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User Manual: PX4i&PX6iServiceManual
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Service Manual EasyCoder PX4i and EasyCoder PX6i Bar Code Label Printers 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, reproduced, or used for any other purpose without written permission of Intermec. Information and specifications contained in this document are subject to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation. © 2004 by Intermec Technologies Corporation. All rights reserved. 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, RoutePower, TE 2000, Trakker Antares, UAP, Universal Access Point, and Virtual Wedge are either trademarks 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 benefit 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. Kimdura is a registered trademark of Kimberly Clark. 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. Valeron is a registered trademark of Valéron Strength Films, an ITW Company. Windows is a trademark of Microsoft Corporation. Contents Contents Before You Begin................................................................................................................. vii Safety Summary ................................................................................................. vii Safety Icons ....................................................................................................... vii Global Services and Support .............................................................................viii Warranty Information ............................................................................. viii Web Support........................................................................................... viii Telephone Support.................................................................................. viii Who Should Read This Document? ........................................................ viii Related Documents................................................................................. viii Introduction ........................................................................................................................ ix 1 Models and Options 2 Front and Keyboard 3 Covers and Doors 4 Chassis 5 Media Supply 6 Label Slack Absorber 1.1 1.2 1.3 1.4 1.5 2.1 2.2 2.3 3.1 3.2 3.3 4.1 4.2 4.3 4.4 5.1 5.2 5.3 5.4 5.5 6.1 6.2 Identification..............................................................................................................2 EasyCoder PX4i Specifications ...................................................................................8 EasyCoder PX6i Specifications .................................................................................10 Measures EasyCoder PX4i ........................................................................................12 Measures EasyCoder PX6i ........................................................................................13 Front........... .............................................................................................................16 Keyboard/Display ...................................................................................................17 Console pcb. ............................................................................................................21 Right-Hand Door ....................................................................................................26 Front Door...............................................................................................................27 Left-Hand Cover ......................................................................................................28 Description ..............................................................................................................30 Center Section .........................................................................................................32 Bottom Plate ............................................................................................................32 Rear Plate .................................................................................................................33 Internal Supply ........................................................................................................36 Paper Sensor .............................................................................................................39 Three-inch Adapters .................................................................................................40 Media Roll Retainer .................................................................................................41 Fan-Fold Guides.......................................................................................................42 Description ..............................................................................................................46 Dismantling .............................................................................................................47 EasyCoder PX4i and PX6i Service Manual iii Contents 7 Transfer Ribbon Mechanism 8 Print Unit 9 Liner Takeup Kit 10 Label Taken Sensor 11 Paper Cutter 12 Electronics Compartment 13 Power Supply iv 7.1 7.2 7.3 7.4 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 9.1 9.2 9.3 10.1 10.2 10.3 10.4 11.1 11.2 11.3 11.4 11.5 11.6 Description ..............................................................................................................50 Ribbon Supply Unit .................................................................................................51 Ribbon Rewind Unit................................................................................................54 Ribbon Sensor..........................................................................................................57 Description ..............................................................................................................60 Platen Roller ............................................................................................................67 Stepper Motor ..........................................................................................................70 Belts .........................................................................................................................72 Label Stop Sensor .....................................................................................................76 Printhead .................................................................................................................84 Headlift Sensor ........................................................................................................93 Headlift Mechanism .................................................................................................96 Ribbon Assist Roller ...............................................................................................100 Media Feed Principles ............................................................................................102 Description ............................................................................................................106 Main Parts..............................................................................................................109 Liner/Batch Takeup Unit........................................................................................111 Description ............................................................................................................114 Installation .............................................................................................................115 Activating the LTS .................................................................................................116 Adjustment ............................................................................................................116 Description ............................................................................................................118 Installation .............................................................................................................119 Controlling the Cutter ...........................................................................................122 Media Load ............................................................................................................122 Servicing ................................................................................................................123 Spring Replacement ...............................................................................................124 11.1 Introduction...........................................................................................................126 11.2 Accessing the Electronics Compartment .................................................................126 11.3 Main Parts..............................................................................................................127 13.1 13.2 13.3 13.4 Description ............................................................................................................130 Replacements .........................................................................................................133 Components ..........................................................................................................134 Schematics .............................................................................................................136 EasyCoder PX4i and PX6i Service Manual Contents 14 Driver Board 15 CPU Board 16 Interfaces 17 Troubleshooting 14.1 14.2 14.3 14.4 15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.10 17.1 17.2 17.3 17.4 17.5 17.6 17.7 17.8 17.9 17.10 17.11 17.12 17.13 17.14 17.15 17.16 17.17 Description ............................................................................................................138 Replacement ..........................................................................................................138 Components ..........................................................................................................140 Schematics .............................................................................................................142 Description ............................................................................................................144 Circuits ..................................................................................................................145 Connections ...........................................................................................................150 Test Points..............................................................................................................151 Startup ...................................................................................................................152 Components ..........................................................................................................153 Schematics .............................................................................................................155 Replacing the CPU board ......................................................................................164 Introduction...........................................................................................................166 Serial Communication Port "uart1:" ......................................................................167 USB Interface.........................................................................................................168 Bar Code Wand Interface .......................................................................................169 Installing an Optional Interface Board ...................................................................170 Serial/Industrial Interface Board .............................................................................174 Double Serial Interface Board ................................................................................184 IEEE 1284 Parallel Interface Board ........................................................................194 EasyLAN Ethernet Interface Board ........................................................................198 EasyLAN Wireless Interface Board .........................................................................203 Diagnosing ............................................................................................................ 210 No Reaction at Power Up ...................................................................................... 213 Printer Stops Working after Startup....................................................................... 214 CPU Board Failures .............................................................................................. 216 Power Supply Unit Failures ................................................................................... 218 Driver Board Failures ............................................................................................ 219 Console Errors ...................................................................................................... 220 Error Messages ...................................................................................................... 222 No Communication (general) ............................................................................... 224 No Serial Communication .................................................................................... 225 No Network Communication ............................................................................... 227 Sensor Malfunctions.............................................................................................. 231 Label Stop Sensor (LSS) ................................................................................. 231 Headlift Sensor ............................................................................................... 232 Label Taken Sensor (LTS) ............................................................................... 232 Ribbon Sensor ................................................................................................ 233 Paper Sensor ................................................................................................... 233 Printing Troubles ................................................................................................... 234 Transfer Ribbon Troubles ...................................................................................... 238 Liner Takeup Troubles ........................................................................................... 240 Memory Card Troubles ......................................................................................... 241 Paper Cutter Troubles............................................................................................ 242 EasyCoder PX4i and PX6i Service Manual v Contents A Program Overviews B Firmware Upgrading C Measuring the Break Torque vi Intermec Shell Overview ...................................................................................................246 Setup Mode Overviews (Fingerprint) ...............................................................................247 Setup Mode Overviews (IPL) ............................................................................................256 Introduction......................................................................................................................262 General Principles .............................................................................................................262 Upgrading From a Memory Card ......................................................................................263 Upgrading From the Host .................................................................................................265 Measuring the Brake Torque .............................................................................................270 EasyCoder PX4i and PX6i Service Manual Before You Begin Before You Begin This section provides you with safety information, technical support information, and sources for additional product information. Safety Summary Your safety is extremely important. Read and follow all warnings and cautions 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 circumstances. Someone capable of providing first aid must always be present for your safety. First aid Always obtain first 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 breathing. Any delay could result in death. To work on or near high voltage, you should be familiar with approved industrial first 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 authorized emergency work on energized equipment, be sure that you comply strictly with approved safety regulations. 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 guidelines to avoid damaging the equipment you are servicing. Note: Notes either provide extra information about a topic or contain special instructions for handling a particular condition or set of circumstances. EasyCoder PX4i and PX6i Service Manual vii Before You Begin 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 distributor. 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 representative, from the Intermec web site, click Contact. Who Should Read This Document? This Service Manual provides you with in-depth information about the EasyCoder PX4i and PX6i printers and how to maintain, repair, and troubleshoot them. It is primarily intended for authorized service technicians. Related Documents The Intermec web site at http://www.intermec.com contains our current documents that you can download in PDF format. To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor. We recommend that the service technician keeps the following manuals easily accessible in electronic or printed form: • Intermec EasyCoder PX4i, User’s Guide (Fingerprint version) • Intermec EasyCoder PX6i, User’s Guide (Fingerprint version) • Intermec EasyCoder PX4i, User’s Guide (IPL version) • Intermec EasyCoder PX6i, User’s Guide (IPL version) • Intermec EasyCoder PX4i and PX6i, Spare Parts Catalog • Installation Instructions for various options • Intermec Direct Protocol v8.30 (or later), Programmer’s Reference Manual • Intermec Fingerprint v8.00 (or later), Tutorial • Intermec Fingerprint v8.30 (or later), Programmer’s Reference Manual • IPL Programming, Reference Manual (rev. 007 or later) • EasyLAN Interface Kit, Installation Instructions • EasyLAN Wireless Interface Kit, Installation Instructions • EasyLAN, User’s Guide • EasyLAN Network Setup, User’s Guide viii EasyCoder PX4i and PX6i Service Manual Before You Begin Introduction This Service Manual is intended to facilitate installation, troubleshooting and repair of the Intermec EasyCoder PX4i and PX6i printers in the versions delivered at the date of publishing. Thus, all information on the Intermec Fingerprint (FP) firmware is based on version 8.30 and information on the Intermec Programming Language (IPL) is based on version 2.30. The on-going product improvement can be followed in the Printer Technical Bulletins from Intermec. Note that even if the printers are technical identical (with the exception of the keyboard overlay), Fingerprint and IPL make the printer work quite differently and certain devices and options are not supported by IPL. Generally, illustrations in this manual show printers with a Fingerprintcompatible keyboard. 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 380V, 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 programming languages (Fingerprint or IPL) and their related standard application programs. It is also assumed that the reader has access to the standard tools of an electronics workshop. EasyCoder PX4i and PX6i Service Manual ix Before You Begin x EasyCoder PX4i and PX6i Service Manual 1 Models and Options This chapter describes how to identify the various models in the EasyCoder PX4/6i-series of printers, provides comprehensive technical specifications, and gives all important measurements. EasyCoder PX4i and PX6i Service Manual 1 Chapter 1 — Models and Options 1.1 Identification Main Models The EasyCoder PX4i and PX6i constitute a series of direct thermal/thermal transfer printers, which can run either Intermec Fingerprint Programming Language (FP) v8.30 (or later) or Intermec Programming Language (IPL) v2.30 or later. Externally, the difference is visible on the keyboard overlay. Fingerprint printers have 23 keys or a full alphanumeric keyboard and IPL printers have 8 keys (see Chapter 2). EasyCoder PX4i has a maximum print width of 112 mm (4.4 in). EasyCoder PX6i has a maximum print width of 167.4 mm (6.59 in). Printers running Fingerprint are available with an 8 dots/mm (203.2 dpi) or 11.81 dots/mm (300 dpi) printhead density, whereas printers running IPL only are available with an 8 dots/mm (203.2 dpi) printhead. A number of options and accessories, such as cutter, internal liner takeup, label taken sensor, and various types of interface boards, allow the printers to be tailor-made or adapted for specific applications. EasyCoder PX4i Fingerprint model EasyCoder PX4i IPL model EasyCoder PX6i Fingerprint model EasyCoder PX6i IPL model Note: Unless otherwise stated, illustrations in this manual show an EasyCoder PX4i running Intermec Fingerprint. 2 EasyCoder PX4i and PX6i Service Manual Chapter 1 — Models and Options To identify the printer, start by reading the machine label attached to the rear of the printer. The machine label contains type, part number, serial number, and signs of approval. The printer can use any 90 to 265 VAC, 45 to 65Hz voltage. The switched power supply eliminates the need for any manual voltage selector. Machine label EasyCoder PX4i and PX6i Service Manual 3 Chapter 1 — Models and Options Options for EasyCoder PX4i The EasyCoder PX4i can be fitted with a number of options: • Label Taken Sensor (see Chapter 10) • Integral Liner/Batch Takeup Unit (see Chapter 9) • 3-inch Adapter (for media supply hub) (see Chapter 5) • Media Roll Retainer (for media supply hub) (see Chapter 5) • Fan-Fold Guides (see Chapter 5) • Cutter (see Chapter 11) • Real Time Clock Circuit (not IPL) (see Chapter 15) • Alphanumeric keyboard (not IPL) (see Chapter 2) • One or two interface boards of various types (only one parallel board with IPL) (see Chapter 16) • EasyLAN interface (Ethernet or Wireless) (see Chapter 16) 3-inch adapter (included) EasyLAN antenna Fan-fold guide Alphanumeric keyboard (Fingerprint only) Media roll retainer Label taken sensor Cutter Liner/batch takeup unit 4 EasyCoder PX4i and PX6i Service Manual Chapter 1 — Models and Options Options for EasyCoder PX6i The EasyCoder PX6i can be fitted with a number of options: • Label Taken Sensor (see Chapter 10) • Integral Liner Takeup Unit (see Chapter 9) • 3-inch Adapter (for media supply hub) (see Chapter 5) • Fan-Fold Guides (see Chapter 5) • Cutter (see Chapter 11) • Real Time Clock Circuit (not IPL) (see Chapter 15) • Alphanumeric keyboard (not IPL) (see Chapter 2) • One or two interface boards of various types (only one parallel board with IPL) (see Chapter 16) • EasyLAN interface (Ethernet or Wireless) (see Chapter 16) EasyLAN antenna 3-inch adapters (included) Fan-fold guide Alphanumeric keyboard (Fingerprint only) Label taken sensor /PEN #LOSED Cutter Liner takeup unit EasyCoder PX4i and PX6i Service Manual 5 Chapter 1 — Models and Options Interfaces The printers are as standard provided with one serial RS-232 port, one serial USB port, and one wand interface. The wand interface is not supported by IPL. In addition, one EasyLAN interface and one or two extra interface boards can be fitted, see Chapter 14. IPL does only support one EasyLAN interface and one parallel interface board. Provision for EasyLAN antenna Provision for Ethernet connector Provision for one or two interface boards (only the left slot used with IPL) Wand interface (not used with IPL) Serial Port (RS-232) USB Port 6 EasyCoder PX4i and PX6i Service Manual Chapter 1 — Models and Options Checking Hardware and Firmware Finally, you may want to inspect the electronics compartment. To do so, carefully follow the instructions in Chapter 12. Always switch off the power and remove the power cord before removing the cover over the electronics compartment! Dangerous voltage! In the electronics compartment, check: • Type of CPU board? - Check number and size of Flash SIMMs. - Check size of SDRAM SIMM. • Any optional interface board fitted? - Check type, straps, and optional circuits. Refer to Chapters 15 and 16 for more information. Being delivered with either Intermec Fingerprint v8.30 programming language or IPL v2.30 (or later versions), the printer can easily be converted from Fingerprint to IPL or vice versa using a firmware card or special software. The keyboard overlay will also need to be replaced. The type of firmware is indicated by the messages in the display window at startup. Fingerprint only If the printer is working and possible startup program can be interrupted, the type of program in the printer can be identified. 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 files 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 Intermec Fingerprint firmware. You can read the setup in the Setup Mode or using Intermec Shell, which also allows you to print test labels containing the present setup values. To enter Shell if a custom-made autoexec-file prevents access, lift the printhead and press any key on the printer's keyboard (except thekey), then turn on the power while continuing to press the key. When the Shell countdown begins, release the key and press to start Shell. Do not forget to lower the printhead if you want to print anything, for example test labels. Refer to the User’s Guide and to Appendix A 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. IPL only The Test/Service part of the Setup Mode allows several types of test labels to be printed (see the User’s Guide and Appendix A). IPL also has a number of commands that return valuable information on the printer’s status (see IPL Programming, Reference Manual). EasyCoder PX4i and PX6i Service Manual 7 Chapter 1 — Models and Options 1.2 EasyCoder PX4i Specifications Printing Print Technique Direct Thermal and Thermal Transfer Printhead Resolution 8 dots/mm (203.2 dpi) or 11.81 dots/mm (300 dpi) Print Speed (variable) 100 to 300 mm/sec. (≈ 4 to 12 in./sec.) Print Width (max) 112 mm (4.4 in.) Print Length (max) 32767 dots = 409.5 cm (161.25 in.) at 203.2 dpi1 = 277.5 cm (109.23 in.) at 300 dpi1 Media Width (min/max) 25 to 120 mm (1 to 4.72 in.) Media Roll Diameter (max) 213 mm (8.38 in.) 205 mm (8.07 in.) Media Roll Core Diameter 38 to 40 mm (1.5 in.) or 76 mm (3 in.) with adapter fitted Ribbon Width (min/max) 55 to 120 mm (2.16 to 4.72 in.) Ribbon Roll Diameter (outer), max. 80 mm (3.15 in.) Ribbon Roll Core Diameter (inner) 25 mm (1.00 in.) Print Directions 4 Not supported by IPL Tear-off & Cut-off Peel-off & batch takeup ≈ 450 m (1476 ft) length Modes of Operation Tear-Off (Straight-through) Yes Cut-Off Option With cutter Peel-Off (Self-strip) Option With rewinder Internal Batch Takeup Option With rewinder Operating System Intermec Fingerprint v8.30 Incl. Direct Protocol Smooth Fonts TrueDoc and TrueType fonts Resident Scaleable Fonts 15 Resident Bar Codes 59 Startup Program (std) Intermec Shell v8.2 Fingerprint Firmware Unicode fonts2 IPL Firmware Operating System IPL v2.30 Smooth Fonts 13 scaleable + 21 simulated bitmap Resident Bar Codes 44 Physical Measures Dimensions (W × L × H) 275 × 482 × 238 mm (10.8 × 19.0 × 9.4 in) Weight (excluding media) 12.85 kg (28.4 pounds) Ambient Operating Temperature +5°C to +40°C (+41°F to +104°F) Storage Temperature -20°C to +70°C (-4°F to +152°F) Humidity 10 to 90% non-condensing Electronics Microprocessor 32 bit RISC On-board Flash SIMMs 2 sockets for 4MB or 8MB each Std. 1 x 4MB On-board SDRAM SIMM 1 socket for 16MB (Std. 16MB) 8 EasyCoder PX4i and PX6i Service Manual Chapter 1 — Models and Options Power Supply AC Voltage 90 to 265 VAC, 45 to 65 Hz PFC Regulation IEC 61000-3-2 Power Consumption Standby 20W; Continuous, average 175W; Peak 400W Sensors Label Gap/Black Mark/Out of Media Yes Printhead Lifted Yes Ribbon End/Ribbon Low Yes Paper Sensor Yes Variable position Controls Indicator Lamps 3 Display 2 x 16 character LCD Keyboard (Fingerprint) 22 keys membrane-switch type Keyboard (IPL) 7 keys membrane-switch type Print (FP) or Feed/Pause (IPL) button 1 Beeper Yes Background light Data Interfaces Serial 1 x RS-232 + 1 x USB Bar Code Wand Yes Not supported by IPL Connection for Optional Interface Boards 1 EasyLAN + 2 other (Fingerprint/DP) IPL: 1 other + 1 EasyLAN Cutter Interface 1 Memory Card Adapter 1, for CompactFlash cards IPL: Not as memory Integral Self-strip Unit with Liner Takeup Option3,4 For peel-off and batch takeup Media Roll Retainer Option5 Fan-fold Guide Option5 Cutter Option5 Label Taken Sensor Option3,4 Real Time Clock Option3,4 RS-232 Cable Option Parallel Interface Cable Option Parallel Interface Board Option Double Serial Interface Board Option3,4 Not supported by IPL Serial/Industrial Interface Board Option3,4 Not supported by IPL Accessories and Options Not supported by IPL 3,4 EasyLAN Ethernet Interface Option EasyLAN Wireless Interface Option3,4 Built-in Alphanumeric Keyboard Option3,4 Not supported by IPL 5 External Keyboard Converter Option CompactFlash Cards Option5 8MB-1GB CompactFlash Protection Plate Option5 1 /. The max. print length is also restricted by the amount of free SDRAM memory. 2 /. Latin, Greek, and Cyrillic fonts according to Unicode standard are included. 3 /. Factory installed option 4 /. Field-installable kit. Installation should be performed by a service technician. 5 /. Operator-installable option. EasyCoder PX4i and PX6i Service Manual 9 Chapter 1 — Models and Options 1.3 EasyCoder PX6i Specifications Printing Print Technique Direct Thermal and Thermal Transfer Printhead Resolution 8 dots/mm (203.2 dpi) or 11.81 dots/mm (300 dpi) Print Speed (variable) 100 to 225 mm/sec. (≈ 4 to 8.85 in./sec.) Print Width (max) 167.4 mm (6.59 in.) Print Length (max) 32767 dots = 409.5 cm (161.25 in.) at 203.2 dpi1 = 277.5 cm (109.23 in.) at 300 dpi1 Media Width (min/max) 76 to 170 mm (3 to 6.69 in.) Media Roll Diameter (max) 213 mm (8.38 in.) 205 mm (8.07 in.) Media Roll Core Diameter 38 to 40 mm (1.5 in.) or 76 mm (3 in.) with adapter fitted Ribbon Width (min/max) 76.2 to 170 mm (3 to 6.69 in.) Ribbon Roll Diameter (outer), max. 80 mm (3.15 in.) Ribbon Roll Core Diameter (inner) 25 mm (1.00 in.) Print Directions 4 Not supported by IPL Tear-off & Cut-off Peel-off & batch takeup ≈ 450 m (1476 ft) length Modes of Operation Tear-Off (Straight-through) Yes Cut-Off Option With cutter Peel-Off (Self-strip) Option With rewinder Operating System Intermec Fingerprint v8.30 Incl. Direct Protocol Smooth Fonts TrueDoc and TrueType fonts Resident Scaleable Fonts 15 Fingerprint Firmware Resident Bar Codes 59 Startup Program (std) Intermec Shell v8.2 Unicode fonts2 IPL Firmware Operating System IPL v2.30 Smooth Fonts 13 scaleable + 21 simulated bitmap Resident Bar Codes 44 Physical Measures Dimensions (W × L × H) 335 × 482 × 238 mm (13.2 × 19.0 × 9.4 in) Weight (excluding media) 14.8 kg (32.6 pounds) Ambient Operating Temperature +5°C to +40°C (+41°F to +104°F) Storage Temperature -20°C to +70°C (-4°F to +152°F) Humidity 10 to 90% non-condensing Electronics Microprocessor 32 bit RISC On-board Flash SIMMs 2 sockets for 4MB or 8MB each Std. 1 x 4MB On-board SDRAM SIMM 1 socket for 16MB (Std. 16MB) 10 EasyCoder PX4i and PX6i Service Manual Chapter 1 — Models and Options Power Supply AC Voltage 90 to 265 VAC, 45 to 65 Hz PFC Regulation IEC 61000-3-2 Power Consumption Standby 20W; Continuous, average 175W; Peak 400W Sensors Label Gap/Black Mark/Out of Media Yes Printhead Lifted Yes Ribbon End/Ribbon Low Yes Paper Sensor Yes Variable position Controls Indicator Lamps 3 Display 2 x 16 character LCD Keyboard (Fingerprint) 22 keys membrane-switch type Keyboard (IPL) 7 keys membrane-switch type Print (FP) or Feed/Pause (IPL) button 1 Beeper Yes Background light Data Interfaces Serial 1 x RS-232 + 1 x USB Bar Code Wand Yes Not supported by IPL Connection for Optional Interface Boards 1 EasyLAN + 2 other (Fingerprint/DP) IPL: 1 other + 1 EasyLAN Cutter Interface 1 Memory Card Adapter 1, for CompactFlash cards IPL: Not as memory Option3,4 For peel-off operation Accessories and Options Integral Self-strip Unit with Liner Takeup 5 Fan-fold Guide Option Cutter Option5 Label Taken Sensor Option3,4 Real Time Clock Option3,4 RS-232 Cable Option Parallel Interface Cable Option Parallel Interface Board Option Double Serial Interface Board Option3,4 Not supported by IPL 3,4 Not supported by IPL Serial/Industrial Interface Board Option 3,4 EasyLAN Ethernet Interface Option EasyLAN Wireless Interface Option3,4 Built-in Alphanumeric Keyboard Option3,4 Not supported by IPL 5 External Keyboard Converter Option CompactFlash Cards Option5 CompactFlash Protection Plate Not supported by IPL 8MB-1GB 5 Option 1 /. The max. print length is also restricted by the amount of free SDRAM memory. /. Latin, Greek, and Cyrillic fonts according to Unicode standard are included. 3 /. Factory installed option 4 /. Field-installable kit. Installation should be performed by a service technician. 5 /. Operator-installable option. 2 EasyCoder PX4i and PX6i Service Manual 11 Chapter 1 — Models and Options 1.4 Measures EasyCoder PX4i Front View MM M M 2 MM MM MM MM MM MM $OT .O Side View MM 0APER SLOT MM 2 M M MM 0APER SLOT MM MM MM MM MM 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. 12 EasyCoder PX4i and PX6i Service Manual Chapter 1 — Models and Options 1.5 Measures EasyCoder PX6i MM 2 M M Front View MM MM MM MM MM MM $OT .O Side View MM 0APER SLOT MM 2 M M MM 0APER SLOT MM MM MM MM MM 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. EasyCoder PX4i and PX6i Service Manual 13 Chapter 1 — Models and Options 14 EasyCoder PX4i and PX6i Service Manual 2 Front and Keyboard This chapter describes the keyboard and display fitted at the front of the EasyCoder PX4i and PX6i printers in both Fingerprint and IPL versions, the only differences being the designation on the overlay and the width of the front moulding. Illustrations in this chapter shows an EasyCoder PX4i running Fingerprint. EasyCoder PX4i and PX6i Service Manual 15 Chapter 2 — Front and Keyboard 2.1 Front The moulded front part is attached to the center section using four #T20 screws and to the bottom plate using two #T20 screws. The front moulding is provided with holes for mounting a cutter connector (4-pin female DIN-type). Keyboard/display assy. Provision for cutter connection Front moulding At the top part of the front moulding, there is a cavity for the keyboard/ display assy. This assembly is affixed using two 2 mm hexagon grub screws underneath the keyboard part of the front moulding. 16 EasyCoder PX4i and PX6i Service Manual Chapter 2 — Front and Keyboard 2.2 Keyboard/Display The keyboard/display assy. is connected to J50 at the front of the CPU board via a 10-p flat cable. This cable must be disconnected before the keyboard/display can be removed. The keyboard/display must be manipulated carefully when it is lifted out of its cavity. Do not use any force! If the assembly seems to be stuck, open the right-hand door and remove the left-hand cover to check that the grub screws do not interfere with the brackets. We also recommend you to remove the left-hand cover before you start to fit the keyboard/display assy. back into the front moulding, because it makes it easier to align the brackets with the grub screws. The keyboard/display assy. consists of a plate with two brackets, a selfadhesive membrane switch keyboard, an self-adhesive overlay, and a console pcb. The membrane switch keyboard is connected to P2 on the console pcb. via a semi-transparent cable running through a slot in the plate. Console pcb. Keyboard plate Overlay (5 types) EasyCoder PX4i and PX6i Service Manual Membrane-switch keyboard 17 Chapter 2 — Front and Keyboard Keyboard Overlays The keyboard overlays are self-adhesive with a non-permanent adhesive to allow easy replacement. Custom-made overlays could also be printed and used to replace the standard overlays for customized applications or in areas, where the English text is not acceptable. Pulling away an overlay and replacing it with another is a simple operation that the customer easily can perform himself. Use isopropyl alcohol to remove any adhesive residue. There are three types of overlay for each printer model: EasyCoder PX4i Fingerprint version EasyCoder PX4i Fingerprint version, Alphanumeric keyboard (option) EasyCoder PX4i IPL version 18 EasyCoder PX4i and PX6i Service Manual Chapter 2 — Front and Keyboard EasyCoder PX6i Fingerprint version EasyCoder PX6i Fingerprint version, Alphanumeric keyboard (option) EasyCoder PX6i IPL version EasyCoder PX4i and PX6i Service Manual 19 Chapter 2 — Front and Keyboard Keyboard The keyboard is of membrane switch type and is glued to the keyboard plate. There are 54 switches, but only 23 of these are used unless the printer has an alphanumeric overlay (Fingerprint only). One switch is a Shift key, that provides a dual functionality to each of the other keys. The keys have fixed functions in the immediate and setup modes, but can also be assigned various functions in Intermec Fingerprint programs. In IPL, the keys are not user-programmable. A flat cable connects the membrane-switch keyboard to P2 on the console pcb. Keyboard Plate The keyboard plate keeps the assembly together and to affix it in the cavity of the front moulding. There are one slot for the display and another for the cable running from the membrane-switch keyboard to the console pcb. Two brackets at the lower edge are used to connect the plate to the front moulding using two 2 mm hexagon grub screws. 20 EasyCoder PX4i and PX6i Service Manual Chapter 2 — Front and Keyboard 2.3 Console pcb. The console pcb manages the keyboard, the display and two of the three LED indicators using a slave processor. The communication to and from the CPU board goes via an I2C bus on a 10-p flat cable. This cable is permanently affixed to the console pcb and connected to J50 a the front end of the CPU board. The display is a LCD display with background light. It has 2 × 16 character with a 5 × 7 dots matrix. There is no display contrast adjustment. The left-hand LED indicator (marked “Power”) shines green when the power is on. Power on is also indicated by the display’s background light. The center LED (marked “Status”) is solid green (OK), flashing green (communicating) or solid red (error). The right-hand LED (Intermec Readiness Indicator) is solid blue, flashing blue, or off which indicates the readiness of the printer to work as a part of a network solution (see the User’s Guide). In Fingerprint, the Status LED is programmable using the instructions LED ON and LED OFF. There is no such functionality in IPL. Intermec Readiness Indicator (blue) Status LED (green or red) Power On LED (green) LCD display EasyCoder PX4i and PX6i Service Manual 21 0 22 $ $ $ 0 2 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 # 2 # 2 # 2 # 2 # 2 # 2 # 2 # 2 # 2 2 2 % )# )# 2 2 # 2 # 2 2 # 2 2 2 2 2 0 2 " # # 2 # 2 2 # 2 # 2 2 # 2 2 2 2 2 2 2 .# 0 + 2 2 # ! 