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Intermec EasyCoder 501XP, Service Manual

The Intermec EasyCoder 501XP is a cutting-edge label printer, designed to streamline your printing tasks. To maximize your user experience, a Supplementary Manual is available for free download on manualshive.com, providing detailed instructions and troubleshooting tips. Get the most out of your printer with our comprehensive manual.

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Intermec EasyCoder 501 XP & 601 XP – Service Manual

172

Chapter 17     Troubleshooting

17.1 Diagnosing the 
Printer, cont.

Use this short-list to fi nd the symptom that applies to the printer:

Symptom                                                                                                   See 

•    No reaction at power up                                                17.2

•    Printer stops working after startup                                17.3

•    CPU board failures                                                        17.4

•    Power supply unit failures                                             17.5

•    Console errors                                                                17.6

•    Error messages                                                               17.7

•    No communication (general)                                        17.8

•    No serial communication                                              17.9

•    No parallel communication                                           17.10

•    Sensor malfunctions                                                      17.11
     - Label stop sensor
     - Headlift sensor
     - Ribbon end sensor
     - Ribbon low sensor
     - Label taken sensor

•    Printing troubles                                                             17.12

     - No printout at all
     - Overall weak printout
     - Weaker printout on either inner or other part of label
     - Overall dark printout (bleeding)
     - Weak or missing printout of some dots
     - Unexpected black printout (completely or partial)
     - Only fi rst part of label printed
     - Media feed does not work properly

•    Transfer ribbon troubles                                                17.13
     - Transfer ribbon gets wrinkled
     - Transfer ribbon breaks

•    Liner/batch takeup troubles                                           17.14

•    Cutter troubles                                                                17.15

•    Memory card troubles                                                   17.16

                                                                                                          

Summary of Contents for EasyCoder 501XP

Page 1: ...Service Manual EasyCoder 501 XP 601 XP Bar Code Label Printers ...

Page 2: ...ec Technologies Corp The word Intermec the Intermec logo InterDriver and PrintSet are trademarks of Intermec Technologies Corp Centronics is a registered trademark of Genicom Corporation Microsoft is a registered trademark of Microsoft Corporation Torx is a registered trademark of Camcar Division of Textron Inc TrueDoc is a registered trademark of Bitstream Inc TrueType is a trademark of Apple Com...

Page 3: ... Center Section 28 4 3 Bottom Plate 28 4 4 Rear Plate 29 5 Media Supply 5 1 Internal Supply 30 5 2 External Supply 34 6 Label Slack Absorber 6 1 Description 37 6 2 Dismantling 39 7 Transfer Ribbon Mechanism 7 1 Description 40 7 2 Ribbon Supply Unit 41 7 3 Ribbon Rewind Unit 43 7 4 Ribbon End Sensor 45 8 Print Unit 8 1 Description 47 8 2 Platen Roller 53 8 3 Stepper Motor 56 8 4 Belts 58 8 5 BeltAd...

Page 4: ...ptional Interface Boards 136 16 5 Industrial Serial Interface Board 139 16 6 Double Serial Interface Board 149 16 7 EasyLAN 100i Interface Board 159 16 8 Industrial Interface Board 164 17 Troubleshooting 17 1 Diagnosing the Printer 171 17 2 No Reaction at Power Up 173 17 3 Printer Stops Working after Startup 174 17 4 CPU Board Failures 175 17 5 Power Supply Unit Failures 176 17 6 Console Errors 17...

Page 5: ... Manual 3 Chapter 0 Introduction 0 1 Contents cont Appendix 2 Measuring the Break Torque 199 Appendix 3 Firmware Upgrading 200 Introduction 200 Upgrading From a Memory Card 201 Upgrading From the Host 202 Upgrading EasyLAN 100 i Firmware 205 ...

Page 6: ...arts Catalog Intermec EasyCoder 501 XP 601 XP Installation Instructions for various options Intermec Direct Protocol v7 50 Programmer s Guide Intermec Fingerprint v7 50 Programmer s Guide Intermec Fingerprint v7 61 Programmer s Reference Manual Pleasenotethattheoperationsdescribedinthismanualonlyshould be carried out by skilled and authorized personnel with proper training and full understanding o...

Page 7: ...tial area is likely to cause interference in which case the user at his own expense 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 regul...

Page 8: ...ation relates are in conformity with the following standards Electrical Safety EN 60950 EMC Emissions EN 50081 1 92 EN 55022 94 EN 61000 3 2 95 EMC Immunity EN 50082 2 95 EN 61000 4 2 95 EN 61000 4 3 96 ENV 50204 95 EN 61000 4 4 95 EN 61000 4 6 96 following the provisions of Directives 89 336 EEC and 73 23 EEC Mölndal 1998 09 01 Mats Gunnarssom President 1 Intermec assumes no responsibility regard...

Page 9: ...l 7 Chapter 1 1 Models and Options 1 1 Identification The EasyCoder 501 XP and 601 XP each come in one main model a combined direct thermal thermal transfer printer with a setup keyboard and a 12 dots mm printhead EasyCoder 501 XP EasyCoder 601 XP ...

Page 10: ...e printers can use any 100 to 240 VAC 50 to 60 Hz voltage There is no voltage switch over The machine label on the printer s rear plate contains type part number serial number and signs of approval EasyCoder 501 XP EasyCoder 601 XP Machine Label 1 1 Identification cont Machine Label ...

Page 11: ...options Paper Cutter see Chapter 11 Label Taken Sensor see Chapter 10 Liner Batch Takeup Unit see Chapter 9 Media Roll Retainer see Chapter 5 Fan Fold Guides Kit see Chapter 5 Ribbon Low Sensor see Chapter 12 1 1 Identification cont Paper Cutter Label Taken Sensor Liner Batch Takeup Unit Media Roll Retainer Fan Fold Guides Ribbon Low Sensor ...

Page 12: ...fitted with a number of built in options Paper Cutter see Chapter 11 Label Taken Sensor see Chapter 10 Liner Takeup Unit see Chapter 9 Fan Fold Guides Kit see Chapter 5 Ribbon Low Sensor see Chapter 12 1 1 Identification cont Paper Cutter Label Taken Sensor Liner Takeup Unit Fan Fold Guides Ribbon Low Sensor ...

Page 13: ...ully follow the instructions in Chapter 13 CAUTION Always turn off the power and remove the power cord before opening the cover over the electronics compartment Dangerous voltage In the electronics compartment check Type of CPU board Check number of Flash SIMMs Check number and size of DRAM SIMMs Any optional interface board fitted Check type straps and optional circuits Refer to Chapters 15 and 1...

Page 14: ...f Intermec Shell which also allows you to print test label 5 containing the present setup values To enter Shell if a custom made autoexec file prevents access lift the printhead and press any key on the printer s keyboard except the Shift key then turn on the power while continuing to press the key When the Shell countdown begins release the key and press Enter to start Shell Do not forget to lowe...

Page 15: ...internal takeup unit Internal Liner Batch Takeup Optional With internal takeup unit Cut Off Optional With cutter Firmware Operating System Fingerprint v7 63 incl Intermec Direct Protocol Smooth Fonts TrueDoc and TrueType fonts Built in scaleable fonts std 15 Unicode fonts2 Built in bar code symbologies std 38 Startup Program std Intermec Shell v4 8 Physical Measures Dimensions W x D x H 275 x 480 ...

Page 16: ...or SRAM card Accessories Automatic Paper Cutter Option Liner Batch Takeup Unit Option factory installed only For peel off rewind Label Roll Retainer Option Fan Fold Guides Kit Option For external supply RS 232 Cable Option Centronics Cable Option Double Serial Interface Board Option EasyLAN 100i Interface Board Option Ethernet Industrial Interface Board Option Industrial Serial Interface Board Opt...

Page 17: ...ar Off Yes Peel Off Optional With internal takeup unit Cut Off Optional With cutter Firmware Operating System Fingerprint v7 63 incl Intermec Direct Protocol Smooth Fonts TrueDoc and TrueType fonts Built in scaleable fonts std 15 Unicode fonts2 Built in bar code symbologies std 38 Startup Program std Intermec Shell v4 8 Physical Measures Dimensions W x D x H 335 x 482 x 238 mm 13 1 x 19 0 x 9 4 in...

Page 18: ...dapter 1 Flash or SRAM card Accessories Automatic Paper Cutter Option Liner Takeup Unit Option factory installed only For peel off operation Fan Fold Guides Kit Option For external supply RS 232 Cable Option Centronics Cable Option Double Serial Interface Board Option EasyLAN 100i Interface Board Option Ethernet Industrial Interface Board Option Industrial Serial Interface Board Option ExternalAlp...

Page 19: ...83 68 8 mm 2 71 Dot No 0 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 12 mm 0 47 37 mm 1 46 Paper slot Paper slot An optional paper cutter increases the printer s total length by 28 mm 1 1 inches At least 90 mm 3 5 inches of free space behind the printer is required for the connectors and for inserting and removing a memory card ...

Page 20: ...hes At least 90 mm 3 5 inches of free space behind the printer is required for the connectors and for inserting and removing a memory card 259 mm 10 20 238 mm 9 37 R 3 2 3 m m 1 2 7 2 168 mm 6 61 135 4 mm 5 33 335 mm 13 18 68 8 mm 2 71 Dot No 0 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 12 mm 0 47 38 mm 1 50 Paper slot Paper slot ...

Page 21: ...oard display assy is connected to P37 at the front of the CPU board via a 10 p flat cable This cable must be disconnected before the keyboard display can be removed The keyboard display must be manipulated carefully when it is lifted out of its cavity Do not use any force If the assembly seems to be stuck open the right hand door and remove the left hand cover to check that the grub screws do not ...

Page 22: ... can perform himself Use isopropyl alcohol to remove any adhesive residue Keyboard The keyboard is of membrane switch type and is glued to the key board plate There are 54 switches but only 23 of these are used One switch is a Shift key that provides a dual functionality to each of the other keys A resistor ladder gives different voltages from each line and column on the keyboard so the slave proc...

Page 23: ...equency between 104 and 9 999 Hz It is used to acknowledge when a key is pressed and to produce various audi ble signals The key acknowledge signal can be controlled by the Fingerprint instruction KEYBEEP whereas other signals are con trolled using the instructions BEEP and SOUND The left hand LED control lamp marked Power shines green when the power is on Power on is also indicated by the display...

Page 24: ...e 1 971604 27 Soldering Side Test Points 5C C14 Lower soldering GND C14 Upper soldering D2 D3 D4 DISPLAY 1 971704 01 B1 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 IC1 IC2 IC3 P1 P2 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 X1 1 971604 01 P01 P1 P1 ...

