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.
© Copyright Intermec Printer AB 1999. All rights reserved. Published in Sweden.
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
15
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
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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
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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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