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88-2243-00 Rev.

/CKPVGPCPEG /CPWCN

Corporate Headquarters 4501 Parkway Commerce Blvd. Orlando, Fl 32808 Phone: 407-578-8007 Fax: 407-578-8377

Asia-Pacific 19 Loyang Way #01-01 CILC Building Singapore 508724 Phone: +65 542-2611 Fax: +65 542-3611

Datamax International Herbert House 12 Elizabeth Way, Pinnacles Harlow, Essex CM19 5FE UK Phone: +44 1279 772200 Fax: +44 1279 424448

FIRMWARE(SOFTWARE) AGREEMENT: The enclosed Firmware(Software) resident in the EPROMs is owned by Licensor or its suppliers and is licensed for use only on a single printer in the users Trade or Business. The User agrees not to, and not to authorize or permit any other person or party to, duplicate or copy the EPROMs or the information contained in the EPROMs. The Firmware(Software) is protected by applicable copyright laws and Licensor retains all rights not expressly granted. In no event will Licensor or its suppliers be liable for any damages or loss, including indirect, incidental, economic, special or consequential damages, arising out of the use or inability to use the Firmware(Software).

Information in this document is subject to change without notice and does not represent a commitment on the part of DATAMAX. No part of this manual may be reproduced or transmitted in any form or by any means, for any purpose other than the purchasers personal use, without the expressed written permission of DATAMAX. Copyright 1999 by DATAMAX All rights reserved.

Printed in the United States of America

Agency Compliance and Approvals:


UL1950 Information Technology Equipment

EN60950
For 230 Volt Operation (Europe): Use a cord set, marked "HAR," consisting of a min H05VV-F cord which has a minimum 0.75 square mm diameter conductors, provided with an IEC 320 receptacle and a male plug for the country of installation rated 6A, 250V Fr 230 Volt (Europa): Bentzen Sie ein Kabel, das mit "HAR" markiert ist, bestehend mindestens aus einem H05VV-F Kabel, das mindestens 0,75 Quadratmillimeter Drahtdurchmesser hat; sowie eine IEC320 Steckdose und einen fr das Land geeigneten Stecker, 6A, 250 Volt.

C22.2 No. 950-M93

As an Energy Star Partner, the manufacturer has determined that this product meets the Energy Star guidelines for energy efficiency. The manufacturer declares under sole responsibility that this product conforms to the following standards or other normative documents: EMC: EN 55022 (1993) Class B EN 50082-1 (1992) EN45501 (1992) IEC 801-2 (1991), 8kV CD; 15kV AD IEC 801-3 (1984), 3 V/m IEC 801-4 (1988), 1kV Signal Lines 2kV AC Power Lines This product complies with the requirements of EN 60950 (1992), A1 (1993), A2 (1993), & A3 (1995)

Safety:

Gost-R

FCC: This device complies with FCC CFR 47 Part 15 Class A. Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instructions in this manual, it may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Contents

I-Class

1 2 3 4 5 6 7 8 9 10

Introduction Printer Setup Printer Options Configuring the Printer Maintenance and Adjustments Troubleshooting Removal and Replacement Circuit Description Printer Assemblies Schematic Diagrams

ii

Introduction

1.0 Introduction ......................................................................... 1 1.1 About this Printer ................................................................ 2 1.2 Printer Specifications ......................................................... 4

ii

Introduction

1.0

Introduction

The I-Class hereafter referred to as the printer, is a user-friendly printer that blends quality and durability at an affordable price. The front panel was designed to make operation of the printer a simple task. The printer offers direct thermal and optional thermal transfer printing as well as RS232 serial and parallel interfaces for ease of connection to your host system. This manual provides all the information necessary to perform general repair and maintenance to the printer. If you wish to write custom programs, a copy of the Programmers Manual is included on the Datamax Accessories CD or at our website, http//www.datamaxcorp.com.

1-1

Introduction

1.1

About this Printer

This printer offers the following standard and optional features:

1.1.1 Standard Features Printing


Direct Thermal Printing On Demand and Batch Printing Simple Media Loading Media Tearbar Fan-fold media inlet from the bottom or rear of the printer

Memory
1 MB FLASH Downloadable Program Memory 8 MB DRAM Memory

Interfaces
This printer is equipped with a RS-232 serial interface and a IEEE 1284 compliant parallel interface.

Operational
2 X 20 backlit LCD and 5 function keys CG Triumvirate Scalable font w/AGFA Scalable font engine Printhead Resistance Verification English, French, Italian, German and Spanish LCD languages support

1-2

Introduction

1.1.2 Optional Features Standard Cutter


A standard duty cutter is available for cutting labels and tags with a maximum thickness of .010 (.254mm).

Backing Only Cutter


A Backing Only cutter is available for cutting material with a maximum thickness of .005 (.127mm).

Cutter Tray
The cutter tray is available for use in conjunction with an optional cutter. The cutter tray will collect the labels and tags after they have been cut.

Internal Rewind
An Internal Rewind option is available to rewind backing material (up to 6) when used in conjunction with the Peel and Present option.

Thermal Transfer
Thermal transfer printing requires the use of a ribbon. The ink/wax from the ribbon transfers to the media by the printer to create an image. Thermal transfer printing provides exceptional clarity and scannability.

Present Sensor
Easily installed, this option is used for on-demand label dispensing, printing labels only when detecting removal of the previously printed label.

Peel and Present


Easily installed, when used in conjunction with the internal rewind option automatically removes printed labels from their backing material. If accompanied by the present sensor option, the printer will Pause until the presented label has been removed.

External Keyboard Support


Allows for the connection of the DMX Passport external keyboard to the printer.

1-3

Introduction

1.2

Printer Specifications
Width Depth Height Weight Operating Temperature 12.62" (32.055 cm) 18.60" (47.24 cm) 12.70" (32.26 cm) 45 lbs. (20.5 kg) 40 F to 100 F (4 C to 38 C)

Mechanical

Printer Specifications
Print Type Print Speed Resolution SDRAM Memory FLASH Memory Direct Thermal or optional Thermal Transfer 2 6 IPS (50 152 mm/second) 203 DPI (8 dots/mm) 8 MB 1 MB

Media/Ribbon
Media Types Max. Media Width Min. Media Width Max. Print Width Max. Print Length Min. Print Length Media Thickness Supply Roll Capacity Media Core Range Max. Ribbon Length Roll-Fed, Die-Cut, Continuous, Fan-Fold 4.65" (118.1 mm) 1" (25 mm) 4.1" (104.0 mm); 203 DPI 15" (2514.6 mm) .25 (6.4 mm) .0025 - .01" (.06 mm - .25 mm) 8" (203.2 mm) O.D. 1.5 3.0 (38 mm 76.2 mm) 1968 Feet (600 Meters)

1-4

Introduction

Communications
Interface Baud Speed Handshaking Parity Stop Bits Data Bits RS-232/DB-25, and IEEE 1284 Centronics Parallel 2400 to 38.4K bps Xon/Off, CTS, DTR Even, Odd, or None 1 or 2 7 or 8

Electrical
Input Voltage 90 - 264 VAC @ 47-63 Hz.

Fonts
9 Bit Map fonts Rotated 0, 90, 180, 270 degrees CG Triumvirate Scalable font (optional)

Available Bar Codes


Code 39, Interleaved 2 of 5,Code 128 A, B & C, Codabar, LOGMARS, UPC-A, UPC-E, UPC 2&5, EAN-8, EAN-13, EAN 2&5, UPC Random Weight, Code 93, Plessy, USCS, Code 128 MOD 43, Postnet, Uss/EAN-128 Random Weight, Telepen, UPS Maxicode, PDF417, and Datamatrix

Approved Media
To achieve optimum print quality and maximum printhead life, Datamax recommends the use of DATAMAX brand media and ribbons. These supplies are specially formulated for use in our printers; use of non-Datamax supplies may affect the print quality, performance, and life of the printer or its components. For a current list of approved media and ribbons for use in direct thermal and thermal-transfer applications, please contact a Media Representative at (407) 523-5650.

1-5

Introduction

1-6

88-2243-02 Rev. A

Printer Setup

2.0 Introduction ......................................................................... 1 2.1 Connecting the Printer........................................................ 1


2.1.1 Interfacing to the Printer............................................................................. 2

2.2 Loading Media ..................................................................... 3 2.3 Loading Ribbon ................................................................... 6 2.4 Printing a Configuration Label ........................................... 6

ii

Printer Setup

2.0

Introduction

This chapter explains how to connect your printer, load media and ribbon, and print a configuration label.

2.1

Connecting the Printer


Ensure that the printers power switch is off when connecting the AC power cord or data cables.

Note:

Connect the AC power cord located on the back of the printer and the other end into a properly grounded outlet. The Printer can be connected to your host computer with a parallel cable or an RS-232 serial cable.

2-1

Printer Setup

2.1.1

Interfacing to the Printer

The Printer is equipped with both parallel and serial interface ports for versatile host connectivity. The printer automatically detects data on either port. Once an active port is inactive for the specified Host Timeout Value, (default 3 seconds) both ports will then be scanned again for data. If a label format is partially received when a communications port times out the data transmitted will be lost. The parallel interface requires a standard 36 pin Centronics type cable. For RS-232 serial interfacing, a specific cable pin-out is required. This interface supports both XON/XOFF and CTS/DTR handshaking. At serial transfer speeds greater than 9600 baud, CTS/DTR handshaking is recommended. These cable configurations and part numbers are shown below (contact your reseller for ordering information).

Null Modem (MXM)

PC (DB9P) to Printer

Part number 556000 Cable used for typical connection to other DCE equipment with XON/XOFF flow control.

Part number 556001 Cable used for connection to a PC compatible with DB9P communication ports. Flow control is either XON/XOFF or CTS/DTR.

PC (DB25P) to Printer

Part number 556002 Cable used for connection to a PC compatible with DB25 communication ports. Flow control is either XON/XOFF or CTS/DTR.

2-2

Printer Setup

2.2

Loading Media

This section explains the loading instructions for loading the printer with media. Turn the Printer Off. Lift open the Cover. Unlatch the Printhead. Rotate the Media Hub Guide down and slide a roll of media onto the Media Supply Hub all the way back against the Centerplate. Rotate the Media Hub Guide up and slide it in against the Roll Media.

There are several loading configurations possible dependant on the type of media and the options installed on your printer. Refer to the following pages for your loading configuration. Once the media is loaded, close the printhead, turn the printer on, and push and hold the Feed button for three seconds. The printer will perform a Quick Calibration to sense the Top of Form of your media. If the printer does not sense the Top of Form of your media see Section 5.6.1 Perform Calibration to set the Top of Form.

2-3

Printer Setup

Internal Media Loading:

External Media Loading (Fan-Fold):

2-4

Printer Setup

Internal Media Loading with Rewind:

Remove the Front Fascia. Loosen and remove the Thumbscrew and remove the Tear Plate.

Position the Rewind Plate on the Printer and install and tighten the Thumbscrew

2-5

Printer Setup

2.3

Loading Ribbon

If your printer is equipped with the Thermal Transfer Option you may wish to use Thermal Transfer Printing. The printer must be set for Transfer printing either by using the Front Panel or Host commands.
Turn the Printer Off. Lift open the Cover. Unlatch the Printhead. Slide a roll of ribbon completely onto the Ribbon Supply Hub, (it should rest fully against the flange on the left of the Ribbon Supply Hub.) Route the ribbon under the Ribbon Roller and through the throat of the printer. Lower the printhead and pull the ribbon up around the Ribbon Take-up Hub as shown.

2.4

Printing a Configuration Label

After you have completed setting up your printer you can print a Configuration Label to verify that the printer is configured for your application. To print a Configuration Label: Press the button. Using the button scroll to Print Configuration Label. Press the button again, the printer will print one Configuration Label. See Section 4.2 Quick Tests for other available self tests and sample labels.

2-6

88-2243-03 Rev. A

Printer Options

3.0 Introduction ......................................................................... 1 3.1 Internal Rewind Option ....................................................... 1 3.2 Thermal Transfer Option..................................................... 3 3.3 Present Sensor Option ....................................................... 5 3.4 Peel and Present Option ..................................................... 8

ii

Options

3.0

Introduction

This chapter contains instructions for installing all available options for the printer. For replacement parts see Chapter 9 for a parts breakdown.

3.1

Internal Rewind Option (78-2302-01)

This kit contains the following items:

Internal Rewind Assembly, p/n 15-2773-01 Rewind Bracket, p/n 11-5220-01 Thumbscrew, p/n 17-2858-01 (3) Screws, p/n 10-2903-03

Tools Required
The Internal Rewind Option only requires a #2 Phillips head screwdriver for installation.

Preparing the Printer

Turn the power off and unplug the printer. Remove any installed media from the printer. Open the cover and remove the Screw and the Rewind Cover Plate.

3-1

Options

Installing the Internal Rewind Assembly

Position the Internal Rewind Assembly in the printer as shown and secure using the three provided Screws.

Setup and Configuration

Remove the Front Fascia. Loosen and remove the Thumbscrew and remove the Tear Plate.

Position the Rewind Plate on the Printer and install and tighten the Thumbscrew. Refer to the Operators Manual or Chapter 2 for media loading information.

3-2

Options

3.2

Thermal Transfer Option (78-2300-01)

Contents of the Thermal Transfer Kit


This kit contains the following items:

Thermal Transfer Assembly, p/n 15-2765-01 (3) Screws, p/n 10-2903-03

Tools Required
The Thermal Transfer Option only requires a #2 Phillips head screwdriver for installation.

Preparing the Printer

Turn the power off and unplug the printer. Remove any installed media from the printer. Open the cover and remove the Screw and the Thermal Transfer Cover Plate.

3-3

Options

Installing the Thermal Transfer Assembly

Position the Thermal Transfer Assembly in the printer as shown and secure using the three provided Screws.