Page 25: ...C GND VCC C A GND GND GND GND GND VCC GND VCC GND GND VCC VCC VCC GND 1 2 4 5 6 7 8 9 28 27 26 25 24 10 13 14 15 16 17 18 19 23 22 21 20 3 1 3 5 6 4 7 8 9 10 11 12 13 14 2 15 16 1 2 3 4 5 6 7 8 9 10 2 1 6 5 1 3 2 4 4 3 8 9 13 11 12 10 6 5 8 9 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Beeper ST6265 IC1 X1 8MHz C3 C2 DISPLAY DISPLAY P1 RED D3 GREEN D2 R1 R2 C1 74HC05 IC3A 74HC74 IC2A R9 74HC05 IC3B...

Page 26: ...il the snap lock at the rear hinge becomes disengaged At the inside of the door there is a label showing how to load the media and transfer ribbon Illustration shows the right hand door of an EasyCoder 501 XP The door of the EasyCoder 601 XP has a wider top part The hinges can be adjusted using two pairs of T10 Torx screws visible on the outside Possibly the other parts of the hinges which are fit...

Page 27: ...ght 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 see Chapter 11 Alignment is performed in the same way as the right hand door see previous page The fron...

Page 28: ... and the power cord is disconnected before the left hand cover is removed After having disconnected the power cord open the right hand door Using a T10 Torx screwdriver remove the four screws along the lower edge first then remove the four upper screws Put the cover plate aside on a soft cloth or similar material to avoid scratches When replacing the left hand cover press it forcefully inwards to ...

Page 29: ...assis The printer s chassis is made up by three main parts The center section The bottom plate The rear plate 4 1 Description Bottom Plate Center Section Rear Plate Bottom Plate Rear Plate Rubber Foot x4 Center Section Rubber Foot x4 EasyCoder 501 XP EasyCoder 601 XP ...

Page 30: ...ment it is impera tive that the printer stands on an even surface and the center section is straight If such problems should occur especially after transpor tation check that the center section has not been bent The bottom plate is fitted with four easily replaceable rubber feet These feet could be removed and the holes used to bolt the printer to a frame table or similar The holes have a diameter...

Page 31: ...ar Plate On Off Switch AC Power Cord Receptacle Memory Card Slot RS 232 Serial Interface uart1 Centronics Parallel Interface centronics Provision for Optional Interface Board s Bar Code Wand Interface not used Upper External Media Intake Lower External Media Intake On Off Switch AC Power Cord Receptacle Memory Card Slot RS 232 Serial Interface uart1 Centronics Parallel Interface centronics Provisi...

Page 32: ... from the electronics compartment The hub modules are spring loaded in order to fit media roll cores with an inner diameter between 38 and 40 mm 1 5 inches Alarge crescent shaped plate keeps the media roll aligned with the print mechanism Maximum diameter of an internal media roll is 205 mm 8 inches and maximum width is 120 mm 4 7 inches for EasyCoder 501 XP and 168 mm 6 61 inches for EasyCoder 60...

Page 33: ...g is stopped The brake torque should be 70 20 Nmm1 The code disc fitted at the innermost part of the hub package has no use in EasyCoder 501 601 XP but is retained for logistic rea sons common assembly with EasyCoder 501 Be careful to fit the studs of the innermost hub module into the holes in the code disc when the package is assembled 5 1 Internal Supply cont 1 RefertoAppendix2foradescrip tion o...

Page 34: ...pply hub in order to accept media rolls with 76 mm 3 inches cores EasyCoder 501 XP has one adapter and EasyCoder 601 XP has two Each adapter is locked using a T20 Torx screw Be careful not to let the screw hit the leaf springs or the cams of the hub modules EasyCoder 501 XP EasyCoder 601 XP 5 1 Internal Supply cont 3 inch Adapter 3 inch Adapters ...

Page 35: ...tainer An optional media roll retainer can be pressed on the hub package but not on the adapter of an EasyCoder 501 XP in order to hold large media rolls and to prevent the media from getting misaligned on the roll The retainer is not intended for EasyCoder 601 XP 5 1 Internal Supply cont ...

Page 36: ...ia path is properly aligned in parallel with the printer s center section Therefore Intermec offers an optional Fan Fold Kit consisting of a bracket with two guides that can be fitted in either the upper or lower slot in the rear plate The outer guide is adjustable for different media widths EasyCoder 501 XP EasyCoder 601 XP 5 2 External Supply Fan Fold Guides Fan Fold Guides Max Media Width Fan F...

Page 37: ...s are the same for EasyCoder 501 XP and EasyCoder 601 XP the former is illus trated on this and the next page Insertthecompleteunitthroughtheslotfromtheoutsideandattach 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...

Page 38: ...supply 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 39: ... loaded absorber can then return towards its original position During the printing the absorber will flutter back and forth compensating for the variations in tension To facilitate media load the label slack absorber can be rotated 180 clockwise It cannot be locked in open position For demanding applications with high speed printing an edge guide can be fitted on the label slack absorber to preven...

Page 40: ...Intermec EasyCoder 501 XP 601 XP Service Manual 38 Chapter 6 Label Slack Absorber 6 1 Description cont Edge Guide not fitted as standard Label Slack Absorber EasyCoder 601 XP ...

Page 41: ...he label slack absorber unit is fitted to the center section using two T20 Torx screws inserted through the center section from the electronics compartment The shaft should be screwed into the flange with a tightening torque of 5 Nm Edge Guide green T20Torx Screws 2x Flange T10Torx Screw Shaft Torsion Spring Grip green Edge Guide green EasyCoder 501 XP EasyCoder 601 XP ...

Page 42: ...r ribbon mechanism is standard but can be omitted on special order The mechanism consists of three main units Ribbon supply unit see Chapter 7 2 Ribbon rewind unit see Chapter 7 3 Ribbon end sensor see Chapter 7 4 Ribbon Supply Unit Ribbon Rewind Unit Ribbon End Sensor Ribbon Supply Unit Ribbon Rewind Unit Ribbon End Sensor ...

Page 43: ...pivoting point of the hub is centered in relation to the ribbon width There fore the shaft is provided with six grooves which correspond to the standard widths of Intermec transfer ribbons see table to the left The three innermost grooves are used with EasyCoder 501 XP whereas the three outermost grooves only are used with the wider EasyCoder 601 XP By compressing the hub its snap lock will diseng...

Page 44: ... value replace the grease We recommend Castrol Sin plex 2 The expected interval between replacing the grease is 8 to 10 million print cycles When the rotating force ceases the spring tends to pull back the ribbon keeping it tight The code disc is only used in connection with the optional ribbon low sensor see Chapter 12 but is nevertheless always fitted Dismantling The shaft rotates in bearings fi...

Page 45: ... 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 Theribbonrewindunitisfittedtothecentersectionusingtwo T20 Torx screws inserted from the electronics compartment One of the screws runs in a crescent shaped slot to allow adjustment or removal of the belt Adjustment The braking torque can...

Page 46: ...off the bobbin the compres sion spring and the nylon washer Then you can inspect the fric tion 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 5 and tighten the screws that hold the flange...

Page 47: ...d a com bined mirror bracket Working Principles The ribbon end sensor works like this A narrow beam of light is emitted from the sensor and is either absorbed by the black transfer ribbon or reflected back by a 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 Se...

Page 48: ...ING 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 pitch tone If...

Page 49: ...iption The print unit is partly integrated with the ribbon rewind unit see Chapter 7 3 and optional liner batch takeup unit see Chapter 9 EasyCoder 501 XP EasyCoder 601 XP Print Unit Ribbon Rewind Unit Liner BatchTakeup Unit option Print Unit Ribbon Rewind Unit LinerTakeup Unit option ...

Page 50: ...e heat that melts the ink on the transfer ribbon or blackens the direct thermal paper in patterns that make up the letters graphics or bar codes The headlift mechanism presses the printhead against the media or transfer ribbon or raises the printhead to allow media and ribbon load The print unit is a self contained module and attached to the print er s center section by means of four T20 Torx scre...

Page 51: ...Service Manual 49 Chapter 8 Print Unit 8 1 Description cont Platen Roller Stepper Motor Tear Bar Printhead Headlift Mechanism Ribbon Assist Roller Liner Drive Roller Belt to Ribbon Rewind Unit Label Stop Sensor hidden EasyCoder 501 XP ...

Page 52: ...0 Chapter 8 Print Unit Platen Roller Stepper Motor Tear Bar Printhead Headlift Mechanism Ribbon Assist Roller Liner Drive Roller Belt to Ribbon Rewind Unit Label Stop Sensor hidden Locking Handle in open position 8 1 Description cont EasyCoder 601 XP ...

Page 53: ...asyCoder 501 XP This overview illustrates the various parts in the print unit The idle pulley fitted to the center section and the ribbon rewind unit are not included Note that some of the parts illustrated here are not available as separate spare parts but must be bought as ready assembled units ...

Page 54: ...asyCoder 601 XP This overview illustrates the various parts in the print unit The idle pulley fitted to the center section and the ribbon rewind unit are not included Note that some of the parts illustrated here are not available as separate spare parts but must be bought as ready assembled units ...

Page 55: ...tepper motor so it comes free from both belts Remove the stepper motor Remove the belt from the pulley of the platen roller Insert a 2 mm hexagon key through the semicircular slot in the front plate and loosen the grub screw that holds the pulley on the shaft of the platen roller Using a T20 screwdriver remove the bracket that holds the outer end of the platen roller and pull out the entire packag...

Page 56: ... illustration below the upper parts of the print unit and the label stop sensor have been omitted to improve visibility Stepper Motor T20Torx Screw T20Torx Screw 1 Belt to Platen Roller Belt to Ribbon Rewind Unit Pulley Ball Bearing Plastic Bearing Spacer Bracket Ball Bearing Plastic Bearing Platen Roller T20Torx Screw ...

Page 57: ... illustration below the upper parts of the print unit and the label stop sensor have been omitted to improve visibility Stepper Motor T20Torx Screw T20Torx Screw 1 Belt to Platen Roller Belt to Ribbon Rewind Unit Pulley Ball Bearing Plastic Bearing Spacer Bracket Ball Bearing Plastic Bearing Platen Roller T20Torx Screw ...

Page 58: ...orx screws The pulleys of the stepper motor are glued to the motor s shaft Replacement EasyCoder 501 XP and 601 XP Replace the stepper motor as follows Switch off the power and disconnect the power cord Open the front and right hand doors Remove the cover over the electronics compartment which is held by eight T10 Torx screws Disconnect the cable to the stepper motor from P420 on the CPU board Rem...

