Intermec EASYCODER PD4 User manual

Service Manual

EasyCoder PD4

Bar Code Label

Printer

Intermec Technologies Corporation

Corporate Headquarters

6001 36th Ave. W.

Everett, WA 98203

U.S.A.

www.intermec.com

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

customers to operate and service Intermec-manufactured equipment and is not to be released, repro-

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

Information and speciﬁ cations contained in this document are subject to change without prior notice

and do not represent a commitment on the part of Intermec Technologies Corporation.

The word Intermec, the Intermec logo, Norand, ArciTech, CrossBar, Data Collection Browser,

dcBrowser, Duratherm, EasyCoder, EasyLAN, Enterprise Wireless LAN, EZBuilder, Fingerprint,

i-gistics, INCA (under license), InterDriver, Intermec Printer Network Manager, IRL, JANUS,

LabelShop, Mobile Framework, MobileLAN, Nor*Ware, Pen*Key, Precision Print, PrintSet, Route-

Power, TE 2000, Trakker Antares, UAP, Universal Access Point, and Virtual Wedge are either trade-

marks or registered trademarks of Intermec Technologies Corporation.

Throughout this manual, trademarked names may be used. Rather than put a trademark (™ or ®)

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

editorial fashion, and to the beneﬁ t of the trademark owner, with no intention of infringement.

There are U.S. and foreign patents pending.

The name Centronics is wholly owned by GENICOM Corporation.

Windows is a trademark of Microsoft Corporation.

Intermec EasyCoder PD4—Service Manual iii

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 inter-

ference 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.

EMS and EMI Compliance Statement

This equipment has been tested and passed with the requirements relating to electromagnetic com-

patibility based on the standards EN50081-1 (EN55022 CLASS A) and EN61000-4-2/-3/-4/-5/-

6/-8/-11 (IEC Teil 2,3,4). The equipment also tested and passed in accordance with the European

Standard EN55022 for the both Radiated and Conducted emissions limits.

iv Intermec EasyCoder PD4—Service Manual

Intermec EasyCoder PD4—Service Manual v

Contents

Before You Begin .................................................................................................................vii

Safety Summary .................................................................................................vii

Safety Icons ......................................................................................................viii

Global Services and Support ................................................................................................ ix

Warranty Information .........................................................................................ix

Web Support ......................................................................................................ix

Telephone Support .............................................................................................ix

Related Documents ..............................................................................................................ix

About this Manual ................................................................................................................ x

1

Models and Options

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

1.2 Options ......................................................................................................................3

1.3 Technical Speciﬁ cations ..............................................................................................5

2

Front Panels

2.1 Front Panel (no display)........... ..................................................................................8

2.2 Front Panel (with display) .........................................................................................9

2.3 Replacing the Front Panel ........................................................................................10

2.4 Bottom Right-Hand Panel .......................................................................................11

2.4 Console pcb. ............................................................................................................12

3

Side Panels

3.1 Right-Hand Door ....................................................................................................16

3.2 Left-Hand Panel .......................................................................................................17

4

Chassis

4.1 Chassis...................................................................................................................... 20

4.2 Rear Plate .................................................................................................................21

5

Media Supply

5.1 Media Supply Post ...................................................................................................24

6

Transfer Ribbon Mechanism

6.1 Ribbon Module ........................................................................................................28

6.2 Ribbon Module Belt ................................................................................................29

6.3 Ribbon Supply and Rewind Units ............................................................................30

6.4 Ribbon Out Sensor ..................................................................................................31

6.5 Ink Position Knob ....................................................................................................32

7

Print Mechanism

7.1 Print Unit ................................................................................................................34

7.2 Motor, Pulleys, and Belts ..........................................................................................35

7.3 Platen Module ..........................................................................................................37

7.4 Media Guides ...........................................................................................................38

7.5 Label Gap Sensor Module ........................................................................................39

vi Intermec EasyCoder PD4—Service Manual

Contents

7.6 Headlift Sensor ........................................................................................................41

7.7 Printhead Module ....................................................................................................42

8

Rewinder Module

8.1 Rewinder Module ....................................................................................................50

9

Strip Module

9.1 Strip Module ............................................................................................................54

10

Cutter

10.1 Cutter....................................................................................................................... 58

11

Switching Power Module

11.1 Switching Power Module ..........................................................................................64

12

Main Board

12.1 Description...............................................................................................................68

12.2 Replacement ............................................................................................................69