Setup and Configuration


In order to use thermal transfer printing the printer must be loaded with ribbon and the Select Media Type menu function must be set to Ribbon Transfer. For proper loading of ribbon see the Ribbon Loading instructions in the Operators Manual. Follow the steps below to set the printer to Ribbon Transfer. Verify the printer is in the Ready Mode

Press the button. The Select Media Type menu function should be displayed, press the button. Using the button scroll to Ribbon Transfer. Press the button to select the displayed setting, an asterisk will appear to the left of the setting indicating that it is selected. Once you have selected the desired setting press the button repeatedly until the Save Changes message is displayed. Press the button to save the changes or the button to discard the changes.

3-4

Options

3.3

Present Sensor Option (78-2293-01)

Contents of the Present Sensor Kit


This kit contains the following items:

Present Sensor Assembly, p/n 24-2518-01 Reflective Block, p/n 16-2576-01

Tools Required
There are no tools required for installing the Present Sensor Option.

Preparing the Printer


Turn the power off and unplug the printer. Remove any installed media from the printer. Open the cover and remove the Front Fascia by gently pulling it from the printer.

Remove the Sensor Cover by pulling it from the printer in the direction of the arrows as shown.

3-5

Options

Installing the Present Sensor

Position the Present Sensor in the printer as shown and rotate the sensor until it snaps into place

Route the Present Sensor Cable along the Baseplate and plug it into the Options Connector as shown.

Install the Reflective Block by inserting the top Catch into the Notch on the Tearplate. Rotate the block downward until it snaps into place.

3-6

Options

Setup and Configuration


The printer will automatically sense the presence of the Present Sensor and allow for it to be enabled for present printing. If you wish to enable the Present Sensor it must be enabled within the menu system. To Enable or Disable the Present Sensor follow the steps below. Verify the printer is in the Ready Mode

Press the button. Using the scroll to Printer Options and press the

button button.

Using the button scroll to Present Sensor and press the button.

Using the button scroll to either Enable or Disable. Press the button to select the displayed setting, an asterisk will appear to the left of the setting indicating that it is selected. Once you have selected the desired setting press the button repeatedly until the Save Changes message is displayed. Press the button to save the changes or the button to discard the changes. Note: The use of the present sensor can also be controlled via software commands from the host.

3-7

Options

3.4

Peel and Present Option (78-2294-01)

Contents of the Peel and Present Kit


This kit contains the following items:

Peel and Present Assembly, p/n 15-2815-01

Tools Required
The Peel and Present Option only requires a #2 Flathead screwdriver for installation.

Preparing the Printer

Turn the power off and unplug the printer. Remove any installed media from the printer. Open the cover and remove the Front Fascia by gently pulling it from the printer. Loosen and remove the Thumbscrew and then remove the Tear Plate

3-8

Options

Installing the Peel and Present Assembly

Positon the Peel and Present Assembly on the front of the printer and then tighten the mounting screw.

Route the Present Sensor Cable along the Baseplate and plug it into the Options Connector as shown.

3-9

Options

Setup and Configuration


The printer will automatically sense the presence of the Present Sensor and allow it to be enabled for present printing. If you wish to enable the Present Sensor it must be enabled within the menu system. To Enable or Disable the Present Sensor follow the steps below. Verify the printer is in the Ready Mode

Press the button. Using the scroll to Printer Options and press the

button button.

Using the button scroll to Present Sensor and press the button.

Using the button scroll to either Enable or Disable. Press the button to select the displayed setting, an asterisk will appear to the left of the setting indicating that it is selected. Once you have selected the desired setting press the button repeatedly until the Save Changes message is displayed. Press the button to save the changes or the button to discard the changes. Note: The use of the present sensor can also be controlled via software commands from the host.

Media Loading

3-10

88-2243-04 Rev. A

4
4.0.1 4.0.2 4.0.3 4.0.4 4.0.5 4.0.6

Configuring the Printer

4.0 Front Panel Operation......................................................... 1


Ready Mode: Normal Operation (Ready Light On)................................... 1 Menu Mode: Configuration (Ready Light Flashing). ................................. 2 Test Mode: Print Test Labels. .................................................................... 3 Indicator Lights........................................................................................... 4 Display (LCD)............................................................................................. 4 Factory Default Reset ................................................................................ 4

4.1 The Menu System ................................................................ 5


4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 Media Settings ........................................................................................... 5 Print Control ............................................................................................... 5 Printer Options ........................................................................................... 7 System Settings ......................................................................................... 8 Communications ...................................................................................... 10 Diagnostics .............................................................................................. 11 Enter and Exit Prompts ............................................................................ 11

4.2 The Quick Tests................................................................. 12


4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 Print Quality Label.................................................................................... 12 Print Configuration Label ......................................................................... 13 Ribbon Test Label.................................................................................... 14 Dot Test Pattern Label ............................................................................. 15 User Defined Label .................................................................................. 15

ii

Configuring the Printer

4.0

Front Panel Operation

The printers front panel is equipped with five buttons, 3 indicator lights and a 20 x 2 character Liquid Crystal Display. The functions of the buttons are mode dependent. The three functional modes, READY, MENU and TEST are described below.

4.0.1 Ready Mode: Normal Operation (Ready Light On).


: The PAUSE button toggles the Pause condition.

: The FEED button feeds a label, and clears any faults that have been corrected. Pressing and holding the FEED button for three seconds will cause the printer to perform a Quick Calibration to sense Top of Form. : The CANCEL button cancels a job and Pauses the printer.

Press and hold for four seconds to reset the printer and clear all temporary host settings.
: The MENU button toggles functions between the READY and MENU Modes. In READY Mode, press and hold for 3 seconds to change the display contrast.

: The TEST button enters the Test Mode.

4-1

Configuring the Printer

4.0.2 Menu Mode: Configuration (Ready Light Flashing).

The DOWN ARROW moves to the previous (reverse) menu item; also decrements numerical values within certain menu selections.
:

The UP ARROW moves to the next (forward) menu item; also increments numerical values within certain menu selections.
:

The ENTER button selects a displayed function or value (indicated with an *); also moves between fields in multiple parameter selections.
:

The ESCAPE button moves to the previous menu level and finally back to the READY mode.

4-2

Configuring the Printer

4.0.3 Test Mode: Print Test Labels.

Scrolls to the previous test function.


: Scrolls to the next test function.

Pressing CANCEL will toggle the quantity of the selected test to be printed.
Preset choices are; 2, 100, 1000, and 9999. You can also hold down the button and scroll to a desired quantity.

Pressing the MENU button will exit the Test Mode.


:

Pressing the TEST button will print the selected test label.

Note:

While printing a test, pressing

or

buttons will abort printing.

4-3

Configuring the Printer

4.0.4 Indicator Lights


: On indicates READY mode

Slow Blink indicates MENU mode. Fast Blink indicates the printer is receiving data.
:

On indicates a Paused state.


:

Fast Blink indicates an error condition. Slow Blink indicates a warning condition. To clear, press the FEED button. See section 6.2 for a list an explanation of possible error and warning conditions.

4.0.5 Display (LCD)


Display LCD The LCD shows several types of information. After the power on sequence is complete, the LCD displays the READY message. The time and date will only be displayed if the printer has received it from the host, front panel, or the Time and Date Option is installed. When a label format is printing, a label counter is displayed. If an error has occurred, the LCD will indicate the error message.

4.0.6 Factory Default Reset


Press and hold the Pause and Cancel buttons while turning on the printer. Continue to hold the buttons down until the READY message appears. This will reset the printer to its factory defaults and return the menu system to the English Language.

4-4

Configuring the Printer

4.1

The Menu System

The menu system is used to control the printers mode of operation. One of its primary functions is to allow the operator to configure the printer to operate with specific media and installed options. The configuration can be saved in the printers non-volatile memory so that when power is removed the same configuration will be restored when power is turned back on. A security feature can be enabled to prevent accidental changes. Commands from the host computer for the same menu items will override the printers menu settings. If a reset command is sent by the host the current configuration, (including host changes) will be saved. The printers current selection is indicated with a * on the LCD. Settings designated with a q require a printer reset before changes to this item will become effective. A printer reset will be automatically invoked upon exiting the menu system and answering Yes to saving changes. Note: Refer to Section 4.02 for specific button functions when in MENU mode. From the READY mode, enter the Menu by pressing the button.

Note: Entering the menu system will clear the printers memory of any menu settings sent from the host, unless the host has reset the printer and saved these settings in permanent (non-volatile) memory.

4.1.1 Media Settings MEDIA TYPE


DIRECT THERMAL RIBBON TRANSFER Sets printing for either direct thermal or thermal transfer stock. For use with direct thermal stock, heat sensitive. For use with stocks requiring a ribbon. Select the sensor type which matches your label stock. Printer recognizes labels by sensing gaps in stock. No sensing, user must set a continuous label length. Printer senses black stripes on backside of media. Label/Page length used to determine top of form when CONTINOUS SENSOR TYPE is selected. Select the maximum length between gaps or registration marks. If this limit is exceeded, a top of form fault is declared. Adjusts media sensors for use with a particular stock Printer adjusts the media sensors as the stock is sampled. User directly inputs values to adjust media sensors. Set thresholds for stock, gap, and registration mark detection. Entry for paper, gap/mark, and empty thresholds. Set SENSOR GAIN and observe A/D reading. Adjust the sensitivity of the sensor for custom label stock. Higher gain means more sensitivity, but if set too high, the printer loses the ability to distinguish gap or mark from paper.

SELECT SENSOR TYPE


GAP CONTINUOUS REFLECTIVE

LABEL LENGTH 04.00in (0-99.99) MAXIMUM LABEL LENGTH 8.00in (0-99.99) SENSOR CALIBRATION
PERFORM CALIBRATION ADVANCED ENTRY SENSOR LEVELS SENSOR GAIN

4.1.2 Print Control


4-5

Configuring the Printer

HEAT 10

(0-30)

Controls the BURN TIME of the printhead. HEAT SETTING along with the DARKNESS SETTING determines the Print Darkness. 2-6 IPS; Default = 6 IPS

PRINT SPEED 6.0 in/sec (2-6) FEED SPEED 6.0 in/sec (2-8) REVERSE SPEED 4.0 in/sec (2-6) ROW OFFSET 00.00in (0-99.99) COLUMN OFFSET 00.00in (0-99.99) LABEL WIDTH 4.10in q (0-4.10) PRESENT DISTANCE 0.00in (0-9.99)

2-8 IPS; Default = 6 IPS

2-6 IPS; Default = 4 IPS; Shifts the vertical start of print position upward relative label.

Shifts the horizontal start of print position to the right.

Sets the maximum limit for width of the printable surface. Objects extending beyond this limit will not print. When possible, smaller LABEL WIDTH values can provide more efficient use of system memory, longer print buffer space. Sets the label stop position past the start of print.

Note: If the printer is in PAUSE mode and the PRESENT DISTANCE setting is larger than zero then a label will remain presented until the pause button is pressed (confirming label removal). At this point the printer will automatically backfeed the media and if instructed from the host, print and present the next label. If the printer is equipped with the Present Sensor Option and the Present Sensor is enabled then a label will remain presented until it is removed. At this point the printer will automatically backfeed to the start of print position and then print and present the next label. Otherwise the PRESENT DISTANCE is ignored.

CUSTOM ADJUSTMENTS

DARKNESS 32 (1-64) ROW ADJUST 064 (1-128) COLUMN ADJUST 000 (1-128) PRESENT ADJUST 064 (1-128)

Includes settings which allow for calibration adjustments for each individual printer by the factory. These setting are intended to fine-tune the print positions and print darkness due to mechanical and media tolerances. Adjusts the BURN TIME of the printhead to give optimum performance at a nominal HEAT setting of 10. This is the factory adjustment / fine-tune of the HEAT setting. Skews the vertical start of print position upward on a label. This is the factory adjustment / fine tune of the ROW OFFSET setting. Shifts the horizontal start of print position point to the right. This is the factory adjustment / fine tune of the COLUMN OFFSET setting. Adjusts the present distance to compensate for mechanical tolerance of the printer, cutter, or tearplate. This is the factory adjustment / fine tune of the PRESENT DISTANCE setting.

4-6

Configuring the Printer

4.1.3 Printer Options MODULES


PRINT DIRECTORY PRINT FILE FORMAT MODULE Physical presence of a memory module(rear of printer) must be detected to show the Module Function selections in the menu system. Physical presence of the Present Sensor must be detected to show the ENABLE/DISABLE selections in the menu system.

PRESENT SENSOR
ENABLE DISABLE NOT DETECTED

CUTTER
ENABLE DISABLE NOT DETECTED

Physical presence of the Cutter must be detected to show the ENABLE/DISABLE selections in the menu system.

BARCODE VERIFIER
ENABLE DISABLE NOT DETECTED

Physical presence of the Verifier must be detected to show the ENABLE/DISABLE selections in the menu system.

RIBBON SAVER
ENABLE DISABLE NOT DETECTED

Physical presence of the Ribbon Saver must be detected to show the ENABLE/DISABLE selections in the menu system.