Page 59: ...nt unit have been omitted to improve visibility Note that the bracket does not need to be removed when the stepper motor is replaced T20Torx Screw T20Torx Screw T20Torx Screws 3x Stepper Motor Bracket Inner Print Unit Gable Belt to Platen Roller Belt to Ribbon Rewind Unit and Ribbon Assist Roller Fitted to Center Section Fitted on Ribbon Assist Roller Shaft Fitted on Platen Roller Shaft ...

Page 60: ... is held by eight T10 Torx screws Remove the tension of the belt to the ribbon rewind unit by loosening the two T20 screws that holds the unit Dismantle the stepper motor from the bracket by removing the two T20 Torx screws Free the belt from the pulley of the ribbon rewind unit and manipulate the stepper motor so it comes free from both belts Remove the stepper motor Replace the defective belt or...

Page 61: ...y part of the center section is shown There is no need to completely remove the ribbon rewind unit only to rotate it in order to remove the tension to the belt The prin ciples for EasyCoder 501 XP and 601 XP are the same except for the width of the print unit Stepper Motor T20Torx Screw T20Torx Screw T20Torx Screw T20Torx Screw Ribbon Rewind Unit Belt Belt ...

Page 62: ... position of the stepper motor relative to the bracket to be adjusted so the tension of the belt does not become too tight causing unnecessary wear Check that the platen roller can be rotated freely by the belt which should flex just a little when you press it with your finger Stepper Motor Stepper Motor Pulley Belt Platen Roller Pulley T20Torx Screw T20Torx Screw ...

Page 63: ... tight yet will flex slightly when you press it with a finger Tighten the screws Check that the parts can rotate freely and without any unpleasant sound and that the belt does not jump the cogs when you rotate the ribbon rewind unit forcefully The ribbon return roller should be easy to rotate manually Once the motor starts the belt will be tight and will drive the ribbon assist roller If the idler r...

Page 64: ...media feed corresponding to more than 150 of the set label length Setup Media Media Size Length a next label not found condition is assumed If a renewed print operation gives the same result an out of paper condition is assumed Ticket w mark A beams of light is emitted from the lower sensor1 The beam can either be reflected back to the same sensor by the white media or be absorbed by a black mark T...

Page 65: ...he Sensitivity EasyCoder 501 XP and 601 XP TheLSSshouldalwaysbeadjustedafterchangingtoanotherbrand sometimes even batch of media and when a defective sensor has been replaced This is especially the case with self adhesive labels on liner backing paper since the transparency of the liner may vary and the difference between labels and gaps may be too small Before starting the adjustment check that b...

Page 66: ...tion to the media is best checked by looking head on into the print unit when the printhead is raised Align the centerpoint of theV shaped upper sensor with the center of the slots or marks 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 m...

Page 67: ...65 Chapter 8 Print Unit Upper part of LSS Adjustment Screw Detection Slot Linear Markings 8 6 Label Stop Sensor cont Adjustment of the Lateral Position EasyCoder 501 XP and 601 XP cont EasyCoder 601 XP Upper part of print unit omitted to improve view ...

Page 68: ...ut To remove the lower guide plate disengage the snap lock accessible through a slot in the lower gable using for example a screwdriver and lift the outer end of the guide plate Then pull it out When cleaning the guide plates use a soft cloth moistened with isopropyl alcohol Do not use any other type of chemicals Be care ful not to scratch the windows Warning Isopropyl alcohol CH3 2 CHOH CAS 67 63...

Page 69: ...he electronics compartment Remove the upper and lower plastic guide plates Adjust the LSS to approximately center position Disconnect the cables from P53 and P54 on the CPU board Disengage the snap lock using a screwdriver from the media compartment side and push the outer end of the LSS bracket upward Then pull the bracket out from the carriage taking care not to damage the cables Note The snap l...

Page 70: ...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 P54 marked LSS BOT and the cable from the upper sensor to P53 marked LSS TOP on the CPU board Put back the...

Page 71: ...comes 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 much wider range of face materials for printing for example papers boards plasti...

Page 72: ...y aligned with the platen roller There are no facil ities for adjusting the position of the printhead relative the platen roller neither longitudinally nor laterally There are two cables from the printhead to the CPU board The outermost cable protected by a black plastic tube is used for the power to the printhead and is connected to X2 on the Power Supply board The innermost cable 20 p blue flat c...

Page 73: ...DOW PRINT WINDOW max 120 mm 4 7 in 106 6 mm 4 2 in Print Window EasyCoder 501 XP The 12 dots mm 304 8 dpi printhead contains 1280 dots which give a maximum print width of 106 7 mm 4 199 inches The same unit of measure dots can be used both across and along the feed direction Specifications Density 12 dots mm 304 8 dpi Print width 106 7 mm 4 199 in Number of dots 1280 Dot size 0 083 mm 3 28 mils ...

Page 74: ... width of 168 mm 6 61 inches The same unit of measure dots can be used both across and along the feed direction Specifications Density 12 dots mm 304 8 dpi Print width 168 mm 6 61 in Number of dots 1984 Dot size 0 083 mm 3 28 mils FEED DIRECTION Dot 0 Dot line on printhead X start Width Origin Length Dot 1983 2 7 mm 0 11 in 1 0 mm 0 04 in PRINT WINDOW PRINT WINDOW max 168 mm 6 61 in 165 3 mm 6 49 ...

Page 75: ...ue dry with printhead in closed position The glue requires 1 minute to dry but full strength is not obtained until after 20 hours Disconnect the hooked fingers at the rear of the bracket from the headlift shaft and pull out the printhead as far as the cables allow Disconnect the two cables from the printhead Note the snap lock on the white connector and pull at the con nectors rather that at the ca...

Page 76: ...Intermec EasyCoder 501 XP 601 XP Service Manual 74 Chapter 8 Print Unit 8 7 Printhead cont Replacing the Printhead EasyCoder 501 XP Replacing the Printhead EasyCoder 601 XP ...

Page 77: ...o not use a higher Contrast setting than necessary especially not in combination with high Paper Type Constant settings Do not use a higher printhead pressure than necessary Never print outside the media Dots not in contact with the media will not be cooled properly Use transfer ribbons wider than the media if available When using media with less than full width be careful to adjust the printhead ...

Page 78: ...cted to P50 marked HEADL on the CPU board The arm that blocks the light through the sensor is attached to the headlift shaft by means of a T10 Torx screw If the screw is not tightened sufficiently or if the arm is not fitted in the correct angle a malfunction will occur Adjusting the Sensor Arm EasyCoder 501 XP and 601 XP Perform an adjustment of the printhead pressure as described in Chapter 8 9 Wi...

Page 79: ...O 40 1000 BREAK 1 OFF 1010 END RUN Sensor Replacement EasyCoder 501 XP and 601 XP Before replacing the sensor check that the sensor arm is properly adjusted and that the sensor is free from dust paper shreds and other things that can block the light Replace the sensor as follows Switch off the power remove the power cord and remove the cover over the electronics compartment Check that the printhea...

Page 80: ...he platen roller depending on type of media print method media thickness and other circum stances The headlift shaft is connected to the headlift sensor arm on the inside of the print unit see Chapter 8 8 On the headlift shaft the S shaped headlift arm is also fitted At the tip of the headlift arm is a magnet that engages the printhead bracket The arm can be moved along the headlift shaft so the pr...

Page 81: ...Unit Description EasyCoder 501 XP and 601 XP cont 8 9 Headlift Mecha nism cont Headlift Sensor Headlift Arm Pressure Adjuster Linkage Headlift Shaft Eccenter Printhead Lift Lever Return Spring Sensor Arm Printhead Pressure Grub Screw factory adjustment EasyCoder 601 XP ...

Page 82: ...ounoticeanincreased resistance Using a 2 mm hexagonal key loosen the factory adjustment grub screw see illustration on previous page until the print head starts to come up Carefully tighten the grub screw until you just start noticing a small resistance when trying to pull out the media see note Apply some locking fluid on the grub screw Raise and lower the printhead EasyCoder 501 XP Turn the knob ...

Page 83: ...r 501 XP 601 XP Service Manual 81 Chapter 8 Print Unit Adjustment Knob green 8 9 Headlift Mecha nism cont Printhead Pressure Adjustment EasyCoder 501 XP and 601 XP Adjustment Knob green EasyCoder 501 XP EasyCoder 601 XP ...

Page 84: ...r media the arm should be adjusted or the print out on the outer part of the media could be weak To adjust the printhead lift arm proceed as follows Raise the printhead by turning the printhead lift lever to Open position Remove the ribbon if any Loosen the knob that holds the lift arm Move the arm inwards or outwards until the arrow on the tip of the arm becomes cen ter aligned with the media If ...

Page 85: ...e Manual 83 Chapter 8 Print Unit Center of Media Tip of Headlift Arm Knob 8 9 Headlift Mecha nism cont Printhead Pressure Alignment Adjust EasyCoder 501 XP and 601 XP Tip of Headlift Arm Knob Center of Media EasyCoder 501 XP EasyCoder 601 XP ...

Page 86: ...en the locking screw that runs in the crescent shaped hole in front of the headlift lever By turning the Torx screwdriver you can move the outer end of the roller back and forth Turn it clockwise to move the end of the roller forward Turn it counterclockwise to move the end of the roller rear ward If the ribbon gets wrinkled at the inner edge you should move the end of the roller slightly rearward...

Page 87: ...rewdriver Ribbon Assist Roller Locking Screw 8 10 Ribbon Assist Roller cont Adjustment EasyCoder 501 XP and 601 XP cont Wrinkling Turn Screwdriver Inner side counterclockwise Outer side clockwise T20Torx Screwdriver Ribbon Assist Roller Locking Screw EasyCoder 501 XP EasyCoder 601 XP ...

Page 88: ... of media or liner the thickness of the media the type of ribbon etc The platen roller may be worn giving it a slightly smaller diameter There is also a certain amount on inexactness in the media feed mechanics and belts and so on Therefore you cannot expect to reach exact Start and Stop Adjust values simply by calculation Use the measurements given in this chapter to calculate rough starting poin...

Page 89: ...rt and Stop Adjust The cutting edge of the cutter is situated approxi mately 35 mm 1 38 inches in front of the dot line and 20 mm 0 79 inches in front of the tear bar To cut between labels you must use a StopAdjust of around 270 dots 22 5 mm 0 89 inches to feed out the required extra 20 mm 0 79 inches of media after the printing is completed and beforethecutterisactivated Now thismeansthatyouwills...

