5 P2 F11 IC2 IC3 IC7 IC1 RN1 D2 R4 F1 C8 C4 Q1 C3 R7 C1 Y1 P3 P6 5V EXT C19 P4 F5 F6 F7 F8 F9 F12 F10 IC10 IC8 IC6 IC5 IC4 C12 C15 C14 C13 R1 R3 R6 R2 R5 RN2 2 WIRE 4 WIRE C7 P9 P8 MASTER R13 R14 P10 P11 R15R16 END F2 F3 F4 D1 C20 S1 S2 S3 S4 S5 P7 R9 R10 R11 R12 C17 C16 R8 ...

Page 171: ... 5 4 2 1 RXDB CTSB DSRB TXDB RTSB DTRB C12 C14 X1 CLK X2 RESET CS WR RD INT A3 A2 A1 A0 D7 D6 D5 D4 D3 D2 D1 D0 RXDA TXDA RXDB TXDB I 6 I 5 I 4 I 3 I 2 I 1 I 0 07 06 05 04 03 02 01 00 5V C13 C15 GND F6 F8 F10 F7 F11 F12 GNDC TXDB RXDB RTSB CTSB DSRB GNDI 5VEXT DTRB F9 26 27 GNDC GNDE 5 R2 6 7 8 5 R1 6N136 2 IC4 6 7 8 3 GNDE 5 R3 2 6 7 8 3 5V 1 2 IC3A F RTSA R6 2 3 5V 74AC14M 3 4 IC3B RXDA R5 74AC1...

Page 172: ...ons or be factory installed The following types of interfaces can be selected uart1 Fitted on printer s CPU board RS 232 Standard RS 422 or 20 mA CL Option Additional circuits required centronics Fitted on Parallel interface pcb Centronics parallel interface The setup is in no way affected by the Parallel Interface Board since the Centronics interface does neither require any communi cation setup ...

Page 173: ...xternal 5V unintentionally which may cause harm to the terminal computer or other device connected to this port Busy Signal S 1 Jumper fitted BUSY signal ON until end of ACK signal No jumper fitted ACK after BUSY signal as on previ ous versions of this board S 2 31 Jumper fitted on S 2 BUSY signal on falling edge of STROBE signal that is according to specifications Jumper fitted on S 3 BUSY signal...

Page 174: ...4 0 THEN GOSUB 2000 1000 BUSY4 1010 RETURN 2000 READY4 2010 RETURN Also see BUSY and READY statements and PRSTAT function in the Intermec Fingerprint v6 14 Reference Manual 22 3 Connector Config uration Pin Signal Dir Remarks 1 STROBE In 2 DATA 0 In 3 DATA 1 In 4 DATA 2 In 5 DATA 3 In 6 DATA 4 In 7 DATA 5 In 8 DATA 6 In 9 DATA 7 In 10 ACK Out 11 BUSY Out 12 PE Out See note 13 SELECT Out 14 15 not ...

Page 175: ...Intermec EasyCoder 501 Service Manual Ed 7 174 Chapter 22 Parallel Interface Board 22 4 Components Diagram Parallel Interface Board 1 971704 41 ...

Page 176: ...BUSY IC8C 9 8 ACK 10 74AC00 SLCTIN INPRM 9 7 4 5 6 3 8 RN4 1 5V 10 9 8 7 6 5 4 RN3 BUSY F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 10 2 F14 F15 F16 F17 F18 5V R3 F19 F20 GNDC CONNECTED TO CHASSIS GROUND MOUNTING HOLES ON CONTACT P2 5V P1 1 19 2 20 3 21 4 22 5 23 6 24 7 25 8 26 9 27 16 28 P1 29 30 34 12 32 14 15 33 13 11 10 35 18 31 36 17 P1 37 38 ADBUS GNDI 26 12V 25 A1 24 12V 23 A3 22 A2 21 A4 20...

Page 177: ...be controlled by PORTOUT ON OFF state ments The Industrial Interface Board can either be bought separately as a kit complete with installation instructions or be factory installed With the Industrial Interface Board installed the following means of communication becomes available uart1 Fitted as standard on the printer s CPU board RS 232C Standard RS 422 or 20 mA CL Option Additional circuits requ...