4-7

Configuring the Printer

4.1.4 System Settings MEMORY SETTINGS


INTERNAL MODULE 1024 (100-8192) SCALEABLE FONT CACHE 0232 (100-8192) Sets the number of 1K blocks allocated for the internal RAM module. Sets the number of 1K blocks allocated for the scaleable font engine. Selects the code page used by the printer unless otherwise specified in DPL. 29 selections are Standard, see the Programmers Manual for listings. Allows the user to set Date/Time Shows the number of inches since the date it was last reset. The number inches printed from the value set for beginning of printers life. User cannot reset. The number of inches printed from the date last reset. User may reset. Resets the printers resettable counters to zero. Prints the effective configuration of the system. In addition, if settings were changed which require a reset to become effective, this will be indicated. If you wish to update the software inside the printer, the hardware and software compatibility levels must match for the update to be accepted. This information is displayed here and printed on the configuration coupon. Each printer has a unique KEY number of the form 4206-PA01990615-123 where: 4206 represents the model number of the software loaded. PA01 represents configuration level PA represents main board hardware compatibility 01 represents software compatibility level, (can be upgraded) 990615 is a manufacturing date code (s.a. June 15, 1999) UPGRADE PRINTER CODE 123 is a unique time stamp You may only update your printer with a software level of equal or lesser value than the printers software computability level. However, the printers software compatibility level can be increased by purchasing and entering the proper upgrade code here

SYMBOL SET SELECT


29 Standard Symbol Sets

DATE / TIME MEDIA COUNTERS


ABSOLUTE COUNTERS RESETTABLE COUNTERS RESET COUNTERS

PRINT CONFIGURATION CONFIGURATION LEVEL


PRINTER KEY

4-8

Configuring the Printer

FACTORY DEFAULTS
SET FACTORY DEFAULTS Overwrite the current settings with the factory default settings. Note: ALL settings in menu are restored except the factory adjustment and calibration section. If necessary the printer will reset automatically. Prints the current printer settings to a label. Settings which will become effective after a reset are prefixed with a & symbol on the label Affects the manner in which overlapping text and graphics are treated when the label is printed. The available choices are TRANSPARENT, XOR, and OPAQUE, which are explained in the Programmers Manual. Instructs the printer whether it can pre-image the label format. This is useful when printing the printers date and time information. This selection can effect throughput. This mode produces the fastest throughput. Printer images the label after the previous label has been successfully printed. Date/Time stamp is current. When enabled, PAUSE MODE suspends printing between each label until the pause button is pressed. Printer requires operator to un-pause after each label. Printer completes label batch without pausing between labels. Provides the user with the ability to password protect all printer settings made through the operator panel. Enable or disable the front panel menu system security lockout Yes No Modify the password required to access the front panel menu when security is enabled. Selects the measurement system in which the systems settings are represented in the menu system and on configuration labels.

PRINT CONFIGURATION

FORMAT ATTRIBUTES
TRANSPARENT XOR OPAQUE

IMAGING MODE
MULTIPLE LABELS SINGLE LABELS

PAUSE MODE
ENABLE DISABLE

SECURITY
SELECT SECURITY ENABLE DISABLE MODIFY PASSWORD

UNITS OF MEASURE
METRIC IMPERIAL
q

SELECT LANGUAGE

ENGLISH
FRENCH GERMAN SPANISH ITALIAN USER DEFINED

Selects the language in which the menu system messages and configuration coupon settings are displayed. English French German Spanish Italian Allows the use of a download set of message strings

4-9

Configuring the Printer

4.1.5 Communications SERIAL PORT


q BAUD

Controls serial port settings. Determines the baud rate at which the serial port communicates

RATE 38400 28800 19200 9600 4800 2400 q PROTOCOL BOTH SOFTWARE HARDWARE NONE q PARITY NONE ODD EVEN q DATA BITS 8 (7-8) q STOP BITS 1 (1-2)

Sets Protocol XON/XOFF CTS/DTR No handshaking Sets Parity

Sets Word length Sets Stop Bits Controls parallel port settings. Determines if messages are sent from the printer to the host via the parallel port. Enables IEEE 1284 back channel operation. No Yes

PARALLEL PORT
PORT DIRECTION

UNI-DIRECTIONAL
BI-DIRECTIONAL

HOST TIMEOUT VALUE The number of seconds a communications port must be idle before processing data from a different port. 03 (1-60) CONTROL CODES
STANDARD CODES ALTERNATE CODES Allows the operator to change the prefix of the commands listed in the Programmers manual, as they are interpreted by the printer. Hex 01 = SOH command; Hex 02 = STX command; count-by = ^ Hex 5E = SOH command; Hex 7E = STX command; count-by = @ Returns a 0x30, [RS], after each label successfully prints, and a 0x31, [US], after each batch of labels in printed. Yes No

FEEDBACK MODE
ENABLE DISABLE

4-10

Configuring the Printer

4.1.6 Diagnostics HEX DUMP MODE


ENABLE DISABLE Most commonly used mode for trouble shooting. Prints data & instructions received from the host rather than interpreting them. Yes No Tests currently installed options

OPTIONS TESTING
TEST PRESENT SENSOR TEST CUTTER TEST VERFIER TEST RIBBON SAVER

TEST INPUT/OUTPUT
MONITOR GPIO INPUT TEST GPIO OUTPUT

Test the optional GPIO port when installed.

PERFORM DOT CHECK SENSOR READINGS


THR TRAN RIBM 24V -> 255 255 255 255 <- PS HD RANK 255 255 255

Performs a printhead dot check test. Analog Sensor Readings Live sensor values may be viewed. Views are toggled with previous and next arrows. Maximum values are shown here, (TRAN is replaced by REFL when the SENSOR TYPE is set to REFLECTIVE. Live sensor values may be viewed. Views are toggled with previous and next arrows. Maximum values are shown here.

4.1.7 Enter and Exit Prompts


The following table shows the possible Prompts the printer may display and their descriptions. Prompt ENTER PASSWORD 0 0 0 0 SAVE CHANGES? ENTER = YES Description You are attempting to enter MENU MODE. Security has been enabled on your printer, and now requires that you provide the correct userdefinable password to access the MENU MODE functions. You are now exiting the menu, but have made changes to the settings of your printer. Pressing ENTER at this point will save these changes. If you do not, your printer will discard any changes and revert to previously saved settings. If changes have been made that require a printer reset, the printer will automatically invoke a printer reset.

Entering the menu system will clear the printers memory of any menu settings sent from the host, unless the host has reset the printer and saved these settings in permanent (non-volatile) memory.

4-11

Configuring the Printer

4.2

The Quick Tests

This section explains the functions from each of the four separate Quick Tests that can be accessed by pressing the TEST button located on the Front Panel. Note: Pressing or buttons will abort printing.

4.2.1 Print Quality Label


The Print Quality Label provides a good indicator of overall print quality. Containing standard and rotated barcodes, various text sizes and graphic fill patterns, this label can be used to ensure symbology conformance as well as visual aesthetics, at selected heat and speed settings. To print a Print Quality Label perform the following steps: Press the Use the Use the Press the button. button to scroll to Print Quality Label. button to select a quantity, (see Section 4.0.3). button to start printing.

4-12

Configuring the Printer

4.2.2 Print Configuration Label


The Configuration Label provides valuable information about your printer, including: The amount of print memory. The amount of media printed. The version of firmware installed. The available options. All printer settings and adjustments available in the menu system.

To print a Configuration Label, complete the following steps: Press the Use the Use the Press the button. button to scroll to Print Configuration Label. button to select a quantity, (see Section 4.0.3). button to start printing.

4-13

Configuring the Printer

4.2.3 Ribbon Test Label


The Ribbon Test Label includes a bar code that is used to test ribbon-tracking problems. To print a Ribbon Test Label: Press the Use the Use the Press the button. button to scroll to Ribbon Test Label. button to select a quantity, (see Section 4.0.3). button to start printing.

4-14

Configuring the Printer

4.2.4 Dot Test Pattern Label


The Dot Test Pattern Label is used to determine whether the printhead is dirty or faulty. This label is created by filling rectangles with dot patterns. Examples of Dot Test Pattern labels are shown below. To print a Dot Test Pattern Label, perform the following steps: Press the Use the Use the Press the button. button to scroll to Dot Test Pattern. button to select a quantity, (see Section 4.0.3). button to start printing.

Good Test Pattern Label: Indicates that the printhead is operating normally.

Faulty Test Pattern Label: Streaks indicate a dirty or faulty printhead. See Chapter 5 for cleaning information.

4.2.5

User Defined Label

The User Defined Label will print the last label printed. This label can be one of the internal test labels, a label from the host, or a memory module.

4-15

88-2243-05 Rev. A

Maintenance and Adjustments

5.0 Introduction ......................................................................... 1 5.1 Cleaning Schedule .............................................................. 1 5.2 Cleaning the Printhead ....................................................... 2 5.3 Cleaning the Platen Roller .................................................. 3 5.4 Interior and Exterior Surfaces............................................ 3 5.5 Media Sensor Adjustment .................................................. 4 5.6 Media Sensor Calibration ................................................... 5
5.6.1 Perform Calibration .................................................................................... 5 5.6.2 Advanced Entry Calibration........................................................................ 7

5.7 Printhead Adjustments ....................................................... 9


5.7.1 5.7.2 5.7.3 5.7.4 Printhead Leveling Adjustment .................................................................. 9 Printhead Pressure Adjustment ............................................................... 10 Printhead Burn Line Adjustment .............................................................. 11 Ribbon Shield Adjustment........................................................................ 12

5.8 Printhead Voltage Adjustment ......................................... 13 5.9 Updating Printer Firmware ............................................... 14

ii

Maintenance and Adjustments

5.0

Introduction

This chapter covers the cleaning recommendations as well as some printer adjustments. Periodic maintenance will guarantee continued optimum printer performance. The following items will help clean the unit safely and effectively: Isopropyl alcohol Cotton swabs A clean, lint-free cloth Soft-bristle brush Soapy water/mild detergent Compressed air

5.1

Cleaning Schedule

Below is the recommended cleaning schedule for various parts of your printer. For your safety and to avoid damaging the Printer, always power Off and unplug the unit before cleaning. Method Using isopropyl alcohol and a cotton swab, clean the printhead from end to end. Removing all adhesive and particulate build-up. Rotate the platen, remove all adhesive and particle build-up using isopropyl alcohol on a cotton swab or lint-free cloth. Compressed air / soft-bristle brush and isopropyl alcohol. Remove all build-up. Interval Clean after each roll of labels.

CAUTION

Area Printhead

Platen Roller

Clean after each roll of labels.

Media Path

As needed, based on weekly visual inspection.

Media Sensor Interior

Compressed air, isopropyl alcohol if needed. Remove all build-up. Soft-brush or compressed air. Remove all build-up.

Monthly or as needed.

As needed.

Exterior

Mild detergent. Remove all build-up.

As needed.

5-1

Maintenance and Adjustments

5.2

Cleaning the Printhead

When print quality begins to degrade the typical cause is a dirty printhead. Unreadable labels, print dropout areas, streaking and smudging are all possible symptoms. In addition, if this build-up is not removed it can greatly reduce the printheads life. Follow this procedure to clean the printhead: Turn Off and unplug the printer. Open the cover. Unlock and raise the printhead. Gently wipe the underside of the Printhead Burn-line area using a cotton swab moistened (not soaked) with isopropyl alcohol. Allow to dry. Lower and lock the printhead. Close the cover. Plug in and turn On the printer.

Note:

NEVER use a sharp object when cleaning the printhead.

5-2

Maintenance and Adjustments

5.3

Cleaning the Platen Roller

Print quality can be affected if the roller becomes contaminated with dirt or adhesive. To clean the platen roller: Turn Off and unplug the printer. Open the cover. Unlock and raise the Printhead Assembly. Using a clean cotton swab or a lint-free cloth dampened with isopropyl alcohol wipe off all debris from the Platen Roller. Manually rotate the roller to clean the entire surface. Allow to dry. Lower the Printhead Assembly and lock into position. Close the cover. Plug in and turn On the printer.

Note:

NEVER use a sharp object when cleaning the platen.

5.4

Interior and Exterior Surfaces


During normal operation dust particles from label media can build up inside the printer. To prevent build-up, use a soft bristle brush or compressed air as needed for removal.

Interior:

Exterior: The exterior surface can be cleaned using a general purpose cleaner and a damp soft cloth or sponge. Never use abrasive cleansers or solvents.

5-3

Maintenance and Adjustments

5.5

Media Sensor Adjustment

To accommodate and detect a wide variety of media, the printers Media Sensor is adjustable (left and right) across half of the media path. The position of the sensor may need to be adjusted when changing media or media types, (e.g., from wide to narrow stock or from gap to notched tag, etc.) to ensure media detection. The figures below show the location of the Media Sensors Reference Line and its Slide Tab. The Slide Tab moves the Sensor inward or outward. Align the Reference Line with the registration mark, (label gap, black mark, or notch) on your media.

Note: The start of print position can be affected by the location of the media sensor, especially evident on some particular label shapes. This can be compensated for by adjusting the media sensor over the middle of the material (e.g., the apex of a circular label) or by using the Row Offset command. See Advanced Setup/Label Options, the Programmers Manual or your software application.

5-4

Maintenance and Adjustments

5.6

Media Sensor Calibration

The media sensor performs two basic functions. First, it acts as a positioning sensor, allowing the printer to sense the label medias starting point (Top of Form). The sensor also detects a no media condition (Out Of Stock), when the label supply has run out. For these functions to be performed correctly and reliably, several parameters must be determined. Normally the printer will calculate these parameters automatically when the media is loaded and the Feed button is pressed. Advanced calibration is used when the automatic calibration could not be completed due to a particular media characteristic, (e.g., preprinted media).

5.6.1
Empty:

Perform Calibration
Without label media (paper or backing) in the Media Sensor. Only of the backing material (or paper mark). Only of the unmarked paper itself.

The calibration procedure consists of the printer taking three separate readings:

Mark or Gap: Paper:

The printhead is raised to allow media access. Numeric sensor reading values are displayed to guide the operator in determining the best sensor position. The left-right position of the media sensor will affect the label detection. Complete the following steps for Top of Form calibration: Step
1

Display
READY

Operator Action

Comment

Load media and adjust the left-right position Ensure the sensor is not near the of the Media Sensor. edge of the media. Set the printers Sensor Type to the desired See Section 4.1.1. sensing method, Gap, Reflective or Continuous. Lift the printhead for easy access to the Media Sensor and label media. Enter the Media Settings/ Sensor Calibration menu.

MENU MODE MEDIA SETTINGS MEDIA SETTINGS SENSOR TYPE

MEDIA SETTINGS SENSOR CALIBRATION


3

See Section 4.1.1. Press the button. To abort press the Button.

