Intermec EasyCoder 501XP User manual

Service Manual

EasyCoder 501 XP

& 601 XP Bar Code

Label Printers

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, EasyLAN, Fingerprint, and LabelShop are registered trademarks of Intermec Technologies Corp. The

word Intermec, the Intermec logo, InterDriver, and PrintSet are trademarks of Intermec Technologies Corp.

Centronics is a registered trademark of Genicom Corporation.

Microsoft is a registered trademark of Microsoft Corporation.

Torx is a registered trademark of Camcar Division of Textron Inc.

TrueDoc is a registered trademark of Bitstream, Inc.

TrueType is a trademark of Apple Computer Inc.

Unicode is a trademark of Unicode Inc.

Windows is a trademark of Microsoft Corporation.

Intermec EasyCoder 501 XP & 601 XP – Service Manual

1

Chapter 0

0. Introduction

0.1 Contents

0. Introduction

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

0.2 Preface........................................................................................................4

0.3 Notices and Approvals ..............................................................................5

1. Models and Options

1.1 Identiﬁ cation..............................................................................................7

1.2 EasyCoder 501 XP Speciﬁ cations..........................................................13

1.3 EasyCoder 601 XP Speciﬁ cations..........................................................15

1.4 EasyCoder 501 XP Measures .................................................................17

1.5 EasyCoder 601 XP Measures .................................................................18

2. Front and Keyboard

2.1 Front .........................................................................................................19

2.2 Keyboard/Display ...................................................................................19

2.3 Console.....................................................................................................21

3. Hatches and Doors

3.1 Right-Hand Door.....................................................................................24

3.2 Front Hatch ..............................................................................................25

3.3 Left-Hand Cover .....................................................................................26

4. Chassis

4.1 Description...............................................................................................27

4.2 Center Section..........................................................................................28

4.3 Bottom Plate ............................................................................................28

4.4 Rear Plate.................................................................................................29

5. Media Supply

5.1 Internal Supply ........................................................................................30

5.2 External Supply .......................................................................................34

6. Label Slack Absorber

6.1 Description...............................................................................................37

6.2 Dismantling..............................................................................................39

7. Transfer Ribbon Mechanism

7.1 Description...............................................................................................40

7.2 Ribbon Supply Unit ................................................................................41

7.3 Ribbon Rewind Unit ...............................................................................43

7.4 Ribbon End Sensor..................................................................................45

8. Print Unit

8.1 Description...............................................................................................47

8.2 Platen Roller ............................................................................................53

8.3 Stepper Motor..........................................................................................56

8.4 Belts..........................................................................................................58

8.5 Belt Adjustments .....................................................................................60

8.6 Label Stop Sensor....................................................................................62

8.7 Printhead ..................................................................................................69

8.8 Headlift Sensor ........................................................................................76

8.9 Headlift Mechanism................................................................................78

8.10 Ribbon Assist Roller ...............................................................................84

8.11 Media Feed Principles.............................................................................86

9. Liner/Batch Takeup Kit

9.1 Description...............................................................................................88

9.2 Main Parts................................................................................................91

9.3 Liner/Batch Takeup Unit.........................................................................93

10. Label Taken Sensor

10.1 Description...............................................................................................95

10.2 Installation................................................................................................96

10.3 Adjustments.............................................................................................98

Intermec EasyCoder 501 XP & 601 XP – Service Manual

2

Chapter 0 Introduction

11. Cutter

11.1 Description...............................................................................................99

11.2 Controlling the Cutter .......................................................................... 100

11.3 Cleaning ................................................................................................ 100

11.4 Installation............................................................................................. 101

11.5 Spring Replacement ............................................................................. 103

12. Ribbon Low Sensor

12.1 Description............................................................................................ 104

12.2 Installation............................................................................................. 105

13. Electronics Compartment

13.1 Introduction........................................................................................... 106

13.2 Accessing the Electronics Compartment............................................ 106

13.3 Main Parts............................................................................................. 107

14. Power Supply

14.1 Description............................................................................................ 108

14.2 Components...........................................................................................110