Page 90: ...that drives the liner drive roller in the print unit and the liner batch takeup unit The liner drive roller is fitted as standard even when the kit is not installed A liner batch takeup unit that takes up the spent liner or the printed media to be rewound for later use A guide plate EasyCoder 501 XP only that replaces the tear bar when labels or other types of printed media are wound up internally...

Page 91: ...chTakeup Kit EasyCoder 501 XP Peel Off Self strip Operation The liner takeup unit can accommodate the liner from a full roll of labels EasyCoder 501 XP BatchTakeup Operation The batch takeup unit can accommodate approx 1 4 to 1 3 of a full label roll 9 1 Description cont ...

Page 92: ...yCoder 501 XP 601 XP Service Manual 90 Chapter 9 Liner BatchTakeup Kit EasyCoder 601 XP Peel Off Self strip Operation The liner takeup unit can accommodate the liner from a full roll of labels 9 1 Description cont ...

Page 93: ...re 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 by means of two T20 Torx screws that can be accessed through holes in the CPU board switch off the power first A break shaft in front of the takeup unit guides the liner or media under the slack absorber The stepper motor is connected to P421 on the CPU board see Cha...

Page 94: ...01 XP Service Manual 92 Chapter 9 Liner BatchTakeup Kit EasyCoder 601 XP 9 2 Main Parts cont Tension Roller Belt to LinerTakeup Unit Belt to Liner Drive Roller Stepper Motor Motor Support Plate Brace Break Shaft LinerTakeup Unit ...

Page 95: ... held together by a T20 Torx screw at the end of the shaft If the takeup unit does not have enough strength to take up the media or to peel off the labels it may depend on the friction felt having got dried out Dismantle the unit and soak the felt pad in fresh motor oil Remove excessive oil with a piece of tissue and reassemble the unit Not that the Liner Takeup Unit of an Easy Coder 601 XP is not...

Page 96: ...eup Kit EasyCoder 601 XP 9 3 Liner BatchTakeup Unit cont Pulley Ball Bearings Flange Spring Shaft Carrier Friction Washer T20Torx Screw Washer Compression Spring Nylon Washer Slide Bearing Hub Friction Felt T10Torx Screws Hub Plate Hub Gable Grub Screw Slide Bearing Snap Rings ...

Page 97: ...atch see illustration below The photoelectric sensor emits a narrow beam of light which will be reflected back to the sensor by any label ticket tag piece of strip or liner that has not been removed from the outfeed area The LTS is connected to P51 on the CPU board The sensitivity of the receiver can be adjusted by means of the potentiometer WR51 and the intensity of the emitter by a strap on P55 ...

Page 98: ...he 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 WARNING Switch off the power...

Page 99: ...le in the center section of the printer into the electronics compartment Connect the cable to P51 on the CPU board Be careful so the cable does not interfere with any moving mechanical parts or the transfer ribbon Connect the power cord and switch on the power WARNING Theelectronicscompartmentcontainshighvoltagewiresand components Use a non conductive screwdriver to avoid the risk of causing a sho...

Page 100: ...til the beeping starts Adjust the potentiometer WR51 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 P55 to change the inten sity of the LTS emitter Jumper fitted Higher intensity Jumper removed Lower intensity Remove the label The beeping should cease immediately If necessary readjust the potentiometer and or cha...

Page 101: ...sed to cut through any kind of adhesive or other soft material that may stick to the cutting parts and render the cutter inoperable or even damage to the electric motor Maximum paper thickness is 175 µm 175 g m 2 for normal paper based materials Minimum practical copy length is 38 1 mm 1 5 inches The cutter increases the total weight of EasyCoder 501 XPand 601 XP respectively by approx 1 0 1 65 kg...

Page 102: ...utting so printing can start directly at the forward edge Feed adjustment Cut between labels Cut var length strip Start adjust 425 441 Stop adjust 250 375 Should the cutter inadvertently have been used to cut through any adhesive you will have to clean the knife which is a rotating shaft with an edge Tilt down the cutter and use a piece of tissue moistened with isopropyl alcohol or a similar solve...

Page 103: ...as to be removed before the cutter can be fitted see Chapter 10 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 Connect the cable from the cutter unit to the female DIN con nector on the printer s front Press Sideways DIN Connect...

Page 104: ...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 the cutter up 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 11 4 Installation cont Hinge Guide Plates insert media between...

Page 105: ...tually get slack especially if the anvil blade is forced open forexampleduringcleaning Aslackspringmustbereplaced as follows Remove the right hand gable of the cutter two T20 Torx screws Remove the right hand gable of the cutter mechanism two T20 Torx screws three Posidrive screws Replace the spring and assemble in reverse order making sure to put back all the washers ...

Page 106: ...re supported by the standard error handling On the ribbon supply hub is a code disc with 41 gaps When the hub rotates the photoelectric sensor detects when the light is inter rupted and decrements a counter At startup the counter is set to a random value of approximately 65 000 and can be read using SYSVAR 13 see Intermec Fingerprint v7 61 Programmer s Ref erence Manual Thesensorrequiresnoregularc...

Page 107: ... slot between the receiver and transmitter There is no need to remove the ribbon unwind unit Attach the sensor to the center section by means of one T10 Torx screw Check that the code disc can rotate freely Connect the cable to P57 on the CPU board see Chapter 15 3 Put back the left hand cover Switchonthepowerandcheckthatthesensorworksbyreading its values using a PRINT SYSVAR 13 instruction in Int...

Page 108: ...tra interface boards The CPU board is fitted inside the left hand cover plate which is held by a total of eight T10 Torx screws four along the lower edge and another four under the top of the right hand cover WARNING Before removing the cover plate make sure that the printer is switched off and that the power cord is disconnected The power supply unit that is fitted behind the CPU board contains h...

Page 109: ...omplete electronics compartment but with the Centronics interface board removed to improve the view of the CPU board There is no difference between the electronics compartments of EasyCoder 501 XP and EasyCoder 601 XP Ribbon Supply Unit CPU Board Power Supply hidden Liner BatchTakeup Motor Print Unit Stepper Motor Ribbon Rewind Unit ...

Page 110: ... PSU is connected by two cables one to the CPU board and another to the printhead The power supply unit is primary switched with power correction factor controller so as to comply with the CE regulations which require a sinus shaped load curve It is designed for input volt ages in the range of 90 to 264 VAC 45 to 65 Hz without any manual switch The unit delivers 175W continuously and about 400W pe...

Page 111: ...at on the primary side cooler and will improve cooling and spread the heat in the entire machine to avoid local high temperatures Connections X1 Input voltage 90 to 264 VAC 45 to 65 Hz X2 Power to thermal printhead X3 Power to CPU board X4 Power to PSU fan Miscellaneous The power supply unit is also fitted with a switch that can shut off the 24Vto the printhead and cutter and a Power Fail Interrup...

Page 112: ... Service Manual 110 Chapter 14 Power Supply 14 2 Components Low Voltage High Voltage Low Voltage High Voltage FAN Power to CPU Board Power to Printhead 24 V Trim Potentiometer Main Switch Mains Inlet Chassis GND 1 971601 27 Front Side ...

Page 113: ...Intermec EasyCoder 501 XP 601 XP Service Manual 111 Chapter 14 Power Supply 14 2 Components cont 1 971601 27 Back Side ...

Page 114: ...R74 R84 1 2 X4b 1 2 X4a 1 2 FAN1 R90 R91 R100 C63 1 2 TB1 C67 Common P24 1 2 3 4 5 6 7 8 9 10 X2 C49 R88 V32 R87 R124 C48 C 1 A 2 A 3 NC 4 NC 5 A 6 A 7 REF 8 N4 TL431CD R78 R85 R86 C46 COMP 1 NC 2 F B 3 NC 4 IS 5 NC 6 RC 7 GND 8 GND 9 OUT 10 VC 11 VCC 12 NC 13 REF 14 N2 UC3844AD R75 R76 R77 V31 C43 R99 V28 R55 R62 R63 R64 R65 R66 C39 R54 R49 R51 R52 V24 V25 V26 R53 R50 R40 R41 R42 R43 C34 R44 R46 ...

Page 115: ...chematics cont 24V F3 R111 R112 R113 R119 R120 R121 R122 R123 C58 V53 V54 EAI 1 EAO 2 CS 3 VCC 4 OUT 5 GND 6 RAMP 7 REF 8 N6 UC3573D C57 R110 V49 R128 V55 V44 R130 L5 V47 5 3V V46 R118 R115 R116 C60 V45 C65 C61 C62 V50 V51 R131 R132 R114 R146 R117 C59 Comm 1 971601 27 Buck Converter ...

Page 116: ...ions Aprocessor core Stepper motor drivers Thermal printhead driver Sensor drivers Peripheral units such as UART Centronics timers etc Flash memory SIMM for the firmware DRAM SIMM Slave processor Expansion bus 15 CPU Board 15 1 Description CPU CORE I2C BUS Clock Support Chip Reset Watchdog I O DATA TPH Logic Timer Stepper Driver Interrupt Controller Sensors Memory Card Uart Expansion Bus Flash Mem...

Page 117: ...IntelVFMFOS 256K TMParea FOS rom 256K Kernel Fingerprintfirmware barcodes standard 256K Kernel fonts standardimages Shell auxiliary 256K Kernel programs setupvalues EasyLAN100i 256K Kernel homepage2 192K Kernel 16K TMParea Mediafeedinfo odometervalue 16K Parameters 32K Boot Startup IC11 IC304 IC305 P20 P21 P22 P23 P24 P32 P35 P83 P84 CONNECTORS FROM TOP 8 HEADL 6 LSS BOT 5 LSS TOP 4 LTS 3 RI END 2...

Page 118: ...boot sector is fitted in P22 ROM2 on the other board or the boot sector will be overwritten The Intermec Fingerprint firmware is stored in four 256K and one 192K sectors These sectors are called by a common name the Kernel As illustrated in the table on previous page two sectors with a total nominal capacity of 512K plus a 256KTMPsector are used for the Intel VFM Virtual Small Block Manager file o...

Page 119: ... value in dots Calculate the buffersizeaccordingtothisformula No ofdots 8 4 Medialengthindots Buffersize inbytes Buffersizeinbytes 1024 Buffersizeinkbytes Buffer size in kbytes 2 Memory requirement in kbytes Example The numberofdotsontheprintheadis1280 The Media Length issetto 1800 dots 1 50 mm 5 9inches 1280 8 4 1800 1024 2 577K total If a longer print length or more storage space is required the...

Page 120: ...interface also see chapter 15 4 RS 232 Driver IC304 The RS 232 driver circuit is socket mounted to allow replacement if damaged LTS Emitter Strap P55 Thisstrapdecidestheintensitylevelofthelabeltakensensor LTS emitter also see Chapter 10 Jumper fitted High intensity No Jumper Low intensity LTS Potentiometer WR51 This potentiometer decides the sensitivity of the receiver in the label taken sensor al...