SENSOR CALIBRATION RUN CALIBRATION REMOVE LABEL STOCK HIT ANY KEY <yyy>

Remove all label media from the Media Sensor. Lower printhead. Pressing any key starts the Empty calibration.

Calculates the best parameter settings for an Empty condition. yyy is the current sensor reading.

5-5

Maintenance and Adjustments

Step
5

Display
SCAN BACKING HIT ANY KEY <yyy> - or SCAN MARK HIT ANY KEY <yyy>

Operator Action
Place the TOF Mark whether it is a reflective mark, label backing or the label notch under the Media Sensor. Lower printhead. Pressing any key starts the Mark or Gap calibration.

Comment
Calculates the best parameter settings for the Mark or Gap value. yyy is the current sensor reading. The largest possible yyy value is best for black registration marks. The smallest yyy value is best for gap stock. If Select TOF is set to Continuous, the procedure skips the TOF Mark section and goes to Step 6.

SCAN PAPER HIT ANY KEY

<yyy>

Place the label (and backing) under the Media Sensor. Lower printhead. Pressing any key starts the Paper calibration.

Calculates the best parameter settings for the Paper value. yyy is the current sensor reading. Displays for 2 seconds.

GAP MODE CALIBRATION COMPLETE - or REFLECTIVE MODE CALIBRATION COMPLETE

Observe display. Now ready to exit, Press the button to back out of the menu tree, when prompted to save settings: (ENTER KEY = YES) and return to the Main Menu.

If during the procedure the printer encounters a problem, then the following message is displayed: Display
GAP MODE CAN NOT CALIBRATE
Press any key.

Description

Comment
No change in sensor readings were detected or there was not enough difference between readings. Ensure there are no labels stuck in the sensor. Could be a bad sensor. When in reflective mode then REFLECTIVE MODE will be displayed instead of GAP MODE. A faulty sensor condition has been detected. Try the calibration routine again, if the problem persists call for service. When in reflective mode then REFLECTIVE MODE will be displayed instead of GAP MODE.

GAP MODE FAULTY SENSOR

Press any key.

5-6

Maintenance and Adjustments

5.6.2

Advanced Entry Calibration

Advanced Entry calibration overrides all settings calculated by the previous method and should be performed only in extreme cases. The calibration is broken up into two sections: Sensor Gain: Controls sensor sensitivity gain allows the operator to directly input the sensor gain.

Sensor Levels: Allows the operator to directly input values for the Paper, Mark or Gap, and Empty values. Complete the following steps to perform manual calibration: Step
1

Display
READY

Operator Action

Comment

Load media and adjust the left-right position Ensure the sensor is not near the of the Media Sensor. edge of the media. Set the printers Sensor Type to the desired See Section 4.1.1. sensing method, Gap, Reflective or Continuous. Lift the printhead for easy access to the Media Sensor and label media. Enter the Media Settings/ Sensor Calibration/ Advanced Entry menu See Section 4.1.1. Scroll to Sensor Gain and press the button. Place the label under the sensor and lower the printhead. Ensure the label is under the Media Sensor.

MENU MODE MEDIA SETTINGS MEDIA SETTINGS SENSOR TYPE

MEDIA SETTINGS SENSOR CALIBRATION


3

ADVANCED ENTRY SENSOR GAIN GAIN TRAN >*04 5>


OR

<yyy <0 - 1

GAIN REFL *04


5

<yyy> <0 - 15>

GAIN TRAN *04


OR

<yyy> <0 - 15> <yyy> <0 - 15>

GAIN REFL *04

Using the button increment the gain setting and record the sensor reading, (yyy). Repeat for each gain setting. yyy value, range 0 to 255, current sensor reading. You must press the button for each gain setting to allow the sensor reading to change. Place the TOF Mark whether it is a Ensure the TOF Mark is under reflective mark, label backing or the label the Media Sensor. notch under the Media Sensor. Beginning with a Gain default value Using the button increment the gain of 4 will make it easier to determine setting and record the sensor reading, (yyy). when the TOF Mark is under the Repeat for each gain setting. media sensor. You must press the button for each gain yyy value, range 0 to 255, current setting to allow the sensor reading to change. sensor reading.

5-7

Maintenance and Adjustments

Step
6

Display

Operator Action

Comment

GAIN TRAN <011> *10 <0 - 15>


OR

Using the data from Steps 4 and 5, determine Both sensor readings must be above the Sensor Gain setting that provides the 20. largest difference in sensor readings between paper and backing, mark, or notch. Subtracting the two (Paper/TOF Mark) sensor readings for each Gain value will provide a list of differences. The largest difference will be the best gain value. Set TOF GAIN to the value determined in Use the button and scroll to the Step 6. desired gain and press the button. Selection will be indicated with an *. With the GAIN set in Step 7, complete the following steps: yyy value, range 0 to 255, current reading for the selected setting. a) Place the label under the Media Sensor. Record the sensor reading and label it P (paper). b) Place the backing, mark, or notch under the Media Sensor. Record the sensor reading and label it G or M (gap or mark). c) Remove all media from the Media Sensor. Record the sensor reading and label it E.

GAIN REFL <200> *10 <0 - 15>


8

GAIN TRAN <yyy> *04 <0 - 15>

PAPER SENSOR LEVEL P*222 G*136 E*014

Press the button, then press the button, and then the button to enter the Sensor Levels. Set the values determined in the previous step for Paper, Mark or Gap and Empty.

Use the and buttons to set the value calculated. Press the button to select and shift to the next field.

10

CHANGES DEFAULT ENTER KEY = YES

Now ready to exit, Press the Press the FEED button when button to back out of the menu tree, when complete to verify operation. prompted to save settings: (ENTER KEY = YES) and return to the Main Menu.

5-8

Maintenance and Adjustments

5.7

Printhead Adjustments

The printer can use a variety of media widths and thickness. To ensure even and consistent print quality, the printhead is equipped with a Printhead Leveling Adjustment and a Printhead Pressure Adjustment.

5.7.1

Printhead Leveling Adjustment

The Printhead Leveling Adjustment raises and/or lowers the right side of the printhead. This allows the printhead to remain level over the media path when using less than full width label media. The cam is rotated fully clockwise for full width media and counter-clockwise for narrow media. To adjust: Load the label media. Download a label format or use a built-in test label. Start printing. Rotate the Printhead Leveling Cam until the desired print quality is achieved. Correct adjustment is achieved with even print contrast across the width of the label. Incorrect adjustment is indicated when the print begins to fade at one side of the label (too much), or ribbon wrinkling and/or label tracking problems occur (too little). Note: Incorrect adjustment of the Printhead Leveling Cam can cause ribbon wrinkling, label tracking (side to side label movement), excessive wear on the roller and damage to the printhead.

5-9

Maintenance and Adjustments

5.7.2 Printhead Pressure Adjustment


The Printhead pressure is adjustable to accommodate a wide variety of media types and configurations. To increase the pressure applied to the media push and turn the Adjustment Cams counter-clockwise, to decrease the pressure turn the cams clockwise. It is recommended that each of the Printhead Pressure Adjustment Cams be adjusted evenly. Use only the minimum printhead pressure necessary to produce a good quality image. Note: Excessive printhead pressure can cause shortened printhead and platen roller life.

5-10

Maintenance and Adjustments

5.7.3 Printhead Burn Line Adjustment


Turning two Adjustment Screws on the printhead carriage can control the printheads Burn Line position. For many applications the burn line position will not need to be adjusted. There is however certain ribbon and/or label media that will require the Printhead Burn Line Adjustment. To perform the Printhead Burn Line Adjustment: Load the printer with your chosen media and ribbon if you are using thermal transfer media. Lower and latch the Printhead. Loosen the two Locking Screws. Turn the Adjustment Screws counterclockwise until the Printhead Burn Line is past the Platen. Print a Test Label from the Front Panel Test Menu. The label should be light and uneven. Tighten the Locking Screws until they are snug, (the Locking Screws should be tight enough to remove any play in the printhead carriage but yet lose enough to allow the Adjustment Screws to move the printhead carriage. Turn the Adjustment Screws clockwise about a 1/4 (or 1/8 for finer adjustments) of a turn. Print a Test Label from the Front Panel Test Menu. Repeat this step until the printed label is of acceptable quality. Tighten the Locking Screws. Note: When the Locking Screws are snug turning the Adjustment Screws counter-clockwise will not move the printhead outward. If you have adjusted the printhead too far inward you must re-start the entire procedure.

5-11

Maintenance and Adjustments

5.7.4 Ribbon Shield Adjustment


The printer is equipped with an adjustable Ribbon Shield to eliminate any ribbon tracking problems such as rippling or bagging which can cause voids on the printed labels. To adjust the ribbon shield follow the procedure below. 1. Load the printer with media and ribbon (4 wide). 2. Loosen the two Ribbon Shield Screws just enough to allow the movement of the Ribbon Shield. 3. It is usually best to print a continuous run of labels while adjusting the ribbon shield. This way any adjustment made to the ribbon shield can be immediately observed. 4. Slide the Ribbon Shield all the way in towards the printhead. Observe which way the waves in the ribbon are tracking and move the corresponding side of the Ribbon Shield out away from the printhead. Be sure to only move the ribbon shield in very small increments. Once the optimum adjustment is obtained tighten the Ribbon Shield Adjustment Screws.

5-12

Maintenance and Adjustments

5.8

Printhead Voltage Adjustment

Normal replacement of the printhead does not require this voltage adjustment procedure. However this procedure may be necessary when the printers Power Supply is replaced or the factory setting has been changed. Follow the procedure below to perform the adjustment, the illustration to the right will help you located the various boards and connectors referred to in the procedure.

1. Turn Off and unplug the Printer. 2. Remove the cover to gain access to the Printers electronics, (see Sec. 7.1). 3. Remove the printhead data cable from J4(Printhead) on the Backplane Board. Construct and connect the Test Cable shown below to J4(Printhead) on the Backplane Board.

4. Load media into the Printer. Lock down the printhead. 5. Using a DC Voltmeter set to read a voltage between 20 and 30 VDC connect the positive lead to J2(Printhead Power) - pin 1(bottom) and the negative lead to J2(Printhead Power) - pin 6(top), on the Power Supply Board 6. Plug in and turn On the Printer. Wait for the Printer to initialize. After initialization, press the FEED button (this will enable the printhead voltage for approximately 30 seconds). Adjust RP1 on the Power Supply Board for 24.2VDC.

5-13

Maintenance and Adjustments

5.9

Updating Printer Firmware

The Printer stores the DPL firmware program in flash memory located on the printers main PCB. This allows an operator to update the printers firmware through the printers parallel port. These updates will include bug fixes and/or new features.

Updating Instructions: 1. Identifying the New Firmware - Firmware program updates and new features are available from the Datamax web site. Simply download the desired version on to your computers hard drive or a floppy disk. 2. Placing Printer into Download Mode Press the Pause and Test buttons simultaneously while powering up the printer. The printer will first display the Boot Firmware version string then display the following: This information may vary with different printer models and versions. Then

3. Downloading The printer is now ready to accept new printer firmware. Using the DOS copy command enter: copy filename lpt1: Where: filename is the program to download. Such as: 4206pa10_102.zs Note: Printer key hardware compatibility must be PA and software compatibility level must be 10 or higher for the printer to accept the file in the above example, (see CONFIGURATION LEVEL in section 4.1.4).

5-14

Maintenance and Adjustments

After the download starts the following will be displayed: Step 1 The Printer is receiving the new download image. 2 The Printer has successfully received the download image, verified it and is erasing the flash memory. * At this point the previous software programmed into flash has been deleted. The Printer is writing new program into flash LCD Message Description

3. Errors - during the download if an error condition occurs, the download is aborted. If the download process did not reach ERASING FLASH the previous program will be intact. Otherwise the operator must successfully complete a download before the printer is operable. LCD Message

Description
The Printer detected an error in the downloaded image data. Possible causes: 1. Invalid or corrupted file being downloaded 2. Communications errors 3. Firmware being downloaded is not compatible with the printers hardware or software, (see Section 4.1.4 System Settings/Configuration Level). The Printer could not successfully erase the flash memory. Possible causes: 1. Flash chips defective. Try again and if problem persists call for service. The Printer could not successfully write the program into the flash memory. Possible causes: 1. Flash chips defective. Try again and if problem persists call for service.

5-15

Maintenance and Adjustments

5-16

88-2243-xx Rev. A

6
6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7

Troubleshooting

6.0 Overview .............................................................................. 1 6.1 Troubleshooting .................................................................. 1


Initial Steps ................................................................................................ 1 Using the Troubleshooting Charts.............................................................. 1 Problem Isolation Checklist........................................................................ 2 No Power ................................................................................................... 3 Print Quality ............................................................................................... 4 Parallel Communication Faults .................................................................. 5 Serial Communication Faults ..................................................................... 6

6.2 Error and Warning Messages............................................. 7

ii

Troubleshooting

6.0

Overview

This chapter discusses a number of topics related to troubleshooting the Printer. It covers the techniques necessary for isolating and correcting faults. When faults are isolated to the Main Logic or Operators Panel P.C. boards, it is recommended that the entire Logic board be replaced. It is not generally feasible to provide component level service to these boards in the field.

6.1

Troubleshooting

The Printer is designed to provide easy access to most components. Should the Printer malfunction and require service, the following procedures should be used to isolate and correct the malfunction.

6.1.1

Initial Steps
Always unplug the unit before attempting to replace any components, be sure that the Printer has been placed on a level and stable surface.

CAUTION! Before attempting any service, confirm that AC outlet the Printer is connected to is a known good AC outlet of the correct voltage and that unit has been installed in an area that is within acceptable environmental conditions. Perform a visual inspection of the Printer. Excessive accumulation of dirt or dust should be removed. Confirm that the Printer has been correctly loaded with media of an acceptable type.