14.3 Schematics .............................................................................................112

15. CPU Board

15.1 Description.............................................................................................114

15.2 Circuits and Straps.................................................................................115

15.3 Connectors .............................................................................................119

15.4 Special Devices .................................................................................... 120

15.5 Test Points............................................................................................. 122

15.6 Startup ................................................................................................... 123

15.7 Components.......................................................................................... 124

15.8 Schematics ............................................................................................ 125

16. Interfaces

16.1 Introduction........................................................................................... 132

16.2 Serial Communication Port "uart1:" ................................................... 133

16.3 Parallel Interface "centronics:" ............................................................ 134

16.4 Fitting Optional Interface Boards........................................................ 136

16.5 Industrial/Serial Interface Board ......................................................... 139

16.6 Double Serial Interface Board............................................................. 149

16.7 EasyLAN 100i Interface Board........................................................... 159

16.8 Industrial Interface Board .................................................................... 164

17. Troubleshooting

17.1 Diagnosing the Printer.......................................................................... 171

17.2 No Reaction at Power Up .................................................................... 173

17.3 Printer Stops Working after Startup .................................................... 174

17.4 CPU Board Failures ............................................................................. 175

17.5 Power Supply Unit Failures................................................................. 176

17.6 Console Errors...................................................................................... 177

17.7 Error Messages..................................................................................... 178

17.8 No Communication (general).............................................................. 179

17.9 No Serial Communication ................................................................... 180

17.10 No Parallel Communication ................................................................ 181

17.11 Sensor Malfunctions............................................................................. 182

17.12 Printing Troubles .................................................................................. 185

17.13 Transfer Ribbon Troubles .................................................................... 189

17.14 Liner/Batch Takeup Troubles .............................................................. 190

17.15 Cutter Troubles ..................................................................................... 191

17.16 Memory Card Troubles........................................................................ 192

Appendix 1

Intermec Shell v4.8 Overview ......................................................................... 193

Setup Mode Overview, Part 1 (FP v7.63)........................................................ 194

Setup Mode Overview, Part 2 (FP v7.63)........................................................ 195

Setup Mode Overview, Part 3 (FP v7.63)........................................................ 196

Setup Mode Overview, Part 4 (FP v7.63)........................................................ 197

Setup Mode Overview, Part 5 (FP v7.63)........................................................ 198

0.1 Contents, cont.

Intermec EasyCoder 501 XP & 601 XP – Service Manual

3

Chapter 0 Introduction

0.1 Contents, cont.

Appendix 2

Measuring the Break Torque............................................................................ 199

Appendix 3

Firmware Upgrading......................................................................................... 200

- Introduction..................................................................................................... 200

- Upgrading From a Memory Card.................................................................. 201

- Upgrading From the Host .............................................................................. 202

- Upgrading EasyLAN 100 i Firmware........................................................... 205

Intermec EasyCoder 501 XP & 601 XP – Service Manual

4

Chapter 0 Introduction

This Service Manual is intended to facilitate installation, trouble-

shooting and repair of the Intermec EasyCoder 501 XP and 601

XP in the version delivered at the date of publishing. Thus, all

information on the Intermec Fingerprint ﬁ rmware is based on ver-

sion 7.63. The on-going product improvement 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 501 XP; User's Guide

• Intermec EasyCoder 601 XP; User's Guide

• Intermec EasyCoder 501 XP/601 XP; Spare Parts Catalog

• Intermec EasyCoder 501 XP/601 XP; Installation Instructions

(for various options)

• Intermec Direct Protocol v7.50; Programmer's Guide

• Intermec Fingerprint v7.50; Programmer’s Guide

• Intermec Fingerprint v7.61; Programmer's Reference Manual

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 up to 380 VAC, 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 Intermec Fingerprint

programming language and its related standard application pro-

grams. It is also assumed that the reader has access to the standard

tools of an electronics workshop.

0.2 Preface

Intermec EasyCoder 501 XP & 601 XP – Service Manual

5

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.

0.3 Notices and Approvals

Intermec EasyCoder 501 XP & 601 XP – Service Manual

6

Chapter 0 Introduction

0.3 Notices and Approvals, cont.

Declaration of Conformity (CE)

We,

Intermec Printer AB

Idrottsvägen 10

Box 123

S-431 22 Mölndal

Sweden

declare under our sole responsibility

1

that the products

EasyCoder 501 XP

and

EasyCoder 601 XP

to which this declaration relates

are in conformity with the following standards

Electrical Safety: EN 60950

EMC Emissions: EN 50081-1:92

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

EMC Immunity: EN 50082-2:95

(EN 61000-4-2:95; EN 61000-4-3:96; ENV 50204:95;

EN 61000-4-4:95; EN 61000-4-6:96)

following the provisions of Directives

89/336/EEC and 73/23/EEC

Mölndal 1998-09-01

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

Mats Gunnarssom

President

1

/. Intermec assumes no responsibility regarding the CE Directive if the printer is

handled, modiﬁ ed, or installed in other manners than those described in the manuals.