2 # # 2 2 2 2 2 2 2 Chapter 2 — Front and Keyboard 2 $)30 )# # # 1-971653-30 Console pcb, Component Side $ $)30 1-971653-30 Console pcb, Soldering Side EasyCoder PX4i and PX6i Service Manual + C1 VCC IC1 IC2 SCL IC50 I2C_NOTIFY SDA RESET LED2 LED1 2 T AHCT14 6 11 AHCT14 10 13 AHCT14 12 VCC=VCC;GND=GND1 IC50 VCC=VCC;GND=GND1 IC50 4 9 AHCT14 8 VCC=VCC;GND=GND1 IC50 VCC=VCC;GND=GND1 IC50 5 AHCT14 VCC=VCC;GND=GND1 IC 5 0 3 VDISP R/W RS E 15 K DISPLAY A 16 VC C R51 R2 R1 AHCT14 R17 VCC=VCC;GND=GND1 IC50 1 R9 R18 DISP1 D50 L ED R52 R3 VCC 3 5 4 6 1 GND R6 2 VCC R55 D0 D1 D2 D3 D4 D5 D6 D7 7 8 9 10 11 12 13 14 R50 R5 VCC T3 VC C R61 R16 C4 D60 LED R62 R4 2 3 4 5 6 7 1 9 10 8 19 20 VCC D4 D5 D6 D7 E RS R65 V CC VCC GND CLKIN INT/RB0 RB1 CLKOUT RB2 RB3 MCLR/VPP RB4 RB5 RB6 RA0 RA1 RB7 RA2 RA3/VREF RC 0 RA4/TOCKI R A5 RC 1 RC2 RC3 RC 4 RC5 VCC RC6 GND RC7 PIC16F872 IC1 R71 D70 LED P4 COLSH COL0 COL1 COL2 COL3 COL4 COL5 ROW_CLK ROW_CLR ROW_DATA SC L SDA NOTIFY R/W SYSTEM 11 12 13 14 15 16 17 18 1 2 3 4 5 21 22 23 24 25 26 27 28 VPP VCC 2 1 8 9 & 1D<7> 1D<6> 1D<5> 1D<4> 1D<3> 1D<2> 1D<1> 1D<0> 74AHC164 VCC=VCC;GND=GND1 R R19 C1/ IC2 VCC R20 VCC R53 R21 IN-CIRCUIT SERIAL PROGRAMMING R72 R15 D4 R60 R14 R56 R57 1 2 3 4 5 6 7 8 9 10 C2 R63 1 VCC R70 P1 C3 R73 VCC C50 R54 3 1 2 R64 3 2 R66 R67 R75 C21 R74 3 1 2 R76 R77 R22 3 4 5 6 10 11 12 13 R23 C6 C5 R24 C8 C7 R25 C10 C9 C12 C11 C14 C13 C16 C15 C18 C17 EasyCoder PX4i and PX6i Service Manual C20 C19 V CC R42 R43 R26 R2 7 R28 R29 R30 R31 R32 R3 3 R34 R35 R36 R37 R3 8 R39 R40 R41 1 2 P3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 P2 KEYBOARD 9 ROWS 7 COLUMNS Chapter 2 — Front and Keyboard 1-971653-30 Console pcb, Schematics 23 Chapter 2 — Front and Keyboard 24 EasyCoder PX4i and PX6i Service Manual 3 Covers and Doors This chapter describes the covers and doors on the EasyCoder PX4i and PX6i printers. It covers the following topics: • The right-hand door, that is, the doors that cover the print mechanism and media compartment. • The front door, that protects the front of the print mechanism. • The left-hand cover that protects the electronics compartment. EasyCoder PX4i and PX6i Service Manual 25 Chapter 3 — Covers and Doors 3.1 Right-Hand Door Description The right-hand door gives access to: • The media supply • The ribbon supply • The print mechanism The right-hand door is fitted to the bottom plate using two hinges that allow the door to be swung 180˚ downwards to a vertical attitude. The door is kept shut using a magnetic lock. The door can easily be removed from the hinges by pushing it forward until the snap-lock at the rear hinge becomes disengaged. At the inside of the door, there is a label showing how to load the media and transfer ribbon. Magnetic lock Label Hinges Illustration shows the right-hand door of an EasyCoder PX4i. The door of the EasyCoder PX6i has a wider top part. Adjustment The hinges can be adjusted using two pairs of #T10 Torx screws visible on the outside. Possibly, the other parts of the hinges, which are fitted to the bottom plate, may require adjustment too. Shut the door, loosen the screws slightly and align the door with the front moulding. Tighten the screws and check that the door runs freely and is kept shut by the magnetic lock. 26 EasyCoder PX4i and PX6i Service Manual Chapter 3 — Covers and Doors 3.2 Front Door The front door gives access to: • The front part of the print mechanism • The paper cutter connector • The optional label taken sensor The front hatch is fitted to the bottom plate using two hinges of the same type as those of the right-hand door. The front hatch is kept shut by a snap-lock and can be swung down almost to a vertical position. The hatch can be removed from its hinges by pushing it to the left until the snap-lock on the right-hand hinge disengages. The front hatch can be replaced by an optional paper cutter unit, see Chapter 11. Alignment is performed in the same way as the right-hand door, see the previous page. The front hatch can be removed by pushing it to the left when open (illustration shows an EasyCoder PX4i). EasyCoder PX4i and PX6i Service Manual 27 Chapter 3 — Covers and Doors 3.3 Left-Hand Cover The left-hand cover gives access to: • The electronics incl. CPU board, AC connection, power supply, driver board, and any optional interface boards. • The motors, belts and pulleys of the media feed, ribbon feed, and the optional liner/batch takeup unit. The left-hand cover plate is fitted to the printer’s frame using a total of eight #T10 Torx screws; four along the lower edge and another four along the top. The electronic compartment contains wires and components with dangerous voltage (up to 380V). Make sure that the printer is switched off and the power cord is disconnected, before the left-hand cover is removed. Before removing the left-hand cover, take standard precautions to avoid causing any electrostatic discharges. After having disconnected the power cord, open the right-hand door. Using a #T10 Torx screwdriver, remove the four screws along the lower edge first, then remove the four upper screws. Put the cover plate aside on a soft cloth or similar material to avoid scratches. Fit back the left-hand cover in reverse order. Before finally tightening the screws, check that the cover is aligned with the front moulding and the rear plate and that it does not interfere with the right-hand door. #T10 Torx screws (x4) #T10 Torx screws (x4) 28 EasyCoder PX4i and PX6i Service Manual 4 Chassis This chapter describes the center section, bottom plate, rear plate, hinges, and rubber feet, of the EasyCoder PX4i and PX6i printers. EasyCoder PX4i and PX6i Service Manual 29 Chapter 4 — Chassis 4.1 Description The printer’s chassis consists of three main parts: • The center section Rear plate • The bottom plate • The rear plate Center section Hinges (front door or cutter) Bottom plate Hinges (right-hand door) Rubber foot (x4) EasyCoder PX4i 30 EasyCoder PX4i and PX6i Service Manual Chapter 4 — Chassis The main differences between the chassis of EasyCoder PX4i and PX6i are the widths of the bottom plate and the rear plate. Rear plate Center section Hinges (front door or cutter) Bottom plate Rubber foot (x4) Hinges (right-hand door) EasyCoder PX6i EasyCoder PX4i and PX6i Service Manual 31 Chapter 4 — Chassis 4.2 Center Section The center section is where most parts are fitted, such as the print mechanism, the transfer ribbon mechanism, the liner takeup unit, and the media supply. The center section is fitted to the bottom plate by four #T20 Torx screws and to the rear plate using three #T20 Torx screws and a bracket. In the electronics compartment, the CPU board, the driver board, and power supply unit are fitted to the center section. 4.3 Bottom Plate The bottom plate is fitted to the center section using four #T20 Torx screws and to the rear plate using three #T20 Torx screws. In case of EasyCoder PX6i, there are also two #T20 Torx screws holding the outer gable of the print unit. The electronic compartment contains wires and components with dangerous voltage. Make sure that the printer is switched off and the power cord is disconnected before the bottom plate is removed. The bottom plate is fitted with four easily replaceable rubber feet. These feet could be removed and the holes be used to bolt the printer to a frame, table or similar. The holes have a diameter of 7.1 mm (0.28 inches). To reduce noise, fit rubber dampeners between the table and the printer if you bolt it in place. When fitting a replacement foot, insert it through the bottom plate and firmly press the pin so the rivet expands on the upper side of the plate. The bottom plate is provided with two pairs of hinges for the front door or cutter and for the right-hand door. The two keyholes must not be used to bolt the printer to a frame, or the bottom plate may be bent. These holes are intended for fixtures during manufacturing. 32 EasyCoder PX4i and PX6i Service Manual Chapter 4 — Chassis 4.4 Rear Plate The rear plate is attached to the bottom plate using three #T20 Torx screws and to the center section by two #T20 Torx screws. There is also a bracket between the rear plate and the center section. The rear plate has a number of slots for connectors, switches etc., as illustrated below. Provision for EasyLAN Wireless antenna Provision for EasyLAN Ethernet connector Provision for optional interface board(s) On/Off switch CompactFlash memory card slot Bar code wand Interface (not used with IPL) AC power cord receptacle RS-232 serial interface USB interface Upper external media intake Lower external media intake Machine label EasyCoder PX4i and PX6i Service Manual 33 Chapter 4 — Chassis 34 EasyCoder PX4i and PX6i Service Manual 5 Media Supply This chapter explains the rotating media supply hub with the 3-inch adapter, the media roll retainer, and the paper sensor. Finally, it describes how an external media supply can be used in an EasyCoder PX4i and PX6i printer fitted with a fan-fold guide. EasyCoder PX4i and PX6i Service Manual 35 Chapter 5 — Media Supply 5.1 Internal Supply Description The internal media supply consists of a shaft with four or five modular hubs. The shaft is screwed into a flange fitted to an almost circular plate using two #T20 Torx screws. The plate is fitted to the center section using four #T20 Torx screws. The hub modules are spring-loaded in order to fit media roll cores with an inner diameter between 38 and 40 mm (1.5 inches). A large crescent-shaped guide plate keeps the media roll aligned with the print mechanism. Inside the guide plate and protruding through a slot in the circular plate, the paper sensor is fitted to the center section. Maximum diameter of an internal media roll is 213 mm (8.38 inches), except in the case of peel-off and batch takeup operation when the diameter is restricted to 205 mm (8 inches). Maximum width is 120 mm (4.72 inches) for EasyCoder PX4i and 170 mm (6.69 inches) for EasyCoder PX6i. /PEN #LOSED 36 EasyCoder PX4i and PX6i Service Manual Chapter 5 — Media Supply Paper sensor Unwind unit Hub modules Guide plate EasyCoder PX4i and PX6i Service Manual 37 Chapter 5 — Media Supply The media supply hub package can be dismantled by removing the #T20 Torx screw at the end of the shaft. Inside the outermost hub module, there is a spring that presses the hub package towards a felt pad in order to break the rotation. Else, the momentum of a large and heavy media roll might cause excessive media to be unwound when the printing is stopped. The brake torque should be 70 ±20 Nmm (see Appendix C). The rotation of the code disc fitted at the innermost part of the hub package is detected by the paper sensor. Be careful to fit the studs of the innermost hub module into the holes in the code disc when the package is assembled. Code disc Flange Hub modules (4 in EasyCoder PX4i, 5 in EasyCoder PX6i) Plate Disc Felt Pad Shaft (short in EasyCoder PX4i, long in EasyCoder PX6i) Nylon disc Spring Washer #T20 Torx screw 38 EasyCoder PX4i and PX6i Service Manual Chapter 5 — Media Supply 5.2 Paper Sensor Description The paper sensor allows the firmware to detect when the diameter of the remaining media becomes less than a value set in the Setup Mode. In Fingerprint, this affects SYSVAR(46) which switches from 0 to 1. Thus, a Fingerprint program can be created, that reads SYSVAR(46) and uses it to issue for example audible alarms or error messages to notify the operator of a pending out-of-media condition. A trap is also sent that can be detected when the printer is connected to a network via an EasyLAN interface. In IPL, a trap is sent that can be detected when the printer is connected to a network via an EasyLAN interface. The sensor detects the saw-tooth shape of the code disc at the inner end of the media supply hub. By comparing the rotation speed of the hub and the print speed, the firmware can calculate the diameter of media roll. The paper sensor assy is fitted to the center section using a #10 Torx screw and is connected to J57 on the CPU board (see Chapter 15.3). Adjustment Refer to the chapter “Setting Up the Printer” in the User’s Guide for the printer in question. Replacement • Switch off the power, disconnect the power cord, and remove the lefthand cover. • Disconnect the cable from J57 on the CPU board. • Remove the crescent-shaped guide plate, which is held by three #T20 Torx screws. • Remove the entire media supply unit which is held by four #T20 Torx screws. • Remove the single #T10 Torx screw that holds the sensor to the center section. • Carefully pull out the sensor and its cable through the hole in the center section. • Install a new sensor assembly in reverse order. EasyCoder PX4i and PX6i Service Manual 39 Chapter 5 — Media Supply 5.3 Three-inch Adapters One or two adapters (standard accessories) can be fitted onto the media supply hub in order to accept media rolls with 76 mm (3 inches) cores. EasyCoder PX4i has one adapter and EasyCoder PX6i has two. Each adapter is locked using a #T20 Torx screw. Be careful not to let the screw hit the leaf springs or the cams of the hub modules. 3-inch adapter /PEN #LOSED 3-inch adapters 40 EasyCoder PX4i and PX6i Service Manual Chapter 5 — Media Supply 5.4 Media Roll Retainer An optional media roll retainer can be pressed on the hub package (but not on the adapter) of an EasyCoder PX4i in order to hold large media rolls and to prevent the media from getting misaligned on the roll. The retainer is not intended for EasyCoder PX6i Media roll retainer EasyCoder PX4i and PX6i Service Manual 41 Chapter 5 — Media Supply 5.5 Fan-Fold Guides Description Instead of an internal media roll, the EasyCoder PX4i and PX6i printers can also use media from an external supply, for example an external roll or a stack of fan-folded tickets. The media is inserted into the printer through either the upper or lower slot in rear plate. It is important that the media path is properly aligned in parallel with the printer’s center section. Therefore, Intermec offers an optional “Fan Fold Kit” consisting of a bracket with two guides that can be fitted in either the upper or lower slot in the rear plate. The outer guide is adjustable for different media widths. Max. Media Width (Fan-Fold Guides) EasyCoder PX4i: 120 mm (4.72 in) EasyCoder PX6i: 170 mm (6.69 in) Min. Media Width (Fan-Fold Guides) EasyCoder PX4i: 40 mm (1.575 in) EasyCoder PX6i: 76.2 mm (3.00 in) Fan-Fold Guides in upper position (EasyCoder PX4i) 42 EasyCoder PX4i and PX6i Service Manual Chapter 5 — Media Supply Installation The bracket with the two guides can be fitted either at the upper or lower slot in the rear plate, depending on how the media supply is located in relation to the printer. The principles are the same for EasyCoder PX4i and EasyCoder PX6i. Insert the complete unit through the slot from the outside and attach it to the rear plate using two #T20 Torx screws. In case of the upper position, use the screws included in the kit, and in case of the lower position, use the two existing screws that hold the rear plate to the bottom plate. Adjustment Adjust the position of the outer guide to fit the width of the media. EasyCoder PX4i and PX6i Service Manual 43 Chapter 5 — Media Supply Media Load Load the media according to the illustrations below. The external supply should be protected from dust, sand, grit and other particles that may damage the printhead or impair the printout quality. Note: If the printer is to be permanently used with an external media supply only, the entire internal media supply unit could easily be removed (see Chapter 5.1). 44 EasyCoder PX4i and PX6i Service Manual 6 Label Slack Absorber This chapter describes the label slack absorber fitted as standard in the EasyCoder PX4i and PX6i printers. It covers the following topics: • Description • Dismantling EasyCoder PX4i and PX6i Service Manual 45 Chapter 6 — Label Slack Absorber 6.1 Description The label slack absorber compensates for sudden jerks at the media, for example when high speed printing is started and stopped. When the printing starts, the tension is increased and the absorber is pulled forward/ upward. As soon the heavy media roll starts to rotate, the tension decreases. The spring-loaded absorber can then return towards its original position. During the printing, the absorber will flutter back and forth, compensating for the variations in tension. To facilitate media load, the label slack absorber can be rotated 180° clockwise. It can be locked in open position using a snap-lock. Remember to unlock the slack absorber before starting to print. An adjustable edge guide is fitted on the label slack absorber to prevent media misalignment. The guide is fitted as standard, but can be removed to facilitate media load when there are other means of guiding the media, for example a media roll retainer or fan-fold guides (see Chapter 5). Slack absorber Edge guide 46 EasyCoder PX4i and PX6i Service Manual Chapter 6 — Label Slack Absorber 6.2 Dismantling The label slack absorber unit is fitted to the center section using two #T20 Torx screws inserted through the center section from the electronics compartment. The shaft should be screwed into the flange with a tightening torque of 5 Nm. EasyCoder PX4i #T20 Torx screws (2x) Flange Torsion spring #T10 Torx screw Spacer #T10 Torx screw Grip (green) Edge guide (green) EasyCoder PX4i and PX6i Service Manual 47 Chapter 6 — Label Slack Absorber EasyCoder PX6i #T20 Torx screws (2x) Flange Torsion spring #T10 Torx screw Spacer #T10 Torx screw Grip (green) Edge guide (green) 48 EasyCoder PX4i and PX6i Service Manual 7 Transfer Ribbon Mechanism This chapter describes the mechanism that drives the thermal transfer ribbon in the EasyCoder PX4i and PX6i printer. It covers the following topics: • Description • Ribbon supply unit • Ribbon rewind unit • Ribbon sensor EasyCoder PX4i and PX6i Service Manual 49 Chapter 7 — Transfer Ribbon Mechanism 7.1 Description The thermal transfer ribbon mechanism is standard in EasyCoder PX4i and PX6i. The mechanism consists of three main parts: • Ribbon supply unit (see Chapter 7.2) • Ribbon rewind unit (see Chapter 7.3) • Ribbon sensor (see Chapter 7.4) Adjustment of the ribbon assist roller to remedy wrinkling of the ribbon is described in Chapter 8.9. Ribbon Rewind Unit Ribbon Supply Unit 50 Ribbon Sensor EasyCoder PX4i and PX6i Service Manual Chapter 7 — Transfer Ribbon Mechanism 7.2 Ribbon Supply Unit Description The ribbon supply unit is the same for EasyCoder PX4i and EasyCoder PX6i with the exception of the strength of the spring in the spring brake. It is used to accommodate the fresh supply of thermal transfer ribbon. For optimum printout quality and trouble-free operation, only original transfer ribbon from Intermec should be used. The unit is designed to keep the ribbon tight all the time in order to avoid wrinkling, which would ruin the printout. It consists of a shaft on which a hub is fitted. The hub can pivot ± 1.3° on the shaft and the hub can be moved sideways between 6 fixed positions. Adjustment It is most important for avoiding ribbon wrinkling that the pivoting point of the hub is centered in relation to the ribbon width. Therefore, the shaft is provided with six grooves which correspond to the standard widths of Intermec transfer ribbons (see table below). The three innermost grooves are used with EasyCoder PX4i, whereas the three outermost grooves only are used with the wider EasyCoder PX6i. By compressing the hub, its snap-lock will disengage from the presently engaged groove and the hub can be moved sideways to another position. Make sure that the snap-lock has engaged a groove by trying to move the hub without compressing it. Ribbons with a width less than 55 mm (2.16 inches) can be used provided they are wound on a core with a width of at least 45 mm (1.77 inches). Ribbon Width Position (groove) Note 55-60 mm (2.16-2.36 in) 1:st (innermost) PX4i only 88-90 mm (3.5 in) 2:nd All 110 mm (4.3 in) 3:rd All 130 mm (5.1 in) 4:th PX6i only 154 mm (6.0 in) 5:th PX6i only ≤ 166 mm (6.5 in) 6:th (outermost) PX6i only EasyCoder PX4i and PX6i Service Manual 51 Chapter 7 — Transfer Ribbon Mechanism Working Principles The ribbon supply is braked by a spring affixed to the printer’s center section, partly enveloped by a sleeve affixed to the shaft. Initially, the spring expands towards the inner wall of the sleeve, thereby breaking the rotation of the shaft. When the bobbin is forced to rotate (that is, when the ribbon is unwound), the breaking spring is compressed. After approximately half a turn, the diameter of the spring has been compressed enough to allow the sleeve to slip. The brake torque should be 55 ±5 Nmm (see Appendix C). The sleeve is filled with ball bearing grease. If the brake torque deviates from the recommended value, replace the grease. We recommend Castrol Sinplex 2. The expected interval between replacing the grease is 8 to 10 million print cycles. When the rotating force ceases, the spring tends to pull back the ribbon, keeping it tight. Grub screw Brake sleeve Torque spring (differs between models) Grub screw Locking washer Locking washer Ball bearing Fixing ring Flange Ball bearing Shaft Grooves Code disc Pivot assy. 52 EasyCoder PX4i and PX6i Service Manual Chapter 7 — Transfer Ribbon Mechanism Replacement The unit is attached to the center section by two #T20 Torx screws inserted from the media compartment side. #T20 Torx screw #T20 Torx screw EasyCoder PX4i and PX6i Service Manual 53 Chapter 7 — Transfer Ribbon Mechanism 7.3 Ribbon Rewind Unit Description The ribbon rewind unit is the same for EasyCoder PX4i and EasyCoder PX6i. It pulls the transfer ribbon around the printhead and winds it up on a cardboard core. The unit is driven via a belt by the same stepper motor that drives the platen roller. The rewind unit is provided with a friction brake in order to keep the ribbon tight. Adjustment There is no manual adjustment of the ribbon rewind unit other than the tension of the belt to the stepper motor (see Chapter 8.4). 54 EasyCoder PX4i and PX6i Service Manual Chapter 7 — Transfer Ribbon Mechanism Working Principles The ribbon rewind unit is driven by the same motor that drives the platen roller in the print unit via a belt that engages the timing belt pulley. The torque spring allows the stepper motor to drive the rewind hub rotate counter-clockwise only. When the media is fed back, the ribbon will not move. The torque spring arrangement automatically compensates for the gradually increasing diameter of the used ribbon on the rewind hub, so the ribbon will always be fed at the same speed as the media. Timing belt pulley Flange Torque spring Bobbin Brake sleeve Slide bearing Bobbin plate Locking washers (x3) Grub screw Flange Ball bearing Shaft Ball bearing Slide bearing Slide bearing EasyCoder PX4i and PX6i Service Manual 55 Chapter 7 — Transfer Ribbon Mechanism Replacement The ribbon rewind unit is fitted to the center section using two #T20 Torx screws inserted from the media compartment. One of the screws runs in a crescent-shaped slot to allow adjustment or removal of the belt. • Remove the left-hand cover as described in Chapter 3.3. • Remove the two #T20 Torx screws and the single washer that hold the ribbon rewind unit. • Free the belt from the pulley of the rewind unit. • Pull out the unit into the media compartment. • Do not dismantle the ribbon rewind unit. • Fit the new ribbon rewind unit in reverse order, making sure that the belt is properly attached to the pulley, but do not tighten the screws. • Adjust the tension of the belt as described in Chapter 8.5. • Tighten the screws. Belt Pulley (hidden) Washer & #T20 Torx screw #T20 Torx screw 56 EasyCoder PX4i and PX6i Service Manual Chapter 7 — Transfer Ribbon Mechanism 7.4 Ribbon Sensor Description The ribbon sensor is fitted to the center section from the media compartment side and is partly enclosed by the ribbon supply unit (see Chapter 7.2). The sensor consists of a plastic housing with a LED and a photoelectric sensor plus a cable. The light from the LED is intermittently blocked by the saw-toothed edge of the rotating code disc. The signals from the sensor allow the firmware to detect the speed with which the bobbin rotates and compare it with the speed of the media feed. Thus, both “out of ribbon” and “ribbon low” conditions can be detected. If no bobbin rotation is detected during media feed, the Fingerprint firmware assumes an error condition (error 1027 “Out of transfer ribbon”) provided the printer is set for thermal transfer printing. In IPL, the error message “Ribbon out” is displayed. The ribbon sensor is connected to J56 on the CPU board (see Chapter 15.3). Ribbon sensor #T10 Torx screw Ribbon supply unit Replacement • Remove the cover over the electronics compartment as described in Chapter 3.3, taking all precautions against electric shock. • Remove any transfer ribbon from the ribbon supply unit. • Remove the ribbon supply unit as described in Chapter 6.2. • Disconnect the sensor’s cable from J56 on the CPU board. • Remove the #T10 Torx screw that holds the sensor to the center section. • Install a replacement sensor unit in reverse order. EasyCoder PX4i and PX6i Service Manual 57 Chapter 7 — Transfer Ribbon Mechanism Adjustment (Fingerprint) Low diameter In the Setup Mode (see Appendix A), it is possible to specify the diameter (in millimeters) of the ribbon supply roll, when a ribbon low condition should occur. By default, this parameter is set to 0, which disables the function. To enable it, enter the desired value. The status of the ribbon sensor can be polled by reading SYSVAR(26) in a Fingerprint application program. SYSVAR(26) returns 0 if the diameter of the ribbon supply roll is greater and 1 if it is less than the value entered in the Setup Mode. A trap is also sent that can be detected when the printer is connected to a network via an EasyLAN interface. Note that a full forward rotation of the supply bobbin must have been completed. If not, 0 will be returned. Note: When the ribbon low function is enabled, error condition 1083 “Ribbon low” is reported every tenth time SYSVAR(26) = 1 is detected in connection with a PRINTFEED. Sensitivity • Enter the Setup Mode and follow the path: Media/Paper Type/Transfer/Ribbon Sensor • In the Ribbon Sensor menu, press to perform a Testfeed. • The printer will feed out a few labels and feed the ribbon accordingly. • While the ribbon mechanism is operating, the ribbon sensor is autoadjusted and the resulting adjustment value is shown in the lower line of the menu (read-only). Adjustment (IPL) In the Setup Mode (see Appendix A), it is possible to specify the value in millimeters of the ribbon supply roll for the ribbon sensor. When the diameter of remaining ribbon supply roll reaches the set value, an SNMP trap is sent to the printer’s home page, provided the printer has an optional EasyLAN connection. Range: 0-80 with preset values at an interval of 5. A value larger than 80 sets the ribbon sensor to 0. Default value: 0 The ribbon low sensor can also be set using an IPL command: kn There is no facility for adjusting the sensitivity of the ribbon sensor in IPL. 58 EasyCoder PX4i and PX6i Service Manual 8 Print Unit This chapter describes the print unit of the EasyCoder PX4i and PX6i printer and explains how to adjust the various functions and replace part subject to wear. It covers the following topics: • Description • Platen roller • Stepper motor • Belts • Label stop sensor • Printhead • Headlift sensor • Headlift mechanism • Media feed principles EasyCoder PX4i and PX6i Service Manual 59 Chapter 8 — Print Unit 8.1 Description The print unit is partly integrated with the ribbon rewind unit (see Chapter 7.3) and optional liner/batch takeup unit (see Chapter 9). EasyCoder PX4i Provision for liner/batch takeup unit Ribbon rewind unit Print unit EasyCoder PX6i Ribbon rewind unit Provision for liner takeup unit Print unit /PEN #LOSED 60 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit The main parts of the print unit are: • The rubber-coated platen roller drives the media forward under the printhead and provides the necessary counter-pressure. • The stepper motor drives the platen roller via one belt and the ribbon assist roller and the ribbon rewind unit via another. The liner drive roller is idle, unless a liner/batch takeup kit is fitted, see Chapter 9. • The tear bar makes it easier to tear off continuous and pre-perforated media stock. It is also used for peel-off (self-strip) operation. • The label stop sensor (LSS) controls the media feed and checks for outof-paper conditions. • The printhead produces the heat that melts the “ink” on the transfer ribbon or blackens the direct thermal paper in patterns that make up the text, graphics, or bar codes. • The headlift mechanism presses the printhead against the media or transfer ribbon, or raises the printhead to allow media and ribbon load. The print unit is a self-contained module and attached to the printer's center section by means of four #T20 Torx screws. There are also a number of cables running from the print mechanism to the driver and CPU boards (see Chapters 14.1 and 15.3), which are not illustrated. The ribbon rewind unit is driven by a belt from the motor of the print unit via an idle pulley attached to the inside of the center section. The liner drive roller (fitted underneath the platen roller) is either idle or driven by a belt to the optional liner/batch takeup stepper motor. These belts have to be removed before the print unit can be pulled out. EasyCoder PX4i and PX6i Service Manual 61 Chapter 8 — Print Unit EasyCoder PX4i The parts of the EasyCoder PX4i print unit, as seen from the media compartment side of the center section, are illustrated below. Cables are excluded. Pressure arm Stepper motor Belt to ribbon rewind unit Printhead position adjustment Printhead pressure adjustment Pulleys Printhead lift lever Edge guide Platen roller (barely visible) Tear bar Liner drive roller LSS adjustment screw Printhead with bracket 62 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit EasyCoder PX6i The parts of the EasyCoder PX6i print unit, as seen from the media compartment side of the center section, are illustrated below. Cables are excluded. Pressure arm Stepper motor Belt to ribbon rewind unit Printhead position adjustment Pulleys Printhead pressure adjustment Printhead lift lever Platen roller Edge guide Tear bar Liner drive roller Printhead with bracket EasyCoder PX4i and PX6i Service Manual LSS adjustment screw 63 Chapter 8 — Print Unit EasyCoder PX4i This overview illustrates the various parts in the print unit except cables. The idle pulley fitted to the center section and the ribbon rewind unit are not included. Note that many of the parts illustrated here are not available as separate spare parts, but must be bought as ready-assembled units. 64 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit EasyCoder PX6i This overview illustrates the various parts in the print unit except cables. The idle pulley fitted to the center section and the ribbon rewind unit are not included. Note that many of the parts illustrated here are not available as separate spare parts, but must be bought as ready-assembled units. EasyCoder PX4i and PX6i Service Manual 65 Chapter 8 — Print Unit The parts of the print mechanism fitted inside the electronics compartment in an EasyCoder PX4i printer are illustrated below. CPU board Driver board Ribbon rewind unit Idle roller Stepper motor (liner takeup) 66 Pulley & belt (platen roller) Stepper motor (platen roller & ribbon rewind unit) Pulley & belt (liner drive roller) EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit 8.2 Platen Roller Description The platen roller is coated with silicon rubber. It is imperative that the roller is kept clean and is free from uneven wear or dents. The platen roller is identical to the liner drive roller, so these rollers could be switched. The same applies to the pulleys and belts. It is normal that the platen roller needs to be replaced after a period of time depending on print volume and other circumstances. If the platen roller is manually rotated, while the power is switched on, the stepper motor may work as a generator and damage the stepper motor driver on the driver board (see Chapter 14). A typical example is when the operator tears out media that has stuck on the platen roller without switching off the power first. Replacement This description also applies to the liner drive roller. • Switch off the power to the printer and disconnect the power cord. • Open the front and right hand doors. • Remove the cover over the electronics compartment, which is held by eight #T10 Torx screws, see Chapter 3.3. • Remove the tension of the belt to the ribbon rewind unit by loosening the two #T20 screws that holds the ribbon rewind unit. • Dismantle the stepper motor from the bracket by removing the two #T20 Torx screws. • Free the belt from the pulley of the ribbon rewind unit and manipulate the stepper motor so it comes free from both belts. Remove the stepper motor. • Remove the belt from the pulley of the platen roller. • Insert a 2 mm hexagon key through the semicircular slot in the front plate and loosen the grub screw that holds the pulley on the shaft of the platen roller. • Using a #T20 screwdriver, remove the bracket that holds the outer end of the platen roller and pull out the entire package. • Reassemble in reverse order using a fresh set of roller and bearings. When fitting back the pulley on the platen roller shaft, check that the distance between the pulley and the inner gable of the print unit becomes 5 mm (0.2 inches.) • When putting back the stepper motor, fit the short belt first, while letting the long belt hang loosely on the idler in a loop, through which you can insert the pulley of the stepper motor. Do not put the long belt around the pulley of the ribbon rewind unit until you have fitted the stepper motor to the bracket and checked that both belts are engaged by the stepper motor’s pulleys. • Adjust the tension of the belts as described in Chapter 8.4 and put back the cover. EasyCoder PX4i and PX6i Service Manual 67 Chapter 8 — Print Unit EasyCoder PX4i In the illustration below, the upper parts of the print unit and the label stop sensor have been removed to improve visibility. #T20 Torx screw Belt to ribbon rewind unit Stepper motor #T20 Torx screw Belt to platen roller Pulley Ball bearing Plastic bearing Spacer Platen roller Spacer Plastic bearing Ball bearing Bracket #T20 Torx screw 68 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit EasyCoder PX6i In the illustration below, the upper parts of the print unit and the label stop sensor have been removed to improve visibility. #T20 Torx screw Belt to ribbon rewind unit Stepper motor #T20 Torx screw Belt to platen roller Pulley Ball bearing Plastic bearing Spacer Bracket Platen roller Plastic bearing Ball bearing Bracket #T20 Torx screw EasyCoder PX4i and PX6i Service Manual 69 Chapter 8 — Print Unit 8.3 Stepper Motor Description The stepper motor drives the platen roller via a short belt and the ribbon assist roller and the ribbon rewind unit via another, longer belt. A freely rotating pulley attached to the printer’s center section makes the outside of the longer belt drive the ribbon assist roller. The stepper motor is driven in microsteps (8 microsteps per full step) at all speeds. The stepper motor is fitted by two #T20 Torx screws to a bracket, which in its turn is attached to the print unit gable by three #T20 Torx screws. The pulleys of the stepper motor are permanently glued to the motor’s shaft. Replacement Replace the stepper motor as follows: • Switch off the power and disconnect the power cord. • Open the front and right hand doors. • Remove the cover over the electronics compartment, which is held by eight #T10 Torx screws, see Chapter 3.3. • Disconnect the cable to the stepper motor from the driver board. • Remove the tension of the belt to the ribbon rewind unit by loosening the two #T20 screws that hold the unit, see Chapter 7.3. • Dismantle the stepper motor from the bracket by removing the two #T20 Torx screws. • Free the belt from the pulley of the ribbon rewind unit and manipulate the stepper motor so it comes free from both belts. Remove the stepper motor. • When putting back the stepper motor, fit the short belt first, while letting the long belt hang loosely on the idler in a loop, through which you can insert the pulley of the stepper motor. Do not put the long belt around the pulley of the ribbon rewind unit until you have fitted the stepper motor to the bracket and checked that both belts are engaged by the pulleys. • Connect the cable of the stepper motor to upper connector along the inner edge of the driver board (P10). • Adjust the tension of the belts as described in Chapter 8.4 and put back the cover. Refer to illustration on the next page! 70 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit In the illustration below, most parts of the print unit have been omitted to improve visibility. Note: The bracket does not need to be removed from the inner print unit gable when the stepper motor is replaced. #T20 Torx screws (×2) Stepper motor Ribbon rewind unit and ribbon assist roller belt Idle roller with shaft (fitted to center section) Ribbon assist roller pulley Bracket (do not remove!) Platen roller belt Platen roller pulley Inner print unit gable EasyCoder PX4i and PX6i Service Manual 71 Chapter 8 — Print Unit 8.4 Belts Description The print unit has at least two timing belts, one that drives the platen roller and another that drives the ribbon assist roller and the ribbon rewind unit. There is also a third belt if an optional liner/batch takeup unit is fitted (see Chapter 9). The belts are subject to wear and may need periodical replacement. Properly adjusted tension and alignment of the pulleys will increase time between replacements. Replacement • Switch off the power and disconnect the power cord. • Open the front and right hand doors. • Remove the cover over the electronics compartment, which is held by eight #T10 Torx screws, see Chapter 3.3. • Remove the tension of the belt to the ribbon rewind unit by loosening the two #T20 screws that hold the unit, see Chapter 7.3. • Dismantle the stepper motor from the bracket by removing the two #T20 Torx screws. • Free the belt from the pulley of the ribbon rewind unit and manipulate the stepper motor so it comes free from both belts. Remove the stepper motor. • Replace the defective belt or belts. • When putting back the stepper motor, fit the short belt first, while letting the long belt hang loosely on the idler in a loop, through which you can insert the pulley of the stepper motor. Do not put the long belt around the pulley of the ribbon rewind unit until you have fitted the stepper motor to the bracket and checked that both belts are engaged by the pulleys. • Adjust the tension of the belts as described later in this chapter and put back the cover. Refer to illustration on the next page! 72 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit #T20 Torx screws (×2) Stepper motor Ribbon rewind unit and ribbon assist roller belt Ribbon rewind unit Platen roller belt EasyCoder PX4i and PX6i Service Manual 73 Chapter 8 — Print Unit Adjustment; Platen Roll Belt Oversized holes allow the position of the stepper motor relative to the bracket to be adjusted so the tension of the belt does not become too tight, causing unnecessary wear. Check that the platen roller can be rotated freely by the belt, which should flex just a little when you press it with your finger. #T20 Torx screw #T20 Torx screw Stepper motor pulley Stepper motor Belt Platen roller pulley 74 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit Adjustment; Ribbon Rewinder Belt The belt should be adjusted so it neither jump the cogs nor becomes subject to unnecessary wear. Before adjusting this belt, check the tension of the platen roller belt as described on the previous page. Slightly loosen the two #T20 Torx screws that hold the flange of the ribbon rewind unit. Turn the ribbon rewind unit so the belt becomes tight, yet will flex slightly when you press it with a finger. Tighten the screws. Check that the parts can rotate freely and without any unpleasant sound and that the belt does not jump the cogs when you rotate the ribbon rewind unit forcefully. The ribbon return roller should be easy to rotate manually. Once the motor starts, the belt will be tight and will drive the ribbon assist roller. If the idler roller starts to squeak, lubricate the inside of the belt with a small quantity of grease. #T20 Torx screw inside media compartment Ribbon rewind unit pulley Idler roller Ribbon assist roller pulley #T20 Torx screw inside media compartment Belt Stepper motor pulley Stepper motor EasyCoder PX4i and PX6i Service Manual 75 Chapter 8 — Print Unit 8.5 Label Stop Sensor Description The label stop sensor (LSS) controls the media feed and consists of a sliding carriage on which two photoelectric sensors are fitted. Both sensors are identical and contain one light-emitting diode and one light-sensitive receiver. The distance from the light path between the two parts of the LSS to the dot line on the printhead is 46.3 mm (1.82 inches). The sensors can be moved up to 50 mm (1.97 inches) out from the inner edge of the media path using a screw protruding through the lower outer gable of the print unit. In EasyCoder PX6i, this screw is only accessible when the locking handle is folded down. The label stop sensor is hidden inside the print mechanism and covered by two plastic guide plates, which can be removed for cleaning. Working Principles The label stop sensor serves a number of purposes, depending on how the printer is set up in regard of media type in Fingerprint and IPL respectively: Label (w gaps)/Gap A beam of light is emitted from the diode in the lower part and received by the sensor in the upper part. The firmware detects the front of each label, that is, when the light is completely interrupted by the opaque label, as opposed to the semi-transparent liner in the gaps between labels. If no label has been detected during a media feed corresponding to more than 150% of the set label length, a “next-label-not-found” condition is assumed. If a renewed print operation gives the same result, an “out-ofpaper” condition is assumed. Ticket (w mark)/Mark Normally, a beam of light is emitted from the diode in the lower part. The beam is reflected back to the sensor in the lower part by the white media, or is absorbed by a black mark. The firmware detects when the front edge of a black mark passes the sensor, that is, when light starts to be absorbed. If no mark has been detected during a media feed corresponding to more than 150% of the set ticket length, a “next-label-not-found” condition is assumed. If a renewed print operation gives the same result, an “out-ofpaper” condition is assumed. By switching the cables from the upper and lower part of the LSS on the CPU board, black marks on top of the media can be detected. Ticket (w gaps)/Gap The light is emitted from the diode in the lower part and received by the sensor in the upper part. The light will either pass uninterrupted through a detection gap in the media or be blocked by the non-transparent ticket. The firmware detects the rear edges of detection gaps, that is, when the light starts being interrupted. If no ticket has been detected during a media feed corresponding to more than 150% of the set ticket length, a “nextlabel-not-found” condition is assumed. If a renewed print operation gives the same result, an “out-of-paper” condition is assumed. 