Page 178: ...OFF statements are executed in the program Four straps P 2 P 6 P 7 and P 8 control the relation between relay and output signal on output ports 201 to 204 respectively PORTOUT stmt Strap between pins OUT signal PORTOUT nexp ON 1 2 lower position Open PORTOUT nexp ON 2 3 upper position Closed PORTOUT nexp OFF 1 2 lower position Closed PORTOUT nexp OFF 2 3 upper position Open 1 Be careful not to ena...

Page 179: ...N 101 See example on next page 10 not used 10 IN 101 11 not used 11 IN 102 12 not used 12 IN 102 13 not used 13 IN 103 14 not used 14 IN 104 15 not used 15 IN 103 104 16 5VEXT 5V max 200 mA 17 not used 18 not used 19 not used 20 DTRB DTR permanently high 22 not used 23 not used 24 not used 25 not used If strap fitted on P 1 23 3 Connector Config uration OUT signals are controlled using PORTOUT nex...

Page 180: ...Signal Min Typical Max Input Voltage High 10V 24V 40V Input Voltage Low 1V 0V 1V Example of an OUT port 5V 1 2 P 3 REL1 1 OUT1 P 2 3 2 Max AC Load Breaking Capacity Max DC Load Breaking Capacity 1 0 5 0 1 10 20 30 40 50 100 DC Voltage VDC a resistive load b inductive load L R 20 ms DC current A a b Current max 1 A Switching power max 100VA AC Switching voltage max 100V AC ...

Page 181: ...rd 23 4 Components Diagram Industrial Interface Board 1 971709 40 P5 P3 IC2 IC3 IC1 RN1 Q1 C14 R15 C15 Y1 P2 P4 C4 C6 C5 C3 R6 RN2 P1 R9 R10 D1 C2 C1 F11 F5 F6 F7 F8 F10 F9 F12 REL4 REL3 REL2 REL1 IC6 IC4 C16 C9 P6 P7 P8 C8 D2 IC5 R16 R17 R18 R8 R12 R14 R15 C13 R11 C12 R7 C11 R5 C10 ...

Page 182: ... AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7 47k 10 2 5 3 6 4 7 9 8 RN2 RN1 CSX1 WR RD DTRA A4 A3 A2 A1 47k 8 9 10 5 3 7 6 4 2 1 X1 CLK X2 RESET CS WR RD INT A3 A2 A1 A0 D7 D6 D5 D4 D3 D2 D1 D0 RXDA TXDA RXDB TXDB I 6 I 5 I 4 I 3 I 2 I 1 I 0 07 06 05 04 03 02 01 00 5V R9 X1 74AC14 9 8 IC3D R10 Q1 XINT 5V D1 5 3V C9 P1 C8 D2 5 3V 5 3VEXT IC2 RXDB CTSB DSRB MC145407 CEXT CEXT 10V 10V TXDB RTSB DTRB 1 1 3 20 18 ...

Page 183: ... 3 1 REL4 2 3 1 IC5D TTL193B 7 8 9 R5 R6 C10 74AC14 10 5V 10 11 IC3E IN1 R18 5 2 P2 74HC04 9 8 IC6D 5V 1 ULN2003 4 13 IC4D OUT1 4 3 1 REL1 2 3 1 5 2 P6 74HC04 5 6 IC6C 5V 1 ULN2003 3 14 IC4C OUT2 4 3 1 REL2 2 3 1 IC5C TTL193B 5 6 11 R7 R8 C11 74AC14 12 5V 4 3 IC3B IN2 R17 IC5B TTL193B 3 4 13 R11 R12 C12 74AC14 14 5V 12 13 IC3F IN3 R16 IC5A TTL193B 1 2 15 R13 R14 C13 74AC14 16 5V 2 1 IC3D IN4 R15 2...

Page 184: ... LL only See Installation Operation manuals and diagrams inAppen dix 1 There are four different test labels that show the printout quality In most cases one or several additional test labels that show the printer s current setup are also produced Before starting to print the test labels check that the printer is set up for the direct thermal media or transfer ribbon in use and that the print contr...