Intermec EasyCoder 501 XP & 601 XP– Service Manual

7

Chapter 1

1. Models and Options

1.1 Identiﬁ cation

The EasyCoder 501 XP and 601 XP each come in one main

model; a combined direct thermal/thermal transfer printer with a

setup keyboard and a 12 dots/mm printhead.

EasyCoder 501 XP

EasyCoder 601 XP

Intermec EasyCoder 501 XP & 601 XP– Service Manual

8

Chapter 1 Models and Options

The printers can use any 100 to 240 VAC, 50 to 60 Hz voltage.

There is no voltage switch-over.

The machine label on the printer’s rear plate contains type, part

number, serial number, and signs of approval.

EasyCoder 501 XP

EasyCoder 601 XP

Machine Label

1.1 Identiﬁ cation, cont.

Machine Label

Intermec EasyCoder 501 XP & 601 XP– Service Manual

9

Chapter 1 Models and Options

The EasyCoder 501 XP can be ﬁ tted with a number of built-in

options:

• Paper Cutter (see Chapter 11)

• Label Taken Sensor (see Chapter 10)

• Liner/Batch Takeup Unit (see Chapter 9)

• Media Roll Retainer (see Chapter 5)

• Fan-Fold Guides Kit (see Chapter 5)

• Ribbon Low Sensor (see Chapter 12)

1.1 Identiﬁ cation, cont.

Paper Cutter

Label Taken Sensor

Liner/Batch Takeup Unit

Media Roll Retainer

Fan-Fold Guides

Ribbon Low Sensor

Intermec EasyCoder 501 XP & 601 XP– Service Manual

10

Chapter 1 Models and Options

The EasyCoder 601 XP can be ﬁ tted with a number of built-in

options:

• Paper Cutter (see Chapter 11)

• Label Taken Sensor (see Chapter 10)

• Liner Takeup Unit (see Chapter 9)

• Fan-Fold Guides Kit (see Chapter 5)

• Ribbon Low Sensor (see Chapter 12)

1.1 Identiﬁ cation, cont.

Paper Cutter

Label Taken Sensor

Liner Takeup Unit

Fan-Fold Guides

Ribbon Low Sensor

Intermec EasyCoder 501 XP & 601 XP– Service Manual

11

Chapter 1 Models and Options

All prnters are, as standard, provided with one serial RS-232 port

and one parallel Centronics port. In addition, one or two extra

interface boards can be ﬁ tted, see Chapter 16.

Finally, you may want to inspect the electronics compartment. To

do so, carefully follow the instructions in Chapter 13.

CAUTION!

Always turn off the power and remove the power

cord before opening the cover over the electronics

compartment! Dangerous voltage!

In the electronics compartment, check:

• Type of CPU board?

- Check number of Flash SIMMs.

- Check number and size of DRAM SIMMs.

• Any optional interface board ﬁ tted?

- Check type, straps, and optional circuits.

Refer to Chapters 15 and 16 for more information.

Serial Port

RS-232

Parallel Port

Centronics

Provision for

extra interface

board(s)

1.1 Identiﬁ cation, cont.

Intermec EasyCoder 501 XP & 601 XP– Service Manual

12

Chapter 1 Models and Options

If the printer is working and possible startup program can be

interrupted, the type of program in the printer can be identiﬁ ed.

Connect printer and computer, open a suitable communication

program, and start up the printer in Fingerprint’s immediate mode.

The instruction FILES allows you to check what ﬁ les the various

parts of the printer’s memory contain. The statements FONTS and

IMAGES can be used for the same purpose regarding fonts and

images. Use the VERSION$ function to check version of the Inter-

mec Fingerprint ﬁ rmware.

You can read the setup in the Setup Mode or by means of Intermec

Shell, which also allows you to print test label #5 containing the

present setup values. To enter Shell if a custom-made autoexec-ﬁ le

prevents access, lift the printhead and press any key on the printer's

keyboard (except the <Shift> key), then turn on the power while

continuing to press the key. When the Shell countdown begins,

release the key and press <Enter> to start Shell. Do not forget to

lower the printhead if you want to print for example test labels.

Refer to the User’s Guides and to Appendix 1 in this Service

Manual for more information on the Setup Mode and the Intermec

Shell startup program.

If the printer still does not work, you may need to interview the

user.

By now, you should have a fairly good idea what kind of printer

you will be working with. Compare with the list of standard fea-

tures and options on the next page.

