Intermec EasyCoder PC4 User manual

Service Manual

EasyCoder PC4

Bar Code Label

Printer

Intermec Technologies Corporation

Corporate Headquarters

6001 36th Ave. W.

Everett, WA 98203

U.S.A.

www.intermec.com

e information contained herein is proprietary and is provided solely for the purpose of allowing

customers to operate and/or service Intermec manufactured equipment and is not to be released,

reproduced, or used for any other purpose without written permission of Intermec.

Information and speciﬁcations in this manual are subject to change without notice.

EasyCoder, EasyLAN, Fingerprint, and LabelShop are registered trademarks of Intermec Tech

-

nologies Corp. e word Intermec, the Intermec logo, InterDriver, and PrintSet are trademarks of

Intermec Technologies Corp.

e name Centronics is wholly owned by GENICOM Corporation.

Microsoft is a registered trademark of Microsoft Corporation.

Windows is a trademark of Microsoft Corporation.

roughout this manual, trademarked names may be used. Rather than put a trademark (™) symbol

in every occurrence of a trademarked name, we state that we are using the names only in an editorial

fashion, and to the beneﬁt of the trademark owner, with no intention of infringement.

Intermec EasyCoder PC4—Service Manual iii

Preface

Contents

About is Manual ...............................................................................................................v

Notices and Approvals ..........................................................................................................

vi

1

Models and Options 1

1.1 Models............................................................................................................................ 2

1.2 Options ...........................................................................................................................

3

1.3 EasyCoder PC4 Speciﬁcations ........................................................................................

4

1.4 EasyCoder PC4 Measures ...............................................................................................

6

2

Main Parts 9

2.1 Taking the Printer Apart ................................................................................................10

2.2 Reassembling the Printer ...............................................................................................

10

2.3 Exploded View ..............................................................................................................

11

3

Top Cover 13

3.1 Description................................................................................................................... 14

3.2 Tear-Oﬀ Plate ................................................................................................................

15

4

Print Frame 17

4.1 Description.......................................................... .........................................................18

4.2 LED and Feed Switch ...................................................................................................

19

4.3 Top Cover Locks ...........................................................................................................

21

4.4 Base Lock Spring Hooks ...............................................................................................

21

4.5 Printhead ......................................................................................................................

22

4.6 Ribbon End Sensor .......................................................................................................

25

4.7 Label Gap Sensor (Emitter) ...........................................................................................

27

4.8 Ribbon Feed Mechanism ..............................................................................................

28

5

Base Frame 33

5.1 Main Parts..................................................................................................................... 34

5.2 Main Board ...................................................................................................................

35

5.3 Platen Roller .................................................................................................................

36

5.4 Peel-Oﬀ Mechanism ......................................................................................................

37

5.5 Motor assy ....................................................................................................................

39

5.6 Media Guides ................................................................................................................

40

5.7 Base Locks ....................................................................................................................

41

5.8 Label Gap/Black Mark Sensors ......................................................................................

43

5.9 Media Spindle ...............................................................................................................

45

6

Bottom Cover 47

6.1 Bottom Cover ...............................................................................................................48

iv Intermec EasyCoder PC4—Service Manual

Preface

7

Main Board 49

7.1 Description................................................................................................................... 50

7.2 Accessing the Main Board .............................................................................................

51

7.3 Connections ..................................................................................................................51

7.4 Test Points .....................................................................................................................

52

7.5 Block Diagram ..............................................................................................................

54

7.6 Internal Memory ...........................................................................................................

55

7.7 Schematics ....................................................................................................................56

8

Power Supply 61

8.1 Description.................................................................................................................... 62

9

Memory Cartridge (option) 63

9.1 Description................................................................................................................... 64

9.2 Memory Sizes ................................................................................................................

65

9.3 Schematics ....................................................................................................................66

10

Starting Up 67

10.1 Normal Mode .............................................................................................................68

10.2 Test Mode ...................................................................................................................