76 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit Var. Length Strip and Fix Length Strip/Continuous The light is emitted from the diode in lower part and received by the sensor in the upper part. The beam will either be blocked by the media or be completely uninterrupted when the printer runs out of continuous stock. The firmware assumes an out-of-paper condition if the light has not been interrupted within a media feed corresponding to 150% of the set length. General The information on where the gaps or marks are presently positioned relative the LSS (and thereby also relative the dot line on the printhead) is saved as an “invisible” file in the flash memory’s file operating system (see Chapter 15.2). However, if the printhead is raised, or if the power is interrupted during printing, this file may be cleared, which will affect any labels between the LSS and the dot line. In this case, readjust the LSS using a TESTFEED operation (Fingerprint) or by pressing the button (IPL). Note (Fingerprint only): It is possible to decide if the media feed data should be cleared or not when the printhead is raised using the Fingerprint instruction SYSVAR(28). By default, the media feed data are not cleared. The LSS checks for gaps or marks at every dot of positive media feed (feed out/print), but gaps or marks are ignored at negative media feed (retract). Gaps and black marks up to 170 dots (21.3 mm/0.84 inches) are allowed. Testing the LSS In the Print Defines part of the Setup Mode, you have two ways to test the label stop sensor if you encounter a detection problem; LSS Auto and LSS Manual. The menus only provide indications from the label stop sensor unit. The testing menus can determine if the sensor unit is not physically in position, is blocked by dust or stuck labels, or is defective in some way. Furthermore, this is an aid if media has detection complications. Note: There is no way to adjust the LSS-function; the menus only indicate values from the LSS obtained by performing a testfeed operation. LSS Auto is the quick and normal way to determine if the label stop sensor works properly and is able to detect gaps, slots, or black marks. LSS Manual shows the actual setting provided by the latest testfeed operation. It is also possible to try other settings. LSS Manual is primarily intended for service and is not described in the User’s Guide. LSS Auto • Check that the printer is set up for the type of media loaded in your printer. • Perform a testfeed by simultaneously pressing the and keys on the printer’s keyboard (Fingerprint) or by pressing the key (IPL). • Make sure that there is a label—not a gap or mark—at the LSS. EasyCoder PX4i and PX6i Service Manual 77 Chapter 8 — Print Unit • Check that the media is routed as close to the center section as the guides allow. • Enter the Setup Mode and go to Setup Mode→Print Defines→LSS Test→LSS Auto (Fingerprint) or Setup Mode→Test/Service→LSS Test→LSS Auto (IPL). • The menu should look like this with the cursor placed in the center: LSS Auto • Gap or slot detection: Lift the printhead and pull out the media slowly. When the LSS detects a gap or a detection slot, the cursor moves to the right. LSS Auto • Black mark detection: Lift the printhead and pull out the media slowly. When the LSS detects a black mark, the cursor moves to the left. LSS Auto • It is possible to refresh the centered cursor position by pressing the key. • If the cursor behaves as described above, the LSS is working and is properly aligned with the gaps, slots, or black marks. • If the cursor does not react on a gap, slot, or black mark, check this: - Is the LSS laterally aligned with the slots or black marks? - Are both the upper and lower part of the LSS aligned with each other? - Is the transfer ribbon properly loaded so it does not interfere with the LSS? - Are the sensors clean from dust and the LSS guides free from stuck labels or other objects that will interfere with the light that goes from one part of the LSS to the other? If not, clean as described in the User's Guide. - Does the media have some kind of preprint that can disturb the detection? - Is there too little difference between the black marks and the surrounding areas? - Does the liner have too little transparency? - Does the LSS work with another type of media? (Remember to change the Media Type setup and perform a new testfeed.) 78 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit LSS Manual The LSS Manual option shows the actual setting given by the automatic testfeed. The cursor on the lower line indicates the response on the actual testfeed values for the Gain (sensitivity) and Drive (intensity). LSS [G: 2]D: 6 You can toggle between gain (G) and drive (D) using the <`> and <_> keys and decrease or increase the value using the and keys respectively. Note: Changing the gain and drive does not reset the LSS. It only affects the testing. Once you leave the LSS Manual node, the values obtained by the automatic testfeed become effective again. If there are preprinted areas on the liner or cut-out slots etc., it can disturb the automatic testfeed. To identify the problem, manually move the media can check the response from the sensor in detail on the display. The solution is often to move the sensor sideways to a position where the preprint or similar is not disturbing. Other problems, such as low gap opacity, semi-transparent labels when using gap detection, or black marks that do not absorb the light sufficiently, can also be identified by changing the gain and drive manually. If there is no dust or other things mechanically interfering with the LSS, check the hardware by changing first the gain and secondly the drive values. If the cursor is positioned in either the extreme left or right position and refuses to move, check cables, replace the LSS, or—as a last resort— replace the CPU board. Sensitivity Adjustment The LSS should always be adjusted when the user changes to another brand (sometimes even a new batch) of media, and when a defective sensor has been replaced. This is especially the case with self-adhesive labels on liner, because the transparency of the liner may vary and the difference between labels and gaps may be too small. Before starting the adjustment, check that both the upper and lower sensor are clean and free from obstructions and that the edge guides are adjusted so as to guide the media with a minimum of play. Also check that both parts of the LSS are in the same lateral position and aligned with any gaps or black marks. Fingerprint only As standard, there are four ways to adjust the LSS: • Performing a TESTFEED by simultaneously pressing the “Shift” and “Feed” keys on the printer’s built-in keyboard. • Selecting the TESTFEED option in Intermec Shell. • Selecting the TESTFEED option in the Setup Mode. • Executing a TESTFEED statement in a Fingerprint program. The printer feeds out 1.5 times the set label length or less while testing all levels of the LSS at each millimeter of media feed. The LSS is adjusted according to the result of the check and a full label is fed out according to the present feedadjust setup. EasyCoder PX4i and PX6i Service Manual 79 Chapter 8 — Print Unit The label stop sensor/black mark sensor can be turned off for a specified amount of media feed using the LBLCOND statement, see Intermec Fingerprint v8.xx Programmer’s Reference Manual. IPL only The sensitivity of the LSS is configured at startup. To force adjustment of the sensitivity (corresponding to a TESTFEED in Fingerprint), raise and close the printhead and then press the key. Adjustment of the LSS Lateral Position The label stop/black mark sensor (LSS) can be laterally adjusted within a range of 0 to 50 mm (1.96 inches) from the inner edge of the media path by means of a screw accessible through the outer lower gable. Turning the screw clockwise will move the LSS inwards and vice versa. The position of the LSS in relation to the media is best checked by looking head on into the print unit when the printhead is raised. Align the centerpoint of the Vshaped upper sensor with the center of the slots or marks to be detected. The linear markings on the lower guide plate can also be used for positioning of the LSS as they are spaced with an interval of exactly 1 cm (0.39 inches) from the edge that guides the media. This method is especially useful for black marks (measure the lateral position of the black marks with a ruler before loading the media.) If using irregularly shaped labels, align the LSS with the front tips of the labels. /54 /54 80 ). ). EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit Removing the Guide Plates The LSS guide plates will need to be removed for occasional cleaning, replacement and when replacing a defective sensor. • To remove the upper guide plate, just pull it straight out. • To remove the lower guide plate, disengage the snap-lock (accessible through a slot in the lower gable) using for example a screwdriver and lift the outer end of the guide plate. Then pull it out. When cleaning the guide plates, use a soft cloth moistened with isopropyl alcohol. Do not use any other type of chemicals. Blow the sensors free from dust. Isopropyl alcohol [(CH3)2CHOH; CAS 67-63-0] is a highly flammable, moderately toxic, and mildly irritating substance. EasyCoder PX4i and PX6i Service Manual 81 Chapter 8 — Print Unit Replacing the Sensors To remove the LSS bracket from the carriage, for example in connection with cleaning or replacing a sensor, proceed as follows: • Switch off the power, remove the power cord and remove the cover over the electronics compartment. • Remove the upper and lower plastic guide plates. • Adjust the LSS to approximately center position. • Disconnect the cables from J54 and J55 on the CPU board. • Disengage the snap-lock, using a screwdriver from the media compartment side, and push the outer end of the LSS bracket upward. Then pull the bracket out from the carriage, taking care not to damage the cables. Note! The snap-lock is fragile. • Remove the two #TX8 Torx screws that hold the defective sensor and replace it. LSS bracket Upper sensor Lower sensor Snap-lock Carriage 82 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit To reassemble the LSS, proceed as follows: • Thread the cables through the hole in the inner gable. • Place the inner, lower corner of the bracket into the groove in the carriage, almost at the innermost end. • Tilt the bracket up at the outer end and push it inwards so the inner notch in the bracket engages the carriage. • Press down the outer end of the bracket, so the snap-lock engages the outer notch. • Press the bracket inwards as far as it goes and check that the bracket is secured by the snap-lock. • Connect the cable from the lower sensor to J54 (marked “GAP”) and the cable from the upper sensor to J55 (marked “BM”) on the CPU board. • Put back the guide plates, the electronics compartment cover, and the power cord. • Adjust the lateral position of the LSS. Connect to J55 on CPU board Connect to J54 on CPU board Inner notch Outer notch Snap-Lock EasyCoder PX4i and PX6i Service Manual 83 Chapter 8 — Print Unit 8.6 Printhead Description The printing is produced by the thermal printhead, which consists of a line of very small, closely spaced resistors on a ceramic tile fitted across the media path. When a current is led through the resistors, commonly called “dots,” these will be heated very quickly. When the current is shut off, the dots cool down just as fast. As the media is fed past the dots, the hot dots will produce a number of black spots on heat sensitive (direct thermal) media, or on other face materials via a thermal transfer ribbon. The spots can be combined into bitmap patterns, which make up characters, bar codes, images, lines, and boxes. The direct thermal printing method requires special media coated with a thin layer of heat-sensitive chemicals. As the media is fed past the dots, the heat from the dots will make the chemicals react, producing a dark salt, which makes up the imprint under each dot. In the thermal transfer printing method, a special “ink”-coated transfer ribbon is used. When the ribbon is heated by a dot on the printhead, the “ink” melts and sticks to the receiving face material, where the ink immediately becomes solid again, producing a black spot. Transfer ribbons normally do not smear at room temperature, neither before nor after printing. Nor do the printed labels smear, even if the printout may be smudged by extensive rubbing if an unfortunate combination of ribbon and face material is used. The thermal transfer method makes it possible to use a wide range of face materials for printing, for example papers, boards, plastics, foils, etc. However, an original transfer ribbon from Intermec should always be used. Information on how to switch between direct thermal and thermal transfer printing is provided in the User’s Guide. The basis for all measures and positioning in both the Fingerprint and IPL programming languages is the size of printhead dots. In an 8 dots/mm (203.2 dpi) printhead, each dot has a nominal size of 0.125 mm (4.92 mils). This means that a heated dot under standardized conditions will produce a black spot which has a diameter of 0.125 mm (4.92 mils). In an 11.81 dots/mm (300 dpi) printhead (Fingerprint only), each dot has a nominal size of 0.086 mm (3.33 mils). This means that a heated dot under standardized conditions will produce a black spot which has a diameter of 0.086 mm (3.33 mils). Depending on dot temperature, exposure time, media and ribbon characteristics, etc., the spot may actually be somewhat smaller (weak print) or larger (black print), but that does not affect the calculation of distances, sizes, and positions. At startup, the printer auto-detects the printhead density as well as the head resistance. The printhead can also be checked using the Fingerprint instructions HEAD, FUNCTEST, and FUNCTEST$. In IPL, the number and size of the dots in the printhead is returned to the host by the command H . 84 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit The printhead is fitted to a bracket using two screws. The printhead, the printhead ribbon break shaft, and the bracket are always delivered as a complete assembly and must not be dismantled. Two hooked fingers at the rear of the bracket are fitted over the headlift shaft so as to hold the printhead in place. A U-shaped tab on either side of the bracket engage the platen roller bearings when the printhead is closed, making sure that the printhead becomes properly aligned with the platen roller. There are no facilities for adjusting the position of the printhead relative the platen roller, neither longitudinally nor laterally. There are two sets of cables in a harness running to the printhead: • The innermost cable is used for the power to the printhead and is connected to P5 on the driver board. • The outermost cable is used for data to the printhead and is connected to J40 on the CPU board. Note: It is important that the cable harness does not prevent the printhead from moving or adjusting itself when it is lowered. “Finger” Bracket Cable harness Label “Finger” Printhead ribbon break shaft Printhead Illustration shows the printhead of an EasyCoder PX4i. The printhead of EasyCoder PX6i looks in principle the same but is wider. EasyCoder PX4i and PX6i Service Manual 85 Chapter 8 — Print Unit Print Window PX4i The EasyCoder PX4i has an 8 dots/mm (203.2 dpi) printhead or, in the Fingerprint version only, an 11.81 dots/mm (300 dpi) printhead. 8 dots/mm Printhead Density Print width Number of dots Dot size 8 dots/mm (203.2 dots per inch) 112 mm (4.4 inches) 896 0.125 mm (4.92 mils) MM IN 0RINT 7IDTH MAX MM IN $OT LINE ON PRINTHEAD $OT &%%$ $)2%#4)/. $OT -EDIA 7IDTH MM IN 86 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit 11.81 dots/mm Printhead (not IPL) Density 11.81 dots/mm (300 dots per inch) Print width 112 mm (4.4 inches) Number of dots 1322 Dot size 0.085 mm (3.33 mils) MM IN 0RINT 7IDTH MAX MM IN $OT LINE ON PRINTHEAD $OT &%%$ $)2%#4)/. $OT -EDIA 7IDTH MM IN EasyCoder PX4i and PX6i Service Manual 87 Chapter 8 — Print Unit Print Window PX6i The EasyCoder PX6i has an 8 dots/mm (203.2 dpi) printhead or, in the Fingerprint version only, an 11.81 dots/mm (300 dpi) printhead. 8 dots/mm Printhead Density Print width Number of dots Dot size 8 dots/mm (203.2 dots per inch) 167.4 mm (6.59 inches) 1344 0.125 mm (4.92 mils) MM IN 0RINT 7IDTH MAX MM IN $OT LINE ON PRINTHEAD $OT &%%$ $)2%#4)/. $OT -EDIA 7IDTH MM IN 88 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit 11.81 dots/mm Printhead (not IPL) Density 11.81 dots/mm (300 dots per inch) Print width 167.4 mm (6.59 inches) Number of dots 1984 Dot size 0.085 mm (3.33 mils) MM IN 0RINT 7IDTH MAX MM IN $OT LINE ON PRINTHEAD $OT &%%$ $)2%#4)/. $OT -EDIA 7IDTH MM IN EasyCoder PX4i and PX6i Service Manual 89 Chapter 8 — Print Unit Replacing the Printhead The printhead is a consumable part subject to wear from both the thermal paper or transfer ribbon, and from the rapid heating and cooling process during printing. Thus, it will require periodical replacement depending on print volume, type of print media, amount of energy to the printhead, and several other factors. To replace a defective or worn printhead, proceed as follows: • Switch off the power. • Open the front and right-hand doors. • Turn the printhead lift lever to “Open” position. • Remove any media and/or transfer ribbon from the print unit. • Carefully pull the printhead bracket away from the magnet in the lift arm. • Disconnect the hooked fingers at the rear of the bracket from the headlift shaft and pull out the printhead as far as the cables allow. • Disconnect the two cables from the printhead. Note the snap-lock on the inner connector. Pull at the connectors, not at the cables! • Connect the cables to the replacement printhead assy with the ribbon cable to the right. • Insert the printhead assy into the print unit, fitting the bracket’s fingers over the headlift shaft. • Check so the cables will not interfere with the transfer ribbon, prevent the printhead from moving freely, or have become jammed between parts in the print unit. • Turn the printhead lift lever to “Closed” position, so the magnet engages the printhead bracket. • Switch on the power. The printer’s firmware automatically measures the printhead resistance at power-up. • Load media and, if so required, transfer ribbon again. Refer to the illustrations on the next page! Detailed step-by-step illustrations can be found in the User's Guide, Chapter “Maintenance.” 90 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit EasyCoder PX4i EasyCoder PX6i EasyCoder PX4i and PX6i Service Manual 91 Chapter 8 — Print Unit Precautions Some simple measures can be taken by the user to prevent premature wearout: • Clean the printhead regularly, as described in the User’s Guide. Not only will a dirty printhead produce an inferior printout, but any residue on the dots will prevent heat to dissipate through the media. • Follow the Intermec’s recommendations regarding Paper Type or Media Sensitivity setup. Too much energy to the printhead will wear it out rapidly. • Do not use higher Print Speed setting than necessary. • Low ambient temperature requires more energy to the printhead dots than room temperatures and will therefore cause more wear to the printhead. High print speed accelerates the wear. Thus, at low temperatures, select as low a print speed as acceptable. • In Fingerprint, do not use a higher Contrast setting than necessary, especially not in combination with the highest Label Constant or Ribbon Constant settings. • In IPL, do not use a higher Darkness setting than necessary. • Do not use a higher printhead pressure than necessary. • Never print outside the media path. Dots that are not in contact with the media will not be cooled properly. • When using media with less than full width, be careful to adjust the printhead lift arm so there is an even pressure across the media. Not only will an uneven pressure impair the printout quality, but it may also prevent the dots from being properly cooled. Moreover, a sharp outer media edge in direct contact with the printhead may cause excessive mechanical wear on some dots, which may be visible when printing on wider media later. • When using preprinted labels or labels with some type of varnish or non-standard top coating for direct thermal printing, use original Intermec labels or inks recommended by leading manufacturers of direct thermal media. The labels must not contain any aggressive substances such as chloride or grinding substances such as titanium dioxide. • Only use transfer ribbons recommended by Intermec. 92 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit 8.7 Headlift Sensor Description The purpose of the headlift sensor is to detect whether the printhead is raised or lowered. To avoid the risk of overheating the printhead dots, printing can not be performed when the sensor detects that the printhead is raised (the media serves to cool the printhead). An ever so slightly raised printhead would also impair the printout quality. Thus, it is important that the printhead is properly lowered and a sufficient pressure is applied before the sensor detects a “Closed” condition. The photoelectric sensor is attached to the electronics compartment side of the inner print unit gable by means of two #T10 Torx screws. When the printhead is raised, a beam of light is interrupted by an arm connected to the headlift shaft. This is detected by the firmware so an error message will be returned if you try to print a label. In Fingerprint, error message 1022 “Head Lifted” will be returned if you try to print a label with the printhead lifted. In IPL, the error message “Print Head Up/Press Feed” is displayed. The headlift sensor is connected to J58 (marked “HEADL”) on the CPU board. The arm that blocks the light through the sensor is attached to the headlift shaft using a #T10 Torx screw. If the screw is not tightened sufficiently or if the arm is not fitted in the correct angle, a malfunction will occur. Adjusting the Sensor Arm • Perform an adjustment of the printhead pressure as described in Chapter 8.8. • Without switching off the power, remove the cover over the electronics compartment. The electronics compartment contains wires and circuits with dangerous voltage. Take precautions to avoid electrical shock, short-circuits, and electrostatic discharges. • Place a 1 mm (0.04 inches) thick feeler gauge between the printhead and the platen roller and lower the printhead. Be careful not to damage the delicate printhead dots! • Loosen the #T10 Torx screw that holds the sensor arm. • In case of Fingerprint printers, run the program listed on the next page. • Move the sensor arm from open position towards closed position until the Error LED goes out, which indicates the correct position. • Tighten the screw and check that the arm runs freely inside the forkshaped sensor. • Put back the cover. EasyCoder PX4i and PX6i Service Manual 93 Chapter 8 — Print Unit #T10 Torx Screw Headlift shaft Sensor Arm “Printhead Open“ position “Printhead Closed” position Sensor In Fingerprint, run this program which assists you in adjusting the headlift sensor arm: Status LED red = Printhead open. Status LED off = Printhead closed. The correct position is exactly when the Status LED goes off. You can break the program execution either by pressing + on the printer's keyboard or by transmitting the character X (uppercase!) from the host. NEW 10 20 30 40 50 60 70 80 1000 1010 RUN BREAK 1, 88 BREAK 1 ON ON BREAK 1 GOSUB 1000 LED 1 OFF WHILE (PRSTAT AND 1)=0: WEND LED 1 ON WHILE (PRSTAT AND 1)=1: WEND GOTO 40 BREAK 1 OFF END In IPL, check that the sensor is properly adjusted using the Label Path Open Sensor Value command ( L ), see IPL Programming, Reference Manual. 94 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit Sensor Replacement Before replacing the sensor, check that the sensor arm is properly adjusted and that the sensor is free from dust, paper shreds, and other things that can block the light. Replace the sensor as follows: • Switch off the power, remove the power cord, and remove the cover over the electronics compartment. • Check that the printhead is lowered. • Remove the #T10 Torx screw that holds the front of the sensor. • Raise the printhead. • Remove the #T10 Torx screw that holds the rear of the sensor. • Pull out the sensor and disconnect its cable from the CPU board. • Reassemble in reverse order. The sensor’s cable should be connected to J58 (marked “HEADLIFT”) on the CPU board. • In Fingerprint, check that the sensor works properly using a PRSTAT statement, see Intermec Fingerprint v8.xx, Programmer’s Reference Manual. • In IPL, check that the sensor works properly using the Label Path Open Sensor Value command ( L ), see IPL Programming, Reference Manual. EasyCoder PX4i and PX6i Service Manual 95 Chapter 8 — Print Unit 8.8 Headlift Mechanism Description The headlift mechanism is an integrated part of the print unit. The mechanism is activated by the green printhead lift lever at the outside of the upper part of the print unit. The knob is fitted on a shaft, which has a disk with an eccentrically fitted pin on the inside of the upper, outer gable of the print unit. This pin activates a fork-shaped pressure adjuster, that via a linkage is connected to the headlift shaft. The pressure adjuster is fitted with a spring and an adjusting screw. Thus, the operator can easily apply more or less pressure of the printhead against the platen roller depending on type of media, print method, media thickness, and other circumstances. The headlift shaft is connected to the headlift sensor arm on the inside of the print unit (see Chapter 8.7.) On the headlift shaft, the S-shaped headlift arm is also fitted. At the tip of the headlift arm is a magnet that engages the printhead bracket. The arm can be moved along the headlift shaft, so the pressure can be applied laterally at the center of the media path, even when narrow media are used. The hooked fingers of the printhead bracket are hung on the headlift shaft. The concept allows the printhead to align itself vertically to the platen roller, while maintaining a fixed alignment in the other two dimensions. Return spring Sensor arm Headlift shaft Pressure adjuster Linkage Headlift arm Eccenter Printhead pressure grub screw (factory-adjustment) 96 Printhead lift lever EasyCoder PX4i EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit Return spring Sensor arm Headlift shaft Pressure adjuster Headlift sensor Linkage Headlift arm Printhead lift lever Printhead pressure grub screw (factory-adjustment) EasyCoder PX6i EasyCoder PX4i and PX6i Service Manual 97 Chapter 8 — Print Unit Printhead Pressure Adjustment The pressure of the thermal printhead against the ribbon or media is factory adjusted. However, the use of thicker or thinner media than normal could require the printhead pressure to be readjusted. Turn the green adjustment knob clockwise for increased pressure, or counterclockwise for less pressure. Print a few labels, preferably test labels, and check the printout. Increased pressure generally gives a blacker printout and vice versa. Repeat until the desired result is obtained. To find the basic setting, proceed as follows: • Remove the transfer ribbon (if any). • Load the printer with full width media and close the printhead. • Adjust the headlift arm to center position. • Turn the green adjustment knob counterclockwise until it feels loose (no pressure left). • Take up the slack in the green knob until you notice an increased resistance. • Using a 2 mm hexagonal key, loosen the factory adjustment grub screw (see illustration on the previous page) until the printhead starts to come up. • Carefully tighten the grub screw until you just start noticing a small resistance when trying to pull out the media. It is possible to apply very high printhead pressure using the factory adjustment grub screw. Such high pressure may damage the printhead, the platen roller, and the headlift arm. Do not use a higher printhead pressure than necessary, because it may increase the wear of the printhead and thus shorten its life. • Apply some locking fluid on the grub screw. • Raise and lower the printhead. • EasyCoder PX4i: Turn the knob 4 full turns clockwise. Each turn increases the pressure by approx. 1 kp to a total of 4 kp (39.2 N). EasyCoder PX6i: Turn the knob 5 full turns clockwise. Each turn increases the pressure by approx. 1 kp to a total of 5 kp (49.0 N). • Fine-adjust using test labels and the trial-and-error method (if necessary after having loaded the transfer ribbon again). Refer to the illustrations on the next page! 98 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit Adjustment knob (green) EasyCoder PX4i Adjustment knob (green) /PEN #LOSED EasyCoder PX6i EasyCoder PX4i and PX6i Service Manual 99 Chapter 8 — Print Unit 8.9 Ribbon Assist Roller Description (EasyCoder PX4i and PX6i) The purpose of the ribbon assist roller is to help the ribbon rewind unit to keep the transfer ribbon tight, thereby avoiding ribbon wrinkling, which could ruin the printout. The angle of the ribbon assist roller relative to the printhead is adjustable. The ribbon assist roller is subject to very little wear and is expected to last as long as the printer as a whole. Replacement involves removing the belt and pulley as well as the upper, outer gable of the print unit (see illustrations in Chapter 8.8.) Adjustment (EasyCoder PX4i and PX6i) If the ribbon becomes wrinkled, a few checks should be performed before the ribbon assist roller is readjusted: • Is the printhead pressure properly adjusted? • Is the green edge guide correctly positioned? • Is there anything that may interfere with the transfer ribbon, for example the printhead cables. If the wrinkling problem remains, proceed as follows: • Using a #T20 Torx screwdriver, loosen the locking screw that runs in the crescent-shaped hole in front of the headlift lever. • Insert a #T20 Torx screwdriver as illustrated on the next page. By turning the screwdriver, you can move the outer end of the roller back and forth: - Turn the screwdriver clockwise to move the end of the roller forward. - Turn it counterclockwise to move the end of the roller rearward. • If the ribbon gets wrinkled at the inner edge, you should move the end of the roller slightly rearward, that is, rotate the screwdriver counterclockwise and vice versa. • Select an appropriate layout, for example a test label, and print it repeatedly while carefully moving the end of the roller back or forth, depending on which side the wrinkling has occurred. • When the wrinkling ceases, continue the movement ever so slightly to create a small safety margin. The movement is best detected by the relation between the roller bearing and the hole through the upper gable. Another method is to determine the positions where wrinkling starts at either side and adjust the roller to the middle. • You will need to print several labels before a new adjustment has any noticeable effect. • When you are satisfied that the problem is cleared, tighten the locking screw and test again by printing several more labels. Readjust if necessary. Refer to the illustrations on the next page! 100 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit EasyCoder PX4i Ribbon assist roller #T20 Torx locking screw EasyCoder PX6i #T20 Torx screwdriver Ribbon assist roller /PEN #LOSED #T20 Torx locking screw #T20 Torx screwdriver Wrinkling Turn Screwdriver Inner side Counterclockwise Outer side Clockwise EasyCoder PX4i and PX6i Service Manual 101 Chapter 8 — Print Unit 8.10 Media Feed Principles Fingerprint only The Start and Stop Adjust parameters in the Fingerprint Setup Mode control how the media will be positioned in relation to the printhead when the printing starts and after the printing is completed, respectively. By default, the Start and Stop Adjust parameters are both set to 0, which is suitable for tearing off the media against the tear bar, for example between labels or at the perforation in a pre-perforated continuous stock. However, because the dot line on the printhead is situated 15.7 mm (0.62 inches) back from the tear bar, the printing will not start at the top of the label but further back along the media path. MM $EFAULT 4EAR OFF 3TART !DJUST 3TOP !DJUST $OT ,INE ON 0RINTHEAD 4EAR "AR ,ABEL 3TOP 3ENSOR Note: Due to several factors, media feed measurements are not exact and may vary somewhat between applications and individual printers. There is inevitably a small amount of slippage between media and platen roller, which in its turn is affected by printhead pressure, type of media or liner, thickness of the media, roll size, type of media supply device, etc. The platen roller may be worn, giving it a slightly smaller diameter and/or less friction. There is also a certain amount of inexactness in the media feed mechanics and belts and so on. Therefore, the operator cannot expect to reach exact Start and Stop Adjust values simply by calculation. Use the measurements given in this chapter to calculate rough starting points and use the trial-and-error method to find values that give the desired result. 102 EasyCoder PX4i and PX6i Service Manual Chapter 8 — Print Unit In many cases, it is desired to start the printing immediately at the top of the label. Actually, what you want to do is to pull back the edge of the media to the dot line. You can do this by means of a negative Start Adjust value, for example -108 dots = 13.5 mm/0.53 inches for a 8 dots/mm (203.2 dpi) printer. Be careful not to enter too large a value, or the media may come loose from platen roller. MM 4EAR OFF PRINT AT TOP OF LABEL 3TART !DJUST AT DPI 3TOP !DJUST AT DPI $OT ,INE ON 0RINTHEAD 4EAR /FF %DGE ,ABEL 3TOP 3ENSOR When using peel-off operation, the labels would drop from the liner and get stuck on for example the desk if you use the default Start Adjust value 0. Use a Stop Adjust value of around -40/-60 (= 5.5 mm/0.22 inches) instead: that is, after the printing is completed 5.5 mm/0.22 inches less of media feed than normal will be performed. However, if you still want to print from the top of the label, you must compensate by a Start Adjust value of around -80/-115 (= 10.0 mm/0.39 inches). MM 0EEL OFF PRINT AT TOP OF LABEL 3TART !DJUST AT DPI 3TOP !DJUST AT DPI $OT ,INE ON 0RINTHEAD 4EAR "AR ,ABEL 3TOP 3ENSOR A special case is tickets with black marks. It is recommended to place the black mark adjacent to the perforation or the intended tear-off line. If the black mark is placed further down the media, this must be compensated for by a negative Stop Adjust setting. EasyCoder PX4i and PX6i Service Manual 103 Chapter 8 — Print Unit IPL only In IPL, the media feed is affected by the mode of operation. There are three such modes: • Tear-off (straight-through) (default) • Peel-off (self-strip) (enabled/disabled by Tn command) • Cut-off (activated/deactivated when the cutter is enabled/disabled in the Setup Mode or by Cn command) Each mode has a fixed amount of media feed, which can be fine-adjusted using the Label Rest Point parameter in the Setup Mode (See Appendix A, Setup/Media/Lbl Rest Point) or an fn command. The type of detection is decided by the Media Type parameter in the Setup Mode (See Appendix A, Setup→Media→Media Type). 104 EasyCoder PX4i and PX6i Service Manual 9 Liner Takeup Kit This chapter describes the optional liner takeup unit and covers the following topics: • Description • Main parts • Liner/batch takeup unit EasyCoder PX4i and PX6i Service Manual 105 Chapter 9 — Liner Takeup Kit 9.1 Description The liner takeup kit is an optional factory-installed device that makes it possible to auto-dispense self-adhesive labels from the liner (peel-off/ self-strip operation), and—in case of EasyCoder PX4i—also to wind up printed labels, tickets, or continuous stock internally (batch takeup operation.) The kit consists of two or three main parts: • A stepper motor that drives the liner drive roller in the print unit and the liner/batch takeup unit. The liner drive roller is fitted as standard even when the kit is not installed. • A liner/batch takeup unit that takes up the spent liner or the printed media to be rewound for later use. • A guide plate (EasyCoder PX4i only) that replaces the tear bar when labels or other types of printed media are wound up internally (see below). When not used, the guide plate is fitted using one #T20 Torx screw at the rear of the media compartment. When no rewind unit is fitted, the hole through the center section is covered by a plate held by two #T20 screws. Rewind guide (position when not fitted) Tear bar Rewind guide The batch takeup guide plate is only used in EasyCoder PX4i. 106 EasyCoder PX4i and PX6i Service Manual Chapter 9 — Liner Takeup Kit EasyCoder PX4i; Peel-Off (Self-strip) Operation &BTZ $P EFS1 9J The liner takeup unit can accommodate the liner from a full roll of labels. EasyCoder PX4i; Batch Takeup Operation &BTZ $P EFS1 9J The batch takeup unit can accommodate approximately 1/4 to 1/3 of a full label roll depending on media thickness. EasyCoder PX4i and PX6i Service Manual 107 Chapter 9 — Liner Takeup Kit EasyCoder PX6i; Peel-Off (Self-strip) Operation D /PEN #LOSE The liner takeup unit can accommodate the liner from a full roll of labels. 