Page 185: ...intout are symptoms of an unevenly worn pressing roller platen or foreign objects on it A sudden change from darker to weaker printout across the media indicates a small image buffer In extreme cases only part of the pattern will be printed Test Label 3 This test label contains two examples of the Code 39 bar code plus an EAN 13 bar code printed in picket fence attitude that is with the bars runni...

Page 186: ...el 5 In most cases a fifth test label follows This test label shows the printer s present setup If the setup information does not fit into one label for example because of three sets of serial communication parameters and buffers additional labels will be produced until all setup values have been printed After examining the test labels take appropriate action according to the lists in Chapter 24 2...

Page 187: ...hite parts at transfer printing Transfer ribbon wrinkled Adjust See next paragraph Transfer ribbon wrinkles Incorrect edge guide adjustment Adjust Installation Operation Ribbon obstructed by printhead cable Check clear n a Too strong printhead pressure Adjust both knobs Chapter 24 3 Bad ribbon assist roller adjustment Adjust Chapter 24 3 Supply bobbin not centered Adjust Chapter 7 2 Dark lines alo...

Page 188: ... wrinkling and unnecessary wear of the printhead The pressure is factory adjusted but special applications or chang ing between printing methods may require readjustment using the trial and error method Do not use more pressure than necessary to obtain the desired printout quality The print unit is fitted with two adjustable spring packages see Chapter 8 8 which allow the pressure to be set by tur...

Page 189: ...e a rough adjustment like this Turn both adjustment knobs clockwise as far as they go to max imum pressure Release the pressure of the inner spring package by turning the knob 2 1 4 turns counterclockwise 9 clicks Release the pressure of the outer spring package by turning the knob 2 turns counterclockwise 8 clicks Fine adjust the pressure by turning the outer knob while retain ing the setting of ...

Page 190: ...h the transfer ribbon for examplethe printhead cables If the wrinkling problem remains proceed as follows Using a T20 Torx screwdriver loosen the locking screw that runs in the crescent shaped hole in front of the headlift knob Insert the T20 Torx screwdriver through the hole immediately below the locking screw The key will engage cogs in the plate that holds the outer end of the ribbon assist rol...

Page 191: ...d When the wrinkling ceases continue the movement ever so slightly to create a small safety margin The movement is best detected by the relation between the roller bearing and the hole through the upper gable Another method is to determine the positions where wrinkling starts at either side and adjust the roller to the middle You will need to print several labels before a new adjustment has any no...

Page 192: ...e profile see Chapter 8 2 As long as the center screw is not loosened the outer gable can be removed and put back without the adjustment being lost Readjust ment requires a fixture and should not be attempted without such a device The printhead bracket is factory adjusted in relation to the headlift shaft by means of oversized holes for the three screws that hold the two parts together see Chapter...

Page 193: ... Intermec Shell installed customized applications and facilitates LSS adjustment and communication reset The limited Test Mode for EasyCoder 501 S allows a series of test labels to be printed see Chapter 24 1 Enter the mode as follows also see diagram on next page Switch off the printer Lift the printhead Press the Print key and keep pressing it Switch on the power Keep on pressing Print Wait a fe...

Page 194: ... BAUDRATE 9600 PARITY NONE CHAR LENGTH 7 STOPBITS 2 RTS CTS DISABLE ENQ ACK DISABLE XON XOFF DATA FROM HOST ENABLE DATA TO HOST ENABLE NEW LINE CR LF PRINT CONFIG CONTRAST 5 LSS ADJ 80 STARTADJ 0 STOPADJ 0 XSTART 0 WIDTH 832 LENGTH 1200 MEDIA TYPE LABEL w GAPS HEAD RESIST 518 PAPER TYPE UBI HP 20 PERFORMANCE NORMAL MEMORY ALLOC IMAGE BUFF SIZE 48 KBYTE REC BUFF UART1 300 BYTE TRANS BUFF UART1 300 ...

Page 195: ...ter the error is cleared and a new printfeed has been executed next error will be reported When no more error is found the printer will report All systems Go and you can proceed printing the test labels Adjustment of the Label Stop Sensor LSS The adjustment procedure is the same as in the Setup Mode Please refer to the Installation Operation manual Reading the printhead resistance value The resist...