Page 121: ...o cutter interface on printer s front P31 Centronics interface board see Chapter 16 3 Center of Pcb P81 Optional interface board see Chapter 16 4 16 7 P82 Presently not used Front Edge top to bottom P57 Ribbon low sensor option P52 Ribbon end sensor P51 Label taken sensor option P53 Label stop sensor upper part P54 Label stop sensor lower part P50 Headlift sensor P37 Console pcb P41 Thermal printh...

Page 122: ...wer is off Flash Memory Cards There are three types of flash memory cards All such cards are referred to as device rom in Intermec Fingerprint Font Cards Must be present in the printer s memory card adapter before the font stored in the card can be used Font Install Cards Install additional fonts in the printer s memory These fonts can be used without the card being present Firmware Cards Install ...

Page 123: ...of up to 3 or 4 setup parameters Refer to the EasySet Bar Code Wand Setup manual for more information on how to produce setup bar codes The printer will acknowledge that a bar code has been successfully read by emitting a short beep signal If no FNC3 character is found in the bar code the data will be stored in a buffer which could be read by specifying the wand device The buffer is small so it is...

Page 124: ...upply to be tested Test Points GND Ground V 5 3 Feed voltage for V5 0 approx 5 3V V 5 0 Logic power 5V 5 RESET High level active printer V24 Feed voltage for P24 24V 5 P24 Printhead and cutter voltage approx 24V when active V40 Feed voltage for stepper motors 42V 10 15 5Test Points IC11 IC304 IC305 P32 P35 P83 P84 V40 GND POWER KEYB 5 3V VCC P24 V24 RESET ...

Page 125: ...ll be copied to DRAM and the processor will start execute code from DRAM If the printer is fitted with an EasyLAN 100i interface board there are also facilities for updating the firmware via Ethernet See spe cial documentation that comes with the EasyLAN 100i board After the initial boot sequence is performed the number of steps will be taken before Fingerprint starts The startup procedure can be ...

Page 126: ...R15 R16 R17 R18 R19 R21 R22 R23 R31 R32 R33 R35 R36 R81 R82 R83 R84 R100 R101 R102 R103 R104 R105 R106 R107 R108 R109 R110 R111 R112 R113 R114 R115 R116 R117 R201 R202 R203 R204 R205 R206 R207 R208 R209 R210 R211 R212 R301 R302 R303 R304 R305 R306 R307 R308 R309 R401 R402 R403 R404 R405 R406 R407 R408 R409 R410 R411 R412 R413 R414 R415 R416 R417 R418 R419 R420 R421 R422 R423 R424 R425 R426 R430 R4...

Page 127: ...10 I11 IO0 IO1 IO2 IO3 IO4 IO5 IO6 IO7 IO8 IO9 GND IOBUS PWR PIO IOBUS CTRL PWR PIO IOBUS PWR PIO GND GND GND CGND CGND 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 9 10 11 12 15 13 14 7 6 5 4 1 3 2 1 2 3 6 4 5 15 14 13 12 11 10 9 7 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B...

Page 128: ...CC GND AD21 AD20 AD19 AD18 AD17 AD16 AD15 OEMAD TEST CLR LOAD ENT ENP CLK A B C D RCO QA QB QC QD GND XIN XOUT OE S0 S1 S2 XBUF CPUCLK CLKA CLKB CLKC CLKD VCC VCC OC CLK 1D 2D 3D 4D 5D 6D 7D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q OC CLK 1D 2D 3D 4D 5D 6D 7D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q OC CLK 1D 2D 3D 4D 5D 6D 7D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q AD23 AD24 AD25 AD26 VCC GND AD27 AD28 AD29 AD30 AD31 GND VCC CLKIN Rsvd4...

Page 129: ...12 AD11 AD10 AD9 AD8 D30 D29 D12 D11 D10 D9 D8 D24 D27 D26 D25 D28 D13 D14 D31 D15 DATAEN DATAEN DATAEN DATAEN CDM2 CDM1 VCC PBRST VPP PROM FLASH SRAM BANK DRAM BANK1 DRAM BANK0 MEMORY CARD VCC GND G1 G2 A1 A2 A3 A4 A5 A6 A7 A8 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 DIR G A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 DIR G A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 DIR G A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B...

Page 130: ...D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q VCC VCC CS RD WR A0 D0 D1 D2 D3 D4 D5 D6 D7 CAS0 CAS1 CAS2 SP EN IR0 IR1 IR2 IR3 IR4 IR5 IR6 IR7 INT INTA Gnd NC NC NC NC RI RCLK BAUDOUT XOUT XIN MR ADS A2 A1 A0 DDIS RXRDY TXRDY OUT2 OUT1 CS2 CS1 WR RD DCD DSR CTS SIN SOUT RTS DTR INTR CS0 WR RD D7 D6 D5 D4 D3 D2 D1 D0 G1 G2 A1 A2 A3 A4 A5 A6 A7 A8 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 GND GND CGND VCC C A GND C A VCC GND CGND GND...

Page 131: ...D 6D 7D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q C A VCC GND GND GND GND GND 1 2 E B C 1 2 3 4 1 2 3 4 E B C 1 2 3 6 8 5 1 2 1 2 3 4 1 2 3 6 8 5 15 1 2 3 4 5 6 7 9 14 13 12 11 10 0 0 1 6 7 1 2 3 4 12 13 11 8 9 E B C 12 3 2 4 5 E B C E B C 13 3 2 1 14 15 7 6 5 4 9 10 11 12 1 2 3 4 1 2 3 4 1 11 2 3 4 5 6 7 8 9 19 18 17 16 15 14 13 12 E B C E B C 1 2 3 4 5 E B C ã 1 DMUX ã C503 P55 R506 R505 R507 T50 R508 R509 C50...

Page 132: ...K A B C D RCO QA QB QC QD CLR LOAD ENT ENP CLK A B C D RCO QA QB QC QD CLR LOAD ENT ENP CLK A B C D RCO QA QB QC QD CLR LOAD ENT ENP CLK A B C D RCO QA QB QC QD OC CLK 1D 2D 3D 4D 5D 6D 7D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q OC CLK 1D 2D 3D 4D 5D 6D 7D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q GND GND GND V24 GND P24 GND GND GND GND V24 GND GND GND GND VCC A B Y I0 I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 IO0 IO1 IO2 IO3 IO4 I...

Page 133: ...Q 3Q 4Q 5Q 6Q 7Q 8Q IN1 IN2 OUT1 OUT2 VS GND BOOT1 BOOT2 VREF ENABLE SENSE IN1 IN2 OUT1 OUT2 VS GND BOOT1 BOOT2 VREF ENABLE SENSE GND GND GND VCC GND 1 2 3 4 5 6 7 8 5 7 3 1 2 6 4 8 9 11 10 5 7 3 1 2 6 4 8 9 11 10 1 11 2 3 4 5 6 7 8 9 19 18 17 16 15 14 13 12 5 6 7 8 18 19 4 3 12 17 16 15 14 13 5 6 7 8 18 19 4 3 1 1 2 2 12 17 16 15 14 13 1 11 2 3 4 5 6 7 8 9 19 18 17 16 15 14 13 12 5 7 3 1 2 6 4 8 ...

Page 134: ...mputer or for connection of a bar code reader an external keyboard etc see Chapter 16 2 Parallel Communication interface centronics for parallel one way communication with the host computer see Chapter 16 3 Optional interface boards see Chapters 16 4 16 8 The rest of this Chapter will only deal with the three last para graphs By default uart1 is the standard IN and OUT communication port To select...

Page 135: ... signals in a DB 25pin male connector which protrudes through a slot in the printer s rear plate By default the printer is set up as follows Baud rate 9600 Parity None Char length 8 bits Stop bits 1 RTS CTS Disabled ENQ ACK Disabled XON XOFF Disabled both ways New line CR LF The external 5V is limited to 200 mA and is automatically switched off at overload It is intended to drive for example an ex...

Page 136: ...nics default Predefined timing for the ACK and BUSY signals when respond ing to host data is 500 ns ACK BUSY inactivated after ACK finishes IBM Epson type Centronics Predefined timing for the ACK and BUSY signals when respond ing to host data is 2500 ns ACK BUSY inactivated as soon as ACK pulse starts Classic type Centronics Predefined timing for the ACK and BUSY signals when respond ing to host d...

Page 137: ...RESET SYSCLK STROBE ACK BUSY PERR SELECT AF INIT ERROR INT3741 Gnd G A1 A2 A3 A4 Y1 Y2 Y3 Y4 VCC OC CLK 1D 2D 3D 4D 5D 6D 7D 8D 1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q Gnd G A1 A2 A3 A4 Y1 Y2 Y3 Y4 VCC Gnd Gnd CGND CGND Gnd 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 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 ...

Page 138: ...ompartment before the printer is safely disconnected from any AC supply Remove the four T10Torx screws that hold the interface cover plate above the Centronics connector on the printer s rear plate Remove the cover plate Save the cover plate for possible later use Keep the screws If necessary fit or remove circuits and straps to adapt the inter face board according to the descriptions of each boar...

Page 139: ...an Industrial Interface board without any serial port see Chapter 16 8 you can also install a stan dard EasyLAN 100i interface board see Chapter 16 7 This is the only instance when you can install two optional interface boards in the same printer ands requires Intermec Fingerprint v7 60 or later FitthecablerunningfromP81ontheCPUboardtoconnector s on the interface board s 16 4 Fitting Optional Inte...

Page 140: ... parameters IC304 IC305 P32 P35 1 971600 01 P01 P81 C7 R56 R55 R54 R53 R52 R8 R3 R2 R1 JP1 IC7 IC6 IC5 IC2 IC1 C15 C14 C13 C12 C11 C6 C5 C4 C3 C2 C1 C8 C9 C10 C20 C21 C22 C23 C24 C25 C26 C27 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC8 IC9 IC10 IC11 IC12 IC13 IC14 IC15 IC16 IC17 IC18 JP2 P1 P2 P3 P4 R4 R5 R6 R7 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R2...

Page 141: ...T ports can be set be means of PORTOUT ON OFF state ments see Intermec Fingerprint v7 61 Programmer s Reference Manual Thus it is possible to design Intermec Fingerprint pro grams which control not only the printer but also various external devices in for example a production line The digital IN ports can read the status of various sensors and the program can for example switch control lamps on or...