6.1.2

Using the Troubleshooting Charts

After performing the initial checks and confirming that conditions are correct, follow the Problem Isolation Checklist. The Checklist is designed to direct the Technician to the appropriate repair routine. Always begin with Step 1, follow the instruction listed under each Item, and answer the question, Yes or No. The chart will then direct the Technician either to another Step or to one of the Troubleshooting Procedures.

6-1

Troubleshooting

6.1.3

Problem Isolation Checklist


Turn the Printer on. Does the Printer power up? Go to Step

Go to Section 6.1.4 No Power

Press the

button. Using the Go to Step

button scroll to Print Configuration. Press the button again. Does the Printer print a configuration label?

Does an error message appear?

Go to Section 6.2 Error Messages

Check for properly loaded media and ribbon. Possible defective Main Board and/or Front Panel.

Is the print quality on the configuration label satisfactory?

Go to Step

Go to Section 6.1.5 Print Quality

With the Printer on and connected to a host computer, send a label to the Printer. Does the label print?

Test Complete.

Go to Section 6.1.6 or 6.1.7 Parallel/Serial Communication Faults

6-2

Troubleshooting

6.1.4

No Power
Turn the Printer off for 30 seconds. Turn the Printer on. Does the Printer power up?

Return to Section 6.1.3 and complete the Problem Isolation Checklist.

Turn the Printer off and unplug the power cord from the AC outlet. Remove the Cover and then Power Supply Shield. Check the two fuses located on the Power Supply Board. Are either of the fuses blown? Replace the fuse(s). If the fuse continues to fail, the printers Power Supply Board is probably defective.

Turn the Printer off. Disconnect the following connectors from the Power Supply Board: Printhead Power Cable(J2) Stepper Motor (J6) Turn the Printer on. Does the Printer power up?

One at a time reconnect each of the connectors turning the Printer on after each connection until the Printer does not turn on. Inspect and replace the associated components.

Turn the Printer on. On the Power Supply Board there are two green LEDs. Are both of the LEDs on?

Possible defective Main Board and/or Front Panel.

Defective Power Supply

6-3

Troubleshooting

6.1.5

Print Quality
Press the button. Using the button scroll to Print Configuration. Press the button again. Is the label blank? Make sure the Printhead is in it down and latched position If using Direct Mode print method ensure you are using thermal sensitive media Printhead Cable damaged or not properly connected. Defective Printhead, Main Board, or Power Supply

Does the label show streaks or missing dots in the print?

Dirty Printhead Defective Printhead Printhead Cable damaged or not properly connected Defective Main Board

Does the print fade across the width of the label?

Printhead is not adjusted correctly, see Chapter 5 Maintenance and Adjustments.

Try a different ribbon/media combination. Adjust the Heat and/or the Darkness setting on the Printer to a higher value.

6-4

Troubleshooting

6.1.6

Parallel Communication Faults


With the Printer on and properly connected to the host, send a label to the Printer from the host. Did the label print? Parallel communications test complete. If the label does not appear as expected check the label programming commands.

Press the button. Using the button scroll to Print Configuration. Press the button again. Check the Communications column on the Printers Configuration Label, Make sure the Port Direction is set to UniDirectional. Did the Printers Configuration Label and the host communication settings differ?

Reconfigure the Printer. This setting can be found in the menu under Communications/ Parallel Port. Some host computers are not bi-directional compatible.

Place the printer into Dump Mode by using the dump mode (under the Diagnostics level) function in the front panel menu. Send a label to the Printer from the host. Does the Printer print a Hex/ASCII Dump Label?

Check communication settings and label programming commands.

Incorrect or defective Interface Cable

6-5

Troubleshooting

6.1.7

Serial Communication Faults


With the Printer on and properly connected to the host, send a label to the Printer from the host. Did the label print? Serial communications test complete. If the label does not appear as expected check the label programming.

Press the button. Using the button scroll to Print Configuration. Press the button again. Check the Communications column on the Printers Configuration Label with the host computer. Do the Printers Configuration Label and the host communication settings differ?

Reconfigure the Printer or the host settings so they match.

Place the printer into Dump Mode by using the dump mode (under the Diagnostics level) function in the front panel menu. Send a label to the Printer from the host. Does the Printer print a Hex/ASCII Dump Label?

Check communication settings and label programming.

Incorrect or defective Interface Cable

6-6

Troubleshooting

6.2

Error and Warning Messages

The system monitors various operational groups, including electronics, mechanics and resources. If a problem is detected, an error message will be displayed and the ERROR light will blink. A Fast Blink indicates an error condition and a Slow Blink indicates a warning condition. The following tables list error and warning messages with related causes and possible solutions. To clear an error or warning condition press the FEED button. Error Messages: Display Message
ADC FAULT

Alarm Description
The system has detected an analog to digital converter failure.

Action
Try cycling the printer Off and On. If the fault does not clear replace the Main Logic Board.

CUTTER FAULT

The system has detected a cutter mechanism fault.

Make sure the Cutter is properly installed. Carefully examine the Cutter for obstructions. WARNING: Turn Off and unplug the printer power before attempting to clear the cutter.

OUT OF STOCK

The printer cannot detect media.

Load media, possible faulty Media Sensor or Cable.

TOP OF FORM FAULT

The printer could not find the TOF mark or found one in an unexpected place.

Press FEED or re-calibrate.

RAM FAULT

The system has detected a RAM failure.

Replace the Main Logic Board.

RIBBON FAULT

The ribbon sensor detects no movement.

Ensure that the ribbon is correctly loaded. Check the ribbon supply and ribbon take up hubs for obstructions prohibiting movement. Faulty Ribbon Sensor or Backplane Board

RIBBONSAVER FAULT

The ribbon saver operation has failed.

Ensure the printer is equipped with the ribbon saver option.

6-7

Troubleshooting

Display Message
POSITION FAULT

Alarm Description
The printer has determined that the media is not correctly positioned to print. The printer has detected a Direct Memory Access failure. The printer has detected a problem in the print logic. The printer has detected that the 24 volt line is out of limits. The printer has detected a problem applying a heat strobe to the printhead. The printer has shutdown to cool the printhead to prevent over temperature damage. The verifier has detected an error in the barcode(s) on a printed label. Note: The verifier must be disabled during certain testing functions.

Action
Press the FEED button.

DMA FAULT PRINT ENGINE FAULT 24V OUT OF TOLERANCE STROBE TIMING FAULT

Replace the Main Logic Board.

Replace the Main Logic Board.

Replace the Power Supply Board.

Possible faulty Main Logic Board or Power Supply Board.

TPH SHUTDOWN

Turn off power and allow the printer to cool.

VERIFIER FAULT

See the Verifiers front panel for exact nature of the failure. Consult the Verifier operating manual for the appropriate corrective action. When running in certain test modes disable the Verifier and retry test.

Warning Messages: Display Message


RIBBON LOW RTC RAM FAULT

Alarm Description
Ribbon will soon need replacement. The printer was unable to save the printer settings in permanent memory. Excessive printhead temperature detected.

Action
Replace ribbon when needed.

If condition persists, possible faulty Main Logic Board.

TPH TEMPERATURE HOLD

Allow printhead to cool.

GAP MISSED DOT FAILURE HOST CHANGES PENDING

The printer missed detecting a label gap. The printer has detected burnedout dots on the printhead. The printer has received host changes which will not be effective until a host reset command is issued.

If condition persists, possible faulty Media Sensor.

Replace Printhead when print quality degrades.

To save changes send a host reset (DPL) command. To discard changes perform a front panel reset.

6-8

88-2243-07 Rev. A

Removal and Replacement

7.0 Covers .................................................................................. 1 7.1 Platen Roller ........................................................................ 2 7.2 Printhead.............................................................................. 4 7.3 Thermal Transfer Assembly ............................................... 5
7.3.1 Ribbon Supply Hub................................................................................... 5 7.3.2 Ribbon Take-up Hub ................................................................................ 6

7.4 Rewind Assembly................................................................ 7


7.4.1 Rewind Hub .............................................................................................. 7

7.5 Media Sensor ....................................................................... 8 7.6 Drive Motor and Drive Belt ................................................. 9 7.7 Power Supply Board ......................................................... 10 7.8 Main Logic Board .............................................................. 11 7.9 Fuses .................................................................................. 12

ii

Removal and Replacement

7.0

Covers

Removal:

1. Turn the Printer off and unplug the power cord from the printer.

2. Open the Media Cover and remove the two screws.

3. On the other side of the printer remove the two screws that secures the edge of the Electronics Cover. 4. Lift both covers up and off the printer.

Replacement: 1. Position the covers on the printer and reinstall the previously removed screws.

7-1

Removal and Replacement

7.1

Platen Roller

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Open the Media Cover. Unlatch the printhead. 3. Remove the Front Filler Panel by grasping the top of the panel and pulling it away from the printer. 4. Loosen and remove the Thumbscrew and Tear Plate.

5. Remove the Sensor Cover by pulling it from the printer in the direction of the arrows as shown.

7-2

Removal and Replacement

6. Remove the two screws that secure the Bearing Plate onto the printer, remove the Bearing Plate. 7. Remove the entire Platen Roller Assembly from the printer.

Replacement: 1. Place the Outside Bearing onto the Platen Roller Shaft and position the Platen Roller Assembly into the printer. 2. Position the Bearing Plate onto the Printer and secure with the two previously removed screws. 3. Reinstall the Tear Plate, Thumbscrew and Front Filler Panel.

7-3

Removal and Replacement

7.2

Printhead

Removal: 1. Turn the Printer off and unplug the power cord from the printer. Open the Media Cover 2. Loosen the Printhead Mounting Screw. Carefully unlatch the printhead assembly and disconnect the two Cables from the Printhead.

Replacement: 1. Re-connect the Printhead cables. 2. Position the Printhead on the Printhead Assembly and tighten the Printhead Mounting Screw.

7-4

Removal and Replacement

7.3

Thermal Transfer Assembly

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Remove the three Screws that secure the Thermal Transfer Assembly to the Centerplate.

7.3.1 Ribbon Supply Hub


Removal: 1. Remove the Screw and Metal Washer from the back of the Thermal Transfer Housing and then remove the Supply Hub and Nylon Washer.

Replacement: 1. Slide the Supply Hub and Nylon Washer into the Thermal Transfer Housing. Rotate the Supply Hub so the pin, (located on the Supply Hub shaft) slides into the notch on the Thermal Transfer Housing. 2. Reinstall the Metal Washer and Screw.

7-5

Removal and Replacement

7.3.2 Ribbon Take-up Hub


Removal: 1. Remove the E-ring from the end of the Take-up Hubs shaft. Remove the Inner Bearing. 2. Slide the Take-up Hub and the Outer Bearing out of the Thermal Transfer Housing. 3. Remove the Take-up Hub Clutch from the Housing.

Replacement: 1. Install the Outer bearing into the Thermal Transfer Housing. 2. Position the Take-up Hub Clutch into the Thermal Transfer Housing and slide the Take-up Hub shaft through. 3. Install the Inner Bearing and the E-ring.

7-6

Removal and Replacement

7.4

Rewind Assembly

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Remove the three Screws that secure the Rewind Assembly to the Centerplate.

7.4.1

Rewind Hub

Removal: 1. Remove the E-ring from the end of the Rewind Hubs shaft. Remove the Inner Bearing. 2. Slide the Rewind Hub and the Outer Bearing out of the Rewind Housing. 3. Remove the Rewind Hub Clutch from the Housing. 4. To remove the Spur Gear and Idler Post, remove the Screw securing them to the Rewind Housing.

Replacement: 1. Install the Outer bearing into the Rewind Housing. 2. Position the Rewind Hub Clutch into the Rewind Housing and slide the Rewind Hub shaft through. 3. Install the Inner Bearing and the E-ring. 4. Position the Spur Gear and Idler Post onto the Rewind Housing, secure with the Screw

7-7

Removal and Replacement

7.5

Media Sensor

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Remove the covers from the printer, see Section 7.0. 3. Remove the ribbon cable from the Media Sensor. 4. Loosen and remove the Screw that secures the Media Sensor Guide to the Post. 5. Slide the Media Sensor Guide and the Media Sensor out of the printer.

Replacement: 1. Slide the Media Sensor followed by the Media Sensor Guide into the printer and secure with the previously removed Screw. 2. Reconnect the ribbon cable to the Media Sensor.

7-8

Removal and Replacement

7.6

Drive Motor and Drive Belt

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Remove the covers from the printer, see Section 7.0. 3. Remove the three Screws securing the Motor Assembly to the printer as shown below.

4. Remove the four Screws securing the Drive Motor to the Motor Mounting Block. 5. Slip the Belt off the Drive Motors pulley.

Replacement: 1. Position the Drive Motor on the Motor Mounting Block making sure the Belt is routed around the Drive Motors pulley and the Motor Mounting Blocks Gear. Install and tighten the four Screws. 2. Position the Motor Assembly in the printer and Install and tighten the three mounting Screws.

7-9

Removal and Replacement

7.7

Power Supply Board

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Remove the covers from the printer, see Section 7.0. 3. Remove the four cables from their respective connectors on the Power Supply Board. 4. Remove the two Screws on the back of the printer securing the AC Input Connector. 5. Remove the Screw and Washer securing the Ground Wire to the base of the printer. 6. Remove the four Screws securing the Power Supply Board to the printer.

Replacement: 1. Position the Power Supply Board in the printer and install the four Screws that secure the Power Supply Board.

2. Install the Ground Wire to the base of the printer using the previously removed Screw and Washer. 3. Install the two Screws on the back of the printer securing the AC Input Connector. 4. Reconnect the four cables to their respective connectors on the Power Supply Board.

7-10

Removal and Replacement

7.8

Main Logic Board

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Remove any data cables attached to the printer. 3. Remove the two Screws securing the Main Logic Board to the printer. 4. Slide the Main Logic Board out of the printer.

Replacement: 1. Slide the Main Logic Board into the printer. Push the board in until it is fully seated. 2. Reinstall the two previously removed screws.

