Intermec EasyCoder 301 User manual

EasyCoder 301

Bar Code Label Printer

P/N 1-960420-02

Edition 3

September 1999

Service Manual

Intermec EasyCoder 301 – Service Manual Ed. 3

1

Chapter 0

0. Introduction

0.1 Contents

0. Introduction

0.1 Contents ..........................................................................................1

0.2 Preface ............................................................................................3

0.3 Notices and Approvals ....................................................................4

1. Models and Options

1.1 Identification ...................................................................................6

1.2 Specifications ..................................................................................7

1.3 Measures .........................................................................................8

2. Covers

2.1 User Cover ......................................................................................9

2.2 Front Cover ...................................................................................10

2.3 Electrics Cover ..............................................................................11

2.4 Release Button ..............................................................................11

3. Front and Operator Interface

3.1 Front .............................................................................................12

3.2 Interface Module ...........................................................................13

4. Chassis

4.1 Centre-line Wall ............................................................................15

4.2 Bottom Plate .................................................................................15

5. Paper Supply

5.1 Internal Supply ..............................................................................16

5.2 External Supply.............................................................................18

6. Transfer Ribbon Mechanism

6.1 Description....................................................................................19

6.2 Ribbon Unwind Unit .....................................................................20

6.3 Ribbon Rewind Unit .....................................................................21

6.4 Ribbon/Media Sensor ....................................................................22

6.5 Break Shaft ...................................................................................24

7. Print Unit

7.1 Description....................................................................................25

7.2 Platen Roller .................................................................................26

7.3 Stepper Motor ...............................................................................27

7.4 Belts..............................................................................................28

7.5 Ribbon/Media Sensor ....................................................................30

7.6 Printhead .......................................................................................32

7.8 Headlift Mechanism ......................................................................35

8. Media Take-Up

8.1 Media Take-Up Unit .....................................................................37

9. Label-Taken Sensor

9.1 Description....................................................................................38

9.2 Sensor Module ..............................................................................39

9.3 Light Guide ...................................................................................41

10. Electronics Compartment

10.1 Accessing the Electronics Compartment........................................42

10.2 Main Parts .....................................................................................42

11. CPU Board

11.1 Description....................................................................................43

11.2 Replacement .................................................................................45

11.3 Connectors and Straps ...................................................................46

11.4 Firmware Update ..........................................................................47

11.5 Boot Restore .................................................................................47

11.6 Communication Ports ....................................................................48

11.7 Components ..................................................................................50

11.8 Schematics ....................................................................................51

11.9 Test Points ....................................................................................63

Intermec EasyCoder 301

Service Manual

Edition 3, September 1999

Part No. 1-960420-02

Intermec EasyCoder 301 – Service Manual Ed. 3

2

Chapter 0 Introduction

0.1 Contents, cont'd.

Information in this manual is subject to change without prior notice and does not represent a commitment

on the part of Intermec Printer AB.

EasyCoder and LabelShop are registered trademarks of Intermec Technologies Corp.

Centronics is a registered trademark of Centronics Data Computer Corp.

Microsoft is a registered trademark of Microsoft Corporation.

Speedo is a trademark of Bitstream, Inc.

TrueType is a trademark of Apple Computer Inc.

Unicode is a trademark of Unicode Inc.

Windows is a trademark of Microsoft Corporation.

