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EasyCoder 601XP

Intermec EasyCoder 601XP, EasyCoder 501XP User manual

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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.
© Copyright Intermec Printer AB, 2002. All rights reserved. Published in Sweden.
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
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
Paper slot
/