7-11

Removal and Replacement

7.9

Fuses

Removal: 1. Turn the Printer off and unplug the power cord from the printer. 2. Remove the covers from the printer, see Section 7.0. 3. Locate, and if necessary remove and replace fuse F1 or F2 with the same type and rating, (3A/250V Fast Acting).

7-12

88-2243-08 Rev. A

8
8.3.1 8.3.2

Circuit Description

8.0 Introduction ......................................................................... 1 8.1 Features ............................................................................... 1 8.2 General Description ............................................................ 1 8.3 Microprocessor ................................................................... 2
Motorola Coldfire 5307 Processor ............................................................ 2 Background Debug Module ...................................................................... 2

8.4 Bus Architecture.................................................................. 3


8.4.1 8.4.2 8.4.1 Address Bus (ADDR)................................................................................ 3 Data Bus (DATA) ...................................................................................... 3 MBUS (SCL, SDA).................................................................................... 3

8.5 Xilinx Spartan XL30............................................................. 3


8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.5.8 8.5.9 8.5.10 8.5.11 8.5.12 Microprocessor Interface .......................................................................... 3 Code Download ........................................................................................ 3 Print Head Interface.................................................................................. 4 Analog to Digital Converter Interface ........................................................ 4 IEEE 1284 Compatible Parallel Interface ................................................. 4 Paper Edge Sensor .................................................................................. 4 Front Panel interface ................................................................................ 4 General Purpose Interface ....................................................................... 4 Motor Driver Interface ............................................................................... 4 Cutter Interface......................................................................................... 5 Dot Check Interface .................................................................................. 5 Power Down Interrupt ............................................................................... 5

8.6 Flash Memory ...................................................................... 5

8.7 SDRAM ................................................................................. 5 8.8 Expansion Bus Interface .................................................... 5 8.9 RS-232 .................................................................................. 6 8.10 Sensors ................................................................................ 6
8.10.1 8.10.2 8.10.3 8.10.4 Paper Edge Sensor .................................................................................. 6 Ribbon Motion Sensor .............................................................................. 6 Present Sensor......................................................................................... 7 Head Up Sensor ....................................................................................... 7

8.11 Miscellaneous Circuits ....................................................... 7


8.11.1 Analog to Digital Converter....................................................................... 7 8.11.2 Reset Circuit ............................................................................................. 7 8.11.3 Dot Check................................................................................................. 8

ii

8.0

Introduction

This chapter provides a description of the I-Class main logic board hardware and its operation as documented in schematic 51-2278-01.

8.1

Features

The main logic board has the following features: 8MB of SDRAM 1MB of Flash Memory 66MHz Coldfire Processor Dot Check Firmware controlled Paper Edge Detector Circuit IEEE 1284 compatible parallel port

8.2

General Description

The main logic board is capable of driving printheads with up to 8 banks and 8 strobes. The main board has a 182 pin gold plate card edge. The card edge mates with a 182 pin card edge connector on the backplane board of the printer. The backplane distributes power from the power supply to the main board, expansion board, and sensors. All sensor, expansion, and power connections are made on the backplane board. This allows the Main Board to be easily removed and replaced. The main board contains circuitry necessary for interface to the stepper motor driver, sensors, front panel, and printhead for the purpose of thermal label printing.

8-1

8.3
8.3.1

Microprocessor
Motorola Coldfire 5307 Processor

The main processor is the Motorola Coldfire 5307 (U2). The Coldfire is a high performance 32 bit processor with 4 GB of address space. All 32 address bits are available on a separate address bus. There are also 7 programmable chip selects. The 5307 has an integrated synchronous dram controller, duart, MBUS (I2C) 2 channel DMA controller, and 8 bit general purpose I/O port. It runs at an internal clock rate of 66.355MHz. An external 3.3V clock oscillator at a frequency of 33.1775MHz is input to the Coldfires internal Phase Lock Loop at pin XX. The PLL multiplies the external clock by 4 and then divides by 2 to produce the internal clock. The internal clock is then divided by two and becomes the external bus clock. The Coldire is a 32 bit processor. The main board only utilizes the upper 16 bits of the data bus. The lower 16 bits are terminated through 2.2K resistors. The lower 16 bits are used by the processor during reset to determine its out of reset operating state. See the table below for details. Data Bus D[1:0] D[3:2] D[4] D[5:6] D[7] Logic level High : Low Low : High Low Low : High High Condition Set External clock is of Internal Clock Input Clock is between 28 and 38.999Mhz PP[7:0] defined as inputs CS0 (Flash) is set to 16bit port size CS0 auto acknowledge enabled at 15 wait states

An Address Strobe (ASN) signal is available on pin 62 to latch addresses from ADDR<31..0>. When this signal goes low the address on the bus is assumed valid. The R/W signal (R/-W) determines the direction of an access on the data bus. High indicates the processor wants to read while low indicates a write. The Reset In signal (RSTI) on pin 67 resets the processor. The active low reset signal is provided by U8. Pins E10, 11, and 12 were provided for engineering use only. Cutting the trace between E12 and E11 and inserting a jumper between E10 and E11 allows the FPGA to hold the processor in reset while the FPGA accepts download data from configuration prom U7 (not installed). The Reset Out signal (RSTO) is asserted active low any time RSTI is asserted. The RSTO signal is driven high only after the internal clock is stable.

8.3.2

Background Debug Module

The Motorola Coldfire 5307 has a built in debug module that can directly communicate with the processor core. The BDM communicates to a host computer through the 26 pin connector J3. A special interface cable and software are necessary to utilize this port. The PSTCLK signal under debug conditions is the internal clock. The PSTCLK signal is turned off by firmware when running the printer application to reduce EMI radiation.

8-2

8.4

Bus Architecture

The main board has 3 busses. A 32 bit bi-directional data bus, a 32 bit address bus and a serial Mbus.

8.4.1

Address Bus (ADDR)

The ADDR bus is a 32 bit address bus that originates from the 5307 (U2). ADDR<15..13> and ADDR<3..0> have RC filters to reduce EMI.

8.4.2

Data Bus (DATA)

The DATA bus is a 16 bit bi-directional bus. The 5307 requires that the upper 16 bits of the 32 bit data bus be used for 16 bit accesses.

8.4.1

MBUS (SCL, SDA)

The MBUS is a programmable serial bus. In this application it is used to emulate the Philips I2C bus for addressable serial peripherals.

8.5

Xilinx Spartan XL30

The Xilinx Spartan XL30 (U1) is a 30,000 gate Fuse Programmable Gate Array. This configurable logic device is programmed by the firmware during initialization. It is ram based and has no storage ability without power. The FPGA interfaces the processor to several major printer components including the printhead, front panel display, and A/D converter.

8.5.1

Microprocessor Interface

The interface from the Spartan XL30 (U1) to the microprocessor (U2) requires the 16 bit data bus, six address lines, the BCLK_SDRAM clock, ASN, R/WN, and CS2. Three interrupts, IRQ1, IRQ3, and IRQ7 allow U1 to interrupt the processor. DREQ0N is used to request a DMA access from memory to U1. RESETN resets U1 logic during a warm reset. Other signals routed between U1 and U2 are for future use.

8.5.2

Code Download

The Xilinx Spartan XL30 (U1) is a ram base device and must be configured each time power is applied. Code is downloaded to U1 by the processor. The download code is embedded in the firmware. When RSTIN or PGM_FPGA is low U1 internally clears itself. When RSTIN and PGM_FPGA go high U1 reads the level at pin 50. R78 keeps this level low and puts U1 into express download mode. Byte wide data is placed on DATA<23..16> by the processor U2. CS2N goes low. This edge is delayed by two AHC04 inverters (U6) and is used to enable the AHC125 gate (U4). The ASN signal is passed through this enabled gate to the CCLK pin155. The rising edge of ASN then clocks the data present on the data bus. When U1 is configured ISP_EN_ and LDC are driven high. ISP_EN_ is used to light DS1 anytime U1 is not configured. LDC is used for engineering only in conjunction with U7.

8-3

8.5.3

Print Head Interface

The Xilinx Spartan XL30 (U1) contains logic to interface to the printhead. The logic is application specific and depends on the printhead used. The main board supports up to an 8 bank head. There are also 8 strobe lines. A BEO and STROBE line are both available as well as a head clock. Data can be sent to the FPGA via either 16 bit DMA transfers or 16 bit addressed transfers. IRQ1 has also been reserved for printhead operations.

8.5.4

Analog to Digital Converter Interface

The Xilinx Spartan XL30 (U1) contains logic to interface to the A/D converter (U9). The A/D converter communicates with the Xilinx via a synchronized serial data bus. The bus consists of a serial clock running at 500kHz, a chip select for U9, an input data line, and an output data line. The 500kHz clock is derived from the SDRAM_BCLK. It is used for both communications and for data conversions. An internal state machine within the Xilinx controls the serial communications to select one of eight channels and convert the serial data received from U9 into parallel data to be read by the firmware.

8.5.5

IEEE 1284 Compatible Parallel Interface

The Xilinx Spartan XL30 (U1) contains logic that allows the firmware to communicate with the IEEE 1284 standard as well as run in Centronics compatible mode.

8.5.6

Paper Edge Sensor

The Xilinx Spartan XL30 (U1) contains logic to interface to the paper edge sensor circuitry. The PESC<3..0> bus interfaces with a 4 bit 2N ladder to convert 4 bit digital to one of 16 voltage levels. PESLED1 and PESLED2 interface to circuitry that can turn on either the transmissive or reflective LEDs. The PESLED1 and PESLED2 switch from tristate to ground. They will never be at 0V simultaneously.

8.5.7

Front Panel interface

The Xilinx Spartan XL30 (U1) contains logic to interface to the front panel. Communication to the display is done by two wire synchronized serial. The LCDCLK carries the clock while the LCDDATA is the data line. The data is unidirectional and originated from the Xilinx. The signal LCD_D/-R is to be used by a graphic display. Switch data is received by the Xilinx by the FPSW<4..0> signals. LED data is sent to the front panel by the FPLED<2..0> and MENU signals. A state machine in the Xilinx converts the data to serial format for transmission.

8.5.8

General Purpose Interface

The Xilinx Spartan XL30 (U1) contains logic to interface to the general purpose interface port. GPIN<2..1> is a two bit input bus from the backplane connector. GPOUT<7..3> is a five bit output bus from the Xilinx to the backplane connector.

8.5.9

Motor Driver Interface

The Xilinx Spartan XL30 (U1) contains logic to interface to the motor driver. The signals MOTOR<3..0> and MOTORHL originate from the Xilinx and connect to a motor driver through the backplane connector.

8-4

8.5.10 Cutter Interface


The Xilinx Spartan XL30 (U1) contains logic to interface to a cutter. The signal CUTOUT is an output from the Xilinx to the backplane connector. The signal CUTIN is an input to the Xilinx from the backplane connector.

8.5.11 Dot Check Interface


The Xilinx Spartan XL30 (U1) contains logic to interface to the dot check circuitry located on the main board. The DOTCAL signal is an output from the Xilinx to the dot check circuit. When this signal is high it enables the calibration resistor. The signals DOT660, DOT114 and DOT1500 are normally tristated. A dot check test is initiated when one of the signals is set high. The Signal DOTREF should be high any time DOT660, DOT1114 or DOT1500 are high.

8.5.12 Power Down Interrupt


The signal IRQ7 is a non maskable interrupt to the processor. The interrupt originates from the Xilinx and terminates at the Processor. This interrupt also goes to the backplane connector. IRQ7 is to be used as the power down interrupt and is asserted low when the Xilinx detects that 24V is bellow the threshold set by firmware in a storage register.

8.6

Flash Memory

The main board has 1Mbyte of flash installed (U13). The intended flash is an AMD29LV800B or compatible part. A flash memory up to 4Mbyte (2048k x 16) can be installed in location U13 The signal WPN and testpoints TP22 and 23 are for engineering evaluation of Intel flash families.

8.7

SDRAM

The main logic board contains 8Mbyte of SDRAM (U14). Interface to the SDRAM is achieved through an internal sdram controller in the microprocessor.

8.8

Expansion Bus Interface

The main logic board has an expansion bus intended for use with expansion cards via the backplane connector. The bus consists of 32 unbuffered address lines from the processor, 16 buffered data lines, and control signals. The control signals are as follows: CS!N, CS3N, CS4N, CS5N, CS6N, CS7N RESETN, R/WN, BRN, DREQ1N, ASN, TAN, TSN, BGN, BDN, WE1N, WE0N SIZE1, SIZE0, OEN, TOUT1, TIN1, SWCLK, CLKON, IRQ5, IRQ7 TXD2, RTS2, RXD2, CTS2, DTR2 Data and clock are enabled by driving the CLKON signal low. The direction of the data bus is determined by the state of the processor signal R/WN.

8-5

8.9

RS-232

The processor on the main logic board has an internal duart. Channel 1 of the duart is connected to an RS-232 transceiver U11. U11 has internal charge pumps to generate the positive and negative 5 volt supplies and can withstand a 15KV ESD strike. The signals RTS1, TXD1, RXD1, and CTS1 originate from the processor and DTR1 originates from the Xilinx as a register output. The four signals RTS2, TXD2, RXD2, and CTS2 from the second channel of the processors internal duart are routed to the expansion bus through the backplane connector.

8.10 Sensors
8.10.1 Paper Edge Sensor
The Paper Edge Sensor contains two light emitting diodes. One LED is for transmissive sensing while the other is for reflective sensing. A single phototransistor serves as a receiver. The emitter of the phototransistor is connected to ground. The collector is tied to a 4.7k pull up resistor. The voltage at the collector decreases as the light that falls on the phototransistor increases. The voltage at the collector is monitored by the A/D converter on channel 0 (U9 pin 1). LED current can be adjusted to optimize gap or bar detection for media with different translucent or reflective properties. The LED current is set by the 2N ladder made up of R7, R8, R9, R10 and R5||R6 . The voltage at pin 3 of U3 increases from 0 to 1.2 V as PESC<3..0> goes from $0 to $F hex. This voltage is amplified by op amp U3-A by a gain of two. The amplified voltage is then fed to op-amp U3-B which is configured as a voltage to current converter. The current though the diode can be calculated as follows.:

I led

V pin12 100

It is also important to note that when PESLED2 (transmissive LED) is selected resistor R149 (2K) is placed in parallel with R150 (4.75k) This allows the pull-up on the collector of the sensor to be less stiff when using the reflective led.