12. Paper Cutter

12.1 Description....................................................................................64

12.2 Controlling the Cutter....................................................................65

12.3 Installation ....................................................................................65

12.4 Cleaning........................................................................................68

13. Troubleshooting

13.1 Diagnosing the Printer...................................................................68

13.2 No Reaction at Power Up ..............................................................69

13.3 Printer Stops Working after Startup ...............................................69

13.4 Power Supply Failures ..................................................................70

13.5 Interface Module Errors ................................................................70

13.6 Error Messages..............................................................................71

13.7 No Communication (general) ........................................................72

13.8 No Serial Communication .............................................................72

13.9 No Parallel Communication ..........................................................73

13.10 Sensor Malfunctions......................................................................73

13.11 Printing Troubles...........................................................................75

13.12 Transfer Ribbon Troubles..............................................................79

13.13 Rewind Troubles ...........................................................................80

13.14 Memory Card Troubles .................................................................80

13.15 Paper Cutter Troubles....................................................................81

Intermec EasyCoder 301 – Service Manual Ed. 3

3

Chapter 0 Introduction

This Service Manual is intended to facilitate installation, trouble-

shooting and repair of the Intermec EasyCoder 301 in the version

delivered at the date of publishing. Thus, all information on the

firmware is based on version 2.00. The on-going product improve-

ment can be followed in the Printer Technical Bulletins from

Intermec.

This Service Manual is supplemented by the following publica-

tions, which the service technician also should keep easily avail-

able:

• Intermec EasyCoder 301; User's Guide

• Intermec EasyCoder 301 LinerLess; User's Guide

• Intermec EasyCoder 301; Installation & Operation

• Intermec EasyCoder 301 LinerLess; Installation & Operation

• Intermec EasyCoder 301; Spare Parts Catalogue

1

• Intermec EasyCoder 301 Direct Protocol; Programmer's Guide

Please note that the operations described in this manual only should

be carried out by skilled and authorized personnel with proper

training and full understanding of written English. The printers

contain wires and circuits with 100/240V AC voltage, which

implies the risk of electrical shock. Moving parts may also cause

harm, if incorrectly manipulated.

It is assumed that the reader possesses reasonable skills in mechan-

ics and electronics and is familiar with the EasyCoder 301 firmware

and its related standard application programs. It is also assumed that

the reader has access to the standard tools of an electronics

workshop.

Last minute notice!

Posidrive screws will be replaced by Torx screws in production of

EasyCoder 301 during the fall of 1999.

0.2 Preface

1/. The Service manual and the Spare

Parts Catalogue cover both the standard

EasyCoder 301 model and the Easy-

Coder 301 LinerLess model.

Intermec EasyCoder 301 – Service Manual Ed. 3

4

Chapter 0 Introduction

FCC Notice

United States of America

WARNING:

This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with

the instructions manual, may cause interference to radio communications. It has been tested and found to comply with the

limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide

reasonable protection against such interference when operated in a commercial environment. Operation of this equipment

in a residential area is likely to cause interference in which case the user at his own expense will be required to take whatever

measures may be required to correct the interference.

DOC Notice

Canada

Canadian Dept. of Communication

REGULATIONS COMPLIANCE

(DOC-A)

This digital apparatus does not exceed the class A limits for radio noise emissions from a digital apparatus as set out in

the radio interference regulations of the Canadian Department of Communication.

✳ ✳ ✳

Ministère des Communications du Canada

CONFORMITE DE REGLEMENTS

(DOC-A)

Le présent appareil numérique n´émet pas de bruits radio-électriques dépassant les limites applicables aux appareils

numériques de classe A prescrites dans le règlement sur brouillage radioélectrique édicté par le Ministère des

Communications du Canada.

EU Standard EN 55022 (The European Union)

WARNING:

This is a Class A ITE product. In a domestic environment this product may cause radio interference in which case the user

may be required to take adequate measures.

0.3 Notices and Approvals

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 0 Introduction

0.3 Notices and Approvals, cont'd.

DECLARATION OF CONFORMITY

We,

Intermec Printer AB

Idrottsvägen 10

Box 123

S-431 22 Mölndal

Sweden

declare under our sole responsibility

1

that the product

EasyCoder 301

to which this declaration relates

is in conformity with the following standards

Electrical Safety: EN 60950

EMC Emissions: EN 50081-1:92

(EN 55022:94, class B, EN 61000-3-2:95)

EMC Susceptibility: EN 50082-1:92

(IEC 801-2:84, IEC 801-3:84, IEC 801-4:88)

following the provisions of Directives

89/336/EEC and 73/23/EEC

Mölndal 1998-02-02

...................................................................