12.3 Connections .............................................................................................................70

12.4 Components ............................................................................................................73

12.5 Test Points ................................................................................................................74

12.6 Schematics ...............................................................................................................75

12.7 Memory Expansion Card .........................................................................................83

13

Interfaces

13.1 RS-232 Serial Interface .............................................................................................86

13.2 USB Serial Interface .................................................................................................87

13.3 Centronics Parallel Interface .....................................................................................88

14

Troubleshooting

14.1 Error Handling ....................................................................................................... 90

14.2 Troubleshooting Check List .................................................................................... 91

14.3 No Reaction at Power Up ........................................................................................93

14.4 Error During Printing ............................................................................................. 95

14.5 No Printing ............................................................................................................. 96

14.6 Printing Partly Missing along the Feed Direction .................................................... 97

14.7 Printout not in Desired Position .............................................................................. 98

A

Firmware Upgrading

Requirements..................................................................................................................... 102

Instructions .......................................................................................................................102

Before You Begin

Intermec EasyCoder PD4—Service Manual

vii

Before You Begin

This section provides you with safety information, technical support infor-

mation, and sources for additional product information.

Safety Summary

Your safety is extremely important. Read and follow all warnings and cau-

tions in this document before handling and operating Intermec equipment.

You can be seriously injured, and equipment and data can be damaged if

you do not follow the safety warnings and cautions.

Do not repair or adjust alone

Do not repair or adjust energized equipment alone under any circum-

stances. Someone capable of providing ﬁ rst aid must always be present for

your safety.

First aid

Always obtain ﬁ rst aid or medical attention immediately after an injury.

Never neglect an injury, no matter how slight it seems.

Resuscitation

Begin resuscitation immediately if someone is injured and stops breath-

ing. Any delay could result in death. To work on or near high voltage, you

should be familiar with approved industrial ﬁ rst aid methods.

Energized equipment

Never work on energized equipment unless authorized by a responsible

authority. Energized electrical equipment is dangerous. Electrical shock

from energized equipment can cause death. If you must perform autho-

rized emergency work on energized equipment, be sure that you comply

strictly with approved safety regulations.

Before You Begin

viii Intermec EasyCoder PD4—Service Manual

Safety Icons

This section explains how to identify and understand dangers, warnings,

cautions, and notes that are in this document. You may also see icons that

tell you when to follow ESD procedures.

A warning alerts you of an operating procedure, practice, condition, or

statement that must be strictly observed to avoid death or serious injury

to the persons working on the equipment.

A caution alerts you to an operating procedure, practice, condition, or

statement that must be strictly observed to prevent equipment damage

or destruction, or corruption or loss of data.

This icon appears at the beginning of any procedure in this manual

that could cause you to touch components (such as printed circuit

boards) that are susceptible to damage from electrostatic discharge

(ESD). When you see this icon, you must follow standard ESD guide-

lines to avoid damaging the equipment you are servicing.

Note: Notes either provide extra information about a topic or contain spe-

cial instructions for handling a particular condition or set of circumstances.

Before You Begin

Intermec EasyCoder PD4—Service Manual

ix

Global Services and Support

Warranty Information

To understand the warranty for your Intermec product, visit the Intermec

web site at

http://www.intermec.com and click Service & Support. The

Intermec Global Sales & Service page appears. From the Service & Support

menu, move your pointer over Support, and then click Warranty.

Web Support

Visit the Intermec web site at http://www.intermec.com to download

our current documents in PDF format. To order printed versions of the

Intermec manuals, contact your local Intermec representative or distribu-

tor.

Visit the Intermec technical knowledge base (Knowledge Central) at

http://intermec.custhelp.com to review technical information or to request

technical support for your Intermec product.

Telephone Support

Contact your local Intermec representative. To search for your local repre-

sentative, from the Intermec web site, click Contact.

Related Documents

This table contains a list of related Intermec documents and their part

numbers.

Document Title Part Number

EasyCoder PD4 User´s Guide 1-960614-00

Intermec ESim v5.00 Programmer´s Reference Manual 1-960615-00

EasyCoder PD4 Spare Parts Catalog 1-960617-00

The Intermec web site at http://www.intermec.com contains our current

documents that you can download in PDF format. To order printed ver-

sions of the Intermec manuals, contact your local Intermec representative

or distributor.