Page 142: ...circuit fit into their respective slots in the socket and are not bent Also take proper precau tions so as to protect the board and circuits from electrostatic dis charges RS 232 C7 R56 R55 R54 R53 R52 R8 R3 R2 R1 JP1 IC7 IC6 IC5 IC2 IC1 C15 C14 C13 C12 C11 C6 C5 C4 C3 C2 C1 C8 C9 C10 C20 C21 C22 C23 C24 C25 C26 C27 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC8 IC9 IC10 IC11 IC12 I...

Page 143: ... if end of cable 16 5 Serial Industrial Interface Board cont RS 422 Non Isolated C7 R56 R55 R54 R53 R52 R8 R3 R2 R1 JP1 IC7 IC6 IC5 IC2 IC1 C15 C14 C13 C12 C11 C6 C5 C4 C3 C2 C1 C8 C9 C10 C20 C21 C22 C23 C24 C25 C26 C27 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC8 IC9 IC10 IC11 IC12 IC13 IC14 IC15 IC16 IC17 IC18 JP2 P1 P2 P3 P4 R4 R5 R6 R7 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R...

Page 144: ...232 Ring Indicator 23 Shield Optional shield for RS 422 and RS 485 24 25 Not connected 16 5 Serial Industrial Interface Board cont C7 R56 R55 R54 R53 R52 R8 R3 R2 R1 JP1 IC7 IC6 IC5 IC2 IC1 C15 C14 C13 C12 C11 C6 C5 C4 C3 C2 C1 C8 C9 C10 C20 C21 C22 C23 C24 C25 C26 C27 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC8 IC9 IC10 IC11 IC12 IC13 IC14 IC15 IC16 IC17 IC18 JP2 P1 P2 P3 P4 R4 ...

Page 145: ...value 1 true else the value 0 false Signal Description Min Typical Max Vin High Input Voltage High 10V 24V 40V Vin Low Input Voltage Low 1V 0V 1V Connector Configuration Pin Signal Name Description Fingerprint Ref No 10 IN1A Anode Opto In Channel 1 101 40 IN1K Cathode Opto In Channel 1 26 IN2A Anode Opto In Channel 2 102 11 IN2K Cathode Opto In Channel 2 41 IN3A Anode Opto In Channel 3 103 27 IN3K...

Page 146: ...tocoupler 100V Connector Configuration Pin Signal Name Description Fingerprint Ref No 20 Out1c Collector Opto Out Channel 1 221 5 Out1e Emitter Opto Out Channel 1 35 Out2c Collector Opto Out Channel 2 222 21 Out2e Emitter Opto Out Channel 2 6 Out3c Collector Opto Out Channel 3 223 36 Out3e Emitter Opto Out Channel 3 22 Out4c Collector Opto Out Channel 4 224 7 Out4e Emitter Opto Out Channel 4 37 Ou...

Page 147: ... PORTIN functions If a relay is activated PORTIN returns the value 1 true else the value 0 false Max AC Load Breaking Capacity Signal Description Max I Current 1A Psw AC Switching power 100VAAC Usw AC Switching voltage 100V AC Max DC Load Breaking Capacity Connector Configuration Pin Signal Name Description Fingerprint Ref No 16 REL1nc Relay 1 Normally Closed 201 1 REL1no Relay 1 Normally Open 31 ...

Page 148: ...7 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC8 IC9 IC10 IC11 IC12 IC13 IC14 IC15 IC16 IC17 IC18 JP2 P1 P2 P3 P4 R4 R5 R6 R7 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 R50 R51 REL1 REL2 REL3 REL4 RP1 RS422nonisol IC18 S1 S4 S3 S1 S2 S4 1 971606 01 P01 RS232 IC2 RS422isolated IC3 S2 S4 RS485 IC4 S3 ...

Page 149: ...2 IDIDRV ICOM1 IDEIN IDIIN A IRODRV B IVCC1 AC2 AC1 C1 C1 C2 C2 V V T1IN T2IN T3IN T4IN T1OUT T2OUT T3OUT T4OUT R1IN R2IN R3IN R4IN R1OUT R2OUT R3OUT R4OUT GND VCC RO DI GND DO DO RI RI VCC GND VCC GND GND GND 2 1 3 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 2 ...

Page 150: ...2 17 31 1 16 5 6 9 8 11 10 13 12 13 4 12 5 11 6 10 7 IN4K IN4A IN3K IN3A IN2K IN2A IN6K IN6A IN5K IN5A OUT2e OUT1e OUT1c OUT2c OUT4e OUT3e OUT3c OUT4c OUT6e OUT5e OUT5c OUT6c OUT8e OUT7e OUT7c OUT8c IN8K IN8A IN7K IN7A IN1K IN1A REL3com REL4com REL1com REL2com REL4nc REL3no REL3nc REL4no REL2nc REL1no REL1nc REL2no IOBUS IIWR IIRD IOEN IC8C 74HC14 IC17A 74HC14 IC16D TIL193B IC16C TIL193B IC16B TIL...

Page 151: ...EasyCoder 501 XP and 601 XP with two extra serial interfaces uart2 and uart3 uart2 This interface can be fitted with straps and circuits for one of the following alternatives RS 232 RS 422 non isolated RS 422 isolated RS 485 uart3 This interface can be fitted with straps and circuits for one of the following alternatives RS 232 RS 422 non isolated 20 mACurrent Loop uart3 DB 25pin male uart2 DB 25p...

Page 152: ...Double Serial Interface Board cont uart2 Configuration The serial communication port uart2 can be configured for four different types of serial communication RS 232 RS 422 non isolated RS 422 isolated RS 485 By fitting or removing certain circuits and straps the desired type of interface can be selected This is either done at factory or by the customer Caution When fitting circuits yourself do it ...

Page 153: ...3 S2 S4 RS232 IC2 RS422nonisol IC18 S1 S4 C7 R12 R15 R14 R13 R9 R8 R3 R2 R1 JP1 IC7 IC6 IC5 IC2 IC1 C15 C14 C13 C12 C11 C6 RP1 C5 C4 C3 C2 C1 C10 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC18 JP2 P1 P2 P3 P4 R4 R5 R6 R7 R11 R10 RS422nonisol IC18 S1 S4 S3 S1 S2 S4 RS232 IC2 RS422isolated IC3 S2 S4 RS485 IC4 S3 S4 Term if end of cable C8 C9 R20 R21 R23 R22 R30 R35 R33 R32 R34 R31 R2...

Page 154: ...IC12 S5 Term if end of cable RS485 IC4 S3 S4 RS422isolated IC3 S2 S4 RS232 IC2 RS422nonisol IC18 S1 S4 uart2 RS 485 Remove RS 232 circuit on IC2 Fit RS 485 circuit on IC4 Fit strap on S4 if end of cable Fit strap on S3 only Connector Configuration The serial interface uart2 has a DB 25pin female connector Pin Signal Name Description 1 Not connected 2 TxD RS 232Transmitter 3 RxD RS 232 Receiver 4 R...

Page 155: ...not bent Also take proper precau tions so as to protect the board and circuits from electrostatic dis charges uart3 RS 232 standard configuration C7 R12 R15 R14 R13 R9 R8 R3 R2 R1 JP1 IC7 IC6 IC5 IC2 IC1 C15 C14 C13 C12 C11 C6 RP1 C5 C4 C3 C2 C1 C10 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC18 JP2 P1 P2 P3 P4 R4 R5 R6 R7 R11 R10 RS422nonisol IC18 S1 S4 S3 S1 S2 S4 RS232 IC2 RS422...

Page 156: ... JP3 S5 S6 1 971613 00 A01 UART3 UART2 20mA CL IC13 IC14 S6 RS232 IC11 RS422nonisol IC12 S5 Term if end of cable RS485 IC4 S3 S4 RS422isolated IC3 S2 S4 RS232 IC2 RS422nonisol IC18 S1 S4 C7 R12 R15 R14 R13 R9 R8 R3 R2 R1 JP1 IC7 IC6 IC5 IC2 IC1 C15 C14 C13 C12 C11 C6 RP1 C5 C4 C3 C2 C1 C10 D1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 IC3 IC4 IC18 JP2 P1 P2 P3 P4 R4 R5 R6 R7 R11 R10 RS422nonis...

Page 157: ...ed 9 20M1 20 mA current loop 10 20M1 20 mA current loop 11 TXD TXD 20 mA current loop 12 TXD TXD 20 mA current loop 13 20M2 20 mA current loop printer active receiver 14 20M2 20 mA current loop printer active receiver 15 RS422I RS 422 Receive 16 5V 5Volt for external use max 200 mA 1 17 RS422I RS 422 Receive 18 RxD TXD 20 mA current loop 19 RS422O RS 422Transmit 20 DTR RS 232 DataTerminal Ready 21...

Page 158: ...25 F26 F27 F28 F29 F30 F31 F32 F33 F34 IC1 IC2 IC3 IC4 IC5 IC6 IC7 IC10 IC11 IC12 IC13 IC14 IC15 IC18 JP1 JP2 JP3 P1 P2 P3 P4 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 R34 R35 RP1 RP2 Z1 Z2 S6 S5 S2 S1 Term if end of cable RS485 IC4 S3 S4 RS422isolated IC3 S2 S4 RS232 IC2 1 971613 00 A01 S4 RS422nonisol IC18 S1 S4 S3 UART3 20mA CL IC...

Page 159: ...GND CGND GND VCC VCC GND VCC GND A B Y D0 D1 D2 D3 D4 D5 D6 D7 RD WR CS0 INTR DTR RTS SOUT SIN CTS DSR DCD RD WR CS1 CS2 OUT1 OUT2 TXRDY RXRDY DDIS A0 A1 A2 ADS MR XIN XOUT BAUDOUT RCLK RI NC NC NC NC A B Y GND A B Y A0 A1 A2 WP SCL SDA VCC GND GND GND VCC VCC VCC GND V24 IOBUS UARTCS3 RESET VCC GND INT3 CLK8 V24 CGND CGND V24 6 4 5 1 2 3 4 5 2 3 4 5 6 7 8 1 10 12 13 14 11 15 5 18 19 21 2 1 24 20 ...

Page 160: ... A B Y A B Y A B Y VCC C A CA GND VCC RO DI GND DO DO RI RI VCC GND C1 C1 C2 C2 V V T1IN T2IN T3IN T4IN T1OUT T2OUT T3OUT T4OUT R1IN R2IN R3IN R4IN R1OUT R2OUT R3OUT R4OUT V24 V24 2 3 4 5 6 7 8 9 24 20 14 33 37 36 13 11 40 41 42 25 21 15 16 38 35 27 32 26 31 30 29 28 39 18 19 17 10 43 1 12 23 34 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 2 3 8 7 6 5 2 3 8 7 6 5 5 6 4 2 3 1 8...