108 EasyCoder PX4i and PX6i Service Manual Chapter 9 — Liner Takeup Kit 9.2 Main Parts The stepper motor is fitted to the printer’s center section using a motor support plate. It drives the liner/batch takeup unit and the liner drive roller in the print unit via two belts. The tension of these belts can be slightly adjusted by moving the stepper motor and/or support plate before the screws are tightened. The takeup unit is fitted with a brace, that holds the liner or media. The unit is fitted to the printer’s center section using two #T20 Torx screws inserted from media compartment. A break shaft in front of the takeup unit guides the liner or media under the slack absorber. The stepper motor is connected to P11 on the driver board, see Chapter 14. EasyCoder PX4i Stepper motor Motor support plate Belt to liner/batch takeup unit Belt to liner drive roller Tension roller Liner/batch takeup unit Break shaft EasyCoder PX4i and PX6i Service Manual Brace 109 Chapter 9 — Liner Takeup Kit EasyCoder PX6i Stepper motor Motor support plate Belt to liner takeup unit Belt to liner drive roller Tension roller Liner takeup unit Break shaft Brace 110 EasyCoder PX4i and PX6i Service Manual Chapter 9 — Liner Takeup Kit 9.3 Liner/Batch Takeup Unit The liner/batch takeup unit is fitted to the printer’s center section from the media compartment side using a flange with two bearings. The flange is held by two #T20 Torx screws. On the inner side of the center section is a pulley, which is part of a two-way spring brake. The pulley is held by a snap ring. On the outer side, the hub and its attached gable are fitted. The rotation is controlled by the spring brake which works the same way as in the ribbon supply unit (see Chapter 7.2). Thereby, it is possible to wind up liner or media manually without running the motor. The spring brake also takes up sudden jerks. A plate helps to hold possible takeup cores. The assembly is held together by snap rings and a pin inserted through the rewind hub and its shaft. Note: The Liner Takeup Unit of an EasyCoder PX6i is not able to rewind printed labels—only to wind up liner. The wind-up torque should be 310 to 380 Nmm and the slip torque 30 to 70 Nmm. Refer to Appendix 2 for a description of how to check the torque. If the wind-up torque deviates from the recommended value, replace the entire spring brake assy. EasyCoder PX4i Bearing Flange Snap ring Snap ring Bobbin gable Bearing Pulley Bearing Bearing #T10 Torx screws (x2) Pin Flange Spring Brake sleeve Shaft Snap ring Spring brake assy. EasyCoder PX4i and PX6i Service Manual Bobbin Bobbin plate Bearing 111 Chapter 9 — Liner Takeup Kit EasyCoder PX6i Bearing Flange Snap ring Pulley Snap ring Bearing Bearing Bobbin gable Bobbin plate Bearing #T10 Torx screws (x2) Flange Spring Brake sleeve Snap ring Shaft Spring brake assy. 112 Pin Bobbin Bearing EasyCoder PX4i and PX6i Service Manual 10 Label Taken Sensor This chapter describes the optional label taken sensor and covers the following topics: • Description • Installation • Activating the LTS • Adjustment EasyCoder PX4i and PX6i Service Manual 113 Chapter 10 — Label Taken Sensor 10.1 Description The label taken sensor (LTS) is an optional device, which enables the printer's firmware to detect if the latest printed label, ticket, tag etc. has not been removed and hold the printing on the next label until the present label has been taken away from the outfeed area. The label taken sensor is usually factory-fitted, but it is also available as a kit for upgrading of existing printers by an authorized service technician. It cannot be fitted in combination with a paper cutter. The label taken sensor consists of a photoelectric sensor with a bracket and a connection cable. The sensor is fitted inside the front door, see illustration below. Label taken sensor The photoelectric sensor emits a narrow beam of light, which will be reflected back to the sensor by any label, ticket, tag, piece of strip, or liner, that has not been removed from the outfeed area. The LTS is connected to J53 on the CPU board. The sensitivity is adjusted in the Setup Mode, see Chapter 10.4. The point of detection of the LTS is situated 10 mm (0.39 inches) outside the inner edge of the media path and 22 mm (0.87 inches) in front of the dot line on the printhead. 114 EasyCoder PX4i and PX6i Service Manual Chapter 10 — Label Taken Sensor 10.2 Installation The Label Taken Sensor Kit consists of: • One Reflecting Sensor assy. with cable and connector • One Sensor Bracket • One Screw • One Installation Instructions booklet The only tools needed are a set of Torx screwdrivers. Install the label taken sensor this way: • Open the right-hand doors and remove the left-hand cover as described in Chapter 3.3. The electronic compartment contains wires and components with dangerous voltage (up to 380V). Make sure that the printer is switched off and the power cord is disconnected, before the left-hand cover is removed. • Using the screw included in the kit, fit the sensor/bracket assembly to the inner wall of the print unit as shown by the two illustrations below. Fit the cable underneath the top part of the bracket, as illustrated below. LTS cable LTS #T10 Torx screw • Slip the cable of the label taken sensor through the hole in the center section of the printer into the electronics compartment. • Connect the cable to J53 on the CPU board. Be careful so the cable does not interfere with any moving mechanical parts or the transfer ribbon. • Put back the left-hand cover, connect the power cord and switch on the power. EasyCoder PX4i and PX6i Service Manual 115 Chapter 10 — Label Taken Sensor 10.3 Activating the LTS In Fingerprint, the label taken sensor is enabled using the instruction LTS& ON. In IPL, the self-strip mode must be enabled. This can also be done by executing the following commands: R (Enter print/configuration mode) t1 (Enable self-strip) 10.4 Adjustment The sensitivity of the Label Taken Sensor (LTS) may need to be adjusted according to the ambient light conditions and the reflective characteristics of the back side of the media. Fingerprint The sensitivity can be adjusted in the Setup Mode (see Appendix A), or by using setup files or setup strings (see Intermec Fingerprint v8.xx, Programmer’s Reference Manual). In the Setup Mode, the LTS setup options are only displayed if an optional label taken sensor is installed in the printer. • LTS Adjust: Press . A label is fed out. Remove the label and press again. A menu shows the sensitivity automatically selected by the firmware and the range in which the LTS will work. Press again and you will proceed to the LTS Test menu. • LTS Test: Press . A label is fed out. Remove the label and a new label should be fed out automatically. Repeat until you are sure the LTS works properly. Then press to stop and exit. • LTS Value: Press . You can enter a new value in the range indicated in the LTS Adjust menu (see above). Min/max values are in the range 0-10. IPL The sensitivity can be adjusted in the Setup Mode (see Appendix A). • In the Setup Mode, select the Configuration option. • Select LTS Calibration and press the T key. • Press • A number of labels are fed out. Remove the labels and press . • The sensor has now been automatically adjusted and the resulting sensitivity is displayed as a numeric value in the range of 8 to 14. 116 EasyCoder PX4i and PX6i Service Manual 11 Paper Cutter This chapter describes the optional paper cutters for EasyCoder PX4i and PX6i. The chapter covers the following topics: • Description • Installation • Controlling the cutter • Media load • Servicing • Spring replacement EasyCoder PX4i and PX6i Service Manual 117 Chapter 11 — Paper Cutter 11.1 Description The EasyCoder PX4i and PX6i can easily be fitted with an optional cutter unless the printer is not already fitted with an label taken sensor (see Chapter 10). The cutter unit is fitted on the same hinges as the front door, which it replaces, and is connected by a single cable to the DIN-connector on the printer’s front. The cutter is available both as a factory-installed option and as a fieldinstallable upgrading kit. The cutter is intended to cut through continuous non-adhesive paper strip or through the liner between labels. It must not be used to cut through any kind of adhesive or other soft material, that may stick to the cutting parts and render the cutter inoperable or even damage the electric motor. Maximum paper thickness is 175 µm (≈ 175 g/m2) for normal paper-based materials. Minimum practical copy length is 38.1 mm (1.5 inches.) The cutter increases the total weight of EasyCoder PX4i and PX6i respectively by approx. 1.0/1.65 kg (2.2/3.6 pounds). In both cases, the length is increased by 28 mm (1.1 inches). The cutter can be tilted forward in order to facilitate cleaning and media load. The cutting edge will rotate to home position when the power is switched on and when the printer is rebooted. Always keep the cutter unit in closed position during operation 118 EasyCoder PX4i and PX6i Service Manual Chapter 11 — Paper Cutter 11.2 Installation • Switch off the power and remove the power cord. • Open the printer’s front door. • Hold the printer firmly and press the front door sideways to the left so as to disengage the hinges. • Remove the door completely. 0RESS SIDEWAYS • If the printer is fitted with a label taken sensor (LTS), it has to be removed before the cutter can be fitted, see Chapter 10. EasyCoder PX4i and PX6i Service Manual 119 Chapter 11 — Paper Cutter • Fit the cutter unit to the vacant hinges. Make sure that the locking plate snaps into the groove of the right-hand hinge and that the angled plate at the bottom of the cutter is inserted under the printer’s bottom plate. • Connect the cable from the cutter unit to the DIN socket on the printer’s front. DIN socket 0RESS SIDEWAYS • Tilt the cutter unit upwards until it locks into place. If the cutter does not lock properly, the hinges of the cutter unit may need to be adjusted using a #T10 Torx screwdriver. • Connect the power cord and switch on power. The cutter will perform an idle cycle in order to occupy its home position. • Switch off the power. Tilt down the cutter and route the media through the cutter unit between the guide plates (see illustration above). Then tilt the cutter up again and lock it in closed position. Check that the printhead is lowered and switch on the power. Now the printer is ready for operation. 120 EasyCoder PX4i and PX6i Service Manual Chapter 11 — Paper Cutter Hinge Guide plates (insert media between the plates) Hinge EasyCoder PX4i Cutter Hinge Guide plates (insert media between the plates) Hinge EasyCoder PX6i Cutter EasyCoder PX4i and PX6i Service Manual 121 Chapter 11 — Paper Cutter 11.3 Controlling the Cutter Fingerprint The cutter is activated by CUT or CUT ON statements, see the Intermec Fingerprint v8.xx, or the Intermec Direct Protocol v8.xx manuals. Application programs may have related facilities for operating the cutter. The edge will cut through the media approx. 37 mm (1.5 inches) in front of the printer’s dot line. The following values are recommended for cutting: Type of Cutting 8 dots/mm printhead 11.81 dots/mm printhead Start adjust: - 287 dots - 424 dots Stop adjust: + 176 dots + 260 dots Cut between labels w. gaps Cut fix and variable length strip (no liner!) Start adjust: - 294 dots - 434 dots Stop adjust: + 298 dots + 440 dots IPL The cutter can be enabled/disabled in the Configuration part of the setup mode or using the command Cn , where n= 0 disables the cutter and n=1 enables it. When the cutter is enabled, the media feed is automatically adjusted for cut-off operation. When the cutter is not enabled, a cut operation (advance label and cut) can be executed using the command . Also see IPL Programming, Reference Manual. 11.4 Media Load Load media following the descriptions in the User’s Guide for Media Load/ Cut-Off operation (optionally with Quick-Load guides). The cutter is held by a snap lock and can be tilted forward to facilitate media load. Always engage the printhead in order to hold the media before closing the cutter. 122 EasyCoder PX4i and PX6i Service Manual Chapter 11 — Paper Cutter 11.5 Servicing The cutter mechanism becomes accessible when the cover is opened. The cutter shears will need to be cleaned from adhesive residue if the cutter has been used for cutting through labels, something that is not advisable. Use isopropyl alcohol (see warning text on the container), but be careful only to apply it where there is any adhesive residue so you do not dissolve the lubrication. Do not force the spring-loaded anvil blade open more than 5-10 mm (0.2–0.4 inches), or the spring may be damaged. Refer to Chapter 11.6 for information on how to replace the spring. Switch off the power or disconnect the cutter before cleaning. Keep fingers away from cutting parts! Fingerprint only If the following errors occur, clean the shears from adhesive residue. • 1701 “Cutter error1” A cut has been performed but the shear has stopped on its way back to home (bottom) position. • 1702 “Cutter error2” The cutter has failed to cut after several attempt (3 is default) and the shear has returned to home (bottom) position. • 1703 “Cutter error3” The cutter has failed to cut and the shear has stopped before returning to home (bottom) position. If the cutter cable connector has come loose from DIN connector, Error 37, “Cutter device not found” or Error 1059, “Cutter does not respond” will occur. If the microswitch in the cutter assy is faulty, Error 1704, “Cutter open” will occur, even if the cutter in fact is closed. IPL only IPL reports if the cutter has failed to return to home position by displaying the message “Open&shut cutter.” Follow that instruction. If the error persists, clean the shears from adhesive residue and check the microswitch. EasyCoder PX4i and PX6i Service Manual 123 Chapter 11 — Paper Cutter 11.6 Spring Replacement The spring that presses the anvil blade against the rotating shear may eventually get slack, especially if the anvil blade is forced open, for example during cleaning. A slack spring must be replaced as follows: • Remove the right-hand gable of the cutter (two #T20 Torx screws). • Remove the right-hand gable of the cutter mechanism (two #T20 Torx screws + three Posidrive screws). • Replace the spring and assemble in reverse order, making sure to put back all the washers. 124 EasyCoder PX4i and PX6i Service Manual 12 Electronics Compartment This chapter describes how to access the electronics compartment and shows the main parts. The electronics compartment contains wires and circuits with high voltage. Before removing the left-hand cover or the bottom plate, make sure that the power is off and the power cord is disconnected from the printer. Before starting to work inside the electronics compartment, take standard precautions for avoiding electrostatic discharges. EasyCoder PX4i and PX6i Service Manual 125 Chapter 12 — Electronics Compartment 12.1 Introduction The Electronics Compartment is off limits to the normal user, but for the authorized service technician, it contains a number of parts of great interest: • The stepper motor and timing belts of the platen roller and ribbon rewind unit. • The stepper motor and belts of the optional liner/batch takeup unit. • The headlift mechanism and sensor. • The CPU board. • The driver board. • The power supply unit. • Optionally one or two extra interface boards and/or one EasyLAN board. 12.2 Accessing the Electronics Compartment To gain access to the electronics compartment, remove the left-hand cover as described in Chapter 3.3. #T10 Torx screws (x4) #T10 Torx screws (x4) 126 EasyCoder PX4i and PX6i Service Manual Chapter 12 — Electronics Compartment 12.3 Main Parts This is what you may see when you remove the front/left-hand cover from an EasyCoder PX4i or PX6i printer. Power supply (behind CPU board) Optional EasyLAN board Driver board Ribbon rewind unit Stepper motor (platen & ribbon rewind) Optional interface boards CPU board Stepper motor (liner/batch takeup) Platen roller belt and pulley Liner drive roller belt and pulley Headlift sensor EasyCoder PX4i and PX6i Service Manual 127 Chapter 12 — Electronics Compartment 128 EasyCoder PX4i and PX6i Service Manual 13 Power Supply This chapter describes the power supply unit (PSU) which is fitted in the electronics compartment, see Chapter 12. The chapter covers the following topics: • Description • Replacement • Components • Schematics The electronics compartment contains wires and circuits with high voltage. Before removing the left-hand cover or the bottom plate, make sure that the power is off and the power cord is disconnected from the printer. Before touching the driver board, take precautions to avoid any electrostatic discharges. EasyCoder PX4i and PX6i Service Manual 129 Chapter 13 — Power Supply 13.1 Description The Power Supply Unit (PSU) is identical in all EasyCoder PX4i and PX6i-series printers. It is situated inside the electronics compartment between the CPU board and the center section. No attempt to repair this unit is allowed. Never replace a blown fuse, but replace the entire PSU. The power supply unit is primary-switched with power correction factor controller so as to comply with the CE regulations, which require a sinusshaped load curve. It is designed for input voltages in the range of 90 to 265 VAC, 45 to 65Hz. There is no manual switch. The PSU delivers 20W at standby and 400W peak. Typical consumption during printing is approximately 100W. The PSU produces 24 VDC only; all other voltages are transformed from 24 VDC by the driver board and CPU board. The CPU board controls the PSU over the I2C bus via the driver board, where also identification and error signals are transmitted to the CPU board. Voltage and temperature are monitored and the unit is over-current protected. The working principles of the PSU are illustrated by this diagram: 0OWER 3UPPLY "OARD 7 STANDBY 7 PEEK 6!# (Z 6$# 4EMP -ONITOR 0OWER &AIL -AINS "OOSTER #ONVERTER &ORWARD #ONVERTER 2ECTIFIER 6 0ULSE 7IDTH -ODULATOR W 0OWER &ACTOR #ONTR 0ULSE 7IDTH -ODULATOR &ORWARD 4EMPERATURE #ONTROL 0OWER &AIL )NTERRUPT #ONTROL 6OUT 6 130 EasyCoder PX4i and PX6i Service Manual Chapter 13 — Power Supply Power Factor Control The power factor control transforms the AC input voltage to 385 VDC by sensing the shape of the curve of the input voltage and chopping it to short pulses, where the pulse amplitude follows the shape of the curve. The booster is protected by two 7A fuses. Forward Converter The forward converter transforms 385 VDC to 24 VDC 0-17A. The 24 VDC is the bulk voltage. Other voltages needed for internal devices are converted from 24 VDC by the driver board and the CPU board. Connections P2 24 VDC to driver board. P3 Temperature and power fail signals to driver board X1 Input voltage 90 to 265 VAC, 45 to 65Hz Overheating Protection The power supply unit is fitted with a sensor that will shut down the unit in case of overheating (Power Fail Interrupt or PFI) and another sensor that will warn the main CPU if the power supply is getting hot (Notify). A Power Fail Interrupt (PFI) signal will warn the logics so valuable data can be saved before power is lost. Before a print operation is executed, the Notify signal is checked. If the Notify signal is activated, a warning is shown in the display and the main CPU will reduce the power consumption to avoid shutdown by detaining the printing until the Notify signal is deactivated. Primary switched power supplies are generally difficult to repair. If one component fails due to aging or overload, a number of other components will also break as a consequence. They are hard to troubleshoot, because the PSU often is “dead” or the fuses blow immediately. It is also impossible to guarantee the life of a repaired PSU, because components may still work but be on the verge of failing. Thus, if a fuse blows, do not attempt repairing the PSU, but replace the entire unit! EasyCoder PX4i and PX6i Service Manual 131 Chapter 13 — Power Supply Physical Appearance The PSU comes as a complete unit consisting of a large metal bracket to which the following parts are factory-fitted: • Plastic protection sheet • Power supply pcb (attached to the bracket using four #T10 Torx screws and washers) • AC power cord socket (attached to the bracket using two #T10 Torx screws and nuts) • On/off switch (attached to the bracket using snap-locks) • Label The bracket is fitted to the center section and rear plate using a total of five #T20 Torx screws. Protection Sheet (shown separately) Bracket On/Off Switch Label Power cord socket PSU Board Power supply unit (simplified drawing) 132 EasyCoder PX4i and PX6i Service Manual Chapter 13 — Power Supply 13.2 Replacement • Take precautions to avoid any electrostatic discharges. • Switch off the printer and disconnect the power cord and all interface cables on the rear plate. • Remove the left-hand cover as described in Chapter 3.3. • Remove any interface board connected or attached to the CPU board. • Disconnect all cables from the CPU board and remove it (see Chapter 15.3). The CPU board is held to the PSU bracket using four #T20 screws and one hexagonal spacer. • Disconnect the cables that run between the PSU and the driver board. • Remove the three #T20 Torx screws that hold the PSU assy to the center section and two #T20 Torx screw that hold it to the rear plate. • Do not dismantle the PSU. Replace the entire unit! • Assemble in reverse order. Fit the top screw at the rear plate first. Fit this screw first! #T20 Torx screws (x2) #T20 Torx screws (x3) PSU assy Cables to driver pcb EasyCoder PX4i and PX6i Service Manual 133 Chapter 13 — Power Supply 13.3 Components 1-971632-25 Power Supply Unit; Component side 134 EasyCoder PX4i and PX6i Service Manual Chapter 13 — Power Supply 1-971632-25 Power Supply Unit; Soldering side EasyCoder PX4i and PX6i Service Manual 135 Chapter 13 — Power Supply Q1 TY1 13.4 Schematics 1-971632-25 Power Supply Unit; Schematics 136 EasyCoder PX4i and PX6i Service Manual 14 Driver Board This chapter describes the driver board which is fitted in the electronics compartment, see Chapter 12. The chapter covers the following topics: • Description • Replacement • Components • Schematics The electronics compartment contains wires and circuits with high voltage. Before removing the left-hand cover or the bottom plate, make sure that the power is off and the power cord is disconnected from the printer. Before touching the driver board, take precautions to avoid any electrostatic discharges. EasyCoder PX4i and PX6i Service Manual 137 Chapter 14 — Driver Board 14.1 Description While the power supply unit (PSU) transforms the AC input voltage to 24 VDC, the driver board converts the 24 VDC to various voltages and distributes them to CPU board, stepper motors, cutter, and printhead. The driver board is connected to the PSU via two cables (see Chapter 13). One cable, connected to P2, supplies the driver board with 24 VDC and the other one, connected to P3, contains temperature and power fail signals. The driver board converts the 24 VDC to various voltages required by the printer and distributes them as follows: P1 24 VDC to CPU board and control signals between driver board and CPU board P5 24 VDC to thermal printhead P7 0-12 VDC to fan (presently not used) P10 33 VDC to platen roller/ribbon rewind stepper motor P11 33 VDC to liner/batch rewind unit stepper motor P12 24 VDC to cutter interface At start-up, the PIC processor on the driver board checks that the 24 VDC to the printhead and 33 VDC to the stepper motors are within allowed limits. If any extreme values are found, an error condition occurs. 14.2 Replacement • Take precautions to avoid any electrostatic discharges. • Switch off the printer and disconnect the power cord • Remove the left-hand cover as described in Chapter 3.3. • Disconnect all cables to the driver board. • From the media compartment, remove the two #T20 Torx screws that hold the driver board assembly. • The driver board and its plate come as an assembled spare part. Do not dismantle any further. Do not attempt to repair a faulty driver board, but replace it with a new one, unless you know for sure that you have made the fuse blow by causing a short-circuit (see Chapter 17.6). • Assemble in reverse order. 138 EasyCoder PX4i and PX6i Service Manual Chapter 14 — Driver Board The driver board and its attachment plate come as an assembled spare part. EasyCoder PX4i and PX6i Service Manual 139 Chapter 14 — Driver Board , $ ' .# ! # 2" " 2! ! 1 + 1 .# " # 2$ $ # 2# # % 1 2 2 2 5 2 $ # 2! 2" # # # # 0 '.$# .$# # 2 # # # , # 2# 5 2 # 5 , 2" 2 $ 2 2 2! # # # 5 # 0 $# '. .$# 5 .# + ! + $ , ! ! 0! .# 2 2! 2" # 2# # 0# 2 2 2 2 2 0 " " # # 2 2 2 2 2 5 # 2# # ! + 5 # 2 2 2" 2 2 2 2 2 2 2 2 2 # 5 # 2 % # 1 " 2 2 .# 0 0 2# 2 2 % 2 $ 2 2 2 # 2 # # 2 1 % 2! " 1 " 2 2 0 # # # $ # 2 + # ! ' 3 $ 2 : .# 3 $ + 2 # 2 $ 2 " " $ ! # % " 1 2 0 2 1 # 2 ' 2 2# # 2 # ! 2! 2 3 2 2 14.3 Components : # # # , & 1 0 0 '. .$# $# 1-971652-26 Driver Board; Component Side 140 EasyCoder PX4i and PX6i Service Manual # # # Chapter 14 — Driver Board # # # 2 2 # # # # # # # # # 2 # # # # # # # # # # # 2 2 2 # 2 1-971652-26 Driver Board; Soldering Side EasyCoder PX4i and PX6i Service Manual 141 L1 P3 1 2 3 4 PSU CTRL P1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 CPU CON 5V 5V PFI_DET TEMP_MON SCL SDA CUT HOME P24EN PSU_INT_N PSU_NOT_N DRIVER_IO4 DRIVER_IO5 DRIVER_IO6 DRIVER_IO7 PIC_RESET DIR_I STEP1 STEP2 STMC4 STMC3 STMC2 STMC1 TPHV DRIVER_IO10 L4 C25 D1 C3 U7 24VS BC847B R6 Q2 P24ON 39V 5V 5V 5V 5V HOME AD24V ADSTM CUT 8 19 20 2 3 4 5 6 7 1 D5 VCP C B D 1 2 3 4 5 P8 INT/RB0 RB1 RB2 RB3 MCLR/VPP RB4 RB5 RB6 RA0 RB7 RA1 RA2 RA3/VREF RA4/TOCKI RC0 RA5 RC1 RC2 RC3 RC4 RC5 VCC RC 6 GND RC7 GND 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28 ISR CONNECTOR D4 C29 24VS C28 U1 PIC16F872 5V R64 9 CLKIN 10 CLKOUT Z1 15V 24V Q1 GATE DRIVE R66 B C 1 CUTMOTOR BRAKE FAN_PWM S CL SD A RESET_N MS1 MS2 PFI_DET PSU_NOT_N PSU_INT_N P24ON HOMESW P24EN C5 D3 24VS C71 R61 R60 R62 C2 4A VSTM U6 R70 2 3 Q3 5V 8 7 6 5 Q6 R17 24VS P7 1 2 FAN C4 R72 DIR_I STEP1 STEP2 5V R76 R71 VOUT 5.0V 5V R58 UC3845B VREF VCC OUT GND U5 COMP VFB SENSE R/C GND/ADJ VIN 1 2 3 4 R59 C86 Q4 R55 C7 R57 33V STEP UP R54A C22 P5 1 2 3 4 5 6 7 8 9 10 Q7 FAN- FAN+ R73 U2 AHCT1G32 1 U8 AHCT14 U2 AHCT14 C85 Q9 Q8 1 3 5 9 C35 C38 2 4 6 8 P12 1 2 3 4 5 CUTTER AHCT14 U2 AHCT14 U2 AHCT14 U2 AHCT14 U2 R50 VSTM D8 C37 DIR STEP2_N STEP1_N 24VS R77 R75 4 12 10 5V C8 D6 C26 GNDC1 GNDC2 GNDC3 R74 2 1 13 11 Q5 15V Z2 VCP 24VS HOME:NO MOTOR+ MOTORHOME:COM R29 R28 R27 R26 ADSTM 5V STEP2_N DI R MS1 MS 2 RESET_N STEP1_N DI R MS1 MS 2 RESET_N 5V C44 5V C41 10 RC1 1 5 RC 2 1 4 RE F 9 PFD 27 RESET_N 42 SLEEP_N 41 ENABLE_N 4 HOME_N 20 MS1 19 MS2 A3977 31 STEP 5 D IR U3 26 SR_N C40 C60 10 RC1 15 RC2 14 REF 9 PFD 27 RESET_N 42 SLEEP_N 41 ENABLE_N 4 HOME_N 20 MS1 19 MS2 A3977 31 STEP 5 DIR U4 26 SR_N C43 C6 5 C45 OUT1A 6 C42 SENSE2 21 SENSE1 3 OUT2B 28 OUT2A 18 OUT1B 40 OUT1A 6 VSTM C63 SENSE2 21 C64 SENSE1 3 OUT2B 28 OUT2A 18 OUT1B 40 VSTM C11 + 24V TPH OUT C55 R69 C70 24VS R68 24V_PH R23 Q1 R53C VCP 36 C20 L2 C24 C1 R1 C53 F1 R2 R63 C23 L3 R3 R54B R20 R67 3 R5 R54C R21 R56 R54D R22 R52 R51 L5 R53A R24 C27 4 1 2 R4 R11 D2 C66 C36 C54 R19 R53B R25 R30 VREG 32 VREG 32 R65 R7 R8 R9 C52 C50 R12 C80 C51 R34 R35 VDD 16 VDD 16 R31 R32 R33 CP1 37 CP1 37 C32 C30 CP2 38 CP2 38 C72 R15 R16 C83 C81 C6 C34 C84 C82 C62 C57 R46 R38 C61 R36 R37 R47 R39 VBB 43 VBB 25 PGND PGND PGND PGND PGND PGND PGND PGND PGND PGND PGND PGND 1 2 11 12 13 22 23 24 33 34 35 44 VCP 36 C5 8 C59 P11 1 2 3 4 STEPPER 2 R48A R49A P10 1 2 3 4 STEPPER 1 R40A C9 + C33 R48C R49C R41A VBB 43 VBB 25 PGND PGND PGND PGND PGND PGND PGND PGND PGND PGND PGND PGND 1 2 11 12 13 22 23 24 33 34 35 44 C12 + R48B R49B C10 + + C31 + + R40B + + R40C 142 + R41B + R41C 24V POWER IN 24V P2 1 2 3 4 5 6 7 8 Chapter 14 — Driver Board 14.4 Schematics + 1-971652-26 Driver Board EasyCoder PX4i and PX6i Service Manual C56 C21 15 CPU Board This chapter describes the CPU board which is fitted in the electronics compartment, see Chapter 12. The chapter covers the following topics: • Description • Circuits • Connectors • Test points • Startup • Components • Schematics • Replacement Note: Devices and file systems, such as "/c:" or "uart1:", are only used in Fingerprint. Some may also exist in IPL, but are hidden to the user. The electronics compartment contains wires and circuits with high voltage. Before removing the left-hand cover or the bottom plate, make sure that the power is off and the power cord is disconnected from the printer. Before touching the CPU board, take precautions to avoid any electrostatic discharges. EasyCoder PX4i and PX6i Service Manual 143 Chapter 15 — CPU Board 15.1 Description The CPU board is a four-layer board with most of its circuits surfacemounted. Inside the laminate are a combined VCC layer (5V/3.3V/2.5V) and a GND layer. The front and back sides are signal routing layers. The hardware contains of the following main functions: • Processor core • Thermal printhead driver • Stepper motor control logic • Sensor drivers • Communication, such as UART, USB, etc. • Flash memory SIMM for the firmware and non-volatile storage • SDRAM SIMM for working memory • A/D converter for sensor adjustment, etc. • Compact Flash memory card expansion • Expansion bus • PCI bus (custom) .ETWORK CARD 5!24 0#) BUS CUSTOM 7AND I"UTTON "EEPER #05 2)3# CORE -EMORY CONTROLLER 0#) INTERFACE 3$2!#LOCK -(Z "US ISOLATION &LASH MEMORY #,)# 3UPPORT LOGIC "OARD ID 2ESET 3ENSORS !$ CONVERTER 40( #ONSOLE &INISHER #05 BOARD %%02/- #OMPACT &LASH 03! 40( LOGIC 3TEPPER LOGIC )NTERRUPT )# MASTER )# BUS 035-OTOR INTERFACE %XP INTERFACE 53" /PTIONAL BOARD /PTIONAL BOARD ONLY ONE OPTIONAL BOARD IN 0& SERIES 3TEPPER CONTROL SIGNALS 0OWER CONVERSION 6 )N 6 6 6 1-971630-26 CPU board; Block Diagram (numbers refer to schematics in Chapter 15.7) 144 EasyCoder PX4i and PX6i Service Manual Chapter 15 — CPU Board 15.2 Circuits Components mentioned in this chapter are marked with gray in the drawing below. 0/ * * * #/-0!#4 &,!3( * 24# 02/'2!- +%9 5 0ROCESSOR 5 3UPPORT #HIP 0 "//4 &,!3( Processor (U13) The processor is a 32-bit RISC offering about 125 MIPS at the internal clock speed 96MHz. The internal bus speed is twice the external bus speed at 48MHz. The processor has several features, such as integrated SDRAM controller, PCI bridge, DMA, UART, timers, etc. Support Chip (U30) The PSA (Processor Support ASIC) is a programmable logic device, which is programmed by the firmware at each startup. It contains most of the printer-specific and other logic functions, such as • Printhead data and strobe control • Stepper and DC motor logic • Sensor interface • Timers and interrupt control • Control logic for bar code wand and the electronic key/RTC • I2C master • Beeper signal generation • Interface to A/D converter, console, finisher, etc. EasyCoder PX4i and PX6i Service Manual 145 Chapter 15 — CPU Board Flash Memory (J20 and J21) There are two sockets for Flash SIMMs (marked “BOOT FLASH” and “EXP FLASH”). A SIMM (Single Inline Memory Module) must always be fitted in J20 since this bank is the Bootbank. As standard, a single 4MB flash SIMM is fitted. It contains the following sectors: Device1 Size Type – Boot 128K Used for Startup 1 /c 2048K User file system or Kernel FP: Customer’s programs, files, images IPL: Formats, images, fonts /c 1856K User file system FP: Customer’s programs, files, images IPL: Formats, images, fonts – 32K TMP area Media feed info, odometer value, etc. – 32K Parameters Media feed info, odometer value, etc. 1 /. Devices are used in Fingerprint, but are hidden in IPL. /. This sector can be used for the kernel or for the file system (/c). If it is used for the file system, the kernel is placed in the file system under the /c/boot directory, which is the normal configuration, enabling the size difference between 2048K and the real kernel size to be used in /c. Refer to the Intermec Fingerprint v8.xx, Programmer’s Reference Manual for a complete list of files stored in /c and /rom by default. The kernel includes Fingerprint or IPL firmware, bar codes, standard fonts, standard images, Intermec Shell, auxiliary programs, default setup values, and the EasyLAN home page files. 2 The flash memory retains its content at power off without any battery backup. It consists of sectors that can be erased and written to over and over again. This is done automatically in the background. At power-up, the flash memory is reorganized to avoid fragmentation. Before a sector is erased, its content will be copied to a temporary area as a safety measure if something should go wrong, for example a power failure. For the /c file system in Fingerprint, this area is 64K and is included in the sectors in the table above. For the parameters, it is the 32K TMP sector. The Boot sector is necessary for Intermec Fingerprint or IPL to start. There is a boot sector in all flash SIMMs at delivery, but the firmware will only accept the boot sector of a SIMM fitted in J20 (marked “BOOT FLASH”). The boot sector is only protected when the flash SIMM is fitted in socket J20 (”BOOT FLASH”). If you move flash SIMMs from one CPU board to another, make sure that the SIMM containing the boot sector is fitted in J20 (“BOOT FLASH”) on the other board, or the boot sector will be overwritten. The Intermec Fingerprint firmware is either stored in the /c file system or in a dedicated area on the boot flash (2MB large). If it is stored in the file system, removing or exchanging an EXP FLASH in J21 may render the printer unstartable. To cure this condition, use a CompactFlash card containing an upgrade file (kernel) to reload the firmware. As illustrated in the table above, a total nominal capacity of 3904K is used for the /c file system (MIFS, or FOS) and fonts. In Fingerprint, practically, around 2MB are available to the user (about 200-400K less if the kernel is in the dedicated area). Exactly which fonts, images, files, and programs are stored in the Fingerprint file system may vary between customers and applications. 146 EasyCoder PX4i and PX6i Service Manual Chapter 15 — CPU Board The parameters sectors store the PFSVARs (see SETPFSVAR Fingerprint statement), odometer values, and a few other “invisible” files with data, that are required for the printer to start up with the same settings as when it was shut off, for example information on the position of label gaps in relation to the LSS. The printer’s permanent memory can be expanded by fitting a second 4MB or 8MB flash memory SIMMs in sockets J21. 4MB and 8MB flash SIMMs can be mixed at will. Flash SIMMs are custom-made and can only be ordered from Intermec. Note: The first time the printer is started with a SIMM in J21 (“EXP FLASH”), the memory is not increased to enable cloning the first SIMM. The expansion is not done until the second time the printer is started. Flash Memory Available to the User J20 (Boot) J21 (Exp) J20 (Boot) J21 (Exp) SUM 4MB SIMM – 1.8MB – 1.8MB 4MB SIMM 4MB SIMM 1.8MB 4MB 5.8MB 4MB SIMM 8MB SIMM 1.8MB 8MB 9.8MB 8MB SIMM – 5.8MB – 5.8MB 8MB SIMM 4MB SIMM 5.8MB 4MB 9.8MB 8MB SIMM 8MB SIMM 5.8MB 8MB 13.8MB EasyCoder PX4i and PX6i Service Manual 147 Chapter 15 — CPU Board SDRAM Memory (J10) The SDRAM memory (Synchronous Dynamic Random Access Memory) is the printer’s temporary memory (Fingerprint device "tmp:"). It will lose its content when the power is switched off or at a power failure. Thus, it should only be used for data that can easily be recreated or that are only relevant for one power-on cycle. It is much faster than the flash memory. Therefore, at startup the kernel is copied from the Flash memory to the SDRAM, where the various instructions are executed. One SDRAM SIMM (standard size 16MB) must always be installed in socket J10 (SDRAM0-1). The SDRAM is also used for the font cache and various buffers. The remainder is used for the two print image buffers where the bitmap patterns are stored prior to printing. One buffer is used for the label that is being printed, while the other receives the bitmap for next label as the Intermec Fingerprint instructions are processed. By switching between the buffers, batch printing without stopping between labels can be achieved. The size of the buffers depends on two factors: • Number of physical dots on the printhead. • Present label length setup value in dots. Calculate the buffer size according to this formula: (No. of dots / 8 + 4) × (Media length in dots) = Buffer size in bytes (Buffer size in bytes) / 1024 = Buffer size in kbytes Buffer size in kbytes × 2 = Memory requirement in kbytes Example: The number of dots on the 8 dots/mm printhead of an EasyCoder PX4i is 896. “Media; Length” is set to 1500 dots (= 187.5 mm/7.38 inches) [[(896 / 8) + 4) × (1500)] / 1024] × 2 = 340 kbyte total Regardless of memory size there is an absolute print length limit of 32,767 dots (4,095 mm/161.2 inches). 148 EasyCoder PX4i and PX6i Service Manual Chapter 15 — CPU Board Electronic Key Circuit (J30), Fingerprint-only option The optional electronic key circuit is an iButton which contains a real-time clock. It has a built-in battery backup with a life of at least 10 years. When the printer is on, the circuit is power-supplied via the CPU board and will not consume any power from the battery. The circuit also contains 4Kbits (500 bytes) of battery backed-up memory for the devices "lock:" and "storage:". The Electronic Key Circuit (J30) contains an integrated lithium battery. Replace only with original Electronic Key Circuits from Intermec. Dispose of used Electronic Key Circuits according to local regulations for lithium batteries. Since the communication between the RISC processor and the electronic key circuit is comparatively slow, the content of the key circuit is copied to SDRAM at startup and used from there. At power off, the content is read back to the key circuit, provided there is time enough. Thus, there is a small risk that new data may be lost, before it has been saved back to the electronic key circuit. The original data in the electronic key circuit will not be damaged, if the read-back process should fail. Memory Card Adapter (J22) The CPU board has a built-in memory card adapter which can use standard Type I CompactFlash memory cards with a size of 8MB to 1GB (thickness 3.3 mm/0.13 in.). It is not suited for other types of memory or I/O cards! Cards marked “CF+” and Type II cards (thickness 5.0 mm/0.20 in.) cannot be used. In Fingerprint, CompactFlash cards can be used to expand the printer’s memory (device "card1:"). IPL does not support CompactFlash cards as a means of expanding the memory. Memory cards are only detected by the firmware at startup and must thus be inserted in the memory card adapter before the power is switched on or the printer is rebooted. Memory cards must only be emoved when the power is off. Preprogrammed CompactFlash Memory Cards There are four types of preprogrammed CompactFlash memory cards from Intermec. • Font Cards Font stored in font cards can only be used while the card is present in the printer’s memory card adapter. • Font Install Cards (Fingerprint only) Install additional fonts in the printer’s memory. These fonts can be used without the card being present. • Firmware Cards Install a new firmware kernel in the printer including standard fonts. Used for upgrading the firmware or switching between Fingerprint and IPL. • Configuration Cards Configures a CPU board for the type of printer in which it is installed, see Chapter 15.8, or changes the printer’s EasyLAN setup. EasyCoder PX4i and PX6i Service Manual 149 Chapter 15 — CPU Board 15.3 Connections 2)""/. 0/7%2 * * 0#) 0/ #/.3/,% The following connectors on the CPU board are used in the printer for communication with various devices and sensors. * * * 0 * * * (%!$,)&4 "- * '!0 * * 23 7!.$ 02).4(%!$ * 53" * %80 "/!2$ * 0!0%2 * ,43 * &).)3(%2 Left side (from top down) J59 Bar Code Wand (not supported by IPL) J61 RS-232 J60 USB Bottom (from left to right) J62 Expansion board connection (optional interface boards) J57 Paper Sensor J53 Label Taken Sensor (option) J51 Finisher (not used) Top (from left to right) J84 PCI (EasyLAN interface, option) J50 Console (keyboard, display, and print or feed/pause button) Right side (from top down) J56 Ribbon Low sensor J52 Power from driver board J40 Data to printhead J55 LSS (gap) J54 LSS (black mark) J58 Headlift sensor 150 EasyCoder PX4i and PX6i Service Manual Chapter 15 — CPU Board 15.4 Test Points The CPU board is provided with many test points. Only those of immediate interest to the field service technician are shown below. If further testing or servicing is required, exchange the CPU board and return the faulty board to a service center. 0/ $%"5' * & 7!.$ 0 6 $/.% 2 6 '.$ Test Points If available, use an oscilloscope to measure the various voltages. When using for example a multimeter, a fluttering value may indicate an erroneous voltage. GND Ground 2.5V 2.5V –> GND (max ± 0.2V) 3.3V 3.3V –> GND (max ± 0.2V) 5.0V R718 –> GND (max ± 0.2V) 24V F70 left side –> GND (allowed deviation ± 2V) (If no voltage on the left side, check the right side. If voltage there, fuse is blown; else cable, driver board, or PSU trouble.) DONE High level = U30 programmed, see Chapter 15.5 DEBUG Startup check, see Chapter 15.5 WAND Use an oscilloscope. OK if there is a pulse train when the wand is reading a bar code. EasyCoder PX4i and PX6i Service Manual 151 Chapter 15 — CPU Board 15.5 Startup The prerequisite for the printer to start is that a flash memory SIMM with a boot sector is fitted in J20. A SDRAM SIMM must also be installed in J10. At power up, the printer starts executing code in the boot sector and one of the following sequences will be performed: 1. A Compact Flash card with a firmware is recognized. - The firmware will be copied from the memory card to the internal SDRAM. - The processor will start to execute code from SDRAM. - The firmware on the memory card will be copied to the internal flash memory. 