8.10.2 Ribbon Motion Sensor


The ribbon motion sensor interface is designed to be used with a Sharp GP2L09A. R147 (120 ohm) set the led current to 17miliamps. R114 (4.7k ohm) is tied to the collector of the phototransistor. It is assumed that the emitter of the phototransistor and the anode of the LED have been tied to ground on the backplane. The collector voltage of the phototransistor is then read by the A/D converter and is connected to channel 2 (U9 pin 3).

8-6

8.10.3 Present Sensor


The present sensor interfaces through a single line from the backplane. The voltage on this signal line is monitored by the A/D converter on channel 4 (U9 pin 5).

8.10.4 Head Up Sensor


The head up sensor interface has been designed to work with a transmissive optical switch. R148 (120 ohm) feeds voltage to the anode of an LED. The cathode is grounded at the backplane. The phototransistors collector is pulled up through R113 (1k ohm). The collector voltage can be read by the A/D converter channel 6 (U9 pin 6). A 1n4148 diode is connected with the anode to the collector and the cathode to the cathode of the LED. If the sensor is not connected the collector voltage will be 3.3V. When the sensor is connected and blocked the collector voltage will be 2V (1.2V from the led and 0.7V from the diode). When the sensor is unblocked the collector voltage is 0V.

8.11 Miscellaneous Circuits


8.11.1 Analog to Digital Converter
The main logic board uses a TLV0838 A/D converter. A state machine in the Xilinx communicates to the A/D converter to set the A/D multiplexor to one of eight channels and retrieve the conversion data through a synchronized serial bus. Details of the serial communications can be found in the Texas Instruments Data Book for the TLV0838. The eight channels of the A/D converter are distributed as follows: Paper Edge Sensor Thermal Printhead Voltage Ribbon Motion sensor Printhead Thermistor Paper Present Sensor Head Up Sensor Dot Check Voltage Thermal Printhead Rank Resistor Channel 0 Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7

8.11.2 Reset Circuit


The main logic board uses a dual reset chip, Summit part number S4242 (U8) to keep the processor and other circuits in reset when either the 3.3 or 5 volt power supplies are out of tolerance. The 5 volt reset is done internally and is set to +/- 10%. The 3.3 volt reset uses the VSENSE input and is set to trip a 3.0V +/- 1% with the voltage divider made up of R104, R103, and R102. Pins E6 and E5 can be shorted to initiate a reset. The reset generated by U8 is fed to an and gate (U12) along with the BDM_RESET signal. If either reset is asserted low then the signal RSTIN to the processor will be asserted low. The S4242 also has 2k bits of built in EEprom memory that is accessed through the I2C bus. This bus is emulated through the processors built in M-Bus controller. See the Summit data book and 5307 users manual for more information.

8-7

8.11.3 Dot Check


The main logic board is equipped with a dot check circuit for testing printhead dots. The printhead voltage must be turned off with the VPHEN signal before using this circuit. There are three ohm range signals. DOT660 should be used for printheads up 660 ohms. DOT1114 should be used for printheads up to 1114 ohms. DOT1500 should be used for printheads up to 1500 ohms. Calibration data should be gathered to characterize the circuit before use. DOTREF, DOTCAL and one of the ohm range signals should be asserted high. The A/D converter will then read the voltage across R12 (1k ohm). The DOTCAL signal can then be asserted low. This turns Q4 on. Current then flows from the selected ohm range signal through its associated resistor, through FET Q4 and through the printhead. The resistance value of the dots can then be read by loading the head, asserting the strobe and reading the A/D value.

8-8

88-2243-09 Rev.A

Printer Assemblies

9.0 Overview .............................................................................. 1 9.1 Covers 1 of 2 ........................................................................ 2 9.2 Covers 2 of 2 ........................................................................ 4 9.3 Printer Assembly 1 of 2....................................................... 6 9.4 Printer Assembly 2 of 2....................................................... 8 9.5 Printhead Assembly (15-2762-01) .................................... 10 9.6 Drive Motor Assembly (15-2819-01) ................................. 12 9.7 Cable Assemblies.............................................................. 14 9.8 Direct Thermal/Thermal Transfer Options ...................... 16 9.9 Ribbon Supply Hub ........................................................... 18 9.10 Media Rewind/No Media Rewind Options ....................... 20 9.11 Present Sensor and Peel and Present Options .............. 22 9.12 300 DPI Printers................................................................. 24

ii

Spare Parts

9.0

Overview

The following Section provides exploded views and parts listings for the I-Class printers.

9-1

Printer Assemblies

9.1

Covers 1 of 2

9-2

Printer Assemblies

9.1

Covers 1 of 2
PART # 15-2785-01 10-2905-01 10-2903-03 16-2551-01 16-2571-01 16-2581-01 16-2559-01 16-2560-01 16-2557-01 15-2788-01 DESCRIPTION COVER ASSY, MEDIA SIDE NUT, HEX SELF LOCKING, M4 SCREW, PHP, TRILOBAL, M4X10 REAR PANEL BLOCK FILLER COVER, SENSOR FRONT PANEL BUTTON CONTROL PANEL BEZEL FRONT COVER ASSY-LEFT

ITEM # 1 2 3 4 5 6 7 8 9 10

9-3

Printer Assemblies

9.2

Covers 2 of 2

9-4

Printer Assemblies

9.2

Covers 2 of 2
PART # 11-5226-01 10-2903-01 16-2564-01 16-2567-01 16-2556-01 10-2973-01 DESCRIPTION COVER, MEDIA SIDE SCREW, PHP, TRILOBAL, M4X6 FRONT PANEL BLOCK WINDOW, COVER REAR PANEL BLOCK FASTENER, PUSH NUT

ITEM # 1 2 3 4 5 6

9-5

Printer Assemblies

9.3

Printer Assembly 1 of 2

9-6

Printer Assemblies

9.3

Printer Assembly 1 of 2
PART # 45-2013-01 15-2814-01 12-2903-01 12-2931-01 12-2908-01 15-2763-01 15-2761-01 17-2836-01 15-2762-01 17-2893-01 15-2807-01 10-2903-03 20-2181-01 11-5209-01 12-2894-01 17-2310-01 10-2904-01 17-2859-01 10-2104-01 10-2903-04 12-2896-01 11-5219-01 17-2858-01 11-5230-01 12-2932-01 12-2948-01 DESCRIPTION LCD MODULE, CHAR. 2X20 CENTER PLATE ASSY EXTRUSION PRINTHEAD SUPPORT SHAFT MEDIA GUIDE SHAFT RIBBON IDLER MEDIA SUPPLY ASSY PLATEN ASSY SPRING, HEAD OPEN PRINTHEAD ASSY WAVE WASHER COVER ASSY PRINTHEAD SUPORT SCREW TRILOBULAR M4 PHILIPS HEAD 10 PRINTHEAD 203DPI DUAL CONNECTOR MEDIA GUIDE BLOCK MOUNTING PLATEN BEARING FLANGED .375 ID X .875 OD WASHER, FLAT NYLON .50 OD X .281 ID SPRING, COMP .420 X .045 WD X .50 WASHER #8, FLAT SCREW TRILOBULAR M4 PHILIPS HEAD 12 BRACKET RETAINER PLATEN TEAR BAR SCREW, HOLLOW KNURLED M4 X 10 PLATE MEDIA GUIDE BLOCK, GUIDE MEDIA BASEPLATE

ITEM # 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

9-7

Printer Assemblies

9.4

Printer Assembly 2 of 2

9-8

Printer Assemblies

9.4

Printer Assembly 2 of 2
PART # 11-5243-01 51-2278-00 12-2958-01 10-2903-04 51-2279-00 11-5253-01 16-2555-01 10-2903-03 15-2819-01 24-2504-01 17-2810-01 12-2905-01 16-2587-01 10-2903-06 11-5260-01 32-2433-01 12-2926-01 10-0526-01 11-5277-01 51-2271-00 16-2621-01 DESCRIPTION PLATE COVER MAIN BOARD ASSY PLATE MOUNTING REAR SCREW TRILOBULAR M4 PHILIPS HEAD 12 BACKPLANE BOARD ASSY CARD CAGE LIGHT PIPE, RIBBON SENSOR SCREW TRILOBULAR M4 PHILIPS HEAD 10 DRIVE MOTOR ASSY MEDIA SENSOR ASSY GEAR SPUR DELRIN, 24 PITCH 48 TEETH POST IDLER COVER, PROTECTIVE SCREW TRILOBULAR M4 PHILIPS HEAD 25 PLATE CONNECTOR CUTTER CABLE ASSY CUTTER GUIDE, MEDIA SENSOR WASHER #8 SPLIT LOCK PLATE NUT CCA, POWER SUPPLY BOARD CABLE, CLAMP

ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

9-9

Printer Assemblies

9.5

Printhead Assembly (15-2762-01)

9-10

Printer Assemblies

9.5

Printhead Assembly (15-2762-01)


PART # 15-2804-01 10-2908-01 11-5180-01 12-2944-01 20-2179-01 12-2901-01 16-2549-01 16-2550-01 10-2908-02 17-2848-01 17-2859-01 16-2529-01 11-5278-01 DESCRIPTION PRINTHEAD LATCH ASSEMBLY SCREW, M4X8 SLOTTED HEAD GUIDE-RIBBON BRACKET, PRINTHEAD ADJUST SWITCH, HEAD OPEN MOUNT-PRINTHEAD CAP-CAM CAM-MEDIA WIDTH SCREW, M4X16 SLOTTED HEAD SPRING, COMP .420 X .045 WD X .50 SPRING, COMP .300 OD X .030 WD X 1.00 CAM-HEAD PRESSURE CLIP PRINTHEAD

ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13

9-11

Printer Assemblies

9.6

Drive Motor Assembly (15-2819-01)

9-12

Printer Assemblies

9.6

Drive Motor Assembly (15-2819-01)


PART # 17-2879-01 17-2878-01 17-2310-01 12-2984-01 16-2521-01 10-2903-03 24-2505-01 17-2880-01 12-2983-01 DESCRIPTION BELT, TIMING PULLEY, TIMING, 25T 3MM PITCH BEARING, FLANGED .375 ID X .875 OD SHAFT, IDLER PINION COMPOUND, 24/36 SCREW, M4 PHIL STEPPER MOTOR ASSY ISOLATOR, NOISE AND VIBRATION BLOCK, MOUNTING, MOTOR

ITEM # 1 2 3 4 5 6 7 8 9

9-13

Printer Assemblies

9.7

Cable Assemblies

9-14

Printer Assemblies

9.7

Cable Assemblies
PART # 32-2417-01 32-2417-01 32-2433-01 32-2458-01 32-2459-01 32-2439-01 32-2440-01 DESCRIPTION CABLE ASSY, PRINTHEAD POWER CABLE ASSY, PRINTHEAD DATA CABLE ASSY, CUTTER CONNECTOR CABLE ASSY, POWER SUPPLY, POWER CABLE ASSY, POWER SUPPLY, DATA CABLE ASSY, FRONT PANEL CABLE ASSY, MEDIA SENSOR

ITEM # 1 2 3 4 5 6 7

9-15

Printer Assemblies

9.8

Direct Thermal/Thermal Transfer Options

9-16

Printer Assemblies

9.8

Direct Thermal/Thermal Transfer Options


PART # 15-2765-01 10-2903-03 12-2943-01 17-2824-01 17-2869-01 15-2768-01 15-2764-01 17-2310-01 12-2915-01 15-2776-01 10-0563-01 DESCRIPTION RIBBON SPOOL ASSY SCREW TRILOBULAR M4 PHILIPS HEAD 10 COVER RIBBON SPOOL WASHER, FLAT WASHER, FLAT, NYLON SUPPLY ASSY, RIBBON HUB ASSY, TAKE-UP BEARING, FLANGED .375 ID X .875 OD HOUSING, MEDIA TAKE-UP CLUTCH ASSY, RIBBON E-RING 3/8 TRUARC 5133-37

ITEM # 1 2 3 4 5 6 7 8 9 10 11

9-17

Printer Assemblies

9.9

Ribbon Supply Hub

9-18

Printer Assemblies

9.9

Ribbon Supply Hub


PART # 16-2537-01 14-2706-01 12-2907-01 17-2823-01 16-2538-01 10-2104-01 10-2903-03 DESCRIPTION HUB SUPPLY INNER LABEL, RIBBON SENSOR SHAFT, RIBBON SUPPLY SPRING-SUPPLY HUB HUB SUPPLY OUTER WASHER #8 FLAT SCREW TRILOBULAR M4 PHILIPS HEAD 10

ITEM # 1 2 3 4 5 6 7

9-19

Printer Assemblies

9.10 Media Rewind/No Media Rewind Options

9-20

Printer Assemblies

9.10 Media Rewind/No Media Rewind Options


ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 PART # 15-2773-01 10-2903-03 17-2858-01 11-5220-01 12-2941-01 15-2764-01 17-2310-01 17-2860-01 12-2905-01 10-2903-06 10-0563-01 15-2802-01 12-2925-01 DESCRIPTION MEDIA TAKE-UP ASSY SCREW TRILOBULAR M4 PHILIPS HEAD 10 THUMBSCREW REWIND BRACKET COVER, MEDIA TAKE-UP HUB ASSY, TAKE-UP BEARING, FLANGED .375 ID X .875 OD GEAR SPUR DELRIN, 24 TEETH POST IDLER SCREW TRILOBULAR M4 PHILIPS HEAD 25 E-RING 3/8 TRUARC 5133-37 CLUTCH ASSY, MEDIA HOUSING, SPOOL