Page 161: ...ign passwords to restrict both login and printer access The internal EasyLAN 100i web pages allow you to continuously monitor printer status and to upgrade the flash memory of the board when new print server software becomes available EasyLAN 100i supports SNMP for remote monitoring The printer must be fitted with Intermec Fingerprint v7 3 or later The Ethernet port is addressed as device net1 com...

Page 162: ...RAM LOAD FPGA START MODE STRAPS B B B A A A BOOT STRAP 1 971614 00 P02 C14 C50 C51 C52 C53 C54 C55 C71 C72 C73 C74 C75 C76 C80 C81 C82 C83 C84 C85 C86 C87 C88 C89 C90 C91 C92 C93 C94 C95 C96 C97 C98 C99 C100 C101 C102 C103 C104 C105 C106 C107 C108 C109 C110 C111 C112 C113 C114 C115 C116 C117 C118 R2 R3 R5 R13 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R44 R45 R46 R47 R50 R51 R55 R57 R...

Page 163: ...C12 C13 C14 R5 VDD GND VCC VDD 1 5 4 6 2 3 P11 GND EATHERNET RESETE POWER CLK25 ETHERNET INT ETHERNET INT 97161427 21 A14 4 A1 3 A2 2 A3 1 A4 44 A5 43 A6 42 A7 27 A8 26 A9 7 D0 8 D1 9 D2 10 D3 13 D4 14 D5 15 D6 16 D7 23 A12 29 D8 30 D9 31 D10 32 D11 35 D12 36 D13 37 D14 38 D15 5 A0 39 LB 41 OE 19 A16 25 A10 24 A11 18 A17 22 A13 20 A15 6 CS 17 WE 40 UB IC3 SRAM KM616V4000 KM616V4000 R1 R2 1 A0 2 A1...

Page 164: ... XCS05PC84 XCS05PC84 GND 9 A 10 B 8 Y IC36 C 74HCT08 74HCT08 12 A 13 B 11 Y IC36 D 74HCT08 74HCT08 4 A 5 B 6 Y IC36 B 74HCT08 74HCT08 GND 12 A 13 B 11 Y IC35 D 74HCT00 74HCT00 D30 C110 C114 C113 C111 C112 C100 C109 C107 C106 C101 C102 C105 C104 C103 C108 C1 C98 VCC C99 3 2 1 IC37 REG1117 REG1117 VDD C93 C94 C95 C92 C91 C90 C96 C97 C3 GND C117 C118 C115 C116 C89 C88 C87 C81 C82 C83 C86 C85 C84 C80 ...

Page 165: ...COL RXEN 52 TXER 60 TXD3 59 TXD2 58 TXD1 57 TXD0 56 TXEN 43 RXD3 44 RXD2 47 RXD1 48 RXD0 51 RXER 31 TD 30 TD 26 RD 25 RD 49 RXDV 50 RXC 53 TXC 35 LNKLED 36 SPDLED 34 XMTLED INTR 33 RVCLED ACTLED 17 ENERGY_DET 9 RESET IC50 BCM5201 R53 R52 GND C70 C76 C75 C4 C74 C73 C72 C71 GND R50 EATHERNET 1 3 2 6 7 8 4 5 10 9 P50 YCLRJ45 R57 C55 C50 C54 C51 C53 C52 CLK25 RESETE 2 RESET 3 MR IC51 MAX811 POWER R73 ...

Page 166: ...e contains eight digital IN and eight digital OUTports with optocouplers plus four OUT ports with relays The status of all ports can be read using PORTIN functions and the OUT ports can be set be means of PORTOUT ON OFF state ments see Intermec Fingerprint v7 61 Programmer s Reference Manual Thus it is possible to design Intermec Fingerprint pro grams which control not only the printer but also va...

Page 167: ...he value 1 true else the value 0 false Signal Description Min Typical Max Vin High Input Voltage High 10V 24V 40V Vin Low Input Voltage Low 1V 0V 1V Connector Configuration Pin Signal Name Description Fingerprint Ref No 10 IN1A Anode Opto In Channel 1 101 40 IN1K Cathode Opto In Channel 1 26 IN2A Anode Opto In Channel 2 102 11 IN2K Cathode Opto In Channel 2 41 IN3A Anode Opto In Channel 3 103 27 I...

Page 168: ...oupler 100V Connector Configuration Pin Signal Name Description Fingerprint Ref No 20 Out1c Collector Opto Out Channel 1 221 5 Out1e Emitter Opto Out Channel 1 35 Out2c Collector Opto Out Channel 2 222 21 Out2e Emitter Opto Out Channel 2 6 Out3c Collector Opto Out Channel 3 223 36 Out3e Emitter Opto Out Channel 3 22 Out4c Collector Opto Out Channel 4 224 7 Out4e Emitter Opto Out Channel 4 37 Out5c...

Page 169: ...RTIN functions If a relay is activated PORTIN returns the value 1 true else the value 0 false Max AC Load Breaking Capacity Signal Description Max I Current 1A Psw AC Switching power 100VAAC Usw AC Switching voltage 100V AC Max DC Load Breaking Capacity Connector Configuration Pin Signal Name Description Fingerprint Ref No 16 REL1nc Relay 1 Normally Closed 201 1 REL1no Relay 1 Normally Open 31 REL...

Page 170: ...2 C23 C24 C25 C26 C27 D1 IC3 IC8 IC9 IC10 IC11 IC12 IC13 IC14 IC15 IC16 IC17 P1 P2 P4 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 REL1 REL2 REL3 REL4 RS422nonisol IC18 S1 S4 S3 S1 S2 S4 1 971606 02 P01 RS232 IC2 RS422isolated IC3 S2 S4 RS485 IC4 S3 S4 Term if end of cable 1 971606 30 Industrial Interface pcb ...

Page 171: ...VCC2 IRLED FS GND2 VCC4 DI VCC3 SD GND1 D2 D1 VCC2 VCC1 RO VCC1 VCC2 D1 D2 GND1 SD VCC3 DI VCC4 DE GND2 RO VCC5 FS IRLED ICOM2 IDEDRV IVCC2 IDIDRV ICOM1 IDEIN IDIIN A IRODRV B IVCC1 AC2 AC1 C1 C1 C2 C2 V V T1IN T2IN T3IN T4IN T1OUT T2OUT T3OUT T4OUT R1IN R2IN R3IN R4IN R1OUT R2OUT R3OUT R4OUT GND VCC RO DI GND DO DO RI RI VCC GND VCC GND GND GND 2 1 3 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14...

Page 172: ...2 36 6 21 35 5 20 34 4 19 33 3 18 32 2 17 31 1 16 5 6 9 8 11 10 13 12 13 4 12 5 11 6 10 7 IN4K IN4A IN3K IN3A IN2K IN2A IN6K IN6A IN5K IN5A OUT2e OUT1e OUT1c OUT2c OUT4e OUT3e OUT3c OUT4c OUT6e OUT5e OUT5c OUT6c OUT8e OUT7e OUT7c OUT8c IN8K IN8A IN7K IN7A IN1K IN1A REL3com REL4com REL1com REL2com REL4nc REL3no REL3nc REL4no REL2nc REL1no REL1nc REL2no IOBUS IIWR IIRD IOEN IC8C 74HC14 IC17A 74HC14 ...

Page 173: ...noffthe power Lifttheprinthead Press down any key on the printer s built in keyboard with the exception of the Shift key andkeeppressingit Turnonthepower Theprinter willstarttheinitializationprocedure Release the key Theprinter willstartupIntermec Shell Press Enter before the 5sec countdowniscompleted Inside Intermec Shell you have a variety of options regardless of any autoexec program for exampl...

Page 174: ... No parallel communication 17 10 Sensor malfunctions 17 11 Label stop sensor Headlift sensor Ribbon end sensor Ribbon low sensor Label taken sensor Printing troubles 17 12 No printout at all Overall weak printout Weaker printout on either inner or other part of label Overall dark printout bleeding Weak or missing printout of some dots Unexpected black printout completely or partial Only first part...

Page 175: ...ds of power cord Try again Faulty power cord Replace and try again Cable between CPU board and power supply not properly con nected Test as described in Chapter 17 5 using test points on CPU board see Chapter 15 5 Power Supply overload Too high a temperature in the power supply unit Leave the power on and wait for the power supply to cool off may take up to half an hour When the temperature return...

Page 176: ...software commands There is no reaction on any keys on the printer s keyboard Possible Causes and Suggested Remedies The printer s main program has halted due to high external dis turbances from other electrical sources Restart the printer and find out if there are disturbances coming via theAC wall socket via a communication channel or from other electrical appliances CPU board failures Refer to Ch...

Page 177: ...es Flash or DRAM SIMMs not properly fitted A SIMM is not fully inserted in its socket Remove all SIMMs and fit them back again making sure they are being firmly held by the snap locks No Boot Flash SIMM in socket ROM2 A Flash SIMM containing a boot sector must be fitted in socket ROM2 or the printer will not start Startup error Execution of the initial boot sequence can be checked as described in Cha...

Page 178: ...y for extreme operating condi tions is available as a spare part Cooling fan does not work Repeated power supply overloads at normal ambient temper atures and normal printing conditions may indicate that the cooling fan at the bottom of the power supply unit is either defective or out of power Replace if necessary The fan is controlled by a thermostat and will only run when the temperature exceeds...

Page 179: ...d find out if there are disturbances coming via the AC supply via a communication channel or from other electrical appliances Keys disabled or keyboard remapped by a custom made pro gram If the printer does not react on any keys in the Test Mode the keyboard is defective and needs to be replaced Keybeep disabled by a custom made program IfnobeepisheardwhenthekeysarepressedintheTestMode but the prin...

Page 180: ... OUTchannel serial communica tion only provided the verbosity is not turned off The same applies if programming errors are detected when the program is run When a program is executed the same errors as in the Imme diate Mode will be returned and the execution stops Taking care of this requires some kind of error handler for example ERRHAND PRG Intermec Direct Protocol Five error conditions can be ...

Page 181: ...cal damage Remove the cable and put it back a few times to rub off pos sible oxide Try using another identical cable Defective cable between interface board and CPU board This does not apply to the serial port uart1 which is fitted directly on the CPU board Check that the cable is correctly inserted and that it is of cor rect type Inspect cable for physical damage Remove the cable and put it back ...

Page 182: ... noisy No supply voltage Verify that the supply voltages 5V are present see Chapter 15 5 No external 5V Some external devices require current supply from the printer 5V Typically this applies to the Intermec External Key board or a bar code scanner The printer supplies max 200 mA and is automatically turned off at higher loads Check the consumption of the connected device The polyswitch RP30 on th...