69

10.3 Dump Mode ...............................................................................................................

70

11

Firmware Upgrading 71

11.1 Requirements ..............................................................................................................72

11.2 Step-by Step Instructions ............................................................................................

73

12

Troubleshooting 75

12.1 Checklist..................................................................................................................... 76

Intermec EasyCoder PC4—Service Manual v

Preface

About This Manual

is Service Manual is intended to facilitate installation, troubleshooting

and repair of the Intermec EasyCoder PC4 in the version delivered at the

date of publishing. us, all information on the ESim ﬁrmware is based on

version 6.xx. e on-going product improvement can be followed in the

Technical Bulletins published at the Intermec Knowledge Center.

is Service Manual is supplemented by the following publications, which

the service technician also should keep easily available in their latest ver

-

sions:

• Intermec EasyCoder PC4, Quick Start Guide (multilingual)

• Intermec EasyCoder PC4, User’s Guide

• Intermec EasyCoder PC4, Spare Parts Catalog

• ESim v6.xx, Programmer’s Reference Manual

Please note that the operations described in this manual only should be car

-

ried out by skilled and authorized personnel with proper training and full

understanding of written English. Moving parts may cause harm, if incor

-

rectly manipulated.

It is assumed that the reader possesses adequate skills in mechanics and

electronics and is familiar with the ESim protocol and its related standard

application programs. It is also assumed that the reader has access to the

standard tools of an electronics workshop.

vi Intermec EasyCoder PC4—Service Manual

Preface

FCC Notice (United States of America)

WARNING

is equipment generates, uses, and can radiate radio frequency energy

and if not installed and used in accordance with the instructions manual,

may interfere with radio communications. It has been tested and found to

comply with the limits for a Class A computing device pursuant to Sub

-

part J of Part 15 of FCC Rules, which are designed to provide reasonable

protection against such interference when operated in a commercial envi

-

ronment. 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 the appropriate measures needed to correct the problem.

DOC Notice (Canada)

Canadian Dept. of Communication

REGULATIONS COMPLIANCE

(DOC-A)

is digital apparatus does not exceed the class A limits for radio noise

emissions from a digital apparatus as set out in the radio interference regu

-

lations 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 dépas-

sant 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

is 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.

Notices and Approvals

Intermec EasyCoder PC4—Service Manual 1

1

Models and Options

is chapter provides information on the various models of the EasyCoder

PC4 and contains speciﬁcations and physical measures.

2 Intermec EasyCoder PC4—Service Manual

Chapter 1—Models and Options

1.1 Models

ere are two main models of the EasyCoder PC4; one dedicated direct

thermal (DT) model and one dual-capable direct thermal/thermal transfer

(TTR) model. Both models are based on a common double clam-shell

mechanical platform and have the same type of electronics, so except from

the fact that the direct thermal model has no transfer ribbon mechanism,

there are very few diﬀerences.

Both models are available with two diﬀerent printheads; one with a density

of 203.2 dots per inch (8 dots per mm) and a maximum print width of 4.1

inches (104 mm), and another with a density of 300 dots per inch (11.81

dots per mm) and a maximum print width of 4.02 inches (102.2 mm).

Since there is no need to open the top cover in the DT model, the top

cover locks are cut oﬀ in ﬂush with the bottom of the print frame.

e machine label, which provides information on model, part number,

serial number, etc. is attached to the bottom of the base frame.

e EasyCoder PC4 has a separate power supply unit that delivers 24

VDC to the printer's main board, where it is transformed to the various

voltages required by the printhead, motor, and logics (see Chapter 8.1).