Page 196: ...s in the printer s RAM memory will not be reset Enter the Test Mode as follows also see diagram on next two pages Switch off the printer Lift the printhead Press the Print key and keep pressing it Switch on the power Keep on pressing Print Wait a few moments until this message appears in the display TESTMODE TESTPRINT Release the Print key and lower the printhead Follow the instructions in the dia...

Page 197: ...LSS value 10 steps Increase LSS value 10 steps Reset communication to default values on uart1 std I O LSS Adjustment Communication Reset Auto adjust LSS Testfeed 618 ohms 8 dots CODE39 CODE39 1 234567 890128 UART1 BAUDRATE 9600 PARITY NONE CHAR LENGTH 7 STOPBITS 2 RTS CTS DISABLE ENQ ACK DISABLE XON XOFF DATA FROM HOST ENABLE DATA TO HOST ENABLE NEW LINE CR LF PRINT CONFIG CONTRAST 5 LSS ADJ 80 ST...

Page 198: ...e LSS value 10 steps Reset communication to default values on uart1 std I O LSS Adjustment Communication Reset Auto adjust LSS Testfeed 618 ohms 8 dots CODE39 CODE39 1 234567 890128 UART1 BAUDRATE 9600 PARITY NONE CHAR LENGTH 7 STOPBITS 2 RTS CTS DISABLE ENQ ACK DISABLE XON XOFF DATA FROM HOST ENABLE DATA TO HOST ENABLE NEW LINE CR LF PRINT CONFIG CONTRAST 5 LSS ADJ 80 STARTADJ 0 STOPADJ 0 XSTART ...

Page 199: ...utput voltage from the transformer to the CPU board pin 3 4 red cables which should be 33V AC If so the problem is probably caused by a malfunction on the CPU board Check the output voltage from the 5 3 V switch left side of R 323 If this voltage is too high immediately switch off power again The cause of power failure is probably to be found on the power supply If the output voltage was correct i...

Page 200: ...300 D 301 D 304 or D 306 is probably damaged If the cause of malfunction is still not found it is bound to lie in the cables or components between theAC power cord recep tacle and the CPU board Check that cables are correctly connected and not defective and check all cable shoes for bad contact A further cause of power failure may reside in the transformer or in theAC power cord receptacle With po...

Page 201: ...et holes Perform a checksum calculation by means of an EPROM pro grammer and compare the result with the same EPROMs from another printer Check that the GAL circuit on IC 04 is fitted correctly and is of the correct type P N 1 971805 xx Check that the GAL circuit on IC 700 is fitted correctly and is of the correct type EasyCoder 501 S P N 1 971803 xx EasyCoder 501 E SA P N 1 971804 xx EasyCoder 50...

Page 202: ...oards were installed in EasyCoder 501 printers manufactured before Sep tember 30 1996 CPU boards with Part No 1 040700 29 or later in combina tion with 8 dots mm printheads with Part No 1 01010 91 or with any 12 dots mm printheads do not cause this problem The problem is easy to fix First make sure that the printhead really is of the type 1 010010 93 and that the CPU board really is of the type 1 ...

Page 203: ...e keyboard interface board Check cable and connector P 2 on CPU board for possible damage or bad contact Potentiometer WR 1 for display brightness adjustment may need to be adjusted A malfunction may also be due to the fact that the customized program sends no messages to the display Enter the Test Mode or the Setup Mode If there is no display function the display is definitely out of order No key...

Page 204: ...n error handling program for example ERRHAND PRG see the Intermec Fingerprint v6 13 Programmer s Guide or the error handler of the Intermec Direct Protocol See Intermec Direct Protocol v6 13 Programmer s Guide Such programs will usually also signal detected errors by lighting up the red error LED lamp and possibly emit some kind of audible signal In case the CPU is unable to access data on a given...

Page 205: ...ral The following actions are valid for all communication interfaces installed in the printer Refer also to trouble shooting of the inter face in question Check that the interface cable is correctly inserted and that it is of correct type and configuration There are several ways to find out what parameters a certain printer interface is set up for If the printer is fitted with an Intermec Shell st...

Page 206: ...voltage transients from the inter face Being socket mounted these circuits are easily replace able Repeated damage is however an indication of insufficient cable screening or the electrical environment being too noisy No communication standard serial interface See also above No communication general Check that the jumper on connector P 202 of the CPU Board is correctly inserted so as to give the d...