1.1 Identiﬁ cation, cont.

Intermec EasyCoder 501 XP & 601 XP– Service Manual

13

Chapter 1 Models and Options

1.2 EasyCoder 501 XP Speciﬁ cations

Printing

Print Technique Direct Thermal & Thermal Transfer

Printhead Resolution 12 dots/mm (304.8 dots/inch)

Print Speed (variable) 100 to 300 mm/sec (4 to 12 inches/sec)

Print Width (max) 106.6 mm (4.20 inches)

Media Width (max/min) 120 mm (4.72 inches)/25.4 mm (1.00 inch)

Print Length (max) 32,767 dots = 2,730 mm/107.5 inches

1

Internal Media Roll Diameter (max) 205 mm (8 inches)

Media Roll Core Diameter 38 to 40 mm (1.5 inches) or 76 mm (3 inches)

Ribbon Length (max) 450 metres (1475 feet)

Ribbon Width (max) 110 mm (4.33 inches)

Print Directions 4

Modes of Operation

Tear Off Yes

Peel Off Optional With internal takeup unit

Internal Liner/Batch Takeup Optional With internal takeup unit

Cut Off Optional With cutter

Firmware

Operating System Fingerprint v7.63 incl. Intermec Direct Protocol

Smooth Fonts TrueDoc and TrueType fonts

Built-in scaleable fonts (std) 15 Unicode fonts

2

Built-in bar code symbologies (std) 38

Startup Program (std) Intermec Shell v4.8

Physical Measures

Dimensions (W x D x H) 275 x 480 x 238 mm (10.8 x 18.9 x 9.4 inches)

Weight (excluding media & options) 13 kg (28.7 pounds)

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

Humidity 20 to 80% non-condensing

Electronics

Microprocessor 32 bit RISC

On-board Flash SIMMs 1 to 3 (2 or 4MB each) Std. 1 x 2MB

On-board DRAM SIMMs 1 to 2 (1 x 4MB + 1 x 32MB) Std. 1 x 4MB

Real-Time Clock Yes 10+ years life

Power Supply

Input Voltage >90 to <264 VAC, 45 to 65 Hz

PFC Regulation IEC 61000-3-2

Maximum Power Consumption Continuous 175W; Peek 400W

Intermec EasyCoder 501 XP & 601 XP– Service Manual

14

Chapter 1 Models and Options

Sensors

Label Gap/Black Mark/Out of Paper Yes

Out of Ribbon Yes

Printhead Lifted Yes

Ribbon Low Option

Label Taken Option

Controls

Control Lamps 3

Display 2 x 16 character LCD w. background light

Keyboard 23 keys membrane-switch type

Beeper Yes

Data Interfaces

Serial 1 x RS-232

Parallel 1 x Centronics Parallel

Cutter Yes

Bar Code Wand Yes

Electronic Keys 2 Not used

Optional Interface Boards 1–2 Various types

Memory Card Adapter 1 Flash or SRAM card

Accessories

Automatic Paper Cutter Option

Liner/Batch Takeup Unit Option (factory installed only) For peel-off/rewind

Label Roll Retainer Option

Fan-Fold Guides Kit Option For external supply

RS-232 Cable Option

Centronics Cable Option

Double Serial Interface Board Option

EasyLAN 100i Interface Board Option Ethernet

Industrial Interface Board Option

Industrial/Serial Interface Board Option

External Alphanumeric Keyboard Option

Flash Memory Cards Option 64Mbit (8MB)

MobileLAN

®

access 2102 Kit Option Mounting kit

1

/. The maximum print length is also restricted by the amount of free DRAM memory.

2

/. Latin, Greek, and Cyrillic fonts according to Unicode standard are included.

1.2 Speciﬁ cations EasyCoder 501 XP, cont.

Intermec EasyCoder 501 XP & 601 XP– Service Manual

15

Chapter 1 Models and Options

1.3 EasyCoder 601 XP Speciﬁ cations

Printing

Print Technique Direct Thermal & Thermal Transfer

Printhead Resolution 12 dots/mm (304.8 dots/inch)

Print Speed (variable) 100 to 225 mm/sec (4 to 8.85 inches/sec)

Print Width (max) 165.3 mm (6.49 inches)

Media Width (max/min) 168 mm (6.61 inches)/76.2 mm (3.00 inch)

Print Length (max) 32,767 dots = 2,730 mm/107.5 inches

1

Internal Media Roll Diameter (max) 205 mm (8 inches)

Media Roll Core Diameter 38 to 40 mm (1.5 inches) or 76 mm (3 inches)