Thermal transfer

mechanism

(omitted in DT model)

Printhead

Top cover locks

(differ in DT and

TTR models)

Print frame

Top cover

Base Frame

Bottom Cover

Intermec EasyCoder PC4—Service Manual 3

Chapter 1—Models and Options

e power supply unit (PSU) accepts 100 to 240 VAC/50 to 60 Hz. e

power supply has a standard 2-pin input voltage socket, so various types of

power cords can be used according to local voltages and standards.

e power supply has a ﬁxed 1.5 m (4.9 ft) long cable that is connected to

the printer’s rear plate.

1.2 Options

e available options for the EasyCoder PC4 are memory cartridges, USB,

serial and parallel interface cables, a keyboard/display unit, a paper cutter,

a battery unit and an assortment of power cords. Refer to the EasyCoder

PC4, Spare Parts Catalog

or Spare Parts List for updated information.

4 Intermec EasyCoder PC4—Service Manual

Chapter 1—Models and Options

1.3 EasyCoder PC4 Speciﬁcations

Printing

Print Technique ermal Transfer and/or Direct ermal

Printhead Resolution

203.2 dpi (8 dots/mm) or

300 dpi (11.81 dots/mm)

Print Speed (selectable) 30, 40, 50, 75 or 100 mm/sec.

(1.2,1.6, 2, 3 or 4 in/sec.)

Print Width (max) at 203.2 dpi 104 mm (4.1 inches) = 832 dots

Print Width (max) at 300 dpi

102.2 mm (4.02 inches) = 1208 dots

Print Length (min/max) at 203.2 dpi 6.35/472.5 mm (0.25/18.6 inches) Standard (no cartridge)

Print Length (min/max) at 300 dpi

6.35/220.0 mm (0.25/8.66 inches) Standard (no cartridge)

Media Width (min/max)

25.4 to 118 mm (1.00 to 4.65 inches)

Media ickness (min)

0.06 mm (0.003 inches)

Media ickness, rolls (max)

0.15 mm (0.006 inches)

Media ickness, fan-folds (max) 0.17 mm (0.006 inches)

Media Roll Diameter (max) 127 mm (5.0 inches)

Media Roll Core Diameter 25.4 or 38.1 mm (1.0 or 1.5 inches)

Ribbon Width (min/max)

33 to 110 mm (1.33 to 4.33 inches)

Ribbon Roll Diameter, Outer (max)

41 mm (1.6 inches)

Ribbor Roll Core Diameter, Inner 13 mm (0.5 inches)

Print Directions 4

Modes of operation

Tear Oﬀ (Straight-through) Yes

Peel Oﬀ (Self-strip) Yes

Firmware

Operating System Intermec ESim v6.xx

Fonts 5 resident

Font Magniﬁcation Horizontal max 8 times, vertical max 9 times

Built-in Bar Code Symbologies

33

Physical Measures

Dimensions (W

× L × H) 230 × 257 × 167 mm

(9.06 × 10.11 × 6.58 inches)

Weight (excluding PSU and media) Approx. 2.3 kg (5 pounds) Depending on model

Ambient Operating Temperature

+5°C to +40°C (+41°F to +104°F)

Ambient Storage Temperature

-20°C to +50°C (-4°F to +122°F)

Humidity

10 to 90% non-condensing

Electronics

Microprocessor 16-bit 20 MHz (16M of address space)

On-board Flash memory 1024K (774K ﬁrmware, 250K available to user)

On-board RAM memory 2048K (576K ﬁrmware, 1050K print buﬀer)

Power Supply Unit Separate unit

Input Voltage 100 to 240 VAC, 50 to 60Hz, 1.9A

Output Voltage 24 VDC, 3.0A

Input Voltage (mobile applications) 23.5 VDC ± 0.5V, 6A peak No PSU connected

Intermec EasyCoder PC4—Service Manual 5

Chapter 1—Models and Options

Sensors

Label Gap/Black Mark/Out of Paper Yes

Label Taken Yes Not with cutter

Print Frame Open/Closed Yes

Ribbon End Yes TTR model only

Head up (DOOR L & R) Yes

Controls

Control Lamps

1 Tri-colored LED

Feed Button

1

Data Interfaces

Serial

1 × RS-232 + 1 × USB(v1.1)