Before You Begin

x Intermec EasyCoder PD4—Service Manual

About This Manual

This Service Manual is intended to facilitate installation, troubleshooting

and repair of the Intermec EasyCoder PD4 printers in the versions deliv-

ered at the date of publishing. Thus, all information on the Intermec ESim

ﬁ rmware is based on version 5.00. The on-going product improvement can

be followed in the Printer Technical Bulletins from Intermec.

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. The printers contain wires and circuits

with high 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 mechanics and

electronics and is familiar with the Intermec ESim protocol. It is also

assumed that the reader has access to the standard tools of an electronics

workshop.

All screws are Phillips type (PH1 or PH2).

Intermec EasyCoder PD4—Service Manual 1

1

Models and Options

This chapter describes the various models of the EasyCoder PD4 printer

family, describes the option, and provides technical speciﬁ cations.

2 Intermec EasyCoder PD4—Service Manual

Chapter 1—Models and Options

1.1 Models

The EasyCoder PD4 comes in three main models:

• Printer without display and 200 dpi printhead density

• Printer with display and 200 dpi printhead density

• Printer with display and 300 dpi printhead density

EasyCoder PD4 without display (200 dpi)

EasyCoder PD4 with display (200 or 300 dpi)

Intermec EasyCoder PD4—Service Manual 3

Chapter 1—Models and Options

1.2 Options

The options for the EasyCoder PD4 depend on the printer model:

• External Keyboard/Display Unit (all models)

• EasyLAN 10 External Ethernet Adapter (all models)

• Memory Expansion Board 2MB (display models only)

• Cutter (display models only)

• Rewinder (display models only)

Keyboard/Display Unit

2MB Memory Expansion Card

4 Intermec EasyCoder PD4—Service Manual

Chapter 1—Models and Options

EasyCoder PD4 with cutter

EasyCoder PD4 with rewinder

(right-hand door not shown)

Intermec EasyCoder PD4—Service Manual 5

Chapter 1—Models and Options

1.3 Technical Specifications

Printing

Print Technique Direct Thermal/Thermal Transfer

Printhead Resolutions 8 dots/mm (203.2 dpi) or

11.81 dots/mm (300 dpi)

1

Print Speed (variable) 50.8 to 152.4 mm/sec. (2 to 6 in/sec.)

50.8 to 101.6 mm/sec. (2 to 4 in/sec.)

8 dots/mm (203.2 dpi)

11.81 dots/mm (300 dpi)

Print Width 25 to 104 mm (1 to 4.09 in)

25 to 106 mm (1 to 4.17 in) 8 dots/mm 11.81 dots/mm

Print Length (max) 1,270 mm (50 in)

558.8 mm (22 in)

8 dots/mm (203.2 dpi)

11.81 dots/mm (300 dpi)

Print Directions 4

Media

Media Width 25 to 118.0 mm (1 to 4.65 inches)

Media Roll Diameter (max) 212 mm (8.35 inches)

Media Roll Core Diameter 38.1 to 76.2 mm (1.5 to 3 in)

Media Thickness 60 µm to 250 µm (2.3 to 9.8 mils)

Transfer Ribbon

Material Wax, hybrid, or resin

Winding Ink on either inside or outside

Ribbon Width 30 to 110 mm (1.18 to 4.33 in)

Ribbon Roll Diameter (outer) 76 mm (2.99 in) Equivalent to 450 m (1,471 ft) of

ribbon at ribbon thickness 8 µm

Inner Core Diameter 25.2 to 25.6 mm (1.00 inches)

Modes of Operation

Tear-Off (Straight-through) Yes

Peel-Off (Self-strip) Optional

Cut-Off Optional

Firmware

Operating System ESim v5.xx

Latin Fonts 5 resident alphanumeric fonts.

Windows bitmap fonts can be down-

loaded.

Asian Fonts

Asian fonts can be downloaded:

GB 2312-80

Chinese Big5 level 1 & 2

KS X 11001:1992

JIS X0208:12977

Chinese

Korean

Japanese

Built-in bar code symbologies (stan-

dard)

34

Physical Measures

Dimensions (W × L × H) 276 × 454.6 × 283.0 mm

(10.85 × 17.9 × 11.2 in)

6 Intermec EasyCoder PD4—Service Manual

Chapter 1—Models and Options

Weight (excluding media and options) ≈ 13 kg (28.7 pounds)

Environment

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

Storage Temperature -20°C to +50°C (-40°F to +122°F)