2. A valid firmware is recognized in the internal flash memory. - The firmware will be copied to SDRAM and the processor will start execute code from SDRAM. If the printer is fitted with an EasyLAN interface, there are also facilities for updating the firmware from the printer’s home page. After the initial boot sequence is performed, the number of steps will be taken before the printer starts, which includes programming the support chip (U30). The startup procedure can be followed on the printer’s display. You can also follow the startup from the host provided a strap is temporarily fitted at J23 (DEBUG) on the CPU board. Connection between printer and host should use the default serial communication setup (9600 baud, 8 bits, parity none, 1 stop bit) on the standard serial port "uart1:". For each of the steps, either “OK” or “Fail” is returned on "uart1:". In addition, some other useful information is also returned. Refer to Appendix B for information on how to upgrade the firmware. 152 EasyCoder PX4i and PX6i Service Manual J61 J60 L6 0 L68 L65 L61 L66 L62 L67 L63 L64 J22 MH71 L 52 R603 R604 R602 R620 R619 C62 RP60 C65 C63 L51 L50 R500 WAND C66 C64 U61 R935 R618 R610 R614 R629 R612 R623 R611 R625 R615 R624 R613 A K J83 C R913 R912 R911 B R621 E T80 U81 Y60 C965 C60 R605 C61 U60 B60 C952 NC D50 U80 R915 R914 R936 R939 C540 R601 R600 R938 C951 U51 1 34 R265 35 68 USB_INT_N U92 EXP2_INT_N EXP1_INT_N R206 R893 R894 R895 J2 3 C963 C961 R937 R510 R509 C971 U91 U26 J21 C508 J20 J 57 PP58 C507 C958 R204 R257 R203 R253 R254 R255 R256 R245 R246 R247 R248 R249 R250 R251 R252 C957 R237 R238 R239 R240 R241 R242 R243 R244 C956 C954 R223 R224 R225 R226 R227 R228 R229 R230 C955 R231 R232 R233 R234 R235 R236 R216 R217 R218 R219 R220 R221 R222 C953 PP59 PP57 U52 B C T1 J 53 E U20 U22 U21 U23 J24 R521 U90 C709 J10 U71 C710 R413 R416 R414 R417 R406 R407 R400 R401 R404 R402 R405 U11 R926 R137 R138 R139 R140 R141 R142 R143 R144 R145 R146 R147 R148 R149 R150 R151 R152 R153 R154 R155 R156 R157 R158 R159 R130 R136 R415 R412 R403 C938 2.5V R898 R897 R896 R934 R301 R302 R303 R304 R305 R306 R307 R308 GND U41 A C406 C401 R408 R409 U40 C921 U30 R319 R320 R721 R719 C T72 R713 E T71 B K PP41 D71 NC C10 K NC D70 A R325 R326 R327 R328 R110 PP53 R313 R314 R315 R316 TMS TCK MH70 C708 R700 R701 PP54 R317 R321 R318 R322 R323 R324 D0 C12 C11 U13 CCLK R705 R702 C702 C400 R708 R418 R421 R709 C704 R420 R419 R707 R423 R424 L72 3.3V R101 P P4 0 R309 R310 R311 R312 B E B E T42 T41 T40 T43 B E B E B E B E B T47 T46 T45 U24 U25 R525 R526 C512 Y10 R102 R103 C975 C974 E A R847 R411 R932 C C R100 D40 T44 K NC B C E C C C C C R717 R716 R722 R723 C703 R706 R703 PP31 R215 C973 R714 R715 C964 U72 R920 R200 R921 R711 J30 PP32 C511 R520 C967 C510 C509 R522 R523 R524 R720 R925 R300 R924 R202 R410 C405 C403 C402 R422 C404 R712 C705 TDI DONE PP30 D72 R339 J81 C716 1 J84 L74 L70 INIT PP51 PP52 R985 R981 R980 R978 R977 R975 R974 R973 R972 R970 R969 R967 R966 R989 R990 R992 R993 R995 R996 R998 R965 R963 R962 R960 R959 R999 R957 R955 R954 R952 R951 R983 R892 L71 THY70 PP55 B A K E NC T70 C Z70 R718 PP50 R440 R439 R438 R437 R436 R435 R434 R433 R432 R431 L400 L415 L402 C700 F70 J51 J58 J54 J55 J50 PP56 PSU_INT_N R129 R127 R128 R126 R904 R125 R124 R123 U70 U32 C712 C701 R710 R704 R430 R905 R923 R922 PSA_TDO PROG C706 C717 U31 U42 U43 EasyCoder PX4i and PX6i Service Manual R724 J56 J52 J40 C900 Chapter 15 — CPU Board 15.6 Components 1-971630-51 CPU Board; Component Side 153 C976 U50 J62 C972 C966 J59 R549 R426 C530 R429 R428 R427 C502 R535 R536 C534 R545 R534 R991 R950 R953 R956 R958 R961 R964 R997 R994 R542 R543 C536 R538 C409 C410 R441 C408 R899 R933 C407 C539 C538 R425 R547 C535 R540 R512 R513 R518 R541 R533 R537 R515 R548 C969 C504 R544 C970 C968 R725 C718 C707 R988 R968 R971 R987 R976 R979 C984 C915 C715 R111 C987 C910 R982 C916 C917 C918 R514 C503 C501 C513 R931 R335 C531 R532 R546 R519 C537 C711 C32 C990 C991 C532 R531 R539 R333 C30 C933 C934 C31 C919 C920 R336 R334 C33 C948 C949 C950 C935 C936 C937 R337 R984 R338 C986 C983 C913 R900 C945 C926 C946 C927 C947 C942 C930 C906 C928 C943 C944 C907 C931 C982 C911 C985 R131 R132 R133 R134 R135 R832 R930 R929 R836 C912 R903 C932 C909 C908 R201 C914 C988 C989 R902 C901 C902 R811 C929 C925 R807 R813 R837 R835 R927 R820 R804 R817 R801 R822 R806 R819 R803 R834 R928 R816 R800 R821 R805 R833 R818 R802 R823 R838 R824 R808 R872 R870 R868 R865 R871 R862 R861 R853 R852 R880 R879 R828 R812 R885 R886 R829 R825 R809 R839 R858 R857 R841 R849 R848 R876 R875 R882 R881 R842 R844 R846 R826 R810 R831 R815 R843 R845 R830 R814 R827 R840 C903 C904 C905 C939 C940 C941 C922 C923 C924 R986 C714 R901 C713 R910 R873 R869 R867 R866 R864 R863 R854 R860 R859 R888 R887 R878 R877 R851 R850 R856 R855 R884 R883 R874 R210 C977 C992 R890 C533 R516 R209 R889 154 R530 C979 C980 C978 R626 R627 R628 R329 Chapter 15 — CPU Board 1-971630-51 CPU Board; Soldering Side EasyCoder PX4i and PX6i Service Manual C981 R208 R207 C505 R517 C506 SD_BE0_N SD_BE1_N SD_A12 14 13 10 11 6 7 8 9 2 3 4 5 12Mhz CY2071A OE/FS 2 6 CLKC G ND 5 CLKB D R136 R103 R102 6 14 7 15 4 12 5 13 2 10 3 11 0 8 1 9 D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3.3V VSS5 VSS1 D16 D0 D24 D8 D17 D1 D9 D25 VCC1 VCC5 D1 8 D2 D26 D10 D19 D3 D11 D27 VSS6 VSS2 CLK 0 SDA0 CKE0 SDA1 SDA2 SDA13 SDA3 SDA14 VCC6 VCC2 RAS* SDA4 SDA5 CAS* SDA6 J10 DQM2 SDA7 DQM3 VSS3 VSS7 D20 D4 D12 D28 D5 D21 D29 D13 VCC3 VCC7 D22 D6 D14 D30 D7 D23 D15 D31 VSS4 VSS8 SDA8 EW* SDA9 CS0* CS1* SDA10 NC2 SDA11 VSS9 VCC4 SDA12 NC3 NC4 NC1 PD1 DQM0 PD 0 DQM1 SDRAM_SIMM 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 D 22 30 23 31 20 28 21 29 18 26 19 27 16 24 17 25 3.3V SD_CLK 15 SD_PD1 SD_PD0 SD_WE_N SD_CS0_N SD_CS1_N SD_RAS_N SD_CAS_N SD_BE2_N SD_BE3_N SD_CLK SD_CKE SD_OE_N SD_WE_N SD_CAS_N SD_BE0_N SD_BE1_N 14 15 16 17 18 19 20 21 13 12 5 6 7 8 9 10 11 2 3 4 10 11 20 R137 R138 R139 R140 RESET_N R158 R159 R155 R156 R157 R154 R147 R148 R149 R150 R151 R152 R153 R144 R145 R146 R141 R142 R143 SD_CS2_N SD_CS3_N SD_A12 SD_CS0_N SD_CS1_N SD_RAS_N PSA_CLK CLIC_CLK SDRAM SIMM D R100 8 XTALIN XTALOUT 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 0 1 PCST2 RC32332 VCCO1 SD_CS0_N COLD_RES_N M_D20 M_D11 M_D10 M_A22 VCCO4 GND5 M_A21 M_A20 M_A19 M_A18 M_A17 M_A16 M_A15 M_A14 VCCO3 GND4 M_A13 SD_BE3_N SD_BE2_N SD_CS3_N SD_CS2_N SD_CKE SD_A12 M_A12 VCCI1 GND3 OUT_CLK M_A11 M_A10 M_A9 M_A8 M_A7 M_A6 M_A5 VCCO2 GND2 M_A4 M_A3 M_A2 SD_S1_N SD_S0_N SD_RAS_N SD_CS1_N U13 PCI_AD31 R110 C10 + CPU_CLK C11 C12 R111 PCI_AD7 PCI_BE0_N PCI_AD8 PCI_AD9 PCI_AD10 GND11 VCCO9 PCI_AD11 PCI_AD12 PCI_AD13 PCI_AD14 PCI_AD15 PCI_BE1_N PCI_PAR PCI_SERR_N GND12 VCCO10 PCI_PERR_N PCI_LOCK_N PCI_STOP_N PCI_DS_N PCI_TRDY_N PCI_IRDY_N PCI_FRAME_N PCI_BE2_N GND13 VCCI4 PCI_AD16 PCI_AD17 PCI_AD18 PCI_AD19 PCI_AD20 PCI_AD21 PCI_AD22 PCI_AD23 GND14 VCCO11 PCI_BE3_N PCI_AD24 PCI_AD25 PCI_AD26 PCI_AD27 PCI_AD28 PCI_AD29 PCI_AD30 GND15 VCCO12 PCI_REQ0_N SD_BE1_N GND1 PCI_GNT0_N SD_BE0_N PCI_CLK PCI_GNT1_N SD_CAS_N SD_WE_N SD_245_OE_N UART_RX0 UART_TX0 M_WE3_N M_WE2_N M_D12 M_D19 M_D13 M_D18 12 19 13 18 14 3 M_WR_N M_WE1_N VCCO16 GND20 M_WE0_N M_CS5_N M_D14 GND6 VCCO5 M_D17 M_D16 17 16 4 15 Y10 CPU M_CS4_N M_CS3_N M_CS2_N M_CS1_N M_CS0_N VCCI2 M_D15 MAST_CLK M_D31 M_D0 31 0 30 CPU_CLK CF_CS_N EXP1_CS_N CS2_N PSA_CS_N CS0_N M_RD_N M_OE_N VCCO15 GND19 M_WAIT_N M_245_OE_N M_D30 GND7 VCCO6 M_D1 M_D29 R101 DMA_RDY0_N SPI_MOSI SPI_MISO SPI_SCK SPI_SS_N M_D2 M_D28 M_D3 M_D27 M_D4 1 29 2 28 3 27 4 1 VCCI7 VCCI6 GND18 VCCI5 DB_CPU_DMA_N VCCP GNDP M_D26 M_D5 GND8 26 5 CLKA BUS_DIR_N U11 DMA_N ACK_N ADS_N ID_N EJ_DBOOT DB_CPU_ACK_N DB_CPU_ADS_N DB_CPU_ID_N EJTAG_DBOOT EJTAG_DCLK EJTAG_PCST2 VCCI3 245_DT_R_N M_D25 M_D6 M_D24 M_D7 25 6 24 7 VCC VCCO14 GND17 EJATG_PCST1 EJATG_PCST0 JTAG_TRST_N GND9 VCCO7 M_D23 M_D8 M_D22 23 8 22 9 21 7 VCCO13 GND16 INT1_N INT0_N PCI_RST_N GND10 VCCO8 PCI_AD2 PCI_AD3 PCI_AD4 3.3V M_WAIT_N BUS_EN_N DMA_DONE_N 2 3 4 PCI_INT_N TDI PCST1 PCST0 TRST_N TCK EJ_TMS TMS CPU_TDO TDI JTAG_TCK EJTAG_TMS JTAG_TMS JTAG_TDO JTAG_TDI M_D9 M_D21 NMI_N PCI_AD0 PCI_AD1 0 1 1 INT1_N INT0_N PCI_RES_N PCI_GNT2_N PCI_REQ2_N 208 207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173 172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 PCI_GNT2_N PCI_REQ2_N PCI_AD5 PCI_AD6 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 EasyCoder PX4i and PX6i Service Manual 2 3 4 5 6 CLOCK DRIVER 156 155 154 153 152 1 51 1 50 149 1 48 147 146 145 144 143 142 141 140 139 13 8 137 13 6 135 134 133 132 131 130 12 9 12 8 127 126 125 124 123 122 121 120 119 11 8 117 116 115 114 113 112 111 110 109 108 107 106 105 D 3.3V 7 10 9 8 15 14 13 12 11 23 22 21 20 19 18 17 16 30 29 28 27 26 25 24 31 PCI_CBE0_N PCI_SERR_N PCI_PAR PCI_CBE1_N PCI_CBE2_N PCI_FRAME_N PCI_IRDY_N PCI_TRDY_N PCI_DS_N PCI_STOP_N PCI_LOCK_N PCI_PERR_N PCI_CBE3_N PCI_CLK PCI_GNT0_N PCI_REQ0_N 3.3V M_A<22..1> M_D<31..0> R847 R846 R845 R844 R843 R842 R841 R840 R839 R838 R837 R836 R835 R834 R833 R832 R135 R134 R133 R132 R131 R130 R129 R128 R127 R126 R125 R124 R123 PCI_AD(31..0) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 DMA_N ADS_N ACK_N ID_N PCST2 PCST1 PCST0 MODE (INCL M_A(22..17)) UART<5..0> D Chapter 15 — CPU Board 15.7 Schematics 1-971630-26 CPU Board; Core (Schematics #1) 155 5 3.3V D 2 3 1 LVC02 M_RD_N M_WR_N R202 3.3V VCC=3.3V;GND=DGND M_A<15..1> SD_CLK ADS_N 1 17 25 18 19 20 21 22 23 5 13 6 14 7 15 16 24 8 9 10 11 4 12 D 1 2 3 9 8 7 6 5 4 3 2 1 BUS_DIR_N 9 8 7 6 5 4 3 2 19 4 12 5 13 6 14 7 15 0 8 1 9 2 10 3 11 BUS_EN_N U90 R200 M_D<31..0> R201 9 8 7 6 5 4 3 2 1 19 9 8 7 6 5 4 3 2 1 11 9 8 7 6 5 4 3 2 1 11 9 8 7 6 5 4 3 2 1 11 AHC245 2 U21 2 U22 AHC574 U23 AHC574 AHC541 EN U25 VCC=3.3V;GND=DGND & VCC=3.3V;GND=DGND 1D C1 EN U24 VCC=3.3V;GND=DGND 1D AHC574 C1 EN VCC=3.3V;GND=DGND 1D C1 EN VCC=3.3V;GND=DGND 1 AHC245 3EN2[AB] 3EN1[BA] G3 VCC=3.3V;GND=DGND 1 11 12 13 14 15 16 17 18 12 13 14 15 16 17 18 19 12 13 14 15 16 17 18 19 12 13 14 15 16 17 18 19 11 12 13 14 15 16 17 18 11 12 13 14 15 16 17 18 R257 R256 R255 R254 R253 R252 R251 R250 R249 R248 R247 R246 R245 R244 R243 R242 R241 R240 R239 R238 R237 R236 R235 R234 R233 R 232 R231 R230 R229 R 228 R227 R226 R225 R224 R223 R222 R221 R220 R219 R218 R217 1 15 7 14 6 13 5 12 4 11 3 10 2 9 3 2 1 23 22 21 20 19 18 25 17 24 16 15 7 14 6 13 5 12 4 11 10 9 8 13 14 6 14 7 15 4 12 5 13 3.3V CS2_N 22 21 1 3 2 CS0_N 15 25 24 12 5 13 6 10 3 11 4 8 1 9 2 2 10 3 11 0 8 1 9 0 3 AHC139 DMUX G U26 D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 0 3 AHC139 DMUX G 9 10 11 12 NC8 V SS 7 D5 D13 SYSRD* PD1 3 0 1 2 3 0 1 2 BUS_WR_N BUS_RD_N 7 EXP2_CS_N 6 USB_CS_N 5 ID_CS_N 4 FL_CS0_N FL_CS1_N FL_CS2_N FL_CS3_N NC9 PD0 A6 VCC4 VP P VSS8 A12 A5 RESET* A13 VSS4 VCC7 FCS1* SYSWR* D6 D15 D14 D7 FCS0* NC7 D12 VCC3 NC5 NC6 VSS3 VCC6 A23 A22 A21 D4 A4 A11 A3 A10 A20 V SS 6 A2 VCC=3.3V;GND=DGND 0 U26 J20 A19 VCC2 A17 A9 A24 A18 A1 VSS2 A8 VCC5 NC4 D11 D3 NC3 NC2 NC1 V SS 5 D10 D2 VCC1 D9 A7 A16 A15 A14 D8 V SS1 D0 D1 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 BOOT FLASH VCC=3.3V;GND=DGND 0 1 3.3V A<25..1> D 20 21 22 23 24 17 18 19 14 7 15 16 1 2 J2 3 12 5 13 6 10 3 11 4 8 1 9 2 3.3V DEBUG PSA_DONE PSA_INIT_N PSA_PROG_N PCI_DET_N FL_B_PD1 FL_B_PD0 SD_PD1 SD_PD0 PCI_RES_N RESET_N VPP_EN FL_B_PD0 FL_B_PD1 FL_CS0_N FL_CS1_N BUS_WR_N BUS_RD_N 3.3V R889 0 R890 8 R892 R216 R893 D 6 14 7 15 4 12 5 13 2 10 3 11 0 8 1 9 3.3V R894 R215 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 D D0 VSS1 D8 J21 A21 A20 NC7 D12 D13 VSS7 SYSRD* 3.3V D 1 2 3 4 5 6 7 8 9 10 11 CLIC VCC4 NC9 PD0 PD1 VSS8 A5 A13 VPP RESET* A6 A12 VSS4 VCC7 FCS1* SYSWR* D6 D15 D14 FCS0* D7 VCC3 NC8 NC6 D5 NC5 D4 VCC6 A23 A22 VSS3 A4 A11 A3 A10 VCC2 VSS6 A2 A17 A18 A24 A19 VSS2 A8 A9 VCC5 D11 A1 NC4 NC2 D10 D3 N C1 NC3 D2 VSS5 A16 A15 A7 A14 VCC1 D9 D1 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 EXP FLASH CLIC_TDI CLIC_TMS CLIC_TCK R895 U20 R207 3EN2[AB] IO_GCK3 TCK TMS TDI IO6 IO5 IO4 IO3 GND1 IO2 I O1 D RESET_N VPP_EN U92 IO16 TDO GND3 VCCIO IO17 IO18 IO19 IO20 IO21 IO22 IO_GSR D 4 0 1 2 3 D(15..0) 1 CF_IOCS16_N CF_CD2_N CF_CS0_N ARESET_N CF_WR_N CF_RD_N 3.3V 33 32 31 30 29 28 27 26 25 24 23 FL_CS2_N FL_CS3_N BUS_WR_N BUS_RD_N 20 21 22 23 24 17 18 19 14 7 15 16 3.3V XC9536XL PSA_RES_N P24EN VPP_EN 3EN1[BA] CLIC_CLK IO_GCK2 IO_GCK1 IO28 IO27 IO26 IO7 IO8 IO9 VCCINT1 IO10 USB_RES_N G3 R203 IO25 IO24 IO23 IO_GTS1 VCCINT2 GND2 IO11 IO12 IO13 IO14 1 R204 BUS_WR_N BUS_RD_N CF_CS_N ID_CS_N RESET_N 44 43 42 41 40 39 38 37 36 35 34 IO_GTS2 IO15 12 13 14 15 16 17 18 19 20 21 22 7 6 5 EXP1_RES_N EXP2_RES_N 0 1 2 3 4 5 6 7 D CF_CS_N 4 5 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 J22 CLIC_TCK CLIC_TDO CLIC_TDI CLIC_TMS R206 3.3V CD2* IOCS16* D2 D1 D0 A0 A1 A2 A3 A4 A5 A6 VCC1 A7 A8 A9 ATASEL* AHC32 1 U91 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 D 11 12 13 14 15 8 8 9 10 3.3V 1 U91 AHC32 6 D 3.3V VCC=3.3V;GND=DGND 4 5 VCC=3.3V;GND=DGND 9 10 C_2 GND2 D10 D9 D8 PDIAG* DASP* RFU2 RFU1 IORDY RESET* VS2* CSEL* VCC2 INTRQ WE* IOWR* IORD* VS1* CS1* D15 D14 D6 A1 0 CS0* D7 D12 D13 D5 D11 CD1* D4 D3 GND1 COMPACTFLASH COMPACT FLASH 3.3V MTG1 MTG2 19 R208 D<15..0> R209 156 R210 BUS/ADDRESS ISOLATOR/DRIVER J2 4 1 2 3 4 5 6 VCC G ND CLIC_TCK CLIC_TDO CLIC_TDI CLIC_TMS JTAG PROGRAMMING PORT CF_CS0_N CF_CS1_N MASTER MODE WHEN CSEL*=GND R265 CF_DASP_N CF_PDIAG_N CF_VS2_N RESET_N CF_IORDY CF_INTRQ CF_CS1_N CF_VS1_N CF_RD_N CF_WR_N CF_CD1_N Chapter 15 — CPU Board 1-971630-26 CPU Board; Flash Interfaces (Schematics #2) EasyCoder PX4i and PX6i Service Manual LTS_SEN GAP_PRE BM_PRE BM_DIODE RL_PRE R310 R308 R307 R306 R305 R 3 04 R303 R302 R301 R328 R327 R326 R 325 R324 R323 R322 R321 R320 R319 R318 R 3 17 R 316 R315 R314 R313 R312 1 0 1 2 3 4 5 6 7 3 2 1 0 3 2 1 0 3 2 1 0 3 2 1 0 3 2 LTS_GAIN(7..0) GAP_GAIN(3..0) BM_GAIN(3..0) BM_DRIVE(3..0) RL_GAIN(3..0) PL_GAIN(3..0) 3 2 1 0 RL_GAIN(3..0) GAP_GAIN(3..0) BM_GAIN(3..0) BM_DRIVE(3..0) FIN_IO0 FIN_IO2 FIN_IO1 FIN_NOT_N TPH_GAIN0 TPH_MEAS_EN TPH_CAL2 TPH_CAL1 TPH_CAL0 SDA TPH_GAIN2 TPH_GAIN1 S CL WAND BEEP USB_INT_N IBUTTON PSA_RES_N INT0_N INT1_N EXP2_INT_N EXP1_INT_N D TCK M_RD_N PSA XC2S30, XC2S50, XC2S100, XC2S150 &XC2S200 PINS WITH _NC NOT USED IN XC2S30 IO7 IO8 GND2 M0 GND7 M1 IO36 IO35 IO34 IO33 IO32 IO31_NC IO30 IO29 IO28 GND6 VCCO3 VCCINT3 IO27 IO26 IO25 IO24 IO23 GND5 IO22 IO21 IO20 VCCINT2 IO19 VCCO2 GND4 IO18 IO17 IO16 IO15 IO14 GND3 IO13 IO12 IO11 IO10 IO9 VCCINT1 VCCO1 U30 IO103 VCCO8 PROGRAM_N INIT_N_IO70 IO71 IO72 IO73 IO74 IO75_NC IO76 IO77 IO78 GND14 VCCO9 VCCINT7 IO79 IO80 IO81 IO82 IO83 GND15 IO84 IO85 IO86 VCCINT8 IO87 VCCO10 GND16 IO88 IO89 IO90 IO91 IO92 GND17 IO93 IO94 IO95 IO96 IO97 VCCINT9 VCCO11 GND18 IO98 IO99 IO100 IO101_NC IO102 IO 6 IO4 IO5_NC IO104 DIN_IO105 IO3 DOUT_IO106 IO1 CCLK 156 155 154 153 152 151 150 149 148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125 124 123 122 12 1 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 2.5V PSA_TDO VCCO12 IO 2 PL_INST R311 IO138 IO137 IO136_NC IO135 IO134 IO37 IO38 IO39 IO40_NC IO41 7 6 5 4 3 2 M_WAIT_N CF_INTRQ CF_IORDY 12 19 13 IO133 GND24 VCCO15 VCCINT12 IO132 IO42 IO43 GND8 VCCO5 VCCINT4 1 0 0 18 14 17 16 15 IO131 IO130 IO129 IO128 GND23 IO127 IO44 IO45 IO46 IO47 IO48 GND9 LTS_DIG HEADLIFT R 30 9 PSA_CLK IO126 IO125 VCCINT11 GCK3 VCCO14 IO49 IO50 IO51 VCCINT5 GCK1 2 1 0 PL_PRE GND22 GCK2 IO124 IO123 IO122 VCCO6 GND10 GCK0 IO52 IO53 3 2 1 0 SENSOR ADJUST GND1 TMS 31 30 1 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 29 2 28 3 IO121 GND21 IO120 IO119 IO118 IO54 IO55 GND11 IO56 IO57 TMS M_WR_N DMA_N DMA_DONE_N ACK_N 27 4 26 5 25 IO117 IO116 VCCINT10 VCCO13 GND20 IO58 IO59 IO60 VCCINT6 VCCO7 3 2 1 0 3 TMS PSA_CS_N 10 11 20 VCCO16 TCK IO140 IO139 VCCO4 M2 NC1 NC2 TCK ADS_N 6 24 7 IO115 IO114 IO113 IO112_NC IO111 IO110 GND12 IO61 IO62 IO63 IO64_NC IO65 PL_DIG RL_DIG 2 1 0 3.3V PSA_TDO IO66 IO67 IO68 IO69 GND13 M_D<31..0> CPU_TDO 23 8 22 9 21 IO109 IO108 IO107 TDI GND19 208 207 206 205 204 203 202 201 200 199 198 197 196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173 172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 TDO DONE 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 8 7 6 5 1 2 3 4 0 0 11 10 14 13 12 0 5 4 3 2 1 9 8 7 6 3 .3 V TPH_DATA(8..1) PSA_INIT_N PSA_PROG_N PSA_DONE 1 D G ND DATA J30 2 PP32 R329 PL_SEN D D C33 R333 R336 U32 6 5 LM393M U32 R337 C31 D 1 5V 7 20 19 18 17 16 15 14 13 12 11 5V R 334 C30 LM393M 2 3 TLC0838 5V NC CS* DI CLK SARS DO SE* REF AGND U31 CH0 CH1 CH2 CH3 CH4 CH5 CH6 CH7 COM GND R339 C32 2.5V RL_SEN D 1 2 3 4 5 6 7 8 9 10 PP31 PL_DIG R338 3.3V PP30 RL_DIG R335 3.3V D AD_DO AD_CS_N AD_DI AD_CLK IBUTTON A/D-CONVERTER GAP_SEN BM_SEN TPH_RES RL_SEN PL_SEN THERM LTS_INST DRIVER_IO(14..0) DONE PROG INIT AD_CS_N TPH_STRB_N TPH_LATCH_N TPH_CLK AD_DO AD_CLK AD_DI P24EN CON_IO1 CON_IO2 CON_IO0 CON_NOT_N RL_INST PSU_INT_N PSU_NOT_N PSA_CS_N CCLK R300 3.3V 5V IBUTTON 8 EasyCoder PX4i and PX6i Service Manual 4 D0 Chapter 15 — CPU Board 1-971630-26 CPU Board; PSA (Schematics #3) 157 TPH_GAIN0 TPH_GAIN1 TPH_GAIN2 R 412 B TPH_MEAS_EN D T45 R415 R413 B R406 B R400 B R407 D T46 R416 D T43 D T40 C E C E C E C E R403 R414 B B R408 R401 B 24V_S D T41 R 404 D T47 R417 D C400 T44 D R420 R418 + C402 C401 R409 R402 B R405 D R421 R419 D T42 E C E E C C E 6 5 2 3 D40 D IN LM358M 7 U41 D LM358M 1 U41 R422 C404 C403 3 OUT R441 R423 ADJ U40 D R424 D D C406 TPH_RES C405 PP40 PP41 R 411 R 410 TPHV C410 2 THE CORRESPONDING DIODE ON PSU BOARD MUST BY OF SAME TYPE 8 4 TPH_CAL0 TPH_CAL1 TPH_CAL2 1 158 C DOT RESISTANCE TEST CIRCUIT D 1 2 3 4 5 6 7 8 C409 R 429 R428 C408 R427 R426 TPH_DATA<8..1> TPH_STRB_N TPH_LATCH_N TPH_CLK THERM SCL SDA D 9 8 7 6 5 2 3 4 1 19 2 3 4 5 6 7 8 9 1 19 EN EN VCC=5V;GND=DGND AHCT541 & U43 VCC=5V;GND=DGND AHCT541 & U42 11 12 13 14 15 18 17 16 18 17 16 15 14 13 12 11 D C407 R425 D 5V L415 R440 R439 R438 R437 R436 R435 R434 R433 R432 R431 R430 L402 L400 C_1 GND_TPH 5V_TPH THERMAL PRINT HEAD (TPH) J4 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 I2CDATA THERM1 I2CCLK THERM2 STROBE1 STROBE2 LATCH VCC CLOCK VCC DATA1 G ND DATA2 G ND DATA3 G ND DATA4 G ND DATA5 G ND DATA6 GND DATA7 G ND DATA8 G ND Chapter 15 — CPU Board 1-971630-26 CPU Board; Thermal Printhead Interface (Schematics #4) EasyCoder PX4i and PX6i Service Manual R532 R531 R530 SCL SDA 1 2 3 4 A0 A1 A2 GND 1 2 3 4 5 6 MTG1 MTG2 J59 C532 D C_2 L 52 L51 L50 D VCC WP SCL SDA 24C02A U50 C531 WAND 5V C530 CON_NOT_N R533 CON_IO0 CON_IO1 CON_IO2 C533 8 7 6 5 5V D 5V R537 R536 R535 R534 WAND R500 5V 5V WAND D VCC N/C GND 3 2 D U51 BEEP SMBUS2 SMBUS1 4 5 FIN_NOT_N FIN_IO0 FIN_IO1 FIN_IO2 LTC1694 1 J50 1 2 3 4 5 6 7 8 9 10 D 12 13 R541 R540 R539 R 538 R621 J51 1 2 3 4 5 6 7 8 9 10 D C540 4 5 D 9 10 =1 U80 VCC=5V;GND=DGND AHC86 =1 U8 0 PSU_NOT_N PSU_INT_N P24EN B EEPER D50 D 24V_S 6 8 DRIVER_IO<14..0> 5V PSU_INT_N R545 R544 R543 R542 FINISHER AHC86 C535 VCC=5V;GND=DGND 11 R510 C536 AHC86 =1 U80 R509 D C537 VCC=5V;GND=DGND 5V C534 CONSOLE R547 R546 C539 C538 BUZZER B60 1 2 D R549 R548 24V_I F70 + 8 9 4 5 6 7 0 1 2 3 11 12 13 14 10 C507 J52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PP59 D TPHV LTS_SEN 24IGND C700 5V C508 PSU/ MOTOR DRIVERS + INTERFACES + I2C C510 TONE IN 3 C509 6 IN TIME R520 CAP FILTER OUT FILTER 1 U52 LM567 PP57 PP58 PP55 PP56 PP51 PP50 2 PP53 PP52 BM_SEN OUT GND VCC TONE D 7 4 5 8 5V D R514 D R522 R523 B PL_INST T1 R524 R525 D 5V D D C504 C506 R518 D 5V J55 1 2 3 4 GAP J54 1 2 3 4 5V J56 1 2 3 4 C512 R526 J53 1 2 3 4 LTS LTS_INST 5V D J58 1 2 3 4 5 HEADLIFT R519 R517 J57 1 2 3 4 PAPER LOW R515 5V RIBBBON LOW PP54 C513 5V BLACKMARK BM_DIODE RL_INST R513 HEADLIFT R516 C505 D C503 D LTS_DIG R521 PL_SEN PL_PRE RL_SEN RL_PRE GAP_SEN C502 R512 C501 GAP_PRE BM_PRE C E EasyCoder PX4i and PX6i Service Manual C511 SENSORS Chapter 15 — CPU Board 1-971630-26 CPU Board; Internal Interfaces (Schematics #5) 159 0 1 2 3 4 5 BUS NO. - 3.3V R 625 R624 R623 UART_RX0 UART_TX0 SPI_MOSI SPI_MISO SPI_SCK PCI_GNT1_N CPU PINS UART<5..0> A<24..1> D<15..0> - R600 R XD TXD CTS RTS D SR DTR RS232 7 0 R610 USB_INT_N 0 1 2 3 4 5 6 1 R611 R601 2 R612 4 3 R613 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U60 R 629 C63 R618 C64 USBN9604 CLKOUT CS* RD* XOUT WR_SK XIN INTR MODE0 DRQ MODE1 DACK* GND A0_ALE_SI VCC D0_SO GND DD1 D2 D+ D3 V3.3 D4 AGND RESET* D5 D6 D7 4 R614 USB_CS_N BUS_RD_N BUS_WR_N USB_INT_N 5 R615 2 13 16 21 20 18 24 23 22 19 17 D D R619 1 3 28 25 28 27 26 25 24 23 22 21 20 19 18 17 16 15 3.3V EN* R605 V- V+ VCC MAX3237E MBAUD SHDN* R1IN R2IN R3IN T1OUT T2OUT T3OUT T4OUT T5OUT U61 USB_RES_N C61 R1OUTB R1OUT R2OUT R3OUT T1IN T2IN T3IN T4IN T5IN C2+ C2- C1+ C1- GND C60 160 + 3.3V C6 2 15 14 8 9 11 5 6 7 10 12 4 27 26 D 3.3V R602 C_2 C66 L60 R604 R603 R620 3. 3 V D C6 5 D 24Mhz Y60 5V D L67 L66 L65 L64 L 63 L62 L61 L68 RP60 NC C_2 MTG1 MTG2 1 2 3 4 J60 C_2 1 2 3 4 5 6 7 8 9 DCD RD SD DTR SG DSR RTS CTS RI - IBM EXP1_RES_N EXP1_CS_N EXP1_INT_N SCL S DA STANDARD DB9 EXP2_INT_N EXP2_INT_N EXP2_CS_N EXP2_RES_N EXP1_INT_N DATA CARRIER DETECT RECEIVE DATA TRANSMIT DATA - DATA TERMINAL READY SIGNAL GROUND - DATA SET READY - REQUEST TO SEND - CLEAR TO SEND RING INDICATOR - REFERENCE - 1 2 TXD 3 RX D 4 DSR 5 GND 6 DT R 7 CTS 8 RTS 9 MTG1 MTG2 J61 RS232 VDD DD+ GND USB M_WAIT_N R626 R627 BUS_WR_N BUS_RD_N R628 3.3V 5V 9 10 11 12 5 6 7 8 1 2 3 4 14 15 12 13 10 11 8 9 6 7 4 5 2 3 0 1 D NC NC 24V_S J62 1 35 2 36 3 37 4 38 5 39 6 40 7 41 8 42 9 43 10 44 11 45 12 46 13 47 14 48 15 49 16 50 17 51 18 52 19 53 20 54 21 55 22 56 23 57 24 58 25 59 26 60 27 61 28 62 29 63 30 64 31 65 32 66 33 67 34 68 SCL SA1 RESET CS INT DREQ DACK DACK DREQ IN T CS RESET SA1 SPARE SPARE S DA EXP BUS SLOT SLOT 2 1 Chapter 15 — CPU Board 1-971630-26 CPU Board; External Interfaces (Schematics #6) EasyCoder PX4i and PX6i Service Manual L71 24IGND R700 5V C709 R701 + D + R704 R705 R706 R707 C703 C713 3 U71 VOUT GND/ADJ VIN D 2 C714 + D C710 3.3V 5V TO 3.3V R703 R702 C702 R709 R708 3 .3 V C704 DTC FB RT CT 1IN+ 1IN2IN+ 2INOC 4 3 6 5 1 2 16 15 13 14 REF 7 8 9 11 10 C1 E1 C2 E2 GND 12 VCC R710 B T70 D7 0 B 5V C711 3 U72 D GND/ADJ VIN TAB VOUT 2 D C715 + T71 C712 2.5V 5V TO 2.5V TL594 U70 R712 R711 C E 2.5V D71 C705 R713 C716 + C717 R714 C706 MOUNTHOLE AT LOWER LEFT ON PCB C_2 D72 T72 MH71 L74 G 24V_S D S L72 C E C701 1 R715 L70 D GND R717 R716 C_1 C718 MH70 R718 R721 R723 R722 R724 C707 3 THY70 Z70 + D C708 SHORT CIRCUIT DIGITAL GROUND (D) WITH MH70 IN THIS POINT AND IN THIS POINT ONLY! SOURCE R725 MOUNTHOLE CLOSEST TO 24V R719 R720 2 1 24V_I 1 EasyCoder PX4i and PX6i Service Manual 4 C A 24V TO 5V CONVERTER 5V Chapter 15 — CPU Board 1-971630-26 CPU Board; Power (Schematics #7) 161 CF_CD1_N CF_CD2_N 3.3V 1 2 R864 17 R863 16 R862 15 R861 14 R860 13 R859 12 R858 11 R857 10 R856 9 R855 8 R854 7 R853 6 R852 5 R851 4 R850 3 R849 2 R848 1 R958 8 R957 7 R956 6 R955 5 R954 4 R953 3 R952 2 R951 1 R950 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3 R900 R901 E_RESET_N TCK EJ_TMS R913 B D T80 R914 3.3V 1 2 J83 R915 2 4 TPS3825 RESET* EXT.RESET D VDD R ESET U81 GND MR* 3 1 5 3.3V RESET GENERATOR D R902 TDI CPU_TDO ARESET_N R959 9 PCI_REQ0_N PCI_GNT0_N PCI_INT_N PCI_CBE3_N PCI_CBE2_N PCI_LOCK_N PCI_STOP_N PCI_TRDY_N PCI_PAR R960 10 26 27 29 21 22 16 18 14 15 8 9 11 3 4 6 D PCI_AD1 VSS4 PCI_IRDY_N PCI_AD30 PCI_GNT_N0 PCI_CLK SDA TRST_N 24V PCI_DET_N VSS10 TDI NC1 SCL TDO VCC9 PCI_RST_N PCI_REQ_N2 TMS TCK VSS9 PCI_INT_N VCC8 PCI_AD28 PCI_AD31 PCI_REQ_N0 PCI_AD27 PCI_AD29 VSS8 VCC7 PCI_AD25 VSS7 PCI_AD26 PCI_AD23 PCI_AD24 PCI_AD22 PCI_CBE_N3 VCC6 PCI_AD20 PCI_AD21 VSS6 PCI_AD17 PCI_AD19 PCI_AD18 PCI_AD16 VCC5 PCI_FRAME_N PCI_DEVSEL_N PCI_STOP_N PCI_CBE_N2 VSS5 PCI_TRDY_N VCC4 PCI_PERR_N PCI_PAR PCI_LOCK_N PCI_CBE_N1 PCI_SERR_N PCI_AD15 VCC3 PCI_AD13 VSS3 PCI_AD14 PCI_AD10 PCI_AD12 PCI_AD11 VCC2 PCI_CBE_N0 PCI_AD9 PCI_AD8 VSS2 PCI_AD5 PCI_AD7 VCC1 PCI_AD2 PCI_AD6 J84 SCA80 PCI PCI_AD4 PCI_AD3 VSS1 PCI_AD0 R961 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 R962 12 0 R963 13 R905 R964 14 TRST_N R965 15 J81 R966 16 3.3V R967 17 E_RESET_N VCC=5V;GND=DGND AHC86 =1 U80 R865 18 R968 18 C EJTAG R866 19 R969 19 E M_D(31..0) R867 20 R970 20 R903 PCI_AD(31..0) R868 21 R971 21 3.3V R869 22 BUS PULL-UPS R870 23 R972 22 D(15..0) R911 R871 24 R973 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 5V 28 30 31 23 24 25 17 19 20 10 12 13 5 7 1 2 R873 23 A(25..1) R912 R872 25 R974 24 R874 0 R975 R875 1 25 R876 2 R976 R877 3 26 R878 4 R977 R879 5 27 R880 6 R978 R881 7 28 R882 8 R979 R883 9 29 R884 10 R980 R885 11 30 R886 12 R981 R887 13 31 R888 14 162 15 3.3V SCL SD A PCI_DET_N PCI_CLK PCI_REQ2_N PCI_RES_N PCI_DS_N PCI_IRDY_N PCI_FRAME_N PCI_CBE1_N PCI_SERR_N PCI_PERR_N PCI_CBE0_N 3 .3 V R815 R814 R813 R812 R811 R810 R809 R808 R807 R806 R805 R804 R803 R802 R801 R800 30 29 1 3 5 7 9 11 13 15 17 19 21 23 25 27 R 831 R830 R829 R828 R 827 R826 R825 R824 R 823 R822 R821 R820 R819 R818 R817 R816 EJ_DBOOT R904 R934 PULL-DOWNS CF_INTRQ MISC 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 31 3 .3 V D CF_IOCS16_N CF_VS2_N CF_VS1_N CF_PDIAG_N CF_DASP_N PCI_CBE0_N PCI_CBE1_N PCI_PAR PCI_SERR_N PCI_PERR_N PCI_LOCK_N PCI_STOP_N PCI_DS_N PCI_TRDY_N PCI_IRDY_N PCI_FRAME_N PCI_CBE2_N PCI_CBE3_N PCI_REQ0_N PCI_GNT0_N PCI_INT_N PCI_REQ2_N PCI_GNT2_N SD_CS3_N SD_CS2_N SD_CS1_N SD_CS0_N SD_OE_N CS2_N CS0_N INT1_N INT0_N DMA_DONE_N M_WAIT_N PSU_NOT_N FIN_NOT_N CON_NOT_N TMS PSU_INT_N USB_INT_N EXP2_INT_N R939 R938 R937 R936 R935 R999 R998 R997 R996 R995 R994 R993 R992 R991 R990 R989 R988 R987 R986 R985 R984 R983 R 982 R930 R929 R928 R927 R926 R925 R924 R 923 R922 R921 R920 R933 R932 R931 R910 R899 R898 R897 R896 PULL-UPS EXP1_INT_N MISC 3 .3 V Chapter 15 — CPU Board 1-971630-26 CPU Board; Pull-ups (Schematics #8) EasyCoder PX4i and PX6i Service Manual C904 C902 EasyCoder PX4i and PX6i Service Manual 3.3V C905 C989 C903 C988 C901 D D C958 C957 C956 C955 C954 C953 C961 C951 3.3V D 3.3V U25 U24 U23 U22 U21 U20 U26 U81 C906 C907 AHC541 AHC574 AHC574 AHC574 AHC245 AHC245 AHC139 RESET GENERATOR C985 47 37 27 17 7 C982 203 59 C986 U13 CPU C983 C913 D C966 C965 C976 C963 C975 C974 3.3V C908 C914 173 U6 1 U60 U90 U91 U1 1 U11 C987 C984 C910 111 CLOCK DRIVER RS232 DRIVER USB DRIVER LVC02 AHC32 5V D C952 C964 C972 C971 C970 C969 C968 C 967 D C920 C919 C917 121 C991 C990 C916 3.3V C918 D D 131 141 151 C915 CLOCK DRIVER C909 89 C912 163 99 C911 193 69 U80 U32 U5 1 U50 U43 U42 U31 U52 D 3.3V C 921 C924 C923 C922 AHC86 LM393 PULL-UP EEPROM AHCT541 IC 3.3V 39 26 12 3.3V AHCT541 A/D LM567 D + 3.3V C929 C925 C930 DECOUPLING/BYPASS 208 53 3.3V C931 3.3V D C973 24V_S C980 C978 C992 C926 D U41 C981 C979 C977 U30 LM358 U92 CLIC C927 PSA 3.3V 105 117 D C937 C936 C935 130 C933 3.3V C934 D D 144 156 C928 C932 D 2.5V D + C941 C940 C939 C938 2.5V 2.5V 38 28 13 2.5V CAPACITORS 170 92 + 183 82 197 65 C942 C943 C945 U30 D 5 6 8 9 11 12 C946 1 U90 LVC02 13 C947 118 128 143 C944 10 4 VCC=3.3V;GND=DGND LVC02 1 U90 VCC=3.3V;GND=DGND LVC02 1 U 90 VCC=3.3V;GND=DGND PSA 2.5V 197 66 184 78 181 76 C900 171 91 3.3V D D D 2.5V C950 C949 C948 Chapter 15 — CPU Board 1-971630-26 CPU Board; Bypass/Decoupling (Schematics #9) 163 Chapter 15 — CPU Board 15.8 Replacing the CPU board Replace the CPU board this way: • Switch off the power. • Remove the left-hand cover as described in Chapter 3.3. • Remove any optional interface boards. • Disconnect all cables from the CPU board. • Remove the four #T20 Torx screws and the hexagonal spacer that hold the CPU board to the plate that covers the power supply unit. • Lift out the CPU board and remove all SIMMs and any real time clock. Take precautions against electrostatic discharges! • Fit the SIMMs and possibly the real-time clock on the new board and install it in reverse order. The same CPU-board can be used for a range of EasyCoder printers. However, the firmware can not detect in which type of printer the CPU board is installed. All replacement CPU boards are preprogrammed for the EasyCoder PF2/4i-series printers, which means that replacement CPU boards always must be reconfigured after being installed in an EasyCoder PX4i or PX6i printer. If the printer feeds out labels in a peculiar way, the CPU board may be configured for the wrong type of printer (there is a difference in the distance between the dot line and the LSS position). You can easily check if the CPU board is correctly configured by printing the “Hardware Info” or “HW” test label in the Setup Mode or sending the Fingerprint instruction PRINT VERSION$(1). If the CPU board needs to be reconfigured, do like this: • Switch off the power. • Insert a configuration card in the memory card slot. • Switch on the power. • Using the same method as in the Setup Mode, select the correct printer type from the menus shown in the display window. • Switch off the power. • Remove the card. • Switch on the power again and check. 164 EasyCoder PX4i and PX6i Service Manual 16 Interfaces This chapter describes the various communication interfaces for the EasyCoder PX4i and PX6i printers. However, some interfaces are not supported by the Intermec Programming Language (IPL) even though the connectors are present. The chapter describes three categories: • Standard built-in interfaces RS-232 interface USB interface Bar code wand interface (Fingerprint only) • Optional interface boards Serial/Industrial interface board (Fingerprint only) Double Serial interface board (Fingerprint only) IEEE 1284 Parallel interface board • EasyLAN interface boards EasyLAN Ethernet interface EasyLAN Wireless interface The EasyCoder PX4i and PX6i can—in addition to the standard built-in interfaces—also be fitted with one or two optional interface boards and one EasyLAN interface board. Note: Device designations, such as "uart1:", "usb1:", or "net1:", only apply to Fingerprint, not to IPL. EasyCoder PX4i and PX6i Service Manual 165 Chapter 16 — Interfaces 16.1 Introduction In Fingerprint, "auto" is by default the standard IN and OUT communication port, that is, the printer will scan all communication channels for incoming data. To select a specific communication port as standard IN and/or standard OUT port, use an Intermec Fingerprint SETSTDIO statement (see Intermec Fingerprint v8.xx, Programmer’s Reference Manual). This gives better performance. Note that many application programs, for example Intermec Shell, contain instructions that select the correct standard I/O for the application in question. The settings for the selected communication channel will appear in the display window when pressing the key on the printer’s keyboard. In IPL, all communication channels are always scanned for incoming data and the firmware automatically switches to the same channel for output too. The settings for the active communication channel will appear in the display window when pressing the key on the printer’s keyboard. The standard interfaces (RS-232, USB, and Wand) are fitted directly on the rear of the CPU board with connectors protruding through slots in the printer’s rear plate. Wand is not supported by IPL. All optional interface boards, except the EasyLAN boards, are fitted in a slot on the printer’s standard rear plate and connected to the CPU board via a flat cable. If no interface board is fitted, the slot is closed by two cover plates. The EasyLAN boards are fitted directly to the front of the CPU board and connected by wire to a connector or antenna. There are provisions for both the wired EasyLAN connector and the EasyLAN wireless antenna on the standard rear plate. All rear plates have slots for two interface boards as well as for the standard interface connectors. 166 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces 16.2 RS-232 Serial Communication Port ("uart1:") The EasyCoder PX4i and PX6i printers are always fitted with one RS232 communication port. In Intermec Fingerprint, this port is designated "uart1:" (uart = Universal Asynchronous Receiver and Transmitter.) The circuitry is fitted on the CPU board (see Chapter 15) and has a fixed set of signals in a DB-9pin female connector which protrudes through a slot in the printer’s rear plate. Protocol Default setup Baud rate: Char length: Parity: Stop bits: RTS/CTS: ENQ/ACK: XON/XOFF: New line: 9600 8 bits None 1 Disabled Disabled Disabled in both directions CR/LF Signals on serial port ("uart1:") MTG DB-9 socket Signal 1 9 RTS out CTS in DTR out 8 7 6 5 4 3 2 1 GND DSR in RXD in TXD out +5V DC MTG Meaning External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) 2 TXD Transmit data 3 RXD Receive data 4 DSR Data set ready 5 GND Ground 6 DTR Data terminal ready 7 CTS Clear to send 8 RTS Request to send 9 – Not used RS-232 socket ("uart1:") EasyCoder PX4i and PX6i Service Manual 167 Chapter 16 — Interfaces 16.3 USB Interface ("usb1:") The EasyCoder PX4i and PX6i printers are, as standard, fitted with a USB (Universal Serial Bus) interface connector on the CPU board. USB ("usb1:") The supported USB version is USB 1.1 (also called “USB 2.0 full speed”). To use the USB interface for printing from a PC, you need a USB-compatible Intermec InterDriver installed in your PC. The printer works only as a “slave”, that is, the USB interface is not suitable for programming. Unlike for example RS-232, there is no communication setup in regard of baud rate, parity, handshaking, etc. Select the USB interface as standard IN/ OUT channel in Intermec Fingerprint, the Intermec Direct Protocol, or Intermec Shell as device "usb1:" (communication channel 6). The EasyCoder PX4i and PX6i printers are so called “self-powered devices.” We recommend that you only connect one printer to each USB port on the host, either directly or via a hub. Other devices, like a keyboard and a mouse, can be connected to the same hub. If you need to connect more than one Intermec USB printer to a host, you should use different USB ports. Using a USB Class A/B cable, connect the Class A plug to the PC or hub and the Class B plug to the printer. USB Class A connector. Connect to PC or hub. 168 USB Class B connector. Connect to USB port on printer’s rear plate. EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces 16.4 Bar Code Wand Interface (wand:) (Fingerprint only) The printer has a socket (J59) on the CPU board for connecting a bar code wand or scanner. The socket is accessible through a slot in the printer’s rear plate. The bar code wand interface is not supported by IPL. If the Code 128 bar code that contains the character FNC3 is read via this port, the data will be treated as a setup string and will change the printer’s setup accordingly. A setup bar code may contain a single parameter or a combination of up to 3 or 4 setup parameters. Refer to the EasySet Bar Code Wand Setup manual for more information on how to produce setup bar codes. The printer will acknowledge that a bar code has been successfully read by emitting a short beep signal. If no FNC3 character is found in the bar code, the data will be stored in a buffer which could be read by specifying the "wand:" device. The buffer is small, so it is recommended to use short bar code data (max. 36 characters) and read the buffer regularly to avoid overflow. For more demanding applications or for reading bar codes other than Code 128, choose a regular bar code scanner from Intermec’s wide product range and connect it to a serial port. Wand interface ("wand:") EasyCoder PX4i and PX6i Service Manual 169 Chapter 16 — Interfaces 16.5 Installing an Optional Interface Board To install an optional interface board, proceed according to the step-bystep instructions below. Note: This chapter does not apply to installation of any type of EasyLAN interface board, which instead is described in Chapter 16.9. • Open the electronics compartment, see Chapter 3.3. Switch off the power and disconnect the power cord. The electronics compartment contains high voltage components and wires. Do not open the electronics compartment before the printer is safely disconnected from any AC supply. • Remove the one or two cover plates depending on how many interface boards you are going to install. Each plate is held by two #T10 Torx screws. Always start installation at the innermost position. Spacer and screw #T10 Torx screws Cover plates #T10 Torx screws • Save the cover plate(s) for possible later use. Keep the screws. • Remove the #T20 Torx screw fitted on the hexagonal spacer at the center of the CPU board. Keep the screw. • If necessary, reconfigure the interface board by fitting or removing circuits and straps according to the descriptions of each board later in this chapter. • Attach the flat cable included in the kit to connector J62 (marked “EXP BOARD”) on the CPU board (see illustration on the next page). • Insert the interface board with the component side facing right, as seen from behind. 170 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces #T10 Torx screws #T20 Torx screw and spacer(s) Inner interface board Flat cable (two types) Component side Outer interface board • Installation of one board: Attach the interface board in the innermost slot in the printer’s rear plate using the two screws left over when you removed the original cover plate. Using the #T20 Torx screw you previously removed, attach the interface board to the hexagonal spacer at the center of the CPU board. P01 C64 C63 • Installations of two boards: First install the inner board, then the outer one. Put the hexagonal spacer included in the kit between the inner and the outer interface board, and finally secure the outer board with the screw. C40 R32 IC23 R33 IC20 IC24 R31 R34 R35 1-971643-01 R36 R37 C21 C22 C60 IC26 R26 IC27 C62 IC25 C65 R41 R51 R42 R52 C23 C24 R54 R43 R53 R44 C25 C26 C27 R45 R55 R46 R56 C28 R47 R57 R48 R58 R38 R27 R25 R24 R23 R22 P3 R21 R28 IC21 REL4 C61 C51 C67 IC22 IC2 IC28 REL3 C36 C34 REL2 IC3 C66 P1 P35 REL1 J62 P1 RS232: IC11, J2A C33 RS422: IC12, J3, J4 C3 C4 RS485: IC13, J1, J4* C35 IC10 * IF END OF CABLE R13 IC11 IC12 R8 R12 R18 J3 J61 R10 IC4 IC6 R16 C56 R9 C57 IC9 R7 R1 R6 R17 C31 C53 J4 Flat cable (two types) R4 R11 IC1 C52 J1 R2 C55 R3 C30 C54 P2 EasyCoder PX4i and PX6i Service Manual C50 R5 IC13 J2 R15 F1 F6 F2 F7 F3 F8 F4 F5 C1 C2 A IC5 B C32 R14 UARTA EXP BOARD Hexagonal spacer 171 Chapter 16 — Interfaces • The kit contains two flat cables, one with two connectors for use with a single interface board and one with three connectors for use with double interface boards. Connect the appropriate flat cable to connector P1 on the interface board, as illustrated below. • The flat cable should run as illustrated below. $16#PBSE 4QBDFS FYJTUJOH $BCMF *OOFS*OUFSGBDF#PBSE 4DSFX FYJTUJOH $16#PBSE 4QBDFS FYJTUJOH $BCMF *OOFS*OUFSGBDF#PBSE 4QBDFS GSPNLJU 0VUFS*OUFSGBDF#PBSE 4DSFX FYJTUJOH • Put back the cover over the electronics compartment. • Connect the communication cables to the connectors on the printer’s rear plate. • Connect the power cord and switch on the power. • In case the interface board provides additional serial communication ports, enter the Setup Mode to set the proper communication parameters for these ports. 