9-21

Printer Assemblies

9.11 Present Sensor and Peel and Present Options

9-22

Printer Assemblies

9.11 Present Sensor and Peel and Present Options


Present Sensor Option:
ITEM 1 2 PART # 16-2576-01 24-2518-01 DESCRIPTION REFLECTIVE BLOCK PRESENT SENSOR ASSEMBLY

Peel and Present Option:


ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PART # 11-5287-01 10-0307-01 24-2527-01 17-2883-01 12-2976-01 10-0447-01 10-2903-01 16-2618-01 11-5296-01 17-2436-01 16-2540-04 11-5288-01 17-2894-01 12-2975-01 DESCRIPTION MOUNT-PEEL MECHANSIM RETAINING RING.125D PEEL/PRESENT SENSOR ASSY CAPTIVE SCREW SHAFT ROLLER E RING. 188 DIA SHAFT SCREW TRILOBULAR M4 PHILIPS BLOCK REFLECTIVE SPRING PEEL MECH. SCR, M3 X 8 THRD CUTTING OVAL ROLLER MOUNT-PINCHROLLER RETAINER, CAPTIVE SCREW SHAFT-PEEL PIVOT

9-23

Printer Assemblies

9.12 300 DPI Printers

9-24

Printer Assemblies

9.12 300 DPI Printers


ITEM 1 2 PART # 12-2985-01 20-2182-01 DESCRIPTION 300 DPI ADAPTER BLOCK 300 DPI PRINTHEAD

9-25

Printer Assemblies

9-26

88-2243-09 Rev.A

Printer Assemblies

9.0 Overview .............................................................................. 1 9.1 Covers 1 of 2 ........................................................................ 2 9.2 Covers 2 of 2 ........................................................................ 4 9.3 Printer Assembly 1 of 2....................................................... 6 9.4 Printer Assembly 2 of 2....................................................... 8 9.5 Printhead Assembly (15-2762-01) .................................... 10 9.6 Drive Motor Assembly (15-2819-01) ................................. 12 9.7 Cable Assemblies.............................................................. 14 9.8 Direct Thermal/Thermal Transfer Options ...................... 16 9.9 Ribbon Supply Hub ........................................................... 18 9.10 Media Rewind/No Media Rewind Options ....................... 20 9.11 Present Sensor and Peel and Present Options .............. 22 9.12 300 DPI Printers................................................................. 24

ii

Spare Parts

9.0

Overview

The following Section provides exploded views and parts listings for the I-Class printers.

9-1

Printer Assemblies

9.1

Covers 1 of 2

9-2

Printer Assemblies

9.1

Covers 1 of 2
PART # 15-2785-01 10-2905-01 10-2903-03 16-2551-01 16-2571-01 16-2581-01 16-2559-01 16-2560-01 16-2557-01 15-2788-01 DESCRIPTION COVER ASSY, MEDIA SIDE NUT, HEX SELF LOCKING, M4 SCREW, PHP, TRILOBAL, M4X10 REAR PANEL BLOCK FILLER COVER, SENSOR FRONT PANEL BUTTON CONTROL PANEL BEZEL FRONT COVER ASSY-LEFT

ITEM # 1 2 3 4 5 6 7 8 9 10

9-3

Printer Assemblies

9.2

Covers 2 of 2

9-4

Printer Assemblies

9.2

Covers 2 of 2
PART # 11-5226-01 10-2903-01 16-2564-01 16-2567-01 16-2556-01 10-2973-01 DESCRIPTION COVER, MEDIA SIDE SCREW, PHP, TRILOBAL, M4X6 FRONT PANEL BLOCK WINDOW, COVER REAR PANEL BLOCK FASTENER, PUSH NUT

ITEM # 1 2 3 4 5 6

9-5

Printer Assemblies

9.3

Printer Assembly 1 of 2

9-6

Printer Assemblies

9.3

Printer Assembly 1 of 2
PART # 45-2013-01 15-2814-01 12-2903-01 12-2931-01 12-2908-01 15-2763-01 15-2761-01 17-2836-01 15-2762-01 17-2893-01 15-2807-01 10-2903-03 20-2181-01 11-5209-01 12-2894-01 17-2310-01 10-2904-01 17-2859-01 10-2104-01 10-2903-04 12-2896-01 11-5219-01 17-2858-01 11-5230-01 12-2932-01 12-2948-01 DESCRIPTION LCD MODULE, CHAR. 2X20 CENTER PLATE ASSY EXTRUSION PRINTHEAD SUPPORT SHAFT MEDIA GUIDE SHAFT RIBBON IDLER MEDIA SUPPLY ASSY PLATEN ASSY SPRING, HEAD OPEN PRINTHEAD ASSY WAVE WASHER COVER ASSY PRINTHEAD SUPORT SCREW TRILOBULAR M4 PHILIPS HEAD 10 PRINTHEAD 203DPI DUAL CONNECTOR MEDIA GUIDE BLOCK MOUNTING PLATEN BEARING FLANGED .375 ID X .875 OD WASHER, FLAT NYLON .50 OD X .281 ID SPRING, COMP .420 X .045 WD X .50 WASHER #8, FLAT SCREW TRILOBULAR M4 PHILIPS HEAD 12 BRACKET RETAINER PLATEN TEAR BAR SCREW, HOLLOW KNURLED M4 X 10 PLATE MEDIA GUIDE BLOCK, GUIDE MEDIA BASEPLATE

ITEM # 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

9-7

Printer Assemblies

9.4

Printer Assembly 2 of 2

9-8

Printer Assemblies

9.4

Printer Assembly 2 of 2
PART # 11-5243-01 51-2278-00 12-2958-01 10-2903-04 51-2279-00 11-5253-01 16-2555-01 10-2903-03 15-2819-01 24-2504-01 17-2810-01 12-2905-01 16-2587-01 10-2903-06 11-5260-01 32-2433-01 12-2926-01 10-0526-01 11-5277-01 51-2271-00 16-2621-01 DESCRIPTION PLATE COVER MAIN BOARD ASSY PLATE MOUNTING REAR SCREW TRILOBULAR M4 PHILIPS HEAD 12 BACKPLANE BOARD ASSY CARD CAGE LIGHT PIPE, RIBBON SENSOR SCREW TRILOBULAR M4 PHILIPS HEAD 10 DRIVE MOTOR ASSY MEDIA SENSOR ASSY GEAR SPUR DELRIN, 24 PITCH 48 TEETH POST IDLER COVER, PROTECTIVE SCREW TRILOBULAR M4 PHILIPS HEAD 25 PLATE CONNECTOR CUTTER CABLE ASSY CUTTER GUIDE, MEDIA SENSOR WASHER #8 SPLIT LOCK PLATE NUT CCA, POWER SUPPLY BOARD CABLE, CLAMP

ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

9-9

Printer Assemblies

9.5

Printhead Assembly (15-2762-01)

9-10

Printer Assemblies

9.5

Printhead Assembly (15-2762-01)


PART # 15-2804-01 10-2908-01 11-5180-01 12-2944-01 20-2179-01 12-2901-01 16-2549-01 16-2550-01 10-2908-02 17-2848-01 17-2859-01 16-2529-01 11-5278-01 DESCRIPTION PRINTHEAD LATCH ASSEMBLY SCREW, M4X8 SLOTTED HEAD GUIDE-RIBBON BRACKET, PRINTHEAD ADJUST SWITCH, HEAD OPEN MOUNT-PRINTHEAD CAP-CAM CAM-MEDIA WIDTH SCREW, M4X16 SLOTTED HEAD SPRING, COMP .420 X .045 WD X .50 SPRING, COMP .300 OD X .030 WD X 1.00 CAM-HEAD PRESSURE CLIP PRINTHEAD

ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13

9-11

Printer Assemblies

9.6

Drive Motor Assembly (15-2819-01)

9-12

Printer Assemblies

9.7

Cable Assemblies

9-14

Printer Assemblies

9.7

Cable Assemblies
PART # 32-2417-01 32-2417-01 32-2433-01 32-2458-01 32-2459-01 32-2439-01 32-2440-01 DESCRIPTION CABLE ASSY, PRINTHEAD POWER CABLE ASSY, PRINTHEAD DATA CABLE ASSY, CUTTER CONNECTOR CABLE ASSY, POWER SUPPLY, POWER CABLE ASSY, POWER SUPPLY, DATA CABLE ASSY, FRONT PANEL CABLE ASSY, MEDIA SENSOR

ITEM # 1 2 3 4 5 6 7

9-15

Printer Assemblies

9.8

Direct Thermal/Thermal Transfer Options

9-16

Printer Assemblies

9.8

Direct Thermal/Thermal Transfer Options


PART # 15-2765-01 10-2903-03 12-2943-01 17-2824-01 17-2869-01 15-2768-01 15-2764-01 17-2310-01 12-2915-01 15-2776-01 10-0563-01 DESCRIPTION RIBBON SPOOL ASSY SCREW TRILOBULAR M4 PHILIPS HEAD 10 COVER RIBBON SPOOL WASHER, FLAT WASHER, FLAT, NYLON SUPPLY ASSY, RIBBON HUB ASSY, TAKE-UP BEARING, FLANGED .375 ID X .875 OD HOUSING, MEDIA TAKE-UP CLUTCH ASSY, RIBBON E-RING 3/8 TRUARC 5133-37

ITEM # 1 2 3 4 5 6 7 8 9 10 11

9-17

Printer Assemblies

9.9

Ribbon Supply Hub

9-18

Printer Assemblies

9.9

Ribbon Supply Hub


PART # 16-2537-01 14-2706-01 12-2907-01 17-2823-01 16-2538-01 10-2104-01 10-2903-03 DESCRIPTION HUB SUPPLY INNER LABEL, RIBBON SENSOR SHAFT, RIBBON SUPPLY SPRING-SUPPLY HUB HUB SUPPLY OUTER WASHER #8 FLAT SCREW TRILOBULAR M4 PHILIPS HEAD 10

ITEM # 1 2 3 4 5 6 7

9-19

Printer Assemblies

9.10 Media Rewind/No Media Rewind Options

9-20

Printer Assemblies

9.10 Media Rewind/No Media Rewind Options


ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 PART # 15-2773-01 10-2903-03 17-2858-01 11-5220-01 12-2941-01 15-2764-01 17-2310-01 17-2860-01 12-2905-01 10-2903-06 10-0563-01 15-2802-01 12-2925-01 DESCRIPTION MEDIA TAKE-UP ASSY SCREW TRILOBULAR M4 PHILIPS HEAD 10 THUMBSCREW REWIND BRACKET COVER, MEDIA TAKE-UP HUB ASSY, TAKE-UP BEARING, FLANGED .375 ID X .875 OD GEAR SPUR DELRIN, 24 TEETH POST IDLER SCREW TRILOBULAR M4 PHILIPS HEAD 25 E-RING 3/8 TRUARC 5133-37 CLUTCH ASSY, MEDIA HOUSING, SPOOL

9-21

Printer Assemblies

9.11 Present Sensor and Peel and Present Options

9-22

Printer Assemblies

9.11 Present Sensor and Peel and Present Options


Present Sensor Option:
ITEM 1 2 PART # 16-2576-01 24-2518-01 DESCRIPTION REFLECTIVE BLOCK PRESENT SENSOR ASSEMBLY

Peel and Present Option:


ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PART # 11-5287-01 10-0307-01 24-2527-01 17-2883-01 12-2976-01 10-0447-01 10-2903-01 16-2618-01 11-5296-01 17-2436-01 16-2540-04 11-5288-01 17-2894-01 12-2975-01 DESCRIPTION MOUNT-PEEL MECHANSIM RETAINING RING.125D PEEL/PRESENT SENSOR ASSY CAPTIVE SCREW SHAFT ROLLER E RING. 188 DIA SHAFT SCREW TRILOBULAR M4 PHILIPS BLOCK REFLECTIVE SPRING PEEL MECH. SCR, M3 X 8 THRD CUTTING OVAL ROLLER MOUNT-PINCHROLLER RETAINER, CAPTIVE SCREW SHAFT-PEEL PIVOT

9-23

Printer Assemblies

9.12 300 DPI Printers

9-24

Printer Assemblies

9.12 300 DPI Printers


ITEM 1 2 PART # 12-2985-01 20-2182-01 DESCRIPTION 300 DPI ADAPTER BLOCK 300 DPI PRINTHEAD

9-25

Printer Assemblies

9-26

88-2243-10 Rev. A

10

Schematic Diagrams

Ribbon Supply Hub

Ribbon Supply Hub


ITEM # 1 2 3 4 5 6 7 PART # 16-2537-01 14-2706-01 12-2907-01 17-2823-01 16-2538-01 10-2104-01 10-2903-03 DESCRIPTION HUB SUPPLY INNER LABEL, RIBBON SENSOR SHAFT, RIBBON SUPPLY SPRING-SUPPLY HUB HUB SUPPLY OUTER WASHER #8 FLAT SCREW TRILOBULAR M4 PHILIPS HEAD 10

Media Rewind/No Media Rewind Options

Media Rewind/No Media Rewind Options


ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 PART # 15-2773-01 10-2903-03 17-2858-01 11-5220-01 12-2941-01 15-2764-01 17-2310-01 17-2860-01 12-2905-01 10-2903-06 10-0563-01 15-2802-01 12-2925-01 DESCRIPTION MEDIA TAKE-UP ASSY SCREW TRILOBULAR M4 PHILIPS HEAD 10 THUMBSCREW REWIND BRACKET COVER, MEDIA TAKE-UP HUB ASSY, TAKE-UP BEARING, FLANGED .375 ID X .875 OD GEAR SPUR DELRIN, 24 TEETH POST IDLER SCREW TRILOBULAR M4 PHILIPS HEAD 25 E-RING 3/8 TRUARC 5133-37 CLUTCH ASSY, MEDIA HOUSING, SPOOL