Page 207: ...n the CPU board If the label stop sensor still does not operate correctly check the condition of its cables and that it they are correctly connected to the CPU board Lower sensor to P 600 Upper sensor to P 601 Check also that the level of the LSS signal on P600 pin 1 varies from low label gap detected to high 4 to 5V no gap detected when a piece of paper is inserted into and subse quently removed ...

Page 208: ...fer ribbon is removed Error 1058 Transfer ribbon fitted Check the sensor for dust or foreign objects and check that the mirror plate is properly aligned Check that the sensor s cable is connected to P 603 on the CPU board Adjust the sensitivity of the receiver by means of potentiometer WR 601 on the CPU board Fit or remove strap on P 604 to change the intensity of the light emitter Note In printer...

Page 209: ...s outer connector to P 301 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 In case of direct thermal printing verify that the media is intended for direct thermal printing not thermal transfer and of approved quality In case of thermal transfer printing check ...

Page 210: ...erall weak printout Weak or missing printout of some dots Examine the printhead and the pressing roller for dust adhesive residue or damage Clean or replace One or two missing dots may be due to mechanical damage to the printhead Try to establish why such damage have occurred in order to prevent future failures of this kind Hard foreign particles electrostatic discharge If the printer has been use...

Page 211: ...ly emitting a whizzing sort of noise Remedy Increase the image buffer as described in the Instal lation Operation manual Setup Memory allocation By doing this you preprocess more data before printing starts which speeds up the printout Or else avoid sending new print data while the printer is busy with a printout The stepper motor could be incorrectly connected P 401 or its drive circuits IC 403 a...

Page 212: ... decide if the adjustment have produced the desired result Check the adjustment of the ribbon assist roller see Chapter 24 3 Do not change the adjustment before you have performed all other checks mentioned above Check that the ribbon supply bobbin is centered in relation to the transfer ribbon as described in Chapter 7 2 Check the brake torque of the ribbon supply and rewind shafts see Chapters 7...

Page 213: ...lly inserted Test that current is supplied through both motor windings by means of an oscilloscope whose one probe is to be connected to GND4 and the other probe to P 400 pins 1 3 5 and 7 sequen tially The voltage should switch between 40V and 0V Also test the motor current by setting the second probe to each pin 16 of IC 400 and IC 401 The curve traced by the oscillo scope should indicate a few t...

Page 214: ...rd The 5V voltage on P 4 pin 1 should switch between high and low when the printhead moves Transfer ribbon is not properly rewound If the headlift does not work see above If the rewind unit does not rotate at all the stepper motor could be incorrectly connected P 2 on the Connection Board or its drive circuits IC 2 and IC 3 on the Connection Board could be damaged Check that all pins in the connec...

Page 215: ...supply additional edge guides should be fitted see Chapter 5 2 When the printer is used for tear off or cut off operation as opposed to peel off and the ribbon save device is activated weak and thin face materials may get jammed Since the face material is pushed forward by the rear pressing roll only when the printhead is lifted a certain stiffness of the face material is required Ribbon gets wrin...

Page 216: ...r 11 3 If still no reaction the sensor is probably defective Refer to Chapter 26 10 for problems with the built in LTS in the LinerLess Cutter Has the clock calendar been set If TIME and DATE instructions give strange results or time is not updated at the right pace replace the clock circuit IC 20 If the malfunction appears only after the printer has been turned off the trouble could be failing ba...

Page 217: ...or foreign objects obstruct the cutting operation Clean as described in Chapter 12 3 If the cutter is stopped from com pleting a cutting operation the motor may be damaged by over load Measure the voltage P24 between pin 1 24V and pin 3 ground of connector P 6 on the CPU board when a CUT command is being issued Pin 2 should get a supply voltage of almost 24V Pin 5 is connected to an internal home ...

Page 218: ... P24 between pin 1 24V and pin 3 ground of connector P 6 on the CPU board when a CUT command is being issued Pin 2 should get a supply voltage of almost 24V Pin 5 is connected to an internal home position sensing micro switch of the cutter The microswitch must be opened disconnecting ground from pin 5 At the very end of a cutting cycle pin 5 is again connected to ground when the microswitch closes...