172 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Allowed interface combinations (Fingerprint) Left-hand slot Ports Right-hand slot Ports Double Serial uart2: + uart3: – – Double Serial uart2: + uart3: Double Serial uart4: + uart5: Double Serial uart2: + uart3: Serial Industrial uart4: Double Serial uart2: + uart3: IEEE 1284 centronics: Serial/Industrial uart2: – – Serial/Industrial uart2: Serial/Industrial uart3: Serial/Industrial uart2: Double Serial uart3: + uart4: Serial/Industrial uart2: IEEE 1284 centronics: IEEE 1284 centronics: – – IEEE 1284 centronics: Double Serial uart2: + uart3: IEEE 1284 centronics: Serial/Industrial uart2: Allowed interface combinations (IPL) Left-hand slot Ports Right-hand slot Ports IEEE 1284 parallel – – Remarks: • The left-hand slot is the slot closest to the center section. • Always start by fitting an interface board in the left-hand slot. • RS-485 is only supported by "uart2:" When fitting driver circuit and straps before installing the interface board, make sure that the circuit is not fitted upside down (see front end markings in the illustrations). Also make sure that the “legs” of the circuit fit into the slots in the socket and are not bent. Take ample precautions to protect the board and circuits from electrostatic discharges. EasyCoder PX4i and PX6i Service Manual 173 Chapter 16 — Interfaces 16.6 Serial/Industrial Interface Board (Fingerprint only) Description The Serial/Industrial Interface Board is a Fingerprint-only optional device for EasyCoder PX4i and PX6i. It provides these printers with two extra interfaces. The Serial/Industrial Interface kit contains: • One Industrial Interface Board fitted with straps and circuits for RS-232 • One hexagonal spacer • Two flat cables • One Installation Instruction booklet Serial Interface ("uart2:", "uart3:", or "uart4:") This interface contains one serial communication port ("uart2:", "uart3:", or "uart4:") which can be configured for one of the following alternatives: • RS-232 non-isolated • RS-422 isolated, full duplex (reconfiguration required) • RS-485 isolated, half duplex (reconfiguration required, "uart2:" only) Selection of type of serial interface is decided by fitting various types of socket-mounted driver circuits and straps. Industrial Interface This interface contains eight digital IN and eight digital OUT ports with optocouplers, plus four OUT ports with relays. The status of all ports can be read by means of PORTIN functions and the OUT ports can be set using PORTOUT ON/OFF statements (see Intermec Fingerprint v8.xx, Programmer's Reference Manual). Thus, it is possible to design Intermec Fingerprint application programs which control not only the printer but also various external devices, for example in a production line. The digital IN ports can read the status of various sensors and the program can, for example, switch control lamps on or off, open or close gates, and start or stop conveyor belts accordingly using the relays and the digital OUT ports. Industrial Interface (DB-44pin socket) Serial Interface "uart2:" (DB-9pin socket) 174 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Serial Port Configuration The serial communication port "uart2:", "uart3:", or "uart4:" are configured for RS-232 as standard but can be reconfigured for two other types of serial communication by fitting certain driver circuits and straps. The circuits can be ordered separately from Intermec: • RS-422 isolated, full duplex • RS-485 isolated, half duplex ("uart2:" only!) P01 C64 C63 RS-232 Non-isolated (standard) C40 R32 IC23 R33 IC20 IC24 R31 R34 R35 1-971643-01 R36 R37 C21 C22 C60 IC26 R26 IC27 C62 IC25 C65 R41 R51 C23 R42 R52 R43 C24 R54 R53 R44 C25 C26 R45 R55 C27 R46 R56 R47 R57 C28 R48 R58 R38 R27 R25 R24 R23 R22 P3 R21 R28 IC21 REL4 C61 C51 C67 IC22 IC2 IC28 REL3 C36 C34 REL2 IC3 C66 REL1 P1 RS232: IC11, J2A C33 RS422: IC12, J3, J4 C3 C4 RS485: IC13, J1, J4* C35 IC10 * IF END OF CABLE R13 R15 IC12 R8 F1 F6 F2 F7 F3 F8 F4 F5 R12 R18 J3 R10 IC4 IC6 R16 C56 R9 C57 IC9 R7 R1 R6 R17 C31 C53 J4 R11 R4 IC1 C52 C55 R3 C30 C54 P2 R2 RS-232 circuit fitted on IC11 IC11 C50 R5 IC13 J2 Strap fitted on J2 A C1 C2 A IC5 B C32 R14 UARTA J1 Connector Configuration (RS-232 on "uart2:", "uart3:", or "uart4:") MTG 9 RTS out CTS in DTR out 8 7 6 5 4 3 2 1 GND DSR in RXD in TXD out +5V DC MTG DB-9 socket Signal 1 Meaning External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) 2 TXD Transmit data 3 RXD Receive data 4 DSR Data set ready 5 GND Ground 6 DTR Data terminal ready 7 CTS Clear to send 8 RTS Request to send 9 – Not used EasyCoder PX4i and PX6i Service Manual 175 Chapter 16 — Interfaces P01 C64 C63 RS-422 Isolated, Full Duplex (reconfiguration required) C40 R32 IC23 R33 IC20 IC24 R31 R34 R35 1-971643-01 R36 R37 C21 C22 C60 R27 IC26 R26 IC27 C62 IC25 C65 R41 R51 C23 R42 R52 R43 C24 R54 R53 R44 C25 C26 R45 R55 C27 R46 R56 R47 R57 C28 R48 R58 R38 R25 R24 R23 R22 P3 R21 R28 IC21 REL4 C61 C51 IC22 IC2 IC28 REL3 C67 C36 C34 REL2 IC3 C66 REL1 P1 RS232: IC11, J2A C33 RS422: IC12, J3, J4 C3 C4 RS485: IC13, J1, J4* C35 IC10 * IF END OF CABLE R13 R15 IC12 R12 R18 J3 R10 IC4 IC6 R16 C56 R9 C57 IC9 R7 R1 R6 R17 C31 C53 J4 R11 P2 R4 IC1 C52 R2 C55 R3 C30 C54 Remove RS-232 circuit on IC11 Fit RS-422 circuit on IC12 C50 R8 F1 F6 F2 F7 F3 F8 F4 F5 Fit straps on J3 and J4 IC11 R5 IC13 J2 Remove strap on J2 A C1 C2 A IC5 B C32 R14 UARTA J1 Connector Configuration (RS-422 Isolated on "uart2:", "uart3:", or "uart4:") MTG DB-9 socket Signal 1 9 -TXD -RXD 8 7 6 176 5 GNDE 4 3 2 1 +RXD +TXD +5V DC if GND strap fitted MTG Meaning External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) provided strap is fitted on J2:A which spoils the galvanical isolation 2 +TXD +Transmit data 3 +RXD +Receive data 4 – 5 GNDE 6 - 7 -RXD -Receive data 8 -TXD -Transmit data 9 – Ground EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces P01 C64 C63 RS-485 Isolated, Half Duplex (reconfiguration required) C40 R32 IC23 R33 IC20 IC24 R31 R34 R35 1-971643-01 R36 R37 C21 C22 C60 R27 IC26 R26 IC27 C62 IC25 C65 R41 R51 C23 R42 R52 R43 C24 R54 R53 R44 C25 C26 R55 R45 C27 R56 R46 R47 R57 C28 R48 R58 R38 R25 R24 R23 R22 P3 R21 R28 IC21 REL4 C61 C51 C67 IC22 IC2 IC28 REL3 C36 C34 REL2 IC3 C66 REL1 Remove strap on J2 A P1 RS232: IC11, J2A C33 RS422: IC12, J3, J4 C3 C4 RS485: IC13, J1, J4* C35 IC10 * IF END OF CABLE R13 R15 IC11 IC12 F1 F6 F2 F7 F3 F8 F4 F5 R8 R12 R18 J3 R10 IC4 R16 C56 R9 C57 IC9 R7 R1 R6 R17 C31 C53 J4 R11 P2 R4 IC1 C52 R2 C55 R3 C30 C54 Fit strap on J1 C50 R5 IC13 J2 Fit strap on J4 if end of cable (terminator) C1 C2 A IC6 B C32 R14 UARTA IC5 Remove RS-232 circuit on IC11 Fit RS-485 driver circuit J1 Connector Configuration (RS-485 Isolated on "uart2:" only) MTG DB-9 socket Signal 1 9 -DATA 8 7 6 5 External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) provided strap is fitted on J2:A which spoils the galvanical isolation GNDE 4 3 2 1 +DATA +5V DC if GND strap fitted MTG Meaning 2 +DATA 3 – 4 – 5 GNDE 6 – 7 – 8 -DATA 9 – Ground Note: The increased use of LAN networks has made the RS-485 interface somewhat obsolete, because RS-485 requires a special communication protocol and a dedicated wiring system limited to 1,200 m (4,000 ft). We only recommend RS-485 for existing applications and advice the customer to consider a LAN network solution for new applications. EasyCoder PX4i and PX6i Service Manual 177 Chapter 16 — Interfaces Industrial Interface Configuration The Industrial Interface provides: • 8 digital IN ports with optocouplers (Opto In) • 8 digital OUT ports with optocouplers (Opto Out) • 4 OUT ports with relays (Relay Out) The Industrial Interface has no straps or circuits to be fitted or removed. All signals are available on a DB-44pin socket and the various ports are controlled by the Intermec Fingerprint instructions PORTIN and PORTOUT ON/OFF (see Intermec Fingerprint v8.xx, Programmer's Reference Manual). Digital Opto In The status of the digital IN ports can be read using PORTIN functions. If a current is led through the optocoupler of the port, PORTIN returns the value -1 (true), else it returns the value 0 (false). Signal Vin [High] Vin [Low] Description Input Voltage High Input Voltage Low Min. 10V -1V Typical 24V 0V Max. 40V 1V Connector Configuration Pin Signal Name Description Fingerprint Ref. No. 10 IN1A Anode Opto In Channel 1 + 101 (301) 40 IN1K Cathode Opto In Channel 1 - 26 IN2A Anode Opto In Channel 2 + 11 IN2K Cathode Opto In Channel 2 - 41 IN3A Anode Opto In Channel 3 + 27 IN3K Cathode Opto In Channel 3 - 12 IN4A Anode Opto In Channel 4 + 42 IN4K Cathode Opto In Channel 4 - 28 IN5A Anode Opto In Channel 5 + 13 IN5K Cathode Opto In Channel 5 - 43 IN6A Anode Opto In Channel 6 + 29 IN6K Cathode Opto In Channel 6 - 14 IN7A Anode Opto In Channel 7 + 44 IN7K Cathode Opto In Channel 7 - 30 IN8A Anode Opto In Channel 8 + 15 IN8K Cathode Opto In Channel 8 - 102 (302) 103 (303) 104 (304) 105 (305) 106 (306) 107 (307) 108 (308) The Fingerprint reference numbers inside the parentheses refer to a second Serial/Industrial interface board. INA INK GND Simplified schematics of a digital IN port. 178 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Digital Opto Out The current to each optocoupler of the digital OUT ports can be turned on and off using PORTOUT ON/OFF statements. The status of the ports can be read using PORTIN functions. If a current is led through the optocoupler of the port, PORTIN returns the value -1 (true), else it returns the value 0 (false). Signal Vceo Veco Description Collector-Emitter breakdown voltage Emitter-Collector breakdown voltage Collector Current Output to ground (optocoupler) Vog Max. 35V 6V 15 mA 100V Connector Configuration Pin Signal Name Description Fingerprint Ref. No. 20 Out1c Collector Opto Out Channel 1 221 (421) 5 Out1e Emitter Opto Out Channel 1 35 Out2c Collector Opto Out Channel 2 21 Out2e Emitter Opto Out Channel 2 6 Out3c Collector Opto Out Channel 3 36 Out3e Emitter Opto Out Channel 3 22 Out4c Collector Opto Out Channel 4 7 Out4e Emitter Opto Out Channel 4 37 Out5c Collector Opto Out Channel 5 23 Out5e Emitter Opto Out Channel 5 8 Out6c Collector Opto Out Channel 6 38 Out6e Emitter Opto Out Channel 6 24 Out7c Collector Opto Out Channel 7 9 Out7e Emitter Opto Out Channel 7 39 Out8c Collector Opto Out Channel 8 25 Out8e Emitter Opto Out Channel 8 222 (422) 223 (423) 224 (424) 225 (425) 226 (426) 227 (427) 228 (428) The Fingerprint reference numbers inside the parentheses refer to a second Serial/Industrial interface board. VCC OUTc OUTa Simplified schematics of a digital OUT port. EasyCoder PX4i and PX6i Service Manual 179 Chapter 16 — Interfaces Relay Out The relays of the OUT ports can be individually activated using PORTOUT ON/OFF statements. The status of the ports can be read by means of PORTIN functions. If a relay is activated, PORTIN returns the value -1 (true), else it returns the value 0 (false). Max AC Load Breaking Capacity Signal I Psw AC Usw AC Description Current Switching power Switching voltage Max. 1A 100VA AC 100V AC Max DC Load Breaking Capacity DC current (A) 1 b a 0.5 0.1 10 20 30 40 50 100 a: resistive load DC Voltage (VDC) b: inductive load L/R=20 ms Connector Configuration Pin Signal Name Description Fingerprint Ref. No. 16 REL1nc Relay 1 Normally Closed 201 (401) 1 REL1no Relay 1 Normally Open 31 REL1com Relay 1 Common 17 REL2nc Relay 2 Normally Closed 2 REL2no Relay 2 Normally Open 32 REL2com Relay 2 Common 18 REL3nc Relay 3 Normally Closed 3 REL3no Relay 3 Normally Open 33 REL3com Relay 3 Common 19 REL4nc Relay 4 Normally Closed 4 REL4no Relay 4 Normally Open 34 REL4com Relay 4 Common 202 (402) 203 (403) 204 (404) The Fingerprint reference numbers inside the parentheses refer to a second Serial/Industrial interface board. VCC REL no REL nc REL com Simplified schematics of a relay OUT port. 180 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces C21 C22 R51 R41 IC26 C40 IC20 IC27 C23 R52 R42 C24 R53 R43 C60 R27 R26 R25 R24 R23 R22 R21 IC21 P3 IC25 R31 R32 R33 R34 R35 R36 R37 R38 C65 C64 R54 C25 IC23 C62 C26 R55 R45 C27 R56 R46 R58 R48 C28 R57 R47 IC24 R44 C63 Components C51 IC28 C61 R28 REL4 C67 IC2 IC22 REL3 C36 C34 REL2 C66 IC3 REL1 1 35 34 68 P1 C33 RS232: IC11, J2A C35 RS422: IC12, J3, J4 C4 C3 C2 C1 RS485: IC13, J1, J4* IC10 R14 A R13 R8 R18 R15 C31 R3 R2 C52 R6 C30 IC1 J1 IC5 R1 IC4 R7 IC6 C53 C57 R11 R4 C54 R9 IC12 IC9 R10 C56 C55 R16 R17 J3 R12 J4 F1 F6 F2 F7 F3 F8 F4 F5 J2 IC13 B IC11 UARTA P2 C50 R5 C32 *: IF END OF CABLE 1-971643-26 Serial/Industrial Interface Board; Component side EasyCoder PX4i and PX6i Service Manual 181 P1 1 35 2 36 3 37 4 38 5 39 6 40 7 41 8 42 9 43 10 44 11 45 12 46 13 47 14 48 15 49 16 50 17 51 18 52 19 53 20 54 21 55 22 56 23 57 24 58 25 59 26 60 27 61 28 62 29 63 30 64 31 65 32 66 33 67 34 68 9 10 11 12 5 6 7 8 1 2 3 4 R1 5V 11 12 SCL SA1 RESET_N CS_N INT_N SDA 14 15 12 13 10 11 8 9 6 7 4 5 2 3 0 1 WR_N RD_N 1 2 3 4 R2 IC1 R3 9 10 C50 + A0 VCC WP A1 A2 SCL GND SDA INTA WR_N 9 10 4 5 1 2 1 2 3.3V RESET_N A<12..1> D<15..0> =1 8 7 6 5 8 8 6 3 1 INT_N 3.3V IC3 VCC 5V 3 R5 3.3V D5 D6 D7 RCLK IC10 SIN NC SOUT 16C550 CS0 CS1 CS2* BAUDOUT* 1.8432MHZ NC/EN_N OUT 3 GND WRB_N CSB_N CSA_N 3 RESET 7 8 9 10 11 12 13 14 15 16 17 GND IC2 CLK VIN VOUT LD1117 C51 C52 C53 C54 C55 C56 C57 5V AHC86 IC5 VCC=3.3V AHC32 IC4 1 VCC=3.3V AHC32 IC4 1 VCC=3.3V AHC32 IC4 1 VCC=3.3V AHC86 IC5 =1 VCC=3.3V 5 6 7 3.3V 2 WAIT_N 1 +24VI 4 4 3 2 1 0 6 5 4 3 2 1 44 43 42 41 40 MR OUT1* DTR* RTS* OUT2* NC INTRPT RXRDY* A0 A1 A2 D4 D3 D2 D1 D0 NC VCC RI* DCD* DSR* CTS* XIN XOUT WR1* WR2 VSS NC RD1* RD2 DDIS TXRDY* ADS* 2 39 38 37 36 35 34 33 32 31 30 29 1 2 3 INTA RESET =1 IC5 =1 12 13 5V 11 9 10 =1 AHCT86 IC6 VCC=5V AHC86 IC5 =1 VCC=3.3V AHCT86 =1 VCC=5V IC6 DSRA_N 6 3 TXDA 11 R4 12 RXDA 13 8 DTRA_N RTSA_N 12 CTSA_N 13 4 5 3.3V AHCT86 IC6 =1 VCC=5V AHCT86 IC6 VCC=5V AHC32 IC4 1 VCC=3.3V AHC86 J1 1 RS485 2 4 5 1 2 11 6 VCC=3.3V R6 5V DCDA_N INTERFACE CONFIGURATION RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE C30 C31 C32 C33 C34 C35 C36 3.3V 18 19 WR_N 20 21 22 23 RD_N 24 25 26 27 28 182 485_DIR 5V R10 + C2 + C1 R11 R9 R7 5V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 10 12 13 14 5 18 19 21 6 4 22 17 R8 RS232 MAX1480 VCC1 AC1 VCC2 AC2 IVCC1 D1 D2 B GND1 IRCDRV FS A SD IDIIN IDEIN VCC3 DI ICOM1 VCC4 IDIDRV DE IVCC2 GND2 IDEDRV RO_N ICOM2 VCC5 IRLED IC13 RS485 MAX1490 VCC1 AC1 VCC2 AC2 D1 IVCC1 IRCDRV D2 A GND1 B FS SD Z VCC3 Y ICOM1 DI VCC4 IDIDRV IVCC2 RO GND2 IRLED IC12 RS422 IC11 MAX238 C1+ VCC C1V+ C2+ VC2GND T1OUT T1IN T2IN T2OUT T3OUT T3IN T4OUT T4IN R1OUT R1IN R2OUT R2IN R3OUT R3IN R4OUT R4IN R18 OVERCURRENT_N 5V_EXT_EN_N 28 27 26 25 24 23 22 21 20 19 18 17 16 15 24 23 22 21 20 19 18 17 16 15 14 13 9 11 15 8 2 1 24 20 7 3 23 16 5V 5V R14 R13 R12 + C4 OUT GND IN OUT IN OUT EN_N OC_N 8 7 6 5 POWER_SWITCH + C3 1 2 3 4 SWITCH FOR EXTERNAL 5V IC9 R15 R17 R16 F8 F7 F6 F5 F4 F3 F2 F1 1 2 1 2 TERM.TRA. J4 J3 C 9 MTG1 MTG2 P2 RS232 1 +5V 2 TXD 3 RXD 4 DSR 5 GND 6 DTR 7 CTS 8 RTS TERM.REC. 1 A J2 2B 3 GND-SHIELD 5V_EXT 9PIN DSUB +DATA -RXD -TXD -DATA GNDE GNDE +TXD +RXD RS422 RS485 Chapter 16 — Interfaces Schematics; Serial Port ("uart2:", "uart3:", or "uart4:") 1-971643-26 Serial/Industrial Interface Board; Schematics 1 EasyCoder PX4i and PX6i Service Manual EasyCoder PX4i and PX6i Service Manual 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 11 12 13 14 15 16 17 18 3 4 7 8 13 14 17 18 1 11 3 4 7 8 13 14 17 18 6 7 & AHC541 EN IC20 VCC=5V ULN2003A IC28 ULN2003A IC28 VCC=3.3V D AHCT273 RESET CLK IC21 VCC=5V AHCT273 D 11 10 9 8 7 6 5 4 3 2 1 19 2 5 6 9 12 15 16 19 2 5 6 9 12 15 16 19 C60 C61 C62 C63 C64 C65 C66 C67 5V C40 3.3V CSB_N RD_N D<15..0> RESET_N WRB_N 8 9 10 11 RESET CLK 1 2 3 4 5 6 7 1 2 3 4 12 R25 11 R26 10 R27 16 R28 15 14 13 ULN2003A IC27 ULN2003A IC27 ULN2003A IC27 ULN2003A R31 R32 R33 R34 R35 R36 R37 R38 16 R21 15 R22 14 R23 VCC=5V IC27 13 R24 ULN2003A IC27 ULN2003A IC27 ULN2003A IC27 ULN2003A IC28 ULN2003A IC28 ULN2003A IC28 8 6 7 4 5 2 3 1 8 6 7 4 5 2 3 1 9 11 10 13 12 15 14 16 8 6 7 4 5 2 3 1 8 9 OPTO_COUPLER 6 7 11 10 2 3 1 9 11 10 13 12 15 14 16 9 11 10 13 12 15 14 16 4 5 IC23 OPTO_COUPLER IC24 OPTO_COUPLER IC25 OPTO_COUPLER IC26 13 12 15 14 16 5V R41 R42 R43 R44 R45 R46 R47 R48 NO 14 11 12 R58 NC COM C21 R51 C22 R52 C23 R53 C24 R54 C25 R55 C26 R56 C27 R57 C28 REL4 REL3 NO NC COM 14 11 12 REL2 NO NC COM 14 11 12 REL1 NO NC COM A1 A1 5V A2 A2 IC28 A1 A1 ULN2003A A2 A2 ULN2003A A1 A1 IC22 A2 A2 1 11 A1 A1 VCC=5V IC28 12 A2 A2 5 14 11 12 C MTG1 MTG2 27 26 11 10 40 42 41 29 28 13 12 44 43 16 1 31 17 2 32 18 3 33 19 4 34 20 5 35 21 6 36 22 7 37 23 8 38 24 9 39 25 30 15 14 P3 SIGNALS REL1NC REL1NO REL1COM REL2NC REL2NO REL2COM REL3NC REL3NO REL3COM REL4NC REL4NO REL4COM OUT1C OUT1E OUT2C OUT2E OUT3C OUT3E OUT4C OUT4E OUT5C OUT5E OUT6C OUT6E OUT7C OUT7E OUT8C OUT8E IN8A IN8K IN7A IN7K IN6A IN6K IN5A IN5K IN4A IN4K IN3A IN3K IN2A IN2K IN1A IN1K DSUB44 Chapter 16 — Interfaces Schematics; Industrial Interface 1-971643-26 Serial/Industrial Interface Board; Schematics 2 183 Chapter 16 — Interfaces 16.7 Double Serial Interface Board (Fingerprint only) Description The Double Serial Interface Board (DUART) is a Fingerprint-only optional device for EasyCoder PX4i and PX6i printers. It provides these printers with two extra serial interfaces. "uart2:", "uart3:", or "uart4:" This interface (marked “UART A” on the interface board) can be fitted with straps and circuits for one of the following alternatives: • RS-232 non-isolated • RS-422 isolated, full duplex • RS-485 isolated, half duplex ("uart2:" only) "uart3:", "uart4;", or "uart5:" This interface (marked “UART B” on the interface board) can be fitted with straps and circuits for one of the following alternatives: • RS-232 non-isolated • RS-422 non isolated, full duplex • 20 mA Current Loop. The Double Serial Interface Kit contains: • One interface board fitted for RS-232 on both ports. • Two flat cables • One hexagonal spacer • One Installation Instruction booklet Circuits for modifying the board for RS-422 non-isolated, RS-422 isolated, RS-485 isolated, or 20 mA current loop can be bought separately from Intermec. "uart3:" (DB-9pin socket) "uart2:" (DB-9pin socket) 184 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces "uart2:", "uart3:" & "uart4" Configuration (connector UART A) The serial communication ports "uart2:", "uart3:", and "uart4:" can be configured for up to three different types of serial communication respectively by fitting or removing certain driver circuits and straps: • RS-232 non-isolated • RS-422 isolated, full duplex • RS-485 isolated, half duplex ("uart2:" only!) RS-232 Non-isolated (standard) IC23 B IC21 C11 C10 A C12 1-971642-01 C63 R24 R27 R30 IC8 C60 R28 NC K A R26 J9 R19 F9 C64 R29 IC7 R25 D1 K Z1 A R21 C62 B J8 A R20 C40 R32 P3 IC24 J5 C C13 IC22 R31 R33 R34 A R22 NC K B Z2 A C R23 F14 F10 F15 F11 F16 F12 J10 R35 J7 C61 F13 C36 RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5 J9*, J10* *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C C41 IC20 C42 C34 IC3 C35 J2 R13 C51 IC11 C32 IC12 R8 R18 R10 R12 R9 R16 IC4 C56 J3 IC6 R1 IC1 R3 J1 R2 R4 C55 C54 P2 R11 C30 IC9 IC5 R7 R17 R6 C31 C53 C57 J4 C52 F1 F6 F2 F7 F3 F8 F4 F5 RS-232 circuit fitted on IC11 C50 R5 IC13 R15 Strap fitted on J2 A IC10 C1 C2 A C33 C3 C4 R14 B P1 IC2 RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE UARTA P01 J6 NC UARTB Connector Configuration (RS-232 on "uart2:", "uart3:", or "uart4:") MTG 9 RTS out CTS in DTR out 8 7 6 5 4 3 2 1 GND DSR in RXD in TXD out +5V DC MTG DB-9 socket Signal 1 Meaning External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) 2 TXD Transmit data 3 RXD Receive data 4 DSR Data set ready 5 GND Ground 6 DTR Data terminal ready 7 CTS Clear to send 8 RTS Request to send 9 – Not used EasyCoder PX4i and PX6i Service Manual 185 Chapter 16 — Interfaces RS-422 Isolated, Full Duplex (reconfiguration required) IC23 B IC21 C11 C10 A C12 R24 IC8 C60 R28 A K NC J9 R19 C64 R29 IC7 R25 D1 K Z1 A R21 C62 B J8 A R20 C40 R32 P3 IC24 J5 C C13 IC22 R31 R33 R34 A R22 K NC Z2 A R23 C63 B R26 C36 RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5 J9*, J10* *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C C41 IC20 C42 C34 IC3 C35 J2 R13 IC11 IC12 R8 R18 R10 R12 R9 R16 IC4 C56 J3 IC6 R1 IC1 R3 J1 R2 R11 C55 C54 P2 R4 C30 IC9 IC5 R7 R17 R6 C31 C53 C57 J4 C52 F1 F6 F2 F7 F3 F8 F4 F5 Fit RS-422 circuit on IC12 C50 C32 IC13 R15 Fit straps on J3 and J4 C51 R5 A IC10 C1 C2 B C33 C3 C4 R14 UARTA P1 IC2 RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE Remove strap on J2 A P01 R27 R30 C C61 F14 F10 F15 F11 F16 F12 J10 R35 J7 F9 Remove RS-232 circuit on IC11 1-971642-01 J6 F13 NC UARTB Connector Configuration (RS-422 Isolated on "uart2:", "uart3:", or "uart4:") DB-9 socket Signal 1 9 -TXD -RXD 8 7 6 186 5 External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) provided strap is fitted on J2:A which spoils the galvanical isolation GNDE 4 3 2 1 +RXD +TXD +5V (0.5 A) if GND strap fitted Meaning 2 +TXD +Transmit data 3 +RXD +Receive data 4 – 5 GNDE 6 - 7 -RXD -Receive data 8 -TXD -Transmit data 9 – Ground EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces RS-485 Isolated, Half Duplex (reconfiguration required) IC23 B IC21 C11 C10 A C12 C63 R24 R27 R30 IC8 C60 R28 NC K A R26 J9 R19 C64 R29 IC7 R25 D1 K Z1 A R21 C62 B J8 A R20 C40 R32 P3 IC24 J5 C C13 IC22 R31 R33 R34 A R22 NC K B Z2 A C F9 C36 RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5 J9*, J10* *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C C41 IC20 C42 C34 IC3 C35 J2 R13 C32 C50 R5 IC13 IC11 IC12 R8 R15 R18 R10 R12 R9 R16 IC4 C56 J3 R1 IC1 R3 J1 R2 R4 C55 C54 P2 R11 C30 IC9 IC5 R7 R17 R6 J4 C31 C53 C57 C52 F1 F6 F2 F7 F3 F8 F4 F5 Fit strap on J4 if end of cable (terminator) C51 IC6 Fit RS-485 driver circuit on IC13 A IC10 C1 C2 B C33 C3 C4 R14 UARTA P1 IC2 RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE Remove strap on J2 A P01 R23 F14 F10 F15 F11 F16 F12 J10 R35 J7 C61 F13 Remove RS-232 circuit on IC11 1-971642-01 J6 NC UARTB Fit strap on J1 Connector Configuration (RS-485 Isolated on "uart2:" only) DB-9 socket Signal 1 9 -DATA 8 7 6 5 GNDE 4 3 2 1 +DATA +5V (0.5 A) if GND strap fitted Meaning External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) provided strap is fitted on J2:A which spoils the galvanical isolation 2 +DATA 3 – 4 – 5 GNDE 6 – 7 – 8 -DATA 9 – Ground Note: The increased use of LAN networks has made the RS-485 interface somewhat obsolete, because RS-485 requires a special communication protocol and a dedicated wiring system limited to 1,200 m (4,000 ft). We only recommend RS-485 for existing applications and advice the customer to consider a LAN network solution for new applications. EasyCoder PX4i and PX6i Service Manual 187 Chapter 16 — Interfaces "uart3:" , "uart4:", and "uart5:" Configuration (connector UART B) The serial communication ports "uart3:", "uart4:", and "uart5:" can be configured for three different types of serial communication by fitting or removing certain driver circuits and straps: • RS-232 non-isolated • RS-422 non-isolated, full duplex • 20 mA Current Loop RS-232 Non-isolated (standard) IC23 B IC21 C11 C10 A C12 1-971642-01 C63 R24 R27 R30 J8 A IC8 C60 R28 NC K A R26 J9 R19 F9 C64 R29 IC7 R25 D1 K Z1 A R21 C62 B R20 C40 R32 P3 IC24 J5 C C13 IC22 R31 R33 R34 A R22 NC K B Z2 A C R23 F14 F10 F15 F11 F16 F12 J10 R35 J7 C61 F13 C36 RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5 J9*, J10* *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C C41 IC20 C42 C34 IC3 C35 J2 R13 C50 C32 IC13 IC11 R5 A C51 IC12 R8 R15 R10 R9 R16 IC4 C56 J3 R1 IC1 R3 J1 R2 R11 C55 C54 P2 R4 C30 IC9 IC5 R7 R17 R6 C31 C53 C57 J4 C52 F1 F6 F2 F7 F3 F8 F4 F5 R18 R12 IC6 B IC10 C1 R14 UARTA C33 C3 C4 C2 RS-232 driver circuit fitted on IC21 P1 IC2 RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE Strap fitted on J6 A P01 J6 NC UARTB Connector Configuration (RS-232 on "uart3:", "uart4:", or "uart5:") MTG DB-9 socket Signal 1 9 RTS out CTS in DTR out 8 7 6 5 4 3 2 1 GND DSR in RXD in TXD out +5V DC MTG 188 Meaning External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) 2 TXD Transmit data 3 RXD Receive data 4 DSR Data set ready 5 GND Ground 6 DTR Data terminal ready 7 CTS Clear to send 8 RTS Request to send 9 – Not used EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces RS-422 Non Isolated, full duplex (reconfiguration required) IC23 B C12 R24 C60 IC22 C13 A K C64 R29 IC7 R28 NC J9 R19 R20 C40 R32 P3 IC24 J5 R25 D1 K Z1 A R21 C62 B J8 A R22 C IC8 A K Z2 NC R31 R33 R34 A C36 RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5 J9*, J10* *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C C41 IC20 C42 C34 IC3 C35 J2 R13 C51 IC11 C50 C32 IC13 R5 A IC10 C1 C2 IC12 R8 R15 R10 R9 R16 IC4 C56 J3 R1 IC1 R3 J1 R2 R4 C55 C54 P2 R11 C30 IC9 IC5 R7 R17 R6 C31 C53 C57 J4 C52 F1 F6 F2 F7 F3 F8 F4 F5 R18 R12 IC6 B C33 C3 C4 R14 UARTA P1 IC2 RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE Remove RS-232 driver circuit from IC21 P01 R23 C63 B F9 Fit RS-422 driver circuit on IC22 1-971642-01 R27 R30 C C61 F14 F10 F15 F11 F16 F12 J10 R35 J7 R26 Fit straps on J7 and J8 C10 J6 F13 Move strap from J6 A to J6 B IC21 C11 A NC UARTB Connector Configuration (RS-422 Non-isolated on "uart3:", "uart4:", or "uart5: ) DB-9 socket Signal 1 9 -TXD -RXD 8 7 6 5 GND 4 3 2 1 +RXD +TXD +5V (0.5 A) Meaning External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) if strap is moved from J6 B to J6 A. 2 +TXD +Transmit data 3 +RXD +Receive data 4 – 5 GNDE 6 - 7 -RXD -Receive data 8 -TXD -Transmit data 9 – EasyCoder PX4i and PX6i Service Manual Ground 189 Chapter 16 — Interfaces 20 mA Current Loop (reconfiguration required) Remove strap from J6 A IC23 B C10 C12 IC8 C60 R28 A K NC J9 R19 C64 R29 IC7 R25 D1 K Z1 A R21 C62 B J8 A R20 C40 R32 P3 IC24 J5 C C13 IC22 R31 R33 R34 A R22 NC K B Z2 A C61 C63 R24 R27 R30 C R26 C36 RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5 J9*, J10* *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C C41 IC20 C42 C34 P1 IC2 RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE IC3 C35 C3 C4 C33 Remove RS-232 driver circuit from IC21 P01 R23 J10 R35 J7 F9 Fit strap on J9 if printer is transmitter: A + C = active B = passive Fit optocouplers on IC23 and IC24 1-971642-01 J6 F14 F10 F15 F11 F16 F12 Fit strap on J10 if printer is receiver: A + C = active B = passive IC21 C11 A F13 NC UARTB IC10 C51 Fit strap on J5 J2 R13 IC13 IC11 C50 R5 A IC12 R8 R15 R10 R9 R16 IC4 C56 J3 R1 IC1 R3 J1 R2 R11 C55 C54 P2 R4 C30 IC9 IC5 R7 R17 R6 C31 C53 C57 J4 C52 F1 F6 F2 F7 F3 F8 F4 F5 R18 R12 IC6 B C32 C1 C2 R14 UARTA Connector Configuration (20 mA Current Loop on "uart3:", "uart4:", or "uart5:") MTG DB-9 socket 9 -TXD -RXD 8 7 6 Signal 1 5 External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) provided a strap is fitted on J6 A which spoils the galvanic isolation. 4 3 2 1 +RXD +TXD +5V DC if GND strap fitted MTG Meaning 2 +TXD +Transmit data 3 +RXD +Receive data 4 – 5 GNDE 6 - 7 -RXD -Receive data 8 -TXD -Transmit data 9 – Ground Note: Max. recommended baud rate 9600. 190 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Components UARTB B A R34 IC21 C62 R33 R21 R25 R28 R29 IC7 A IC24 K R32 R19 R26 D1 K Z1 A J9 A C40 C36 RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5 J9*, J10* *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C J5 C64 R20 IC20 C41 F9 NC F14 B R22 C NC J8 C34 RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE C42 P1 1 35 68 IC2 34 F10 IC8 C60 IC22 R31 F15 C13 C63 K Z2 A J10 A F11 P3 B NC J7 F12 F16 C12 R24 R35 C C10 C61 IC23 R27 R30 F13 R23 C11 J6 C4 C3 C2 C1 C33 C35 IC3 C51 C50 R5 B A J2 R13 R8 R18 R10 C56 F5 R15 F4 R12 C53 C31 IC4 R6 R1 R7 R16 R17 IC6 R2 R3 C52 IC1 J1 R4 R11 C55 IC12 C54 IC5 C30 IC9 IC13 F1 F6 F2 C57 IC11 J3 J4 F3 F8 R9 F7 P2 C32 IC10 R14 UARTA 1-971642-26 Double Serial Interface Board; Component side EasyCoder PX4i and PX6i Service Manual 191 P1 1 35 2 36 3 37 4 38 5 39 6 40 7 41 8 42 9 43 10 44 11 45 12 46 13 47 14 48 15 49 16 50 17 51 18 52 19 53 20 54 21 55 22 56 23 57 24 58 25 59 26 60 27 61 28 62 29 63 30 64 31 65 32 66 33 67 34 68 9 10 11 12 5 6 7 8 1 2 3 4 SCL SA1 RESET_N CS_N INT_N SDA 14 15 12 13 10 11 8 9 6 7 4 5 2 3 0 1 WR_N RD_N 5V 11 12 WAIT_N R1 1 2 3 4 R2 INTA INTB 9 10 C50 + A0 VCC WP A1 A2 SCL GND SDA IC1 R3 4 5 1 2 1 2 9 10 3.3V RESET_N A<12..1> D<15..0> =1 8 7 6 5 8 8 6 3 INT_N CSB_N CSA_N 3 RESET 3 IC2 CLK GND VIN VOUT 3.3V 1.8432MHZ 1 NC/EN_N OUT 3 GND 5V 3.3V D5 D6 D7 RCLK IC10 SIN NC SOUT 16C550 CS0 CS1 CS2* BAUDOUT* IC3 VCC 3.3V 7 8 9 10 11 12 13 14 15 16 17 C51 C52 C53 C54 C55 C56 C57 5V AHC86 IC5 VCC=3.3V AHC32 IC4 1 VCC=3.3V AHC32 IC4 1 VCC=3.3V AHC32 IC4 1 VCC=3.3V AHC86 IC5 =1 VCC=3.3V 5 6 7 3.3V 2 +24VI 1 4 4 3 2 1 0 R5 39 MR OUT1* 38 37 DTR* 36 RTS* OUT2* 35 34 NC 33 INTRPT 32 RXRDY* 31 A0 30 A1 29 A2 6 5 4 3 2 1 44 43 42 41 40 D4 D3 D2 D1 D0 NC VCC RI* DCD* DSR* CTS* XIN XOUT WR1* WR2 VSS NC RD1* RD2 DDIS TXRDY* ADS* 2 1 2 3 INTA RESET 12 13 5V 11 9 10 RS485 4 5 1 2 11 65 =1 IC5 =1 IC6 VCC=5V AHC32 IC4 1 VCC=3.3V AHC86 VCC=3.3V =1 AHCT86 IC6 VCC=5V AHC86 IC5 =1 VCC=3.3V 6 3 12 13 4 11 12 13 8 3.3V AHCT86 IC6 =1 1 2 VCC=5V J1 AHCT86 IC6 =1 VCC=5V AHCT86 UARTA CONFIGURATION RS232: IC11, J2A RS422: IC12, J3, J4 RS485: IC13, J1, J4* *: IF END OF CABLE C30 C31 C32 C33 C34 C35 C36 3.3V 18 19 WR_N 20 21 22 23 RD_N 24 25 26 27 28 192 485_DIR 5V R4 RXDA TXDA DTRA_N RTSA_N CTSA_N DSRA_N DCDA_N R6 5V R10 + C2 + C1 R11 R9 R7 5V RS232 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 MAX1480 AC1 VCC1 VCC2 AC2 D1 IVCC1 B D2 GND1 IRCDRV A FS IDIIN SD IDEIN VCC3 DI ICOM1 IDIDRV VCC4 DE IVCC2 IDEDRV GND2 RO_N ICOM2 VCC5 IRLED IC13 RS485 MAX1490 VCC1 AC1 VCC2 AC2 D1 IVCC1 D2 IRCDRV GND1 A FS B Z SD VCC3 Y ICOM1 DI VCC4 IDIDRV RO IVCC2 IRLED GND2 IC12 RS422 VCC V+ VGND T1OUT T2OUT T3OUT T4OUT R1IN R2IN R3IN R4IN IC11 MAX238 10 C1+ 12 C113 C2+ 14 C25 T1IN 18 T2IN 19 T3IN 21 T4IN 67 R1OUT 43 R2OUT 22 R3OUT 17 R4OUT R8 R18 OVERCURRENT_N 5V_EXT_EN_N 28 27 26 25 24 23 22 21 20 19 18 17 16 15 24 23 22 21 20 19 18 17 16 15 14 13 23 16 9 11 15 8 2 1 24 20 5V 5V IC9 GND IN IN EN_N R14 R13 R12 + C4 OUT OUT OUT OC_N POWER_SWITCH + C3 1 2 3 4 8 7 6 5 SWITCH FOR EXTERNAL 5V R15 R17 R16 F8 F7 F6 F5 F4 F3 F2 F1 5V_EXT 1 2 1 2 TERM.TRA. J4 J3 TERM.REC. 1 A J2 2B 3 GND-SHIELD RS232 P2 C 1 +5V 2 TXD 3 RXD 4 DSR 5 GND 6 DTR 7 CTS 8 RTS 9 MTG1 MTG2 -RXD -TXD GNDE +TXD +RXD -DATA GNDE +DATA RS485 9PIN DSUB RS422 Chapter 16 — Interfaces Schematics UART A 1-971642-26 Double Serial Interface Board; Schematics 1 EasyCoder PX4i and PX6i Service Manual RESET INTB RD_N WR_N CLK CSB_N A<12..1> D<15..0> 5 6 7 C60 5V 7 8 9 10 11 12 13 14 15 16 17 3.3V 4 3 2 1 0 3.3V 6 5 4 3 2 1 44 43 42 41 40 C61 D5 D6 D7 RCLK IC20 SIN NC SOUT 16C550 CS0 CS1 CS2* BAUDOUT* C62 C64 C40 C41 C42 1 2 3 AHC86 IC7 =1 VCC=3.3V 11 CL_EN_N *: TRANSM.=J9, RECEIV.=J10 PASSIVE=B, ACTIVE=A+C 8 12 13 =1 AHCT32 IC8 1 VCC=5V AHCT32 IC8 1 VCC=5V AHC86 IC7 =1 VCC=3.3V AHC86 IC7 VCC=3.3V AHCT32 IC8 1 VCC=5V AHCT32 IC8 1 VCC=5V AHC86 IC7 =1 VCC=3.3V 1 2 20MACL J5 4 5 1 2 65 32 9 10 UARTB CONFIGURATION RS232: IC21, J6A RS422: IC22, J6B, J7, J8 20MACL: IC23, IC24, J5, J9*, J10* C63 12 13 39 38 37 36 35 34 33 32 31 30 29 3.3V MR OUT1* DTR* RTS* OUT2* NC INTRPT RXRDY* A0 A1 A2 D4 D3 D2 D1 D0 NC VCC RI* DCD* DSR* CTS* XIN XOUT WR1* WR2 VSS NC RD1* RD2 DDIS TXRDY* ADS* 18 19 20 21 22 23 24 25 26 27 28 11 8 9 10 3.3V 6 3 4 1 R20 TXDB RXDB DTRB_N RTSB_N CTSB_N DSRB_N DCDB_N R21 5V R26 R25 + C11 + C10 R22 5V 5V 7 6 5 8 3 2 R27 1 2 3 4 6N139 IC24 6N139 IC23 20MACL DS2981 VCC DODO+ RO RIDI RI+ GND IC22 RS422 3 2 7 6 5 8 5 6 7 8 VCC V+ VGND T1OUT T2OUT T3OUT T4OUT R1IN R2IN R3IN R4IN IC21 MAX238 RS232 10 C1+ 12 C113 C2+ 14 C25 T1IN 18 T2IN 19 T3IN 21 T4IN 67 R1OUT 43 R2OUT 22 R3OUT 17 R4OUT R23 R24 D1 23 16 9 11 15 8 2 1 24 20 5V R29 +24VI R28 R30 + C12 + C13 R35 R34 R33 R19 F9 Z1 10V Z2 10V R32 R31 F16 F15 F14 F13 F12 F11 F10 5V_EXT C A C EasyCoder PX4i and PX6i Service Manual A 5V TERM.REC. CURR-FEED TRANSM. CURR-FEED RECEIVER J10 1 A 2 B 3 C 4 TERM.TRA. J8 J7 J9 1 A 2 B 3 C 4 1 2 1 2 1 A J6 2B 3 GND-SHIELD C 9 MTG1 MTG2 RS232 1 +5V 2 TXD 3 RXD 4 DSR 5 GND 6 DTR 7 CTS 8 RTS P3 -RXD -TXD GNDE +TXD +RXD RXDOUT TXDOUT TXDIN RXDIN 20MACL 9PIN DSUB RS422 Chapter 16 — Interfaces Schematics UART B 1-971642-26 Double Serial Interface Board; Schematics 2 193 Chapter 16 — Interfaces 16.8 IEEE 1284 Parallel Interface Board Description The IEEE 1284 Parallel Interface Board is an optional device for EasyCoder PX4i and PX6i printers. It provides these printers with one parallel interface port and is supported by both Fingerprint and IPL. The parallel communication port is addressed in Intermec Fingerprint as device centronics: (communication channel 4). The board is IEEE1284-I compatible. Nibble Mode and device ID is supported. Byte, ECP, and EPP modes from printer to host are presently not supported. The IEEE 1284 Parallel Interface kit contains: • • • • One Parallel Interface Board Two flat cables One hexagonal spacer One Installations Instructions booklet. There are neither any straps nor any other types of physical configuration on this interface board, nor any options in the Setup Mode. IEEE 1284 interface ("centronics:") 194 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Connector Configuration The IEEE 1284 board has a standard 36pin IEEE 1284 B socket with the following configuration: Pin Signal 1 DSTROBE 2 DATA 0 3 DATA 1 4 DATA 2 5 DATA 3 6 DATA 4 7 DATA 5 8 DATA 6 9 DATA 7 10 ACK 11 BUSY 12 PE 13 SELECT 14 AF 15 N/C 16 GND 17 SCREEN 18 Remark External +5VDC max 500 mA (automatic switchoff at overload, short-circuit protected) 19 GND 20 GND 20 GND 21 GND 22 GND 23 GND 24 GND 25 GND 26 GND 27 GND 28 GND 29 GND 30 GND 31 INIT 32 ERROR 33 N/C 34 N/C 35 N/C 36 SELECTIN EasyCoder PX4i and PX6i Service Manual 195 Chapter 16 — Interfaces Components 1-971641-02 P01 F18 F17 R17 F16 R16 F15 R11 F14 R10 F13 R15 F12 R14 F11 R13 F10 R12 F8 R8 F7 R7 F6 R18 R6 F5 R5 IC5 F4 R4 F3 C1 C2 R2 C13 R19 R3 F2 R1 P3 P1 IC3 F1 F9 R9 D1 C9 F19 C3 C11 C8 IC1 IC4 C5 C10 C14 IC6 C4 C7 R21 R22 C12 IC2 R20 C6 1-971641-27 IEEE 1284 Parallel Interface Board; Component side 196 EasyCoder PX4i and PX6i Service Manual P1 1 35 2 36 3 37 4 38 5 39 6 40 7 41 8 42 9 43 10 44 11 45 12 46 13 47 14 48 15 49 16 50 17 51 18 52 19 53 20 54 21 55 22 56 23 57 24 58 25 59 26 60 27 61 28 62 29 63 30 64 31 65 32 66 33 67 34 68 9 10 11 12 5 6 7 8 1 2 3 4 SCL SA1 RESET_N CS_N INT_N SDA 14 15 12 13 10 11 8 9 6 7 4 5 2 3 0 1 WR_N RD_N 5V WAIT_N R20 1 2 3 4 IC2 R22 CS_N 2 WR_N 14 A0 VCC A1 WP A2 SCL GND SDA R21 A<12..1> D<15..0> 8 7 6 5 5V 3 0 INT_N CS_N 7 6 5 4 3 2 1 12 11 10 9 8 + C14 5V RESET_N OSC. NC/EN_N OUT GND AHC1G32 IC6 1 VCC=3.3V 1 IC4 VCC VCC6 PROG_N IO49 IO50/GCK5 IO51 IO52 IO53 IO54 IO55 IO56 IO57 IO58 VCC7 GND7 IO59 IO60 IO61 IO62 IO63 IO64 IO65 IO66/DIN IO67/DOUT CCLK VCC8 IC3 32 VIN 3.3V C11 C12 C13 GND 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 XCS05XL-4 IC1 C1 C2 15 14 13 12 11 10 9 8 7 6 3.3V C3 C4 C5 WR_N RD_N WAIT_N 5 4 3 2 1 0 24 C6 C7 C8 C9 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 C10 3.3V VCC4 M0 GND4 M1 GCK2/IO28 IO27 IO26 IO25 IO24 IO23 IO22 IO21 IO20 VCC3 GND3 IO19 IO18 IO17 IO16 TMS/IO15 TCK/IO14 TDI/IO13 IO12 GCK1/IO11 GND2 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 DONE GND6 GCK4/IO48 IO47 IO46 IO45 IO44 IO43 IO42 IO41 IO40 IO39 GND5 VCC5 INIT_N/IO38 IO37 IO36 IO35 IO34 IO33 IO32 IO31 IO30 GCK3/IO29 PWRDWN_N O/TDO GND8 IO68 IO69/GCK7 IO70/CS1 IO71 IO72 IO73 IO74 IO75 IO76 IO77 GND1 VCC1 IO1 IO2 IO3 IO4 IO5 IO6 IO7 IO8 IO9 IO10/GCK8 VCC2 EasyCoder PX4i and PX6i Service Manual 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 5V OVERCURRENT_N 5V_EXT_EN_N R19 5V 1 2 3 4 OUT OUT OUT OC_N MAX1607 GND IN IN EN_N POWER_SWITCH IC5 8 7 6 5 R18 3.3V R9 R1 R2 R3 R4 R5 R6 R7 R8 R12 R13 R14 R15 R10 R11 R16 R17 ACK BUSY PERROR SELECT AFEED INIT ERROR SELIN STROBE CD0 CD1 CD2 CD3 CD4 CD5 CD6 CD7 3.3V D1 C F19 F18 F17 F16 F15 F14 F13 F12 F11 F10 F8 F7 F6 F5 F4 F3 F2 F1 F9 MTG2 MTG1 BR3 MTG2 MTG1 BR2 MTG2 MTG1 BR1 P3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 EXT-5V SELIN SCREEN GND STROBE GND DATA0 GND DATA1 GND DATA2 GND DATA3 GND DATA4 GND DATA5 GND DATA6 GND DATA7 GND ACK GND BUSY GND PERROR GND SELECT INIT AFEED ERROR 1 19 2 20 3 21 4 22 5 23 6 24 7 25 8 26 9 27 10 28 11 29 12 30 13 31 14 32 15 33 16 34 17 35 18 36 CABLE ASSEMBLY 40-PIN RIBBON CABLE CONNECTOR -> 36-PIN CENTRONICS CONN. 40-PIN 36-PIN Chapter 16 — Interfaces Schematics 1-971641-27 IEEE 1284 Parallel Interface Board; Schematics 197 Chapter 16 — Interfaces 16.9 EasyLAN Ethernet Interface Board Description This section describes how to install an EasyLAN Ethernet network interface in an EasyCoder PX4i and PX6i printer and how to connect it to a 100base TX Fast LAN, WAN, Intranet, or Internet network via a wired connection. The installation instructions describes how to physically install the interface board in a printer. Configuration and setup are described in the EasyLAN Interface Kit, Installation Instructions and the Intermec EasyLAN, User’s Guide on the attached CD-ROM. This interface kit must only be physically installed by an authorized service technician. Printer Firmware The printer must either be fitted with Intermec Fingerprint v8.30 (or later) or IPL v2.30 (or later). In Intermec Fingerprint, the network port is addressed as device "net1:" (communication channel #5). Installation Kit The EasyLAN Interface Kit contains: • One EasyLAN interface board • One light guide • One hexagonal threaded spacer • One network extension cable • One cable tie • One serial number label • One CD-ROM with software and manuals • One Installation Instruction booklet The only tool required for the installation is a #T20 Torx screwdriver. 198 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Installation Instructions Also see illustration on the next page. • Switch off the printer and disconnect the power cord. • Disconnect all communication cables. • Remove the left-hand cover as described in Chapter 3.3. • Remove the LAN connector plug, which is snap-locked at the top of the rear plate. LAN connector plug • Remove the #T20 Torx screw that holds the upper/front part of the CPU board to the power supply unit and replace it with the hexagonal spacer included in the kit. Keep the screw. • Connect the EasyLAN board to the PCI connector (J84) on the CPU board so the hole in the interface board becomes aligned with the spacer. • Secure the EasyLAN board with the #T20 Torx screw you previously removed. • From the inside of the electronics compartment, press the metal socket of the network extension cable into the square hole in the rear plate (where you removed the LAN plug) until it is held by its snap-lock. • Route the extension cable over the SIMMs on the CPU board and connect it to the RJ-45 socket on the EasyLAN interface board (J2). • From the outside, insert the thin end of the light guide through the small hole next to the RJ-45 socket on the rear plate. Press the clear plastic “lamp” in place. Connect the other end to the black plastic socket (D1) on the EasyLAN interface board. • Pull the cable tie through the hole in the upper edge of the CPU board between the SIMMs and the RTC socket. Secure both the extension cable and the light guide with the cable tie. • Fit the serial number label on the rear plate to the left of the RJ-45 socket. • Put back the left-hand cover. Route the cable from the display unit above the ribbon motor. Connect the cable to connector J50 at the upper front corner of the CPU board. • Connect the power cord and switch on the power. • Enter the Setup Mode and print the test label “Hardware Info” in Fingerprint or “HW” in IPL to see if the printer detects the EasyLAN Ethernet interface board. For information on how to enter the Setup Mode and print test labels, refer to the User’s Guide for the printer in question. • After startup, enter the Setup Mode to set up the network parameters. See Appendix A. Setting the network parameters in IPL, when the server does not support DHCP or BOOTP, is described in EasyLAN Interface kit, Installation Instructions. EasyCoder PX4i and PX6i Service Manual 199 Chapter 16 — Interfaces Network extension cable Cable tie Light guide #T20 Torx screw and spacer RJ-45 Ethernet connector EasyLAN Ethernet interface board RJ-45 Ethernet connector ("net1:") Serial number label (MAC address) 200 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Components J2 C26 C5 C27 R1 C15 D1 C4 C28 C14 R9 C23 R11 C29 R7 R8 C22 IC2 R4 C24 C31 R6 C30 C6 Y2 C25 L3 L2 C34 M1 R5 C17 C39 C33 C7 R12 R13 C20 C21 C11 C10 IC1 L1 C16 R2 R3 C36 C37 C38 C35 C19 C32 Y1 C18 C3 IC3 C1 C13 C2 C12 1-971645-26 EasyLAN Interface Board; Component side J1 1 1-971645-26 EasyLAN Interface Board; Soldering side EasyCoder PX4i and PX6i Service Manual 201 C1 5V 5V 1 R3 32.768MHZ OUT EN/NC GND IC3 GND 2 3 R2 VCC Y1 3.3V J1 C2 + C3 3.3V AC RETURN PATHS FOR PCI SIGNALS CROSSING 5V TO 3.3V BOUNDARY VIN VOUT C38 C37 C36 3 26 27 29 21 22 16 18 3.3V C35 PCI_REQ_N PCI_GNT_N PCI_INT_N PCI_CBE3_N PCI_CBE2_N PCI_STOP_N PCI_TRDY_N 14 15 8 9 11 28 30 31 23 24 25 17 19 20 10 12 13 5 1 2 C10 C6 C4 PCI_CLK2 C11 C7 28 27 26 31 30 29 PCI_CLK2 PCI_INT_N PCI_RST_N PCI_GNT_N PCI_REQ_N TPTDM TPTDP TPRDM TPRDP RXAVDD REGEN R4 RXAVDD R4=9K31 FOR DP83815 AND R4=10K FOR DP83816 56/58 33 21 PINS IC1 PINS 3.3V C14 9 C13 C18 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 C19 C22 137 C20 RXAVDD C32 Y1 C23 L1 3.3V SUBGND1/NC83816 VSS_38 AUXVDD_39 VREF RESERVED_41 NC_42 NC_43 VSS_44 TPRDM TPRDP AUXVDD_47 REGEN VSS_49 RESERVED_50 VSS_51 VSS_52 TPTDM TPTDP VSS_55 AUXVDD_56 VSS_57 AUXVDD_58 PMEN/CLKRUN_N PCICLK INTA_N RST_N GNT_N REQ_N VSS_65 AD31 AD30 AD29 PCIVDD_69 AD28 AD27 AD26 IC2 C21 85 125 PINS C15 27 IC1 C16 69/80 94/107 117 3.3V IC1 BYPASS CAPACITORS PCI_RST_N PCI_CLK1 PCI_DEVS_N PCI_IRDY_N PCI_FRAME_N PCI_CBE1_N PCI_SERR_N PCI_PERR_N PCI_CBE0_N C12 C5 + PCI_CLK1 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 3.3V PCI_AD1 PCI_AD2 VCC1 PCI_AD5 PCI_AD7 PCI_CBE_N0 VCC2 PCI_AD10 PCI_AD12 PCI_AD13 VCC3 PCI_CBE_N1 PCI_SERR_N PCI_PERR_N VCC4 PCI_DEVSEL_N PCI_IRDY_N PCI_FRAME_N VCC5 PCI_AD17 PCI_AD19 PCI_AD20 VCC6 PCI_AD23 PCI_AD24 PCI_AD25 VCC7 PCI_AD28 PCI_AD30 PCI_AD31 VCC8 PCI_CLK PCI_REQ_N2 PCI_RST_N VCC9 NC1 SCL SDA PCI_DET_N 24V PCI_CBE3_N SCA80 25 24 PCI_AD0 VSS1 PCI_AD3 PCI_AD4 7 PCI_AD6 VSS2 PCI_AD8 PCI_AD9 PCI_AD11 VSS3 PCI_AD14 PCI_AD15 PCI_PAR VSS4 PCI_LOCK_N PCI_STOP_N PCI_TRDY_N VSS5 PCI_CBE_N2 PCI_AD16 PCI_AD18 VSS6 PCI_AD21 PCI_AD22 PCI_CBE_N3 VSS7 PCI_AD26 PCI_AD27 PCI_AD29 VSS8 PCI_REQ_N0 PCI_GNT_N0 PCI_INT_N VSS9 TCK TMS TDO VSS10 TDI TRST_N C24 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 25MHZ Y2 IC1 TQFP144 DP83815/6 R1 C26 R1=0OHM ONLY POPULATED FOR DP83815 3.3V PIN19 C25 + 23 22 3 4 6 21 20 19 0 C17 C27 PCI_CBE2_N 5V L3 18 17 16 L2 PCI_FRAME_N PCI_IRDY_N PCI_TRDY_N C28 TPRDP TPRDM TPTDP RXAVDD TPTDM R8 R7 R6 R5 C29 C30 MA2/LED100_N MA1/LED10_N MA0/LEDACT_N MD7 MD6 MD5 MD4/EEDO AUXVDD_137 VSS_136 MD3 MD2 MD1/CFGDIS_N MD0 MWR_N MRD_N MCS_N EESEL RESERVED_127 SUBGND3/NC83816 MACVDD2/NC83816 MACVSS2/NC83816 PWRGOOD 3VAUX AD0 AD1 AD2 AD3 PCIVDD_117 AD4 AD5 VSS_114 AD6 AD7 CBEN0 AD8 AD9 RD+ RDCT TD+ NC1 NC2 RD- TDCT TD- 8 9 6 7 4 5 0 1 2 3 M1 R9 IC2 R11 TX- RX+ RXCT TX+ NC4 NC3 RX- TXCT 4 5 DO 3.3V REGEN + C39 3.3V 10 R13 14 13 12 11 15 R12 RX+ RX- TX+ TX- C33 C RJ45 1 2 3 4 5 6 7 8 MTG1 MTG2 MTG3 MTG4 J2 C NORMALLY UNPOPULATED C34 16 9 8 GND VCC D1 C39 ONLY POPULATED FOR DP83816 CS EEPROM SK DI ORG/NC NC PCI_CBE0_N 1 2 3 6 7 1CT:1CT NORMALLY UNPOPULATED C31 8 7 3 4 5 6 2 1 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 3.3V 1 L2+C17 ONLY POPULATED FOR DP83815 PCI_DEVS_N PCI_STOP_N PCI_PERR_N PCI_SERR_N PCI_PAR PCI_CBE1_N 3.3V 15 14 PCI_PAR 1 4 2 PIN19 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 FXVDD/NC83816 VSS_35 NC_34 AUXVDD_33 VSS_32 TXCLK TXEN CRS COL/MA16 AUXVDD_27 VSS_26 TXD3/MA15 TXD2/MA14 TXD1/MA13 TXD0/MA12 AUXVDD_21 VSS_20 C1 X2 X1 VSS_16 RXDV/MA11 RXER/MA10 RXOE RXD3/MA9 RXD2/MA8 RXD1/MA7 AUXVDD_9 VSS_8 RXD0/MA6 RXCLK MDC MDIO MA5 MA4/EECLK MA3/EEDI AD25 AD24 CBEN3 IDSEL VSS_77 AD23 AD22 PCIVDD_80 AD21 AD20 AD19 VSSIO4/NC83816 VDDIO4/NC83816 AD18 AD17 AD16 CBEN2 VSS_90 FRAME_N IRDY_N TRDY_N PCIVDD_94 DEVSEL_N STOP_N PERR_N SERR_N PAR CBEN1 AD15 AD14 VSS_103 AD13 AD12 AD11 PCIVDD_107 AD10 13 12 11 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 10 2 3 202 4 PCI_AD(31..0) RX- TX+ TXRX+ Chapter 16 — Interfaces Schematics 1-971645-26 EasyLAN Interface Board; Schematics EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces 16.10 EasyLAN Wireless Interface Board Description This section describes how to install an EasyLAN Wireless network interface in an EasyCoder PX4i and PX6i printer and how to connect it to a LAN, WAN, Intranet, or Internet network via a wireless connection. The installation instructions describes how to physically install the interface board in a printer. Configuration and setup are described in the EasyLAN Wireless Kit, Installation Instructions and the Intermec EasyLAN, User’s Guide on the attached CD-ROM. This interface kit must only be physically installed by an authorized service technician. The device is country/region specific and must be ordered for the correct country/region. Use of this device in other region than shown on the device home page/test label may violate applicable law. Printer Firmware The printer must either be fitted with Intermec Fingerprint v8.30 (or later) or IPL v2.30 (or later). In Intermec Fingerprint, the network port is addressed as device "net1:" (communication channel #5). Installation Kit The EasyLAN Interface Kit contains: • One EasyLAN adapter board complete with radio module fitted • Rear plate (for EasyCoder PF2/4i-series printers only) • RJ-45 plug (for EasyCoder PM4i, PX4i, and PX6i only) • One light guide • One hexagonal threaded spacer • One antenna extension cable • One antenna • One cable clip • One cable tie • One CD-ROM with software and manuals • One Installation Instruction booklet The only tools required for the installation are #T10 and #T20 Torx screwdrivers and a small wrench. EasyCoder PX4i and PX6i Service Manual 203 Chapter 16 — Interfaces Installation Instructions • Switch off the printer and disconnect the power cord. • Disconnect all communication cables. • Remove the left-hand cover as described in Chapter 3.2. • Remove any present EasyLAN Ethernet interface including cables etc. Fit the RJ-45 plug included in the kit into the square hole left by the RJ-45 Ethernet connector. • Remove the antenna plug, which is snap-locked into the rear plate. • Connect the antenna cable to the radio module, which is factory-fitted on the EasyLAN adapter board, as illustrated below. Support the upper edge of the radio module with a finger while connecting the cable. Adapter board Connect antenna cable here Radio module • Remove the #T20 Torx screw that holds the upper/front part of the CPU board to the power supply unit and replace it with the hexagonal spacer included in the kit. Keep the screw. • Connect the EasyLAN adapter board to the PCI connector (J84) on the CPU board so the hole in the board becomes aligned with the spacer and secure the board with the #T20 Torx screw. • Route the antenna cable over the SIMMs on the CPU board towards the rear plate and secure it using the cable clips included in the kit. One clip is factory-fitted on the EasyLAN adapter board and the other should be fitted in the small hole at the top of the CPU board immediately to the rear of the memory SIMM sockets. • From the inside of the electronics compartment, insert the antenna connector through the round hole in the rear plate and lock it with the washer and nut on the outside. 