Page 183: ...struction SYSVAR 25 see Intermec Fingerprint v7 61 Programmer s Reference Manual Verify that the printer is set for the same type as the host Host does not set SELECT IN signal low applies to non modified Centronics interface pcb P N 1 971603 26 and 1 971603 27 only See edition 1 of this manual for instructions how to modify old Centronics interface boards Damaged interface board or cable Replace ...

Page 184: ... for the type of media in use Bad connection If the label stop sensor still does not operate correctly check the condition of its cables and that they are correctly con nected to the CPU board lower sensor to P54 upper sensor to P53 Note that these two cables could be switched to detect black marks at the top of the media Faulty sensor Replace as described in Chapter 8 6 Description The printer do...

Page 185: ...objects Check that the mirror plate is properly aligned Check that the sensor s cable is undamaged and properly connected to P52 on the CPU board Adjust the sensitivity of the receiver by means of potentiom eter WR52 on the CPU board Fit or remove strap on P56 to change the intensity of the light emitter Description The ribbon low sensor is not working properly Possible Causes and Suggested Remedi...

Page 186: ...ans of a PRSTAT function in the current Intermec Fingerprint pro gram Bad connection Check that the cable is connected to P51 on the CPU board and undamaged Dirty or misaligned sensor Makesurethattheactivepartsofthesensorarenotobstructed by dust or foreign objects and that the bracket is not bent so as to cause misalignment Wrong LTS sensitivity The sensitivity of the sensor s receiver and the lig...

Page 187: ...int head s outer connector to X2 on the power supply Dirty printhead Is the printhead clean Residue from label adhesive or burnt transfer ribbon on the printhead prevents it from functioning correctly Clean as described in the User s Guide Wrong type of receiving media In case of direct thermal printing verify that the stock of media is intended for direct thermal printing not thermal transfer and...

Page 188: ...er printout on either inner or outer part of label Possible Causes and Suggested Remedies Bad printhead pressure alignment Adjust the position of the pressure arm as described in Chap ter 8 9 Description Overall too dark printout bleeding Too dark a printout is particularly troublesome when printing compact bar codes in which case spaces between the bars become less distinctive and consequently le...

Page 189: ... platen roller and possibly also the printhead Preprinted ink has got stuck to the dot line Avoid preprinted labels with ink that has a low melting point less than 225 C Many dots or a block of dots are missing The internal IC circuit of the printhead is probably damaged Replace the printhead Description Unexpected black printout completely or partially Possible Causes and Suggested Remedies Wrong...

Page 190: ...ion or make the media slip Wrong belt tension Check the tension of the belt that drives the platen roller and adjust as explained in Chapter 8 5 Intermec Fingerprint instruction missing Verify that a print command is actually issued in the current Intermec Fingerprint program CPU board malfunction or bad connection Move the cable from P420 to P421 on the CPU board and performaPRINTFEEDorFORMFEED I...

Page 191: ...pter 8 10 Do not change the adjustment before you have performed all other checks mentioned above Bad ribbon supply hub alignment Checkthattheribbonsupplyhubiscenter alignedinrelationto the transfer ribbon as described in Chapter 7 2 Description Transfer ribbon breaks Possible Causes and Suggested Remedies Wrong brand of ribbon Checkifthetransferribbonisanapprovedbrand Ifnot recom mend the custome...

Page 192: ... is some error in the CPU board or power supply Check as for Media feed does not work in Chapter 17 11 If neither the takeup hub nor the liner drive roller rotate at all but the media feed stepper motor is OK the takeup unit stepper motor could be incorrectly connected P421 or its drive circuits IC424 and IC425 on the CPU board could be damaged Check that all pins in the connector of the stepper m...

Page 193: ...fy that no paper shavings adhesive residue or foreign objects obstruct the cutting operation Clean as described in Chapter 12 3 If the cutter is prevented from completing a cut ting operation the motor may be damaged by overload Wrong voltage Measuring the voltage on connector P58 pin 1 P24 to pin 3 GND or pin 2 cutter output to pin 3 GND when a CUT instruction is executed should give a voltage of...

Page 194: ...d Bad connection Pull out and push back the card a few times to eliminate poor contact or oxidation between card and adapter Note The printer must be switched off Error in content of the card If you have access to a PC equipped with a card reader list the memory content of the PC memory card to see if it is cor rect In case of a SRAM card the information stored may have got lost due to some malfun...

Page 195: ...on is started The selected application is started POWER ON Return to previous menu Proceed to next menu Accept displayed option and proceed or execute displayed option Perform a Testfeed anywhere in Intermec Shell Enter the Setup Mode from anywhere in Intermec Shell Legend SHELL SEL APPLICATION SEL APPLICATION Direct Protocol SEL APPL rom LINE_AXP PRG SETUP SER COM UART1 SEL APPLICATION LABELSHOP ...

Page 196: ... DISABLE FLOWCONTROL ENQ ACK ENABLE ENQ ACK DISABLE FLOWCONTROL XON XOFF XON XOFF DATA TO HOST ENABLE DATA TO HOST DISABLE XON XOFF DATA FROM HOST ENABLE DATA FROM HOST DISABLE CR LF SER COM UART1 NEW LINE NEW LINE CR LF SER COM UART1 REC BUF REC BUF 300 SER COM UART1 TRANS BUF TRANS BUF 300 DETECTION FEEDADJ SETUP FEEDADJ FEEDADJ STOPADJ STOPADJ 0 STARTADJ 0 Continued on next page LEGEND Boxes wi...

Page 197: ...IZE XSTART MEDIA SIZE WIDTH MEDIA SIZE LENGTH XSTART 36 WIDTH 1244 LENGTH 1800 MEDIA MEDIA TYPE MEDIA TYPE LABEL w GAPS 2 4 6 8 10 MEDIA TYPE 10 8 6 4 2 CONTRAST 0 PRINT DEFS HEAD RESIST SETUP PRINT DEFS SETUP NETWORK HEAD RESIST nnn PRINT DEFS TESTPRINT ENTER PRINT F5 NEXT 1 Read only value Printhead resistance is automatically set at startup Continued from previous page PRINT SPEED 150 PRINT DEF...

Page 198: ...ER COM UART2 TRANS BUF TRANS BUF 300 If an optional Double Serial or Industrial Interface Board is fitted additional menus will be displayed in case of Double Serial Interface Board also see Overview Part 4 The selected type of hardware connection on uart2 is displayed as one of the following alternatives read only RS232 422 NON ISOLATED 422 ISOLATED RS485 These menus are only displayed if RS 485 ...

Page 199: ...BLE FLOWCONTROL XON XOFF XON XOFF DATA TO HOST ENABLE DATA TO HOST DISABLE XON XOFF DATA FROM HOST ENABLE DATA FROM HOST DISABLE CR LF SER COM UART3 NEW LINE NEW LINE CR LF SER COM UART3 REC BUF REC BUF 300 SER COM UART3 TRANS BUF TRANS BUF 300 If an optional Double Serial Interface Board is fitted additional menus will be displayed The selected type of hardware connection on uart3 is displayed as...

Page 200: ...Overview Part 2 Standard Setup Mode See Overview Part 2 Use keys and 0 9 to enter netmask Use C key to erase Use keys and 0 9 to enter netmask Use C key to erase NETWORK IP SELECTION SETUP NETWORK NETWORK IP ADDRESS IP ADDRESS 10 1 12 79 NETMASK 255 255 0 0 NETWORK NETMASK Use keys and 0 9 to enter router Use C key to erase NETWORK DEFAULT ROUTER DEFAULT ROUTER 10 1 12 1 RARP BOOTP DHCP IP SELECTI...

Page 201: ...nt 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 center 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 Rad...

Page 202: ...set mcsXXXX uff This uff file contains the kernel and optional instructions if necessary images files etc To be stored on a Flash card or SRAM card mcsXXXX net This net file contains the kernel and header footer instructions To be sent via Ethernet to EasyLAN100i omter face boards installed in printers General Principles During upgrading do not switch off the printer Wait and follow the prompts in...

Page 203: ...int only 1 Insert the flash card in the slot at the printer s rear plate 2 Start up the printer and select Intermec Shell 3 Press F5 to browse to SOFTWARE UPDATE 4 Press F5 to browse to UPDATE PC CARD 5 Press Enter 6 Start sending the file using a communication program for example HyperTerminal The communication program must use zmodem There is a one minute time out on the printer side 7 Switch of...

Page 204: ...mec NetPrintSet rel 1 1 can be obtained from the Intermec Printer Sup port Web Cable Suggestions RS 232 Serial Cable DB 9pin female DB 25pin male P N 1 975582 00 Ethernet Cable Intermec does not provide any Ethernet cable The cables are nor mally provideed locally At a straight connection between a host and printer a cross RJ45 cable is needed Parallel Cable P N 1 975583 18 How to use Intermec Pri...

Page 205: ...to select printer to be in the receiving mode Start up Shell and use F5 to browse to Soft ware update Update firmware You have 1 minute to send the file Also chech the printer s baud rate in the Setup Mode Con tinue with items 6 8 How to use command prompt FTP and Ethernet 1 Connect a printer on Ethernet LAN or by a cross cable between Host and printer 2 Open an FTP session to the printer typing t...

Page 206: ... and the printer will boot up with the new one How to make a Flashcard for upgrading 1 Make the mcsXXXX uff file based on mcsXXXX bin using the NetPrintSet software There are two possible ways to con tinue At the PC side 2 Use a computer with a memory card slot and insert the flash card 3 Use a software tool to download the binary uff file to the Flash card Software suggestion Elan Digital System ...

Page 207: ...om version 6 10 to version 6 20 IP adress at printer 198 168 0 2 manual setting and at computer 198 168 0 1 C Firm620 ftp 192 168 0 2 Connected to 192 168 0 2 220 Intermec EasyLAN 100i FTP Print Server V6 10 Mar 30 2000 ready User 192 168 0 2 none root 331 User name ok need password Password pass 230 User logged in ftp hash Hash mark printing On ftp 2048 bytes hash mark ftp bin 200 TYPE set to I f...

Page 208: ...Intermec EasyCoder 501 XP 601 XP Service Manual 206 Notes ...

Page 209: ......

Page 210: ...Intermec Printer AB Idrottsvägen 10 P O Box 123 S 431 22 Mölndal Sweden tel 46 31 869500 fax 46 31 869595 www intermec com 1 960562 00 EasyCoder 501 XP 601 XP Service Manual 1 960562 00 ...

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