Page 219: ...ry backup or an empty battery If you can communicate with the printer via a PC you could see what files are stored in the memory card and the size of them with the aid of the Fingerprint instructions FILES rom non DOS formatted cards or FILES card1 DOS format ted cards In case of non DOS formatted cards compare with the content of the printer s ROM memory when no card is inserted If the memory car...

Page 220: ... present If the printer has to supply 5V to uart3 check that a jumper is fitted on P 6 Verify by means of an oscilloscope that all signals during receiving and transmitting data have the appearance described in Chapter 20 Verify also that oscillatorY 1 on the Serial Inter face Board is running First see No communication general Chapter 26 2 In case of uart2 RS 422 or RS 485 check that the straps o...

Page 221: ... statement see Intermec Fingerprint v6 14 Refer ence Manual Check that the supply voltage 5V is present Verify by means of an oscilloscope that all signals during receiving and transmitting data have the appearance described in Chapter 22 First see No communication general Chapter 26 2 Check that the straps on P 2 and P 6 to P 8 are fitted so the relation between relay position and Out signal is c...

Page 222: ...nthead Up Press Print key Proceed to next menu Legend SHELL SEL APPLICATION SEL APPLICATION Direct Protocol SEL APPLICATION optional applic SEL APPL rom LINE_ALY PRG HU PP SET HD PP VIEW SEL APPLICATION LABELSHOP Enter Terminal Setup by transmitting T T T to printer when menus marked with grey are displayed HU PP Printhead Down Press Print key Accept displayed option and proceed HD PP SHELL TEST L...

Page 223: ...S DRIVER ENTER SHELL 5 sec v 4 01 ENTER SHELL 4 sec v 4 01 ENTER SHELL 3 sec v 4 01 ENTER SHELL 2 sec v 4 01 ENTER SHELL 1 sec v 4 01 Last selected application is started Default Fingerprint v6 14 w std I O uart1 Last selected application is started No action taken POWER ON Return to previous menu in a stack of options Proceed to next menu in a stack of options Accept displayed option and proceed ...

Page 224: ...E U1 XO FROM HOST ENABLE U1 XO TO HOST ENABLE CONTRAST 5 UART1 NEW LINE CR LF LENGTH 1200 MEDIA TYPE LABEL w GAPS PAPER TYPE UBI HP 20 STOPADJ 0 START ADJ 0 HD PP HU PP Menus in this example show default setup for an EasyCoder 501 S with a printhead density of 8 dots mm HD PP LSS ADJUST LABEL 103 GAP TESTFEED HD HU HD HU HD PP HU PP to increase the level in steps of 8 loop 0 127 0 7 15 23 31 111 1...

Page 225: ...TECTION FEEDADJ FEEDADJ STARTADJ STARTADJ 0 FEEDADJ STOPADJ STOPADJ 0 SETUP SERVICE If an optional interface board with at least one serial channel is fitted communication setup menus for each of the channels will be displayed Press F4 key to decrease 1 step Press F5 key to increase 1 step Baudrate 38 400 is only available on uart2 and uart3 Not for RS422 485 on uart2 Only for RS422 485 on uart2 P...

Page 226: ...PAPER TYPE designation designation PAPER TYPE designation PRINT DEFS TESTPRINT PRINT PRINT C EXIT ULTRA HIGH HIGH SERVICE PERFORMANCE PERFORMANCE NORMAL SERVICE MEMORY ALLOC MEMORY ALLOC IMAGE BUFF SIZE IMAGE BUFF SIZE 48Kb PRINT DEFS NEW SUPPLIES NEW SUPPLIES MEMORY ALLOC REC BUF UART1 REC BUF UART1 300 MEMORY ALLOC TRANS BUF UART1 TRANS BUF UART1 300 MEMORY ALLOC REC BUF UART2 REC BUF UART2 300 ...

Page 227: ... transfer ribbon a simple dynamometer and a ruler Fit the ribbon roll on the spool you want to check The larger roll the better accuracy Measure the radius from the centre of the spool to the edge of the ribbon roll Fit the end of the ribbon to the dynamometer and pull Read the dynamometer Calculate the torque using the formula Torque Nmm Radius mm Force N Force Radius Formula Torque Force x Radiu...

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