Hans Lindén

President

1

/. Intermec assumes no responsibility as regards fulfilling the CE Directive if the printer is

handled, modified or installed in other manners than those described in Intermec's manuals.

Intermec EasyCoder 301 – Service Manual Ed. 3

6

Chapter 1

EasyCoder 301

Model #

1-301020-11

Serial #

110-120/220-240V 4/2A 60/50Hz

INTERMEC PRINTER AB, SWEDEN

MADE IN IRELAND

00021

This equipment complies with the requirements for a Class A computing device in FCC Rules

Part 15 Subpart J. Operation of this device in a residential area may cause harmful interference

requiring the user to take whatever steps may be necessary to correct the interference.

Voltage label on rear plate

(hidden)

1. Models and Options

1.1 Identification

The EasyCoder 301 comes in a standard model for direct thermal

and thermal transfer printing and a LinerLess model for direct

thermal printing on standard or linerless direct thermal paper. Both

have a printhead density of 8 dots/mm (203.2 dots/inch). The

standard model has an internal backing paper rewind unit for peel-

off operation and can be fitted with an optional paper cutter,

facilities that har no available for the LinerLess model.

All printers are delivered from factory preset for either 115 or 230

V AC and with power cords according to European 230V, Great

Britain 230V, or US/Canadian 115V standards. The preset voltage

is indicated by a label on the printer's rear plate.

The printer voltage can be altered by the service technician by

moving a strap on the CPU board and exchanging the power cord

and the voltage label.

European type

230 V mains plug

US/Canadian type

115 V mains plug

GB type

230 V mains plug

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 1 Models and Options

1.2 Specifications

Print Technique (std. model) Direct Thermal/Thermal Transfer

Print Technique (LinerLess model) Direct Thermal on standard and Linerless media

Print Resolution 8 dots/mm (203.2 dots/inch)

Quick-mount Printhead Yes

Maximum Print Width 104 mm (4.09")

Maximum Media Width 114 mm (4.5")

Smooth Fonts Yes

Print Directions 4

Maximum Internal Paper Roll Diameter 152 mm (6")

Maximum Ribbon Length ~200 M (656 feet)

Dimensions (W x D x H) 235.5 x 352.9 x 169.3 mm (9.27 x 13.89 x 6.67 ")

Weight (excluding media & options) 4.7 kgs (10.3 lbs)

Ambient Operating Temperature +5°C – +40°C (+41°F – +104°F)

Humidity 20 –80% non-condensing

Sound Emission Level < 60 dB (A)

Microprocessor 32 bit

Firmware Intermec EasyCoder 301 Direct Protocol 2.00

Label and Ribbon End Sensors Yes

Mains Voltage 115/230VAC (+10%/-15%) 4/2A, 60/50Hz Build option

PFC Regulation IEC 61000-3-2

Maximum Power Consumption Stand-by 30W; Typical label 70W; Maximum 250W

Communications Interface Standard 1 x RS 232C Serial and 1 x Centronics Parallel

Print Speed (tear off) 100 or 150 mm/sec (4 or 6 inches/sec)

Print Speed (peel off/roll Ø 152 mm) 100 mm/sec (4 inches/sec) Recommended

Print Speed (LTS enabled) 100 mm/sec (4 inches/sec) F/W restricted

Bar Code Generators 37

On-board Flash EPROMs 2 x 512 kbytes

On-Board RAM Memory 512 kbytes

RS 232C Cable Optional

Centronics Parallel Cable Optional

Real Time Clock (RTC) Optional

Label Taken Sensor (LTS) Fitted

Paper Cutter Optional std. model only

Scalable Fonts Built-in

Memory Card Slot 1 PCMCIA 5V Type 3, or 2 PCMCIA 5V Type 1 or 2

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 1 Models and Options

1.3 Measures

32.2 mm (1.27")

174 mm (6.85")

235.5 mm (9.27")

169.3 mm (6.67")

R 214.5 mm (8.45")

15 mm (0.59")

16 mm (0.62")

33 mm (1.30")

285 mm (11.22")

352.9 mm (13.89")

R 177.8 mm (7.00")

An optional paper cutter increases the printer's total length to 396 mm (15.6").