Ribbon Length (max) 450 metres (1475 feet)

Ribbon Width (max) 166 mm (6.54 inches)

Print Directions 4

Modes of Operation

Tear Off Yes

Peel Off Optional With internal takeup unit

Cut Off Optional With cutter

Firmware

Operating System Fingerprint v7.63 incl. Intermec Direct Protocol

Smooth Fonts TrueDoc and TrueType fonts

Built-in scaleable fonts (std) 15 Unicode fonts

2

Built-in bar code symbologies (std) 38

Startup Program (std) Intermec Shell v4.8

Physical Measures

Dimensions (W x D x H) 335 x 482 x 238 mm (13.1 x 19.0 x 9.4 inches)

Weight (excluding media & options) 15 kg (33 pounds)

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

Humidity 20 to 80% non-condensing

Electronics

Microprocessor 32 bit RISC

On-board Flash SIMMs 1 to 3 (2 or 4MB each) Std. 1 x 2MB

On-board DRAM SIMMs 1 to 2 (1 x 4MB + 1 x 32MB) Std. 1 x 4MB

Real-Time Clock Yes 10+ years life

Power Supply

Input Voltage >90 to <264 VAC, 45 to 65 Hz

PFC Regulation IEC 61000-3-2

Maximum Power Consumption Continuous 175W; Peek 400W

Intermec EasyCoder 501 XP & 601 XP– Service Manual

16

Chapter 1 Models and Options

Sensors

Label Gap/Black Mark/Out of Paper Yes

Out of Ribbon Yes

Printhead Lifted Yes

Ribbon Low Option

Label Taken Option

Controls

Control Lamps 3

Display 2 x 16 character LCD w. background light

Keyboard 23 keys membrane-switch type

Beeper Yes

Data Interfaces

Serial 1 x RS-232

Parallel 1 x Centronics Parallel

Cutter Yes

Bar Code Wand Yes

Electronic Keys 2 Not used

Optional Interface Boards 1–2 Various types

Memory Card Adapter 1 Flash or SRAM card

Accessories

Automatic Paper Cutter Option

Liner Takeup Unit Option (factory installed only) For peel-off operation

Fan-Fold Guides Kit Option For external supply

RS-232 Cable Option

Centronics Cable Option

Double Serial Interface Board Option

EasyLAN 100i Interface Board Option Ethernet

Industrial Interface Board Option

Industrial/Serial Interface Board Option

External Alphanumeric Keyboard Option

Flash Memory Cards Option 64Mbit (8MB)

MobileLAN

®

access 2102 Kit Option Mounting kit

1

/. The maximum print length is also restricted by the amount of free DRAM memory.

2

/. Latin, Greek, and Cyrillic fonts according to Unicode standard are included.

1.3 Speciﬁ cations EasyCoder 601 XP, cont.

Intermec EasyCoder 501 XP & 601 XP– Service Manual

17

Chapter 1 Models and Options

1.4 EasyCoder 501 XP Measures

201 mm (7.91")

238 mm

(9.37")

R 285 mm

(11.22")

120 mm (4.72")135.4 mm (5.33")

275 mm (10.83")

68.8 mm

(2.71")

Dot No. 0

79 mm

(3.11")

363 mm (14.29")

481.5 mm (18.96")

R 139 m

m

(5.47")

20 mm

(0.79")

20 mm

(0.79")

30 mm

(1.18")

186 mm

(7.32")

12 mm

(0.47")

37 mm

(1.46")

Paper slot

An optional paper cutter increases the printer’s total length by 28 mm (1.1 inches).

At least 90 mm (3.5 inches) of free space behind the printer is required for the connectors,

and for inserting and removing a memory card.

Intermec EasyCoder 501 XP & 601 XP– Service Manual

18

Chapter 1 Models and Options

1.5 EasyCoder 601 XP Measures

An optional paper cutter increases the printer’s total length by 28 mm (1.1 inches).

At least 90 mm (3.5 inches) of free space behind the printer is required for the connectors,

and for inserting and removing a memory card.

259 mm (10.20")

238 mm

(9.37")

R 323 mm

(12.72")

168 mm (6.61")135.4 mm (5.33")

335 mm (13.18")

68.8 mm

(2.71")

Dot No. 0

79 mm

(3.11")

363 mm (14.29")

481.5 mm (18.96")

R

139 m

m

(5.47")

20 mm

(0.79")

20 mm

(0.79")

30 mm

(1.18")

186 mm

(7.32")

12 mm

(0.47")

38 mm

(1.50")

Paper slot

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