204 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces • Fit the antenna to the connector of the antenna cable and bend the hinge so the antenna points straight up. • From the outside, insert the thin end of the light guide through the small hole next to the antenna on the rear plate. Press the clear plastic “lamp” in place. Connect the other end to the black plastic socket (D1) at the top of the EasyLAN adapter board. Secure it with the cable tie through the hole at the upper edge of the CPU board. • Put back the left-hand cover. Route the cable from the display unit above the ribbon motor. Connect the cable to connector J50 at the upper front corner of the CPU board. • Connect the power cord and switch on the power. • Enter the Setup Mode and print the test label “Hardware Info” in Fingerprint or “HW” in IPL to see if the printer detects the EasyLAN Wireless interface board. For information on how to enter the Setup Mode and print test labels, refer to the User’s Guide for the printer in question. • Set up the network parameters. There are several methods: - Connect the printer and a PC and run the EasyLAN Network Setup wizard, which can be found on the attached CD-ROM. Requires a PC running Windows 98 or later. - Insert a CompactFlash Card containing a configuration file in the printer and start it up. Configuration Compact Flash cards can be created using the EasyLAN Network Setup wizard on the attached CD-ROM. - Fingerprint: Establish an RS-232 communication with the printer and set it up using Fingerprint setup strings or setup files. IP address, netmask, default router, and name server can also be set using the printer’s built-in keyboard. Only requirement on the PC side is a terminal program that can transmit and receive ASCII characters on an RS-232 line. See EasyLAN Wireless Kit, Installation Instructions. - IPL: Establish an RS-232 communication with the printer and set it up using IPL commands. Only requirement on the PC side is a terminal program that can transmit and receive ASCII characters on an RS232 line. Select the method of obtaining IP address, netmask, default router, and name server automatically from the server using the printer’s built-in keyboard. This requires a server that supports DHCP and/or BOOTP. See EasyLAN Wireless Kit, Installation Instructions. EasyCoder PX4i and PX6i Service Manual 205 Chapter 16 — Interfaces Cable tie Cable clips Light guide #T20 Torx screw and spacer Antenna cable Antenna EasyLAN adapter board Antenna (packed separately when the EasyLAN Wireless interface is factory-installed) 206 EasyCoder PX4i and PX6i Service Manual Chapter 16 — Interfaces Components D1 C11 C11 C12 C12 R29 R29 R5 R5 R9 R9 R4 R4 R8 R8 R6 R6 R7 R7 R28 R28 R30 R30 IC2 IC2 R26 R26 R27 R27 C5 C5 R22 R22 R23 R23 R25 R25 R24 R24 R19 R19 R18 R18 R20 R20 R21 R21 C1 C1 C2 C2 C6 C6 J1 C9 C9 C10 C10 IC1 IC1 Y1 Y1 R1 R1 R2 R2 C7 C7 C3 C3 C4 C4 C8 C8 2 4 1 3 R17 R17 R11 R11 R16 R16 1 R12 R12 R15 R15 R14 R14 R13 R13 124 J2 J2 L1 123 Primary Side Secondary Side 1-971646-26 Adapter Board EasyCoder PX4i and PX6i Service Manual 207 Chapter 16 — Interfaces Schematics PRINTER PCI INTERFACE MINI-PCI INTERFACE PCI_AD(31..0) 5V 0 3 4 6 8 9 11 14 15 PAR STOP_N TRDY_N CBE2_N 16 18 21 22 CBE3_N 26 27 29 REQ_N GNT_N INT_N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 PCI_AD0 PCI_AD1 VSS1 PCI_AD2 PCI_AD3 VCC1 PCI_AD4 PCI_AD5 PCI_AD7 PCI_AD6 PCI_CBE_N0 VSS2 VCC2 PCI_AD8 PCI_AD9 PCI_AD10 PCI_AD11 PCI_AD12 VSS3 PCI_AD13 PCI_AD14 VCC3 PCI_AD15 PCI_CBE_N1 PCI_PAR PCI_SERR_N VSS4 PCI_PERR_N PCI_LOCK_N VCC4 PCI_STOP_N PCI_DEVSEL_N PCI_TRDY_N PCI_IRDY_N VSS5 PCI_FRAME_N J1 PCI_CBE_N2 PCI_AD16 VCC5 PCI_AD17 PCI_AD18 PCI_AD19 VSS6 PCI_AD20 PCI_AD21 VCC6 PCI_AD23 PCI_AD22 PCI_CBE_N3 PCI_AD24 VSS7 PCI_AD25 PCI_AD26 VCC7 PCI_AD27 PCI_AD28 PCI_AD29 PCI_AD30 VSS8 PCI_AD31 VCC8 PCI_REQ_N0 PCI_CLK PCI_GNT_N0 PCI_REQ_N2 PCI_INT_N PCI_RST_N VSS9 TCK VCC9 TMS NC1 SCL TDO SDA VSS10 PCI_DET_N TDI 24V TRST_N 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 3.3V 1 2 J2 5 7 CBE0_N 10 12 13 LED1_GRNP LED1_GRNN CBE1_N SERR_N PERR_N DEVSEL_N IRDY_N FRAME_N C CLK2 REQ_N 17 19 20 31 29 23 24 25 27 25 CBE3_N 28 30 31 23 CLK1 21 19 RST_N 17 CBE2_N IRDY_N CLKRUN_N SERR_N PERR_N CBE1_N 14 12 10 8 7 3.3V 5V IC1 3 C1 + VIN 5V 5 2 VOUT C2 C3 3 C4 + GND 1 1 AC_SYNC AC RETURN PATHS FOR PCI SIGNALS CROSSING 5V TO 3.3V BOUNDARY AC_BIT_CLK AC_CODEC_ID1_N 3.3V 5V 3.3V 4 C5 C10 R1 32.768MHZ EN/NC OUT GND CLK1 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 LED2_YELP LED2_YELN 5V INT_N RST_N GNT_N 30 28 26 24 11 22 20 PAR 18 16 FRAME_N TRDY_N STOP_N DEVSEL_N 15 13 11 9 CBE0_N 6 4 2 0 AC_SDATA_OUT AC_CODEC_ID0_N AC_RESET_N MTG1 MTG2 C7 3 R2 C C8 CLK2 2 1 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 101 103 105 107 109 111 113 115 117 119 121 123 C6 Y1 VCC C9 3.3V LED BLINK ONE-SHOT CIRCUIT LED_LINKP 3.3V COLOR SWITCH RESISTORS SOURCE SIDE R29 LED_ACTP LED_ACTP 5V 1 AHCT123 14 R28 15 R21 1 2 3 REXT/CEXT Q A B Q 13 LED_ACTN 4 LED_LINKN R9 R5 R6 CLR R22 VCC=5V;GND=GND R27 R23 R26 OR R27 ONLY POPULATED IF IC2 POPULATED R24 LED2_YELN D1 GREEN/YELLOW CEXT 3 + R26 R20 LED1_GRNN R8 2 C11 R19 LED1_GRNP R4 IC2 R18 4 LED2_YELP R7 LED_LINKP R25 ONLY IC2 OR R29 OR R30 POPULATED R30 COLOR SWITCH RESISTORS SINK SIDE LED_ACTN LED_LINKN TERMINATION OF UNUSED MINI-PCI SIGNALS 3.3V AC_CODEC_ID0_N R11 AC_CODEC_ID1_N R12 CLKRUN_N R13 AC_SYNC R14 AC_BIT_CLK R15 AC_SDATA_OUT R16 AC_RESET_N R17 DECOUPLING IC2 UNUSED PART 5V C12 IC2 AHCT123 6 7 9 DO NOT POPULATE 10 L1 11 CEXT REXT/CEXT 5 A B Q Q 12 CLR VCC=5V;GND=GND C 1-971646-26 Adapter Board 208 EasyCoder PX4i and PX6i Service Manual 17 Troubleshooting This chapter explains how to diagnose and fix troubles that may occur in an EasyCoder PX4i or PX6i printer, even if great effort has been made to safeguard troublefree printing. Some parts are, however, subject to wear and may need periodical replacement, such as the printhead. Please note that replacement parts are generally only available as complete modules (see the Spare Parts Catalog or Spare Parts List). This chapter is supplemented by the Technical Bulletins that are distributed as soon as any new problem has been reported and a remedy has been found. EasyCoder PX4i and PX6 Service Manual 209 Chapter 17 — Troubleshooting 17.1 Diagnosing To diagnose the printer for faults, take steps in the following order: • In case the printer is running the Intermec Fingerprint firmware, use Intermec Shell to check printer’s setup and functions. Intermec Shell can be accessed regardless of any running autoexec.bat files as described below. • Browse through the remainder of this chapter to find symptoms that apply to the faulty printer. • Refer to the Printer Technical Bulletins for updated information. Fingerprint only The keyboard, display messages, sounds, and other functions will be custom-configured, if a custom-made program is running in the printer. Normally, such a program is started at power-on using an autoexec.bat file. The procedure of starting up Intermec Shell, bypassing any other autoexec.bat files the printer’s memory, is called the Test Mode. In fact, the Test Mode is just a convenient way of accessing Intermec Shell and, via Intermec Shell, also the Setup Mode. Note: Any changes done in the Test Mode will remain after leaving the Test Mode. Entering Intermec Shell in the Test Mode • Switch off the power. • Raise the printhead. • Press any key on the printer’s built-in keyboard, with the exception of , and keep on pressing it. • Switch on the power. • The printer will start the initialization procedure. • Release the key. • The printer will start up Intermec Shell. • Press before the 5 sec. countdown is completed. Inside Intermec Shell you have a variety of options, for example: • Enter the Setup Mode to check or change the setup. Before changing the setup, you should print out or write down the settings so you can restore them before returning the printer. • Make a printout of the present setup values. • Perform testfeed operations. • Print test labels to check the printout quality. • Reset all setup values to default. Before resetting the setup, you should print out or write down the settings so you can restore them before returning the printer. • Enter Intermec Fingerprint, for example to check what files the printer’s memory contains or to list files. 210 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting • Restart the printer and leave the Test Mode. Refer to the Intermec Shell Overview in Appendix 1 or in the User’s Guide. If the printer works normally in the Test Mode, it is likely that the malfunction is either due to communication problems, abnormal conditions at the site of operation, or a custom-made program. Returning to Factory Default Setup ( Fingerprint and IPL) There are four ways to return to the factory default setup of the printer: A Insert a special CompactFlash memory card and restart the printer. B Use the Default Setup option in Intermec Shell (Fingerprint only). C Use the Memory Reset option in the Test/Service part of the Setup Mode (IPL only). D Use the printer’s built-in keyboard as described below: 1 Lift the printhead. 2 Switch on the power to the printer and press the key and wait until the printer beeps. 3 Swiftly press the following keys: t t t 4 The following message will be displayed: Factory Default? Enter=Yes ESC=No 5 Within 10 seconds, press to reset the printer to factory default. The parameters will be reset and the printer will continue the normal startup. If you press or wait until the 10 seconds time-out has passed, the normal startup will continue without any reset being performed. Note: The factory default will remove all files used to store settings. It will not reset settings that already has been read when the files are removed. This means that EasyLAN Wireless settings (SSID, keys, etc.) will retain their values from the previous start. However, the next reboot will reset them to factory default. EasyCoder PX4i and PX6 Service Manual 211 Chapter 17 — Troubleshooting Troubleshooting short-list (Fingerprint and IPL) Use this short-list to find the symptom that applies to the printer: Symptom • No reaction at power up • Printer stops working after startup • CPU board failures • Power supply unit failures • Driver board failures • Console errors • Error messages • No communication (general) See 17.2 17.3 17.4 17.5 17.6 17.7 17.8 17.9 • No serial communication 17.10 • Sensor malfunctions 17.11 - Label stop sensor - Headlift sensor - Label taken sensor - Ribbon end sensor • Printing troubles 17.12 - No printout at all - Overall weak printout - Weaker printout on either inner or other part of label - Overall dark printout (bleeding) - Weak or missing printout of some dots - Unexpected black printout (completely or partially) - Only first part of label printed - Media feed does not work properly • Ribbon troubles 17.13 - Transfer ribbon breaks - Transfer ribbon wrinkles - No transfer printout 212 • Liner takeup troubles 17.14 • Memory card troubles 17.15 • Paper cutter troubles 17.16 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting 17.2 No Reaction at Power Up Description: There is no visible reaction when the power to the printer is switched on. • The Power LED does not light up. • There is no text in the display window. Possible Causes and Suggested Remedies: • No power in AC wall socket. - Check with some other electrical device or a voltage meter. • Power cord connectors not completely inserted in printer’s power cord receptacle or in wall socket. - Disconnect and firmly connect both ends of power cord. Try again. • Faulty power cord. - Replace and try again. • Cables between power supply, driver board and CPU board not properly connected. - Test as described in Chapter 17.5 using test points on CPU board (see Chapter 15.5). • Power Supply overload. - Too high a temperature in the power supply unit. Leave the power on and wait for the power supply to cool off (may take up to half an hour). When the temperature returns to normal, the printer will automatically restart. If the error persists, examine the power supply as described in Chapter 17.5. • Faulty power supply unit. - Refer to Chapter 17.5. • Faulty driver board. - Refer to Chapter 17.6. • Faulty console unit. - Refer to Chapter 17.7. EasyCoder PX4i and PX6 Service Manual 213 Chapter 17 — Troubleshooting 17.3 Printer Stops Working after Startup Description: The printer stops working after a successful startup. • The Power LED is lit. • The , , and keys, work properly. Possible Causes and Suggested Remedies: • Communication problems? - Refer to Chapters 17.9-17.11. • Printer malfunction? - Check if the printer can print test labels in the Setup Mode. Description: The printer stops working after a successful startup. • The Power LED is lit. • There is no reaction on software commands. • There is no reaction on any keys on the printer’s keyboard. Possible Causes and Suggested Remedies: • The printer’s main program has halted due to high external disturbances from other electrical sources. - Restart the printer and find out if there are disturbances coming via the AC supply, via a communication channel, or from other electrical appliances. • CPU board failures. - Refer to Chapter 17.4. • Power Supply Unit failures. - Refer to Chapter 17.5. • Driver board failures. - Refer to Chapter 17.6. • Console errors. - Refer to Chapter 17.7. 214 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting Description: The printer stops working after a successful startup. • The Power LED is not lit. Possible Causes and Suggested Remedies: • Error in the supply of AC power to the printer. - Refer to Chapter 17.2. • Faulty console, faulty power LED, or faulty cabling between CPU board and console. - Refer to Chapter 17.7. EasyCoder PX4i and PX6 Service Manual 215 Chapter 17 — Troubleshooting 17.4 CPU Board Failures Description: The power LED is lit, but the printer has one of the following faults: • The printer refuses to start. • The program execution is halted. • The stepper motor does not work. • At startup, the message “Starting” is displayed followed by the message “Timed Out.” Possible Causes and Suggested Remedies: • Flash or SDRAM SIMMs not properly fitted. - A SIMM is not fully inserted in its socket. Remove all SIMMs and fit them back again, making sure they are being firmly held by the snaplocks. • No Boot Flash SIMM in socket J20. - A Flash SIMM containing a boot sector must be fitted in socket J20, or the printer will not start. • Fluttering voltages. - Check voltages on the CPU board test points, see Chapter 13.4. If a voltage flutters with an interval of approximately one second, there may be a short-circuit on the CPU board. If a voltage is missing, there is probably an error in the power supply unit or the driver board, see Chapters 17.5 and 17.6. • Startup error. - Execution of the initial boot sequence can be checked as described in Chapter 15.5. If the execution stops prematurely, try changing to a Flash SIMM that works in another printer. If that does not help, note where the startup sequence is halted and contact Intermec’s Printer Product Support dept. - If there is no reaction neither on the display nor on the serial channel, there is a major error on the CPU board. Check the Flash and SDRAM SIMMs by installing them in another printer. Inspect the CPU board visually in the area of the processor (U13) and the support chip (U30). If no obvious fault is detected, replace the CPU board. 216 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting Description: The power LED does not become lit when the power is switched on. Possible Causes and Suggested Remedies: • Blown fuse. - First check that the fault is not caused by an interruption of the 90265 VAC input voltage, a faulty power cord, or a disconnected power cord. - Inspect the fuse F70. If the fuse has blown and you are positively sure that the fuse has blown because of a short-circuit of your own doing, you can cut off the legs of the fuse and solder a new fuse in its place. If the fuses blows again, replace the CPU board. EasyCoder PX4i and PX6 Service Manual 217 Chapter 17 — Troubleshooting 17.5 Power Supply Unit Failures Description: The printer refuses to print. • The message “Temperature high please wait" (FP) or “Printhead hot” (IPL) appears in the display window. The power supply unit contains wires and circuits with dangerous voltages. For safety reasons, it is strictly forbidden to try to repair a power supply unit or to replace a blown fuse. Generally, in a primaryswitched power supply, a blown fuse is an indication that components in the power supply has been damaged or degraded. Even if you could get the power supply working by replacing a fuse, there is a risk that it soon will fail again and more components will be damaged. Therefore, whenever a fuse blows, always replace the entire power supply unit. Possible Causes and Suggested Remedies: • Power Failure Interrupt signal activated because of a Power Supply overload. - Too high a temperature in the power supply unit, for example caused by extreme ambient temperatures (possibly in connection with large black areas in the print image, high speed printing, and media that require a high energy level), triggers the automatic overheating protection switch. Leave the power on and wait for the power supply to cool down (may take up to half an hour). When the temperature returns to normal, the printer will automatically restart. If the error persists, examine the power supply (also see Chapter 13). Description: The printer stops working or functions are unstable. • The power LED is unstable, weak or not lit.. Possible Causes and Suggested Remedies: • Wrong or missing 24 VDC voltage from power supply. - Check the 24 VDC output on connector P2. - Check the cables between the power supply unit, the driver board, and the CPU board. If the cables are OK, try to find out whether the power supply or driver board is faulty (also see Chapter 17.6). Replace the faulty unit. - If there is no 24 VDC and you can rule out that the PSU has been shut down because of overheating (see above), check for a blown fuse in power supply. If any of the fuses F1 or F2 has blown, replace the entire power supply unit. Do not replace a blown fuse and do not attempt to repair the power supply unit (see “Warning” notice above). 218 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting 17.6 Driver Board Failures Description: • Some or all of the following functions do not work properly. - Console - Printhead - Platen roller/ribbon rewind stepper motor - Liner rewind stepper motor - Cutter Possible Causes and Suggested Remedies: • Faulty driver board. - Check voltages using the test points on the CPU board, see Chapter 15.4. If all voltages are missing, check the 24 VDC output from the CPU board and the cable between the power supply and the driver board. If the 24 VDC input to the driver board is OK, the trouble is likely to be in the driver board. - Check the 24 VDC to the CPU board on connector P1, pin 1. - Check the 24 VDC to the printhead on connector P5 while performing a print operation. - Check the 33 VDC to the platen roller/ribbon rewinder stepper motor on connector P10 while performing a feed or print operation. The stepper motor driver may be damaged because the platen roller has been manually rotated while power was on, unintentionally making the stepper motor work as a generator. - Check the 33 VDC to the platen roller/ribbon rewinder stepper motor on connector P11 while performing a feed or print operation. - Check the 24 VDC to the cutter on connector P12 while performing a cut operation. If the any of the voltages are missing or are wrong, replace the driver board without attempting to repair it. The only exception is if you are positively sure that the fuse F1 has blown because of a short-circuit of your own doing. In that case, you can cut off the legs of the fuse and solder a new 4A fuse in its place. EasyCoder PX4i and PX6 Service Manual 219 Chapter 17 — Troubleshooting 17.7 Console Errors Description: The complete console is “dead”. • Power LED is not lit. • Green background lighting in display window is not lit. • The 5V on the CPU board is OK (see Chapter 15.4). Possible Causes and Suggested Remedies: • Defective cable. - The cable between the CPU board and the console pcb. may be defective or not properly connected. Check cable and connector J50 on CPU board. • Defective console pcb. - Replace. Do not attempt to repair. Description: No keys on the keyboard seem to be working or no keybeep. • Power LED is lit. • Green background lighting in display window is lit. Possible Causes and Suggested Remedies: • Bad connection between keypad and console pcb. - Check connections on the two flat cables between the keypad and connectors P2 and P3 on console pcb. • Keys disabled or keyboard remapped by a custom-made program (Fingerprint only). - If the printer does not respond to any keys in the Test Mode, the keyboard is defective and needs to be replaced. • Keybeep disabled by a custom-made program (Fingerprint only). - If no beep is heard when the keys are pressed in the Test Mode, but the printer nevertheless responds to the keys, the beeper is out of order. • Keyboard damaged by moisture. - Soaking the keyboard with, for example, water or cleaning fluids, may cause short-circuits. Let it dry, replace if necessary. 220 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting Description: No messages appear in the display window after power-up. • Power LED is lit. • Green background lighting in display window is lit. Possible Causes and Suggested Remedies: • Display not utilized by custom-made program (Fingerprint only). - If there is no display function in the Test Mode, the display is out of order and the console unit needs to be replaced. Else, check out the custom-made program. EasyCoder PX4i and PX6 Service Manual 221 Chapter 17 — Troubleshooting 17.8 Error Messages Description: An error message appears in the display window or is returned via a serial port. • The printer stops functioning. • The Error LED is usually lit. • Consult the Intermec Fingerprint v8.xx, Programmer’s Reference Manual or IPL Programming, Reference Manual for the meaning of the different error codes and use that information to correct the error. Depending on the firmware, printer’s mode, or running program, there are different ways of giving the error message. Immediate Mode (Fingerprint only) • The firmware can detect and return three error conditions, provided the printhead is lowered and a media feed is executed. - Error 1005 (“Out of paper”) - Error 1027 (“Out of transfer ribbon”) - Error 1031 (“Next label not found”) Programming Mode (Fingerprint only) • At every erroneous instruction during programming, the printer transmits an error code on the selected standard OUT channel (serial communication only), provided the verbosity is not disabled. The same applies if programming errors are detected when the program is run. • When a program is executed, the same errors as in the Immediate Mode will be detected. The execution stops and an error message is transmitted. It is recommended to included some kind of error handler in any custom-made application program, for example ERRHAND.PRG. Intermec Direct Protocol (Fingerprint only) • Eleven error conditions can be detected. Note that by default verbosity is off in the Intermec Direct Protocol. - Error 15 ("Font not found") - Error 18 ("Disc full") - Error 37 ("Cutter device not found") - Error 43 ("Memory overflow") - Error 1003 ("Field out of label") - Error 1005 (“Out of paper”) - Error 1006 (“No field to print”) - Error 1022 (“Head lifted”) - Error 1027 (“Out of transfer ribbon”) - Error 1031 (“Next label not found”) - Error 1606 (“Testfeed not done”) The Intermec Direct Protocol has a programmable error-handler. Refer to the Intermec Direct Protocol v8.xx, Programmer’s Reference Manual. 222 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting IPL only • Ten possible errors are indicated by messages in the display window: Error Empty/Paused Out of media Out of ribbon Printhead lifted Cutter error Ribbon fitted Paper fault Power supply error Power supply too hot Printhead too hot Displayed message PAUSE PAPER OUT RIBBON OUT PRINT HEAD UP/PRESS FEED OPEN&SHUT CUTTER RIBBON FITTED PAPER FAULT PSU ERROR PSU OVER TEMP PRINTHEAD HOT Some additional errors can be returned to the host as an ASCII number by the command, see IPL Programming, Reference Manual. Firmware Error • In case the CPU is unable to access data on a given address, the internal program will light up the red error LED regardless of any error-handling program. EasyCoder PX4i and PX6 Service Manual 223 Chapter 17 — Troubleshooting 17.9 No Communication (general) Description: The following actions are valid for all communication interfaces installed in the printer. Possible Causes and Suggested Remedies: • Defective cable between printer and host. - Check that the communication cable is correctly inserted and that it is of the correct type and is correctly configured. - Check that any clips or ground screws are properly engaged. - Inspect cable for physical damage. - Disconnect and connect the cable a few times to rub off possible oxide from the connectors. - Try using another identical cable. • Defective cable between interface board and CPU board. This does not apply to the serial port ("uart1:"), the USB port, or any EasyLAN board which all are fitted directly on the CPU board. - Check that the cable is connected correctly. - Inspect cable for physical damage. - Disconnect and connect the cable a few times to rub off possible oxide from the connectors. - Replace the cable. • Error in host. - Try connecting the printer to another host computer. • Erroneous data. - If using Fingerprint, check if the data string contains the correct characters using the Line Analyzer program included in Intermec Shell (see the User’s Guide). 224 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting 17.10 No Serial Communication Description: The following actions are valid for the standard RS-232 serial interface ("uart1:" in Fingerprint) fitted on the CPU board and to some extent also to any other serial interfaces on optional interface boards. Also see Chapter 17.8. Possible Causes and Suggested Remedies: • Communication setup mismatch. - Press the key or enter the Setup Mode to check that the printer and host are set for the same communication parameters, such as baud rate, parity, character length, stopbits, new line and handshaking. It is strongly recommended to use some kind of handshaking, for example XON/XOFF or RTS/CTS. • Damaged RS-232 driver circuit. - With the aid of an oscilloscope, or some kind of line analyzer (“breakout box”), verify that the interface signals to and from the CPU board are correct. The RS-232 driver (U61) could have been damaged as a result of voltage transients from the interface, necessitating the CPU board to be replaced. Repeated damage is an indication of insufficient cable screening, or the electrical environment being too noisy. • Circuits or straps on an optional interface board missing or fitted incorrectly. - See configuration instructions in Chapter 16. • No supply voltage. - Verify that the +3.3 VDC and +5 VDC voltages are present (see Chapter 15.4). • No external +5 VDC. - The printer supplies max. 500 mA. The current is automatically switched off at higher loads. Check the consumption of the connected device. - The switch (RP60 on the CPU board; IC9 on the Industrial Interface Board and the Double Serial Interface Board) may be out of range and need to be replaced. • Too long communication cables. - RS-232 max. 10-17 m (33-49 ft). - RS-422 max. 1,200 m (4,000 ft). - RS-485 max. 1,200 m (4,000 ft). - Current Loop max. 500 m (1,500 ft). EasyCoder PX4i and PX6 Service Manual 225 Chapter 17 — Troubleshooting • Input buffer on host overflow. - The input buffer should normally be handled by the software of the host. Increase the receive buffer in the printer to a large value, restart the host to empty its input buffer and try again. • No response from printer a custom-made program is run (Fingerprint only). - The verbosity can be controlled using the Fingerprint instructions VERBON/VERBOFF and SYSVAR(18). In the Intermec Direct Protocol, verbosity is disabled by default. Check the program for instructions that affect the verbosity. - Verify that the correct communication port is selected as standard IN/OUT channel. • Interface type mismatch (Fingerprint only). - A communication cable is connected to a port configured for another type of serial interface; for example an RS-232 cable is connected to an RS-422 port. In the Setup Mode, the type of interface for which the interface board is configured is indicated for each communication port ("uart2:" to "uart5:"), see Appendix A. 226 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting 17.11 Network Communication Troubles This section applies both to EasyLAN Ethernet and EasyLAN Wireless communication between a printer and a local area network. It does not cover general network troubles in other types of equipment, such as wiring, access points, routers, switches, servers, etc. It is assumed that the network is in good working order, that is, other devices connected to the network works well and the trouble can be pinpointed to the printer. Description: The printer cannot communicate with the network after the network interface has been installed. Possible Causes and Suggested Remedies: • Defect interface board or bad connection between interface board and CPU board. - Print a Hardware test label in the Setup Mode to see if the printer recognizes the interface board. Also check if the Network node is shown in the Setup Mode. If not, switch off the power, disconnect the interface board, clean the connectors, and connect the interface again. Switch on the power. Print a new Hardware test label. If the troubles remains, replace the interface board. Wireless only: Also check visually that the radio module is properly connected to the adapter board. If the radio module is not connected properly, the Network node will be displayed in the Setup Mode but the wireless interface will not be recognized on the hardware test label. • Bad internal cabling. - Ethernet only: Check that the network extension cable is properly connected to the interface board. Visually check the cable for breaks or shavings. - Wireless only: Check that the antenna cable is properly connected to the connection point marked “MAIN” on the radio module. Visually check the cable for breaks or shavings. Check that the antenna is properly connected and is pointing straight up. • Bad connection between printer and an Ethernet network - Check the network LED indicator at the back of the printer. There should be a green light flashing occasionally showing network activity or a solid yellow background light if connected to a 100 Mbps network. Note that there is no background light indication provided for 10 Mbps wired networks. - Check that the network cable is connected correctly to the network wall socket, hub, or similar and to the RJ-45 socket on the printer’s rear plate. EasyCoder PX4i and PX6 Service Manual 227 Chapter 17 — Troubleshooting - Check that the cable connecting to the network is not of "crossover" type. Use a straight "pin to pin" cable to connect to a LAN, but use a crossover cable to connect directly to a PC. If you are trying to connect the printer directly to a PC via a crossover network cable, you may need to disable the web browser’s proxy settings on your computer to get in contact with the printer’s web pages. • Bad communication between printer and a Wireless network - Check the network LED indicator at the back of the printer. There should be a green light flashing occasionally showing network activity, or a solid yellow background light if the network card is associated with an access point, or flashing yellow light if the network card is searching for an access point. - Press the key on the printer’s front panel and browse to the network information. There you can see the present signal strength and channel. If both are 0, the network card is not associated with any access point and/or the WLAN settings are wrong. - Check if the access point is on. - Check if the access point lists the MAC address of the network card. - Check if other devices associated with this access point are working. - Inspect the location and see if there is any reason why the radio transmission between printer and access point is prevented, such as shielding objects like walls, shelves, fork lifts, metal grids, etc. Sometimes, just moving the printer around a little may help. For demanding applications, Intermec offers a series of high gain antennas that can replace the standard antenna. - Check SSID settings. - Check WEP settings. Note that you must have the same WEP key settings in both the printer and the access point in regard of both the content of the WEP keys and the order of the WEP keys. However, you can have one active WEP key selected in the printer and another in the access point. - Check the region setting, which can be found on the Network Info test label. Description: The printer seems to be physically connected to the network but cannot communicate. Possible Causes and Suggested Remedies: • Bad IP Settings in printer - Use a PC connected to the same network as the printer. First of all verify the network configuration of the printer as described in the Installation Instructions provided with the kit. 228 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting PC Settings You should verify that the PC has a working connection to the network. Do this by opening a Command Prompt and type the command that corresponds to your operating system: - For Windows 95, 98 and ME, use the command WINIPCFG. - For Windows NT4, 2000 and XP, use the command IPCONFIG. The PC will show a table with its configuration containing the settings for IP-address, Subnet Mask and Default Gateway. Verify these settings to be sure that the computer is correctly configured to access your network. Printer Settings Check the IP address of the printer. Press the key on the printer’s keyboard and use the and keys to browse to the IP address. In Fingerprint, a prerequisite is that the standard IN port is set either to "auto" or "net1:", which can be done using Intermec Shell. Another method is using the Setup Mode: Press the key, on the printer’s internal keyboard, and step your way to “NETWORK” using the key. By pressing on the printer, you can step through the configuration to verify the settings. Press to exit the Setup Mode. More information about configuration settings can be obtained by printing a test label. Also check on the printer’s home page (Configuration [TCP/IP]) that the net1 TCP Port Number is correct (default 9100). Verifying IP Address In the User’s Guide of the printer, you will find information on how to print test labels in the chapter “Setting Up the Printer”. Print the network test label and find the IP Address field. If the IP address is set to 0.0.0.0, the network card has not received a IP address. Verify the IP SELECTION setting under the NETWORK menu in the Setup Mode. See the Installation Instructions for information on various methods for setting the IP address automatically or manually. Verifying Subnet Mask Check subnet mask of PC and printer and make sure they belong to the same segment. For example: If they have the subnet mask The numbers in the PC and Printer IP addresses have to be 255.255.255.0 . . . 255.255.0.0 . . . 