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 2

2. Covers

2.1 User Cover

Description

The user cover – like the other covers, the centre-line wall and the

bottom plate – is made of an extremely rugged composite material

and attached to the bottom plate by means of two moulded hinges.

The user cover gives access to the media compartment where the

print mechanism, the internal paper supply, the media take-up unit

1

,

and the transfer ribbon supply

1

are located.

On the inside of the user cover is a label illustrating how to load the

media and ribbon

1

for various modes of operation and containing

important information on printhead and transfer ribbons

1

.

The user cover is attached to the bottom plate using two moulded

hinges and is kept closed by a large circular release button at the top

of the printer.

Replacement

• Open the user cover.

• At one hinge at the time, use your thumb to firmly press the user

cover upwards so the shaft inside the hinge disengages from the

bottom plate moulding. The composite material is surprisingly

sturdy so there is little risk of breaking anything unless you use

some kind of tools.

• Fit the replacement cover in reverse order.

Electrics Cover

User Cover

Release Button

(user cover)

Front Cover

Release

(front cover)

1/. The thermal transfer ribbon mechan-

ism and the backing paper take up are

omitted in the LinerLess model.

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 2 Covers

Description

The front cover – like the other covers, the centre-line wall and the

bottom plate – is made of an extremely rugged composite material

and attached to the bottom plate by means of two moulded hinges.

At the top of the outer side is a self-adhesive label with a clear plastic

window for viewing the LED control lamp and a dome through

which the Feed button can be operated (also see chapter 3).

On the inside, there is light guide for the label stop sensor (LSS), see

chapter 9. The light guide is attached to pins in the front cover

moulding by means of locking washers. On the LinerLess models,

there is also a tear-off edge that enables the paper to be torn off in

an upward direction.

The front cover is kept in closed position using a snap-lock in the

centre-line wall.

Replacement

• Place the printer upside down on some soft material to avoid

scratches.

• Using a piercer, pry out the L-shaped shaft inside each hinge in

direction from the centre and out.

• Fit the replacement front cover in reverse order.

2.2 Front Cover

Front cover (completely opened).

Hinges

Light Guides for LTS

Tear-off Edge

(LinerLess model only)

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 2 Covers

2.3 Electrics Cover

Description

The electrics cover protects the CPU board and the print unit drive

motor. This compartment is off limits to the normal user because of

the risk of electric shock and also the risk of damaging components

by causing short-circuits and electrostatic discharges. The service

technician should take able precautions before removing electrics

cover by switching off the power to the printer and disconnecting

the power cord.

When working on the CPU board, take precautions to prevent

electrostatic discharges and use non-conductive tools to prevent

short-circuits.

The electrics cover is fitted to the centre-line wall by means of two

self-tapping Posidrive screws – one at the rear of the media

compartment and another in the recess for the bar code wand

interface.

Removal or Replacement

• Turn off the power and remove the power cord.

• Disconnect all interface cables at the printer's rear plate.

• Open the front and user covers.

• Remove the Posidrive screw at the rear of the media compart-

ment.

• Remove the Posidrive screw in the recess for the bar code wand

interface.

• Pull out the cover, starting by angling out the front edge and the

pushing the cover rearwards. Take care not to damage the wire-

locks on the Centronics connector on the printer's rear plate.

• Fit back the electrics cover in reverse order. Take care not to

damage the Feed button or the cables to Interface Module and the

Label Taken Sensor.

Description

The release button keeps the user cover closed. It consists of a

circular moulding with a longitudinal shaft. The shaft is fitted into

a recess at the top of the centre-line wall.

Replacement

• Remove the electrics cover as described in chapter 2.3.

• Lift the release button straight up.

• Fit the replacement button in reverse order.