Operating Humidity 30 to 85% non-condensing. Free air

Storage Humidity 10 to 90% non-condensing. Free air

Electronics

Microprocessor 16 bit

Standard Memory 2MB ﬂ ash + 2MB DRAM

Real-time Clock Yes

1

Date/time stamp

Power Supply

AC Voltage 100/240 VAC, 50 to 60 Hz

Power Consumption (approx.) Stand-by 5W; Peak 140W

Sensors

Label Gap/Black Mark/Out of Media Yes Moveable, left-aligned

Printhead Lifted Yes

Ribbon End Yes

Label taken Yes

1

Controls

Control Lamps 3; Power, Ready, and Error Bi-color

Display Yes

1

Graphic LCD with background light

Control Keys 3; Feed, Pause, and Cancel

Beeper Yes

Data Interfaces

Serial 1 x RS-232 + 1 x USB

Parallel Yes

Accessories and Options

Integral Self-strip Unit with Liner

Takeup

Option

1

For peel-off operation

Cutter Option

1

2MB Flash Memory Expansion Card Option

1

Keyboard/Display Unit Option

EasyLAN 10 External Ethernet

Adapter

Option

1

/. Models with graphic display front panel only.

Intermec EasyCoder PD4—Service Manual 7

2

Front Panels

This chapter describes the front panels for various models of the Easy-

Coder PD4 printer family.

8 Intermec EasyCoder PD4—Service Manual

Chapter 2—Front Panels

2.1 Front Panel (no display)

Description

The displayless model of the EasyCoder PD4 has a front panel moulding

with three colored LED control lamps and three control keys.

The control lamp LEDs are ﬁ tted on a console pcb which also contains the

switches for the control keys and a buzzer. An overlay provides the desig-

nations for the LEDs and keys. The overlay is covered with a transparent

plastic window. The console pcb is connected to CN22 on the main board

via a separate ﬂ at cable.

Refer to Chapter 2.3 for replacement instructions.

Flat cable

Console pcb

Dummy strip sensor

E-ring

Screw and washer (x4)

Front panel moulding

Label

Overlay

Clear window

LEDs (green-green-red)

Control keys

(Feed-Pause-Cancel)

PUSH

LCD display

Intermec EasyCoder PD4—Service Manual 9

Chapter 2—Front Panels

2.2 Front Panel (with display)

Description

The display-equipped models of the EasyCoder PD4 have a front panel

moulding with three colored LED control lamps, three control keys, and a

large graphic LCD display.

The control lamp LEDs are ﬁ tted on a console pcb which also contains

the LCD display, the switches for the control keys and a buzzer. An overlay

provides the designations for the LEDs and keys. The overlay is covered

with a transparent plastic window. The console pcb is connected to CN22

on the main board via a separate ﬂ at cable.

Refer to Chapter 2.3 for replacement instructions.

As opposed to the displayless model, there is a working strip sensor, that

can detect whether labels have been removed from the outfeed slot or not.

The strip sensor is further described in Chapter 9.

Flat cable

Console pcb

Strip sensor housing

E-ring

Screw and washer (x4)

Front panel moulding

Label

Overlay

Clear window

LEDs (green-green-red)

Control keys

(Feed-Pause-Cancel)

Strip sensor pcb

(cable not shown)

Screw (x2)

Dust protection

10 Intermec EasyCoder PD4—Service Manual

Chapter 2—Front Panels

2.3 Replacing the Front Panel

To replace the front panel, follow these steps:

1 Remove the left side panel (see Chapter 3.2).

The electronics compartment contains high voltages wires and circuitry.

Disconnect the power cord to eliminate the risk of electric shock and

short circuits.

Take standard precautions against ESD (Electrostatic Discharges)

before touching any electronics components.

2 Disconnect the ﬂ at cable from the main board.

3 From inside the electronics compartment, remove the two screws that

hold the front panel assembly at the top front of the center section.

4 Lift the front panel assembly up/out so the panel moulding disengages

the two keyholes in the center section.

5 In case of a EasyCoder PD4 with display, disconnect the strip module

cable from CN12 on the main board and remove it from the clips, ties,

and plastic spiral binding.

6 Disconnect the ﬂ at cable from the console pcb.

7 If necessary, replace the entire assembly. Individual items, except the

strip sensor assembly, are not available as spare parts.

8 Install the front panel in reverse order.

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Intermec EASYCODER PD4 User manual

Intermec EASYCODER PD4 User manual

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