255.0.0.0 . . . Other subnet masks Contact the network administrator EasyCoder PX4i and PX6 Service Manual 229 Chapter 17 — Troubleshooting In case the addresses are not in the same network segment, the printer may not be reachable from the LAN side. Check the configuration with the administrator. Pinging the Printer Start the Command Prompt. In the Command Prompt, type Ping and then click OK. This command sends an echo command to the EasyLAN to check if the PC and the printer can reach each other through the network. The following figure shows a correct response to the Ping command. The first reply to the first Ping command often takes more time than the following. This is a normal behavior. The first time the Ping command is executed, the PC needs some extra time to perform a “discovery” of the network address (ARP request). The Ping command makes the printer’s network LED flash green. If you have completed the test procedure and all the conditions are met, but you do not get any answer to the Ping command, then you probably have a hardware problem. Description: The performance of a Wireless network connection ceases to work or the performance deteriorates after having worked properly for some time after installation. Possible Causes and Suggested Remedies: • Bad radio connection between printer and access point. - Either the printer or the access point has been moved after installation or some kind of obstruction has come between printer and access point. In principle, there should be a free line-of sight between the access point and the antenna. There is also a distance limit. Check the signal strength. - Check network test label for statistics. - Try moving either the printer or the access point (or both) or consider fitting a higher gain antenna. • Slow response. - Too many devices associated with the same access point. 230 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting 17.12 Sensor Malfunctions Label Stop Sensor (LSS) Description: Label (ticket) gap or black mark not detected by the label stop sensor (LSS) or wrong amount of media feed. Possible Causes and Suggested Remedies: • Lost or obsolete media feed data, for example after a headlift, change of media, or replacement of the sensor. - In Fingerprint, perform a TESTFEED operation, for example by simultaneously pressing and or selecting the Testfeed option in the Setup Mode. - In IPL, adjust the media feed by pressing the Feed/Pause button. • Bad LSS lateral alignment. - Check that the gaps or marks actually pass between the upper and lower parts the label stop sensor (lateral alignment), see Chapter 7.5. - Check that both parts of the LSS are adjusted to the same lateral position, see Chapter 7.5. • Light path obstructed. - Check that both the upper and lower sensors are free from dust and the slots in the upper and lower guide plates are free from stuck labels, or other matters that may interfere with the path of light. • Printer set for wrong media type. - Set up the printer for the correct media type. • Media feed detection using PRSTAT (Fingerprint only). - PRSTAT AND 8 only checks for out-of-media conditions once as opposed to the normal error checking (errors 1005 and 1031) that checks for out-of-media conditions almost continuously. Thus, when using PRSTAT, a dark spot or a bad media angle can give an incorrect out-of-media indication, especially when using tickets (w. mark). • Bad connection - Check the LSS cables and make sure that they are correctly connected to J54 and J55 on the CPU board, see Chapter 13.3. • Faulty sensor or diode. - Replace LSS as described in Chapter 7.5. • CPU board not configured for the right type of printer. - Reconfigure the CPU board as described in Chapter 15.8. Note: The LSS Test option in the Setup Mode is useful for identifying LSS troubles. Refer to Chapter 8.5. EasyCoder PX4i and PX6 Service Manual 231 Chapter 17 — Troubleshooting Headlift Sensor Description: • The printer does not work, although the printhead is lowered. • Error condition 1022 “Head lifted” (FP) or “Print Head UP/Press Feed” (IPL) is indicated at any attempt of printing a label. Possible Causes and Suggested Remedies: • Headlift sensor blocked. - Check the sensor for dust or foreign objects. • Bad connection. - Check that the sensor’s cable is connected to J58 on the CPU board. Inspect cable for damage. • Faulty sensor. - Replace as described in Chapter 7.8. Label Taken Sensor (LTS) Description: The label taken sensor (LTS) is not working properly. Possible Causes and Suggested Remedies: • Intermec Fingerprint instruction missing. - The LTS must either be enabled using an LTS& ON statement, or the status of the LTS must be polled using a PRSTAT function in the current Intermec Fingerprint program. • IPL instruction missing. - The self-strip mode must be enabled using the commands R and t1 . • Bad connection. - Check that the LTS is correctly connected to J53 on the CPU board. - Check that the cable between CPU board and sensor is not damaged. • Dirty sensor. - Make sure that the active parts of the sensor are not obstructed by dust or foreign objects. • Wrong LTS sensitivity. - The sensitivity of the sensor’s receiver and the light intensity of the sensor’s emitter are adjustable, see Chapter 10.4. • Interference from sunlight or lamps. - Shield the sensor from interfering light source. • Defective sensor. - If still no reaction, the sensor is probably defective. Replace. 232 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting Ribbon Sensor Description: The ribbon sensor is not working properly. Possible Causes and Suggested Remedies: • Bad sensor adjustment (Fingerprint only). - Adjust the sensor in the Setup Mode as described in Chapter 6.4. • Bad connection or faulty sensor. - Cable between the ribbon sensor and J56 on the CPU board damaged or not correctly connected? - Sensor blocked by dust or foreign matters? Clean. - Faulty ribbon sensor? Replace. • Bad detection pattern inside ribbon supply bobbin. - Check the black and silvery sector pattern at the inner end of the ribbon supply bobbin for scratches or dust. Paper Sensor Description: The ribbon sensor is not working properly. Possible Causes and Suggested Remedies: • Bad sensor adjustment. - Adjust the sensor in the Setup Mode. • Bad connection or faulty sensor. - Cable between the paper sensor and J57 on the CPU board damaged or not correctly connected? - Sensor blocked by dust or foreign matters? Clean. - Faulty paper sensor? Replace. • Bad detection pattern inside media supply bobbin. - Check the black and silvery sector pattern at the inner end of the media supply bobbin for scratches or dust. EasyCoder PX4i and PX6 Service Manual 233 Chapter 17 — Troubleshooting 17.13 Printing Troubles The best way to start is to get an overall check of the printout quality by printing a series of test labels in the Test Mode. If you suspect a defective printhead, you can check it out using the following Intermec Fingerprint instructions (see Intermec Fingerprint v8.xx, Programmer’s Reference Manual): • FUNCTEST$ ("HEAD") • HEAD • SYSVAR(21) • SYSVAR(22) Description: No printout at all. Possible Causes and Suggested Remedies: • Bad connection. - Is the cable between the printhead and P5 on the driver board fitted correctly and not broken or otherwise damaged? - Is the cable between the printhead and J40 on the CPU board fitted correctly and not broken or otherwise damaged? • Dirty printhead. - Is the printhead clean? Residue from label adhesive, thermal paper topcoating, or preprint ink prevents the printhead from functioning correctly. Clean the printhead as described in the User’s Guide. • Wrong type of direct thermal media. - In case of direct thermal printing, verify that the media is intended for direct thermal printing (not thermal transfer!) and of an approved quality. • Wrong type of thermal transfer ribbon. - In case of thermal transfer printing, verify that the stock of ribbon is of an approved quality. • Transfer ribbon loaded incorrectly. - Verify if the ribbon is loaded with the ink-coated side facing the receiving face material. If not, reload the ribbon as described in the User’s Guide. • Transfer ribbon mechanism failure. - See Chapter 17.14 • Wrong printhead voltage. - Check the printhead voltage +24 VDC ±2V (see Chapter 15.4). If the power on the CPU board is OK, but the trouble remains, disconnect the power cable on the inner side of the printhead and use probes to measure the voltage during printing between two adjacent lines in the socket. If wrong voltage, check driver board and cables. 234 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting • Wrong printhead pressure. - Check the printhead pressure, see Chapter 8.8. • Headlift sensor out of order. - Check the headlift sensor as described in Chapter 17.11. Description: Overall weak printout. Possible Causes and Suggested Remedies: • Various reasons. - Check as for “No printout at all”. • Wrong Contrast/Darkness setup. - Check setup for extremely low value. • Wrong Paper Type/Media Sensitivity setup. - Verify that setup matches the direct thermal media or the combination of transfer ribbon and media. • Wrong printhead voltage. - Measure the +24 VDC on the CPU board, see Chapter 17.3 “No printout at all.” • Printhead pressure too low. - Adjust as described in Chapter 8.8. Description: Weaker printout on either inner or outer part of label. Possible Causes and Suggested Remedies: • Bad printhead pressure alignment. - Adjust the position of the headlift arm as described in Chapter 8.8. Description: Overall too dark printout (bleeding). Too dark a printout is particularly troublesome when printing compact bar codes, in which case spaces between the bars become less distinctive, and consequently less readable. Possible Causes and Suggested Remedies: • Wrong Contrast/Darkness setup. - Check Contrast/Darkness setup for extremely high value. • Wrong Paper Type/Media Sensitivity setup. - Verify that setup matches the direct thermal media or the combination of transfer ribbon and media. • Wrong printhead voltage. - Measure the +24 VDC on the CPU board, see Chapter 17.3 “No printout at all.” EasyCoder PX4i and PX6 Service Manual 235 Chapter 17 — Troubleshooting Description: Weak or missing printout of some dots. Possible Causes and Suggested Remedies: • Dirty printhead or platen roller. - Examine the printhead and the platen roller for dust, adhesive residue, or visible damage. - Clean or replace. • One or two missing dots. - May be due to mechanical damage to the printhead. Try to establish why such damage have occurred in order to prevent future failures of this kind. (Hard foreign particles, electrostatic discharge?) - If the printer has been used for printing on less than full width labels for some time, the platen roller and possibly also the printhead may have become worn from the outer edge of the media. This will show up when reverting to wider labels. Change the platen roller and possibly also the printhead. • Preprinted ink has got stuck to the dot line. - Avoid preprinted labels with ink that has a low melting point (less than +225°C/+437°F). • Many dots, or a block of dots, are missing. - The internal IC circuit of the printhead is probably damaged. Replace the printhead. Description: Unexpected black printout (completely or partially). Possible Causes and Suggested Remedies: • Wrong printhead voltage. - If the printer unexpectedly produces completely or partially black printout, or prints a black line across the media at startup (regardless of label layout), check the printhead voltage +24 VDC ±2V (see Chapter 15.4). If the power on the CPU board is OK, but the trouble remains, disconnect the power cable on the inner side of the printhead and use probes to measure the voltage during printing between two adjacent lines in the socket. If too high, in the range of 40 to 50V during printing, replace the power supply unit. - The printhead is most certainly damaged too and will also need to be replaced. 236 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting Description: Media feed does not work properly. Possible Causes and Suggested Remedies: • Faulty stepper motor. - Connect a replacement stepper motor to P10 on the driver board (see Chapter 14) and perform a print or feed operation. If this motor runs, the original stepper motor is probably damaged and needs to be replaced (see Chapter 7.3). • Dirty or worn platen roller. - Inspect the platen roller for visible wear. Replace if necessary (see Chapter 8.2). - Clean the platen roller using a cleaning card or a soft cloth moistened with isopropyl alcohol. Paper dust or adhesive residue can deteriorate the media feed function or make the media slip. • Intermec Fingerprint instruction missing. - Verify that a print command is actually issued in the current Intermec Fingerprint program. • Power Supply Unit malfunction or bad connection. - The stepper motor could be incorrectly connected to P10 on the driver board, or its drive circuit (U3) on the driver board could be damaged. - Check that all pins in the connector of the stepper motor’s cable are fully inserted. - Measure the +24 VDC on the driver board, see Chapter 14. If there is no power, when an attempt to print is made, the power supply unit or driver board is probably faulty. • CPU board configured for wrong printer model. - A replacement CPU board must be configured for the correct printer model after installation. Refer to Chapter 15.8. Description: Excessive wear of printhead. Possible Causes and Suggested Remedies: • Various reasons. - Refer to Chapter 8.6 “Printhead/Precautions” for advices on how to reduce the wear of the printhead. EasyCoder PX4i and PX6 Service Manual 237 Chapter 17 — Troubleshooting 17.14 Transfer Ribbon Troubles Description: The thermal transfer ribbon breaks. Possible Causes and Suggested Remedies: • Wrong brand of ribbon. - Check if the transfer ribbon is of an approved brand. If not, recommend the customer to use approved brands only. • Bad ribbon load. - Check that the ribbon is routed so it runs above upper guide (that is, the one where the upper part of the LSS is fitted). • Wrong paper type setup. - Check that the printer is set up correctly for the type of thermal transfer ribbon in use, see the User’s Guide. • Wrong printhead voltage. - Check printhead voltage, see Chapter 15.4. Description: The thermal transfer ribbon wrinkles. Possible Causes and Suggested Remedies: • Media misalignment. - Are the edge guides positioned so as to guide the media closely along the printer’s center section? - Is the media supply roll as far in on the hub as possible? • Ribbon misalignment. - Are both the ribbon supply roll and the ribbon rewind core pressed as far in on their hubs as possible? • Ribbon path obstructed. - Check that nothing obstructs the path of the transfer ribbon. • Wrong or uneven printhead pressure. - Check that the pressure arm is center-aligned in the relation to the width of the media, see Chapter 8.8. - Check the printhead pressure, see Chapter 8.8. Decrease the pressure somewhat and test for both wrinkles and printout contrast. You may need to feed out 25-50 cm of ribbon (1-2 ft.) before you can see any effect. • Bad ribbon break shaft adjustment. - Check the adjustment of the ribbon assist roller, see Chapter 8.9. Do not change the adjustment before you have performed all other checks mentioned above. 238 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting Description: No transfer printout. Possible Causes and Suggested Remedies: • Refer to Chapter 17.13 for general printout troubles. • Bad ribbon load. - Transfer ribbon loaded incorrectly so the ink-coated side does not face the receiving face material. Reload ribbon. Description: Ribbon fed out in front of printer. Possible Causes and Suggested Remedies: • Printer is set up for direct thermal printing, but a ribbon is loaded. - Remove ribbon or change the paper type setup to thermal transfer. • Ribbon rewinder belt broken. - Replace as described in Chapter 8.4. EasyCoder PX4i and PX6 Service Manual 239 Chapter 17 — Troubleshooting 17.15 Liner Takeup Troubles Description: The internal liner takeup unit does not work properly. Possible Causes and Suggested Remedies: • Bad liner takeup or bad separation of labels from liner at the tear bar. - Check that the media is routed correctly as described in the User’s Guide. - Check that the liner is securely locked to the takeup hub by the brace, so it cannot slip. - Check the setup for incorrect media type and feed adjust settings. • Takeup unit slips. - Spring clutch inside the takeup hub is broken. - Either the outside of the pulley or the inside of the hub has become worn. • Either the liner drive roller in the print mechanism or the takeup hub is not driven by the stepper motor. - Check if any of the belts from the stepper motor is broken or has come off the pulleys, see Chapter 9.2. • Neither the liner drive roller in the print mechanism nor the takeup hub is driven by the stepper motor. - Check if the stepper motor runs. If not, check as for “Media feed does not work” in Chapter 17.13. - Check if both the belts from the stepper motor are broken or have come off the pulleys, see Chapter 9.2. 240 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting 17.16 Memory Card Troubles Description: The printer cannot read a memory card. Note that in IPL, memory cards are not used to expand the printer’s memory. Possible Causes and Suggested Remedies: • Memory card not inserted at startup. - The card must be inserted before the power is switched on or the printer is rebooted. • Memory card incorrectly inserted. - Check that the card is inserted as far as it goes. • Bad contact between card and adapter. - Switch off the printer. Pull out and insert the card a few times to rub off any oxide on the connectors. • Wrong type of memory card. - The memory cards must be Type I CompactFlash cards (thickness 3.3 mm/0.13 in.) commonly used with digital cameras. PCMCIA-cards or Type II CompactFlash cards (thickness 5 mm/0.20 in.) cannot be used. If a CompactFlash card is marked CF+, it is probably not a regular memory card and cannot be used. • Error in content of the card. - If you have access to a PC equipped with a CompactFlash card reader, list the memory content of the PC memory card to see if it is correct. - If you can communicate with the printer via a PC, you could see what files are stored in the memory card and their sizes with the aid of Intermec Fingerprint command FILES "card1:". - The memory card must be formated for FAT12 or FAT16 - If the memory card is formated for FAT32, an "ERROR 41" message will occur. - Try to format the card in the printer using the Fingerprint instruction FORMAT "card1:",A. Also see Intermec Fingerprint v8.xx, Programmer’s Reference Manual. • Hardware error. - Inspect the memory card for mechanical damage. - Examine the memory card adapter on the CPU board for damaged card mating pins, breakage, or bad soldering. EasyCoder PX4i and PX6 Service Manual 241 Chapter 17 — Troubleshooting 17.17 Paper Cutter Troubles Description: The printer cannot detect the cutter. • In Fingerprint, error 37, “Cutter device not found” or Error 1059, “Cutter does not respond” occurs. Possible Causes and Sugged Remedies: • No reboot has been performed after installation. - Cycle the power to the printer. • Cable between cutter pcb and CPU board is not fitted properly. - Check that the cable has not come loose from the cutter interface connector, see Chapter 11.2. - Check that the cable from the cutter interface connector is properly connected to P12 on the driver board. • Faulty cable, driver board, or CPU board. - Replace one at the time, reboot, and check. Description: The cutter does not cut. Possible Causes and Suggested Remedies: • Error 1704, “Cutter open” occurs in Fingerprint. - Check that the cutter is positively in closed position. - The home position microswitch in the cutter assy may be defect. Replace the cutter assy. - Faulty cable, driver board, or CPU board. Replace one at the time, reboot, and check. • Errors 1701-1703 occurs in Fingerprint. - Check the cutting shears and cutter mechanism for adhesive residue, label shavings, stuck labels, or other things that may prevent the cutter from operating mechanically. Clean if necessary, but do not use any solvent that can dissolve the grease. - Replace the cutter assy or cutter pcb, one at the time. • No error occurs but cutter does still not cut. - If using Fingerprint, check that the application program utilizes the Fingerprint statements CUT or CUT ON/OFF correctly. See the Intermec Fingerprint v8.xx, Programmer’s Reference Manual. - If using IPL, check that the cutter has been enabled in the Setup Mode. 242 EasyCoder PX4i and PX6i Service Manual Chapter 17 — Troubleshooting Description: The cutter cuts at the wrong place. Possible Causes and Suggested Remedies: • Faulty LSS or bad Feedadjust setup. - In Fingerprint, perform a Testfeed to adjust the LSS. - In IPL, adjust the media feed by pressing the Feed/Pause button. - Check Start- and Stopadjust setup values (Fingerprint only). - Check application for FORMFEED instructions (Fingerprint only). EasyCoder PX4i and PX6 Service Manual 243 Chapter 17 — Troubleshooting 244 EasyCoder PX4i and PX6i Service Manual A Program Overviews This appendix shows overviews of the Intermec Shell and the Intermec Fingerprint Setup Mode followed by overviews of the IPL Setup Mode. Refer to the User’s Guides for information on the various parameters and instructions for navigation. EasyCoder PX4i and PX6i Service Manual 245 Appendix A — Program Overviews Intermec Shell v8.2 Overview ENTER=SHELL SHELL SEL. APPLICATION 5 sec. SEL. APPLICATION CURRENT APPL. v.8.2 ENTER=SHELL 4 sec. SEL. APPLICATION v.8.2 Fingerprint 8.30 ENTER=SHELL 3 sec. v.8.2 ENTER=SHELL 2 sec. Last selected application is started v.8.2 Note: Dotted channels are only shown if the corresponding optional interface pcb is fitted. SEL. APPLICATION STD I/O CHANNEL Direct Protocol auto Optional application STD I/O CHANNEL programs uart1: ENTER=SHELL STD I/O CHANNEL 1 sec. uart2: v.8.2 Last selected application is started Default: Fingerprint 8.30 w. std I/O = "auto" STD I/O CHANNEL uart3: STD I/O CHANNEL centronics: Legend: The selected application is started POWER ON STD I/O CHANNEL net1: Return to previous menu. STD I/O CHANNEL Proceed to next menu. usb1: STD I/O CHANNEL Accept displayed option and proceed, or execute displayed option. uart4: STD I/O CHANNEL uart5: Perform a Testfeed anywhere in Intermec Shell. SEL.APPL rom: LINE_AXP.PRG Enter the Setup Mode from anywhere in Intermec Shell. SHELL SETUP: SETUP SER-COM,UART1 SHELL See the chapter “Setup Mode” Prints a list of current setup values (test label “Setup Info”). PRINT SETUP SHELL TESTFEED Performs a Testfeed (feeds out a number of blank copies while autoadjusting the label stop sensor). SHELL Prints test labels “Diamonds”, “Chess”, “Bar Codes #1”, and “Bar Codes #2” in a loop Press Enter for each new label. TEST LABEL SHELL ARE YOU SURE? DEFAULT SETUP DEFAULT SETUP YES=ENTER/NO=ESC PERFORMED SHELL UPDATE: COMPACT FLASH? TRANSFER FILE SOFTWARE UPDATE USING ZMODEM TRANSFER COMPLETED SHELL REBOOT UPDATE: TRANSFER FILE FIRMWARE? USING ZMODEM Restarts the printer (same as power off/on) Printer rebooted automatically. Note: To enter Intermec Shell if an autoexec-file prevents access, lift the printhead and press any key (except the key), then turn on the power while continuing to press the key. When the Shell countdown begins, release the key and press to start Shell. Do not forget to lower the printhead if you, for example, want to print test labels. 246 EasyCoder PX4i and PX6i Service Manual Appendix A — Program Overviews Setup Mode Overview (FP v8.30) EasyCoder PX4i and PX6i Service Manual Ser-Com, uart1: 247 Appendix A — Program Overviews Setup Mode Overview (FP v8.30) 248 Feed Adjust EasyCoder PX4i and PX6i Service Manual Appendix A — Program Overviews Setup Mode Overview (FP v8.30) EasyCoder PX4i and PX6i Service Manual Media 249 Appendix A — Program Overviews Setup Mode Overview (FP v8.30) 250 Print Defs EasyCoder PX4i and PX6i Service Manual Appendix A — Program Overviews Setup Mode Overview (FP v8.30) Ser-Com, uart2 3%4503%450 3%2 #/- 5!24 3%2 #/- 5!24 "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% "!5$2!4% EasyCoder PX4i and PX6i Service Manual 251 Appendix A — Program Overviews Setup Mode Overview (FP v8.30) 252 Ser-Com, uart3 EasyCoder PX4i and PX6i Service Manual Appendix A — Program Overviews Setup Mode Overview (FP v8.30) EasyCoder PX4i and PX6i Service Manual Ser-Com, uart4 253 Appendix A — Program Overviews Setup Mode Overview (FP v8.30) 254 Ser-Com, uart5 EasyCoder PX4i and PX6i Service Manual Appendix A — Program Overviews Setup Mode Overview (FP v8.30) EasyCoder PX4i and PX6i Service Manual Network Communication 255 Appendix A — Program Overviews Setup Mode Overview (IPL v2.30) Serial Communication SETUP: SER-COM SER-COM: BAUDRATE Continued on the next page SER-COM: DATA BITS BAUDRATE: DATA BITS: 9600 8 CHAR LENGTH BAUDRATE; 19200 BAUDRATE; 7 38400 BAUDRATE; 57500 BAUDRATE; 115200 BAUDRATE; 1200 BAUDRATE; 2400 BAUDRATE; 4800 Scroll forward Scroll back 256 SER-COM: PARITY SER-COM: STOP BITS PARITY: STOP BITS: NONE 1 STOP BITS: PARITY: 2 EVEN PARITY: ODD PARITY: Scroll forward SPACE Scroll back Scroll forward Scroll back SER-COM: PROTOCOL PROTOCOL: XON/XOFF ENQ/ACK: STANDARD Scroll forward Scroll back EasyCoder PX4i and PX6i Service Manual Appendix A — Program Overviews Setup Mode Overview (IPL v2.30) SETUP: NETWORK Network (option) These menus will only be displayed when an optional EasyLAN interface board is installed. NETWORK: IP SELECTION NETWORK: IP ADDRESS NETWORK: NETMASK NETWORK: DEFAULT ROUTER NETWORK: NAMESERVER NETWORK: MAC ADDRESS IP SELECTION: DHCP+BOOTP PARITY: MANUAL PARITY: DHCP PARITY: BOOTP IP ADDRESS: 0.0.0.0 Read-only NETMASK: 0.0.0.0 Read-only DEFAULT ROUTER: 0.0.0.0 Read-only NAMESERVER: 0.0.0.0 Read-only MAC ADDRESS: nnnnnnnnnnnn Read-only EasyCoder PX4i and PX6i Service Manual 257 Appendix A — Program Overviews Setup Mode Overview (IPL v2.30) Continued from the previous page Test/Service Continued on the next page SETUP: TEST/SERVICE TEST/SERVICE: TESTPRINT TESTPRINT: CONFIG TESTPRINT: TEST LABELS TESTPRINT: FORMAT TESTPRINT: PAGE CONFIG: SW CONFIG: HW CONFIG: NETWORK TEST LABELS: PITCH TEST LABELS: PRINT QUALITY FORMAT: ALL PAGE: ALL ALL: PRINT FORMATS ALL: PRINT PAGES Scroll forward Scroll back TESTPRINT: UDC Scroll forward Scroll back TESTPRINT: FONT UDC: ALL ALL: PRINT UDC 258 TEST/SERVICE: DATA DUMP TEST/SERVICE: MEMORY RESET TEST/SERVICE: LSS TEST DATA DUMP: NO CONFIG: YES Scroll forward Scroll back MEMORY RESET: ALL CONFIG: CONFIGURATION Scroll forward Scroll back LSS TEST: LSS AUTO LSS AUTO: EasyCoder PX4i and PX6i Service Manual Appendix A — Program Overviews Setup Mode Overview (IPL v2.30) Media Continued from the previous page Continued on the next page SETUP: MEDIA MEDIA : MEDIA TYPE MEDIA : PAPER TYPE MEDIA : LBL LENGTH DOTS MEDIA : SENSITIVITY MEDIA : DARKNESS MEDIA TYPE: GAP CONFIG: MARK CONFIG: CONTINUOUS Scroll forward Scroll back PAPER TYPE: DT CONFIG: TTR Scroll forward Scroll back LBL LENGTH DOTS: 1200 100/200/400/800/ 1200/1600/2000/ 2500/3000/3600/ 4200/4800 SENSITIVITY: 420 120/130/140/160/170/ 180/222/226/236/238/ 366/369/420/440/450/ 460/470/480/513/527/ 533/563/565/567/623/ 627/633/647/673/677/ 687/720/854/864 DARKNESS: 0 0/1/2/3/4/5/6/7/8/ 9/10/-10/-9/-8/-7/ -6/-5/-4/-3/-2/-1 Scroll forward Scroll back Scroll forward Scroll back Scroll forward Scroll back MEDIA : LBL REST POINT MEDIA : FORM ADJ DOTS X LBL REST POINT: FORM ADJ DOTS X: 0 0 0/2/4/6/8/10/15/20/25/ 0/2/4/6/8/10/15/20/25/ 30/-30/-25/-20/-15/-10/ 30/-30/-25/-20/-15/-10/ -8/-6/-4/-2 -8/-6/-4/-2 Scroll forward Scroll back Scroll forward Scroll back EasyCoder PX4i and PX6i Service Manual MEDIA : FORM ADJ DOTS Y MEDIA : RIBBON LOW MEDIA : PAPER LOW FORM ADJ DOTS Y: 0 0/2/4/6/8/10/15/20/25/ 30/-30/-25/-20/-15/-10/ -8/-6/-4/-2 RIBBON LOW: 0 0/5/10/15/20/25/30/35/ 40/45/50/55/60/65/70/ 75/80 PAPER LOW: 0 0/10/20/30/40/50/60/70/ 80/90/100/110/120/130/ 140/150 Scroll forward Scroll back Scroll forward Scroll back Scroll forward Scroll back 259 Appendix A — Program Overviews Setup Mode Overview (IPL v2.30) Continued from the previous page Return to the start of the loop SETUP: CONFIGURATION CONFIGURATION: PWRUP EMULATION CONFIGURATION: PRINT SPEED PWRUP EMULATION: NONE CONFIG: 86XX-10MIL CONFIG: 86XX-15MIL Scroll forward Scroll back CUTTER: PRINT SPEED: NOT INSTALLED 4PRINT IN/SEC SPPED: CONFIG: 5PRINT IN/SEC SPPED: ENABLE CONFIG: 6PRINT IN/SEC SPPED: DISABLE 7PRINT IN/SEC SPPED: Scroll forward 8PRINT IN/SECSPPED: Scroll back 9PRINT IN/SEC SPPED: 10 IN/SEC PRINT SPPED: 11 IN/SEC PRINT SPPED: 12 IN/SEC Scroll forward Scroll back 260 Configuration CONFIGURATION: CUTTER CONFIGURATION: LTS CALIBRATION LTS CALIBRATION: PRESS Labels are fed out REMOVE LABEL AND PRESS ENTER SENSITIVITY 9 OUT OF 8-14 Read only, press EasyCoder PX4i and PX6i Service Manual B Firmware Upgrading This appendix describes various methods for upgrading the printer’s firmware and for switching from Intermec Fingerprint to IPL or vice versa. EasyCoder PX4i and PX6i Service Manual 261 Appendix B — Firmware Upgrading Introduction All EasyCoder PX4i and PX6i printers can use both Fingerprint v8.xx and IPL v2.xx firmware. There are many ways to upgrade or exchange printer’s firmware. Use the most convenient way. You can either do it from host by sending the file to the printer or by inserting a CompactFlash card in the memory card slot at the printer’s rear plate. There are 3 different file types containing the firmware. The file types are related to the way of upgrade procedure. The files can be obtained from Intermec. File Description File name Type of file 1-972020-xx.bin (for FP) 1-972105-xx.bin (for IPL) These .bin files contain the firmware kernel file only. To be sent on serial port to printer using a communication program, for example HyperTerminal or Printset, or via FTP. Can also be stored on a CompactFlash card. 1-972021-xx.bin (for FP) 1-972106-xx.bin (for IPL) These .bin files contain the firmware kernel file and the factory default setup parameter values. To be stored on a CompactFlash card. Note: These files remove all files except the firmware files, so it is advised to make a backup before running such a file. They are primarily intended to allow restoring forgotten passwords. Another format is .uff files, which are created by, for instance, NetPrintSet. They contain the kernel and optional instructions (if necessary), images, fonts, etc. To be stored in CompactFlash memory cards. General Principles • During upgrading, do not switch off the printer. Wait and follow the prompts in the printer’s display. • If changing firmware from IPL to Fingerprint, we recommend to erase memory to factory setup setting [FORMAT "/c",A] after the upgrade procedure is completed. • Some update of Fingerprint may show the error “mcs: Error during setup” at host terminal. This just means that there was an instruction that erased "/c" [FORMAT "/c",A]. This is a normal condition! The error shows that no setup file [.setup.saved] is detected on "/c". The "/rom" setup file is copied automatically into "/c" which gives printer a factory setup setting. • If an EasyLAN interface board is installed, by default only admin is allowed to upgrade. See EasyLAN User's Guide for more information. 262 EasyCoder PX4i and PX6i Service Manual Appendix B — Firmware Upgrading Upgrading From a Memory Card This chapter describes how to upgrade the printer from a CompactFlash card. 1 Insert the card and switch on the printer. The printer’s display will automatically show ongoing steps. The procedure ends with a normal startup of the printer. 2 Switch off the printer and remove the card. Printer is ready for use. CompactFlash cards with firmware (Fingerprint or IPL) can be ordered from Intermec. Empty CompactFlash cards can be ordered from Intermec or procured locally. If there are more than one firmware files on the memory card, it is not foreseeable which one will be selected. However, by renaming the desired file to FIRMWARE.BIN, you can make sure that the file will be selected. How to make an upgrading card There are two possible places to program a CompactFlash card. One is your PC CompactFlash card slot, another is the printer’s card slot. At the PC-side 1 Use a computer fitted with a PCMCIA slot and a CompactFlash adapter and insert the CompactFlash card. 2 Copy the upgrade .bin or .uff file to the CompactFlash card. At the printer side (Fingerprint only) 1 Insert the CompactFlash card in the slot at the printer’s rear plate. 2 Start up the printer and select Intermec Shell. 3 Press to go to the “Sel. Application” menu. 4 Press <⇒> repeatedly to browse to ”SOFTWARE UPDATE”. 5 Press to go to ”UPDATE: COMPACT FLASH?” 6 Press . 7 Start sending the file using a communication program, for example HyperTerminal. The communication program must use zmodem. (There is a one-minute time-out on the printer side.) Shell will automatically rename the file to FIRMWARE.BIN to make sure that this file will upgrade the printer. 8 Switch off the printer and remove the card. EasyCoder PX4i and PX6i Service Manual 263 Appendix B — Firmware Upgrading Note: A special case is if the CompactFlash card already has a Fingerprint firmware. Inserting such card will always install firmware in the printer according to CompactFlash card. However, perhaps you like to install a later firmware version picked from the web. If so, proceed like this: 1 Insert the CompactFlash card with a upgrade firmware on. Switch on and wait for a completed upgrade and the normal startup of the printer so you are in Fingerprint mode. 2 Activate the Shell program from "/rom" like this: LOAD "/rom/SHELLXP.PRG" MERGE "/rom/ERRHAND.PRG" RUN 3 In Shell, select the option “UPDATE: COMPACT FLASH?” and press . 4 Send the .bin or .uff file from the host using zmodem. 264 EasyCoder PX4i and PX6i Service Manual Appendix B — Firmware Upgrading Upgrading From the Host Software Suggestions 1. Intermec PrintSet (IPL and Fingerprint) Install Intermec Printset software and a serial cable. Intermec PrintSet is included in the printer companion CD. It can also be obtained from the Intermec Printer Support Web. 2. Terminal program (Fingerprint only) Use Terminal program included in Windows (95/98/Me or NT/2000/XP) and a serial cable. At serial communication, the software has to be prepared by a protocol Zmodem and have same communication settings on both side. We recommend hardware handshaking (RTS/CTS). 3. Command prompt with FTP Use command prompt in Windows (95/98/Me or NT/2000/XP) and an Ethernet network. 4. Intermec NetPrintSet (Fingerprint only) Use Intermec NetPrintSet software and a serial cable. Intermec NetPrintSet can be obtained from the Intermec Printer Support Web. Cable Suggestions RS-232 Serial Cable DB-9pin female -> DB-9pin male (see Spare Parts Catalog) Ethernet Cable Intermec does not provide any Ethernet cable. The cables are normally provided locally. At a straight connection between a host and printer, a cross RJ-45 cable is needed. Parallel Cable (see Spare Parts Catalog) How to use Intermec PrintSet and serial cable. 1 Connect a serial cable between host and printer 2 Start up the printer and select Fingerprint via Shell and to listen on serial port "uart1:" on for example baud rate 115,200. 3 Start PrintSet. The program will automatically set the communication parameters and is ready for use. 4 Select ”DataXfer\Change firmware”. Depending on settings, PrintSet may ask for the admin password. 5 Send one of the following files: 1-972020-xx.bin (Fingerprint) 1-972105-xx.bin (IPL) 6 After file is received in printer, it will automatically replace the firmware and boot up with the new one. 7 The printer’s display will automatically show ongoing steps. The procedure ends with a normal startup of the printer. EasyCoder PX4i and PX6i Service Manual 265 Appendix B — Firmware Upgrading How to use MS HyperTerminal and a serial cable (Fingerprint only) 1 Connect a serial cable between host and printer. 2 Start the HyperTerminal or a similar terminal program. Select port com1. Use a high communication speed (115,200 baud). 3 Start up the printer and select Fingerprint via Intermec Shell1 to listen on serial port "uart1:". 4 Make sure that your are in contact with printer by typing for example FONTS and the printer will respond showing fonts. 5 Type a download command2 so printer is ready for receiving data: RUN "dlk" Select .bin upgrade file. Now printer waits for about 1 minute to get the file sent using zmodem as protocol. 6 Go to “Send file” and send it. 7 After file is received in printer, it will automatically replace the firmware and the printer will boot up with the new one. 8 The printer’s display will automatically show ongoing steps. The procedure ends with a normal startup of the printer. 1 /. In Intermec Shell it is also possible to select printer to be in the receiving mode. Start up Intermec Shell and use <⇒> to browse to “Software Update\Update:Firmware”. (You have one minute to send the file.) Also check the printer’s baud rate in the Setup Mode. Continue with items 6-8. If the printer is fitted with an EasyLAN board, user must be allowed to upgrade. 2 /. dlk only works if the current user is allowed to update. RUN "su admin" could be required. 266 EasyCoder PX4i and PX6i Service Manual Appendix B — Firmware Upgrading How to use command prompt FTP and Ethernet 1 Connect a printer on Ethernet LAN or by a cross cable between host and printer 2 Open an FTP session to the printer typing this command from your Windows command prompt: FTP 3 You will get a prompt asking you for User: type admin or user. You may get a prompt for a Password: type pass (default; case sensitive). Note: The user you log in as must be allowed to upgrade. 4 After some answers on your screen you will see the prompt FTP>. At this point type bin + , then type hash + . 5 Now send the firmware to the printer with the command: put FLASH 6 Some ###### will appear on your screen showing the ongoing transfer. 7 The printer’s display will automatically show ongoing steps. The procedure ends with a normal startup of the printer. 8 Close FTP session typing bye + . 9 After file is received in printer it will automatically replace the firmware and the printer will boot up with the new one. The printer’s display will automatically show ongoing steps and the procedure ends with a normal startup of the printer. How to use Intermec NetPrintSet and serial cable (Fingerprint only) What is NetPrintSet NetPrintSet is a printer configuration utility for Intermec printers that allows you to upgrade or configure the printer. Makes font upgrades and other maintenance a child’s play. Available both as Netscape plugin and standalone executable. • NetPrintSet can merge printer’s necessary file to one file either using a CompactFlash card or download direct to printer. Necessary files are for example Images, Fonts, Firmware, or other custom-made files. • How to use? Please refer to the Help included in the software. If upgrading directly via NetPrintSet and printer 1 Start up the printer and select Shell. Press to go to the “SEL. APPLICATION” menu. Use <⇒> to browse to “SOFTWARE UPDATE”. Press to go to the “UPDATE: COMPACT FLASH?” menu. Use <⇒> to go to “UPDATE: FIRMWARE?”. Finally, press . User might not be allowed to update. 2 Start to send the file from the software. (There is a one-minute time-out before the printer exits the receive mode.) 3 After file is received in printer, it will automatically replace the firmware and the printer will boot up with the new one. EasyCoder PX4i and PX6i Service Manual 267 Appendix B — Firmware Upgrading 268 EasyCoder PX4i and PX6i Service Manual C Measuring the Brake Torque This appendix describes a simple way to measure the brake torque when advanced tools are not available. EasyCoder PX4i and PX6i Service Manual 269 Appendix C — Measuring the Break Torque Measuring the Brake Torque If you do not have access to a torque-measuring instrument, you could easily make a provisional instrument using a roll of spent transfer ribbon, a simple dynamometer and a ruler: • Fit the ribbon roll on the spool you want to check. The larger roll, the better accuracy. • Measure the radius from the center of the spool to the edge of the ribbon roll. • Fit the end of the ribbon to the dynamometer and pull. • Read the dynamometer. • Calculate the torque using the formula: Torque (Nmm) = Radius (mm) × Force (N) Dynamometer Force Formula: Torque = Force x Radius ius Rad 270 EasyCoder PX4i and PX6i Service Manual Intermec Technologies Corporation Corporate Headquarters 6001 36th Avenue West Everett, WA 98203 U.S.A. tel 425.348.2600 fax 425.355.9551 www.intermec.com EasyCoder PX4i & PX6i Service Manual *1-960624-00* *1-960624-00*
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