2.4 Release Button

WARNING!

Before removing the electrics

cover, turn off the printer and

disconnect the power cord. High volt-

age wires and circuits inside.

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 3

3. Front and Operator Interface

3.1 Front Panel

The printer's front panel is located at the top of the front cover (also

see chapter 3.2) and comprises a clear plastic window through

which a multi-colour LED (light-emitting diode) is visible and a

dome through which the Feed button switch can be activated.

The actual LED and switch are located on the Interface Module, see

chapter 3.2.

LED Control Lamp

The control lamp indicates the following conditions:

LED shows: Meaning:

No light Power Off

Green (steady) Power On

(flashing) Busy (executing or receiving data)

(single flash) Bar code successfully read

Amber (steady) Bar code wand active (lasts max. 10 sec:s)

(momentarily) During power on

Red (steady) Bar code wand inactive

Error, e.g.:

- Printhead lifted

- Out of paper

- Out of ribbon

1

- Paper jam in cutter

1

(single flash) Bar code reading failed

Feed Button

The Feed button can be used for the following purposes:

• To feed out a blank label (before any label design has been

downloaded to the printer).

• To print a label after a label design has been downloaded to the

printer and the Feed button has been set up to work as a Print

button by means of a PRINT KEY ON command.

• To print a Test label and execute a TESTFEED operation. In this

case the Feed button must be kept pressed down during power

up. By pressing and holding the Feed button for 3 seconds after

printing the Test label, the printer will return to its default setup.

1

/. Not in the LinerLess model.

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 3 Front and Operator Interface

3.2 Interface Module

Description

The Interface Module consists of a simple printed circuit board on

which a push button switch, a multi-colour LED and a cable are

fitted. The Interface Module is fitted in rails at the front part of the

centreline wall and its cable is connected to J2 on the CPU board.

Replacement

In case of a defect Interface Module, do not try to repair it but replace

the entire module.

• Turn off the power to the printer and remove the power cord.

• Open the front cover.

• Remove the electrics cover (see chapter 2.3).

• Remove the CPU board (see chapter 11.2).

• Insert a narrow screwdriver or similar into the hole in the centre

of the Interface Module pcb and pry it out of the rails.

• Disconnect the connector from J2.

• Fit the replacement Interface Module in reverse order.

Connector J2

CPU Board

WARNING!

Before removing the electrics

cover, turn off the printer and

disconnect the power cord. High volt-

age wires and circuits inside.

Interface Module

Push Button Switch

LED Control Lamp

Intermec EasyCoder 301 – Service Manual Ed. 3

14

Chapter 3 Front and Operator Interface

3.2 Interface Module,

cont'd.

Components

Schematics

Intermec EasyCoder 301 – Service Manual Ed. 3

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Chapter 4

4. Chassis

The chassis consists of two main parts; the bottom plate and the

centre-line wall. These parts should not be separated. Being made

of the same rugged composite material as the covers, they are not

likely to break and are thus not available as spare parts.

Description

The centre-line wall separates the media and electronics compart-

ments. Most modules in the printer are fitted to the centre-line wall,

with the exception of the user and front covers.

Description

The bottom plate holds the centre-line wall with all its connected

modules, the front cover, and the user cover. It also supports the

outer end of the platen roller and the tear-off edge. On the bottom

side of the bottom plate, there are four rubber feet and a product label

(see chapter 1.1).

Rubber Feet Replacement

• Turn the printer upside down of some kind of soft material to

avoid scratches.

• Using e.g. a screwdriver, lift out the worn rubber foot.

• Insert a replacement rubber foot in the hole and press so its

shoulder engages the bottom plate.

4.1 Centre-line Wall

4.2 Bottom Plate

Intermec EasyCoder 301 – Service Manual Ed. 3

16

Chapter 5

5. Paper Supply

5.1 Internal Supply

The printer can accommodate an internal paper roll with a diameter

of max. 152 mm (6")

1

and a width of 25.4 mm – 114 mm (1 – 4.5").