Parallel

1 × Centronics

Accessories and Options

Parallel Interface Cable Standard

RS-232 Cable Option

Memory Cartridge Option 1MB ﬂash

Keyboard/Display Unit Option

Paper Cutter Option

V-spring for stiﬀ/thick media Option

>150µm/5.9 mils

Mobile Battery Unit Option

Battery Pack Option

Battery Charger Option

USB cable Option

6 Intermec EasyCoder PC4—Service Manual

Chapter 1—Models and Options

259 mm (10.20 in)

166 mm (6.54 in)

314 mm (12.36 in)

333 mm (13.11 in)

1.4 EasyCoder PC4 Measures

Side View

Intermec EasyCoder PC4—Service Manual 7

Chapter 1—Models and Options

50 mm (1.97 in) 133 mm (5.24 in)

77 mm (3.03 in)

Front View

Rear View

8 Intermec EasyCoder PC4—Service Manual

Chapter 1—Models and Options

230 mm (9.06 in)

188 mm (7.40 in

)

39 mm (1.54 in)

17 mm (0.67 in)

9 mm (0.35 in)

168 mm (6.61 in)

209 mm (8.83 in)

150 mm (5.91 in)

4.6 mm (0.18 in

)

184 mm (7.24 in)

154 mm (6.06 in

)

Top View

Bottom View

Intermec EasyCoder PC4—Service Manual 9

2

Main Parts

is chapter shows the printer’s main parts and explains how the printer is

taken apart and reassembled. Each of the main parts is described in more

detail in the chapters that follow.

10 Intermec EasyCoder PC4—Service Manual

Chapter 2—Main Parts

2.1 Taking the Printer Apart

e EasyCoder PC4 is a so called double clam-shell design, where the print

frame and the top cover are hinged to a base frame.

e bottom part of the base frame is enclosed by the bottom cover, which

is held by four Phillips screws. Once the bottom cover has been removed,

the two pairs of bolts and E-rings that hold the base frame, the print frame,

and the top cover become accessible. You will also need to disconnect a

number of cables from the main board.

In most cases, you do not need to dismantle the base frame, print frame,

and top cover.

In the illustration in Chapter 2.3, all cables have been omitted. Detailed

descriptions of the main parts and their sub-assemblies can be found in

Chapters 3 to 7.

All screws are Phillips-type of various sizes.

2.2 Reassembling the Printer

Reassemble the printer in reverse order. Refer to Chapter 7.3 for a connec-

tion diagram, which helps you put all the cables back correctly. When put

-

ting the printer back into the bottom cover, tilt it a little so the rear plate is

inserted ﬁrst, then carefully manipulate the front part in place. Secure the

assembly with the four Phillips screws.

Intermec EasyCoder PC4—Service Manual 11

Chapter 2—Main Parts

2.3 Exploded View

Top Cover

Print Frame

Base Frame

Bottom Cover

Bolts

E-ring

12 Intermec EasyCoder PC4—Service Manual

Chapter 2—Main Parts

Intermec EasyCoder PC4—Service Manual 13

3

Top Cover

is chapter describes the parts of the top cover and explains how to

replace the tear-oﬀ plate.

14 Intermec EasyCoder PC4—Service Manual

Chapter 3—Top Cover

3.1 Description

e top cover encloses the print frame. It is attached to the base frame

using the same pair of bolts and E-rings as the print frame. e top cover

and the print frame opens together when the base locks on either side of

the printer are pressed. en the top cover can be released from the print

frame by pressing the two green locks at either side of the print frame, as

shown below. Note that in case of a PC4 DT printer, the locks are cut oﬀ

and you will need to insert a ﬂat screwdriver or similar to release the locks.

Base locks

Top cover locks

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Intermec EasyCoder PC4 User manual

Intermec EasyCoder PC4 User manual

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