The paper roll should have a core with a diameter of either 38.1 mm

(1.5") or 76.2 mm (3").

Media Hanger

The paper roll is hung on a hanger at the rear of the media

compartment. The hanger can be fitted in two positions; upper and

lower. The upper position is used for 76 mm (3") core and the lower

for 38.1 mm (1.5") core.

To loosen the hanger, turn it about 30° back and forth in any

direction and pull it out. Insert it in the hanger in the appropriate slot

and press it firmly down. Its top and bottom ends should match the

grooves in the centre-line wall.

Adjust the moveable guide so its position matches the width of the

paper roll.

38.1 mm (1.5") core

76 mm (3") core

1

/. When using a full size paper roll

(diameter = 152 mm/6") in connection

with peel-off operation, it is recom-

mended to use normal print speed (100

mm per sec./4" per sec.). No such

restrictions apply to smaller paper rolls

or full size paper rolls in connection with

tear-off operation.

Intermec EasyCoder 301 – Service Manual Ed. 3

17

Chapter 5 Paper Supply

5.1 Internal Supply,

cont'd.

Media Guides

To ensure that the paper is fed straight through the print unit, there

are two identical shafts with rollers and adjustable guide rings fitted

to the centre-line wall of the standard model and one shaft on the

LinerLess model. The upper, front one is used for the paper going

into the print unit and the rear, lower one

1

is used for the backing

paper in connection with peel-off operation.

Each roller is fitted with two guide rings. The inner, smaller one

should be in flush with the inner end of the roller, while the outer,

larger one should be adjusted according to the with of the paper web.

The roller is locked on the shaft using a circlip.

Refer to the EasyCoder 301 (LinerLess) Installation & Operation

manual for complete loading instructions.

Shaft

Inner Guide Ring

(fixed position)

Outer Guide Ring

(adjustable)

Roller

Circlip

Media Guides

1

/. Not in the LinerLess model.

Intermec EasyCoder 301 – Service Manual Ed. 3

18

Chapter 5 Paper Supply

5.2 External Supply

The user cover is provided with a slot that allows the paper supply

to be placed outside the media compartment, e.g. in the form of a

box of fan-folded tickets. For smooth operation, such a supply

should be located lower than the intake of the printer.

Measures should be taken to protect the paper from sand, dust, grit

and other hard particles which may damage the printhead or impair

the printout quality.

It is also important that such an external supply is protected against

any conditions that may harm the paper. This is especially impor-

tant in case of direct thermal paper, which may be vulnerable to

direct sunlight, heat, airborne solvents, plasticizers, grease etc.

Refer to the EasyCoder 301 (LinerLess) Installation & Operation

manual for complete loading instructions.

Intermec EasyCoder 301 – Service Manual Ed. 3

19

Chapter 6

6. Transfer Ribbon Mechanism

6.1 Description

The transfer ribbon mechanism is only found on the stanbadrd

moidel as opposed to the Linerless model. It is fitted to the centre-

line wall and consists of the following main parts:

• Ribbon unwind unit (see chapter 6.2)

• Ribbon rewind unit (see chapter 6.3)

• Ribbon/media sensor (see chapter 6.4)

• Break shaft (see chapter 6.5)

The ribbon goes from the unwind spool and under the print

mechanism, where it passes above the ribbon/media sensor. Then

it goes forward under the printhead, where it is exposed to heat from

the printhead resistor elements which melts the ink and leaves the

imprint on the receiving face material. On its way to the ribbon

rewind unit, the ribbon passes a break shaft which can be adjusted

to prevent ribbon wrinkling. Finally, the used-up ribbon is wound

up on the ribbon rewind spool.

Refer to the EasyCoder 301 Installation & Operation manual for

complete loading instructions.

Ribbon Unwind Unit

Break Shaft

Ribbon Rewind Unit

Ribbon/Media Sensor

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Intermec EasyCoder 301 User manual

Intermec EasyCoder 301 User manual

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