Intermec Technologies 02CN3 CN3 User Manual part 3

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6822
Series 80-Column Printer
Photo of printer not
available at this
time
User’s
Manual
6822
User’s
Manual
Series 80-Column Printer
6
Troubleshooting
This chapter helps you correct printing problems that may
occur. If you experience a printing problem, you can perform
several tests to find and possibly correct the problem. In this
chapter you will find these sections:
•
Checking the power source
•
Aligning the printer mechanism
•
Troubleshooting system components
•
Communications pin-out configurations
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Chapter 6 — Troubleshooting
Checking the Power Source
Press any button on the printer control panel. If there is power, the power
indicator (green LED) turns on and the printhead moves to its starting
position. If the printer emits beeps and any of the other indicators light
up or flash, observe the number of beeps and indicator flashes and see
“Printer Failure Indicators” on page 102
If there is no reaction from the printer after you press a key on the
control panel, or only the green power light blinks, verify that the power
cables are properly connected between the printer mechanism and its
power source (internal battery, vehicle cable, or ac). If none of these
steps “wake” up the printer with the problem, then you need to return the
printer for service.
•
Internal battery
Check the battery and its cable by installing into another knowngood printer.
•
Vehicle cable
Attach the printer in question to another vehicle power cable.
•
AC power
Plug the printer into another outlet.
Aligning the Printer Mechanism
If head jams occur, you may need to align the printer mechanism.
To align the printer mechanism
1 Open the printer top cover, then install a ribbon cartridge (see
page 15) and position the printhead to the far left toward the green
thumb wheel.
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Chapter 6 — Troubleshooting
2 Check the area between the printhead and the printer cavity. If the
ribbon cartridge touches the pivot frame, the printer mechanism
needs realignment.
Pivot frame
Printhead at far left in the printer
3 Loosen the four screws that hold the mechanism in place using a
Phillips screwdriver (see the following illustration).
4 Push the printer mechanism to the right away from the green thumb
wheel.
5 Press on the right side of the printer mechanism to the back as far as
it will go.
Note: In this position, the right back edge of the printer
mechanism may touch the pivot frame. The left side must not
touch the pivot frame.
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Chapter 6 — Troubleshooting
6 Hold the printer mechanism in place and tighten the screws in the
sequence shown below.
1 Top right
3 Top left
2 Bottom
left
4 Bottom
right
Four screws hold down the printer mechanism
Troubleshooting System Components
The printing system is composed of four basic components: printer,
computer, power source, and communications. Any one of these
components can prevent the printer from functioning properly.
Verifying the Printer Components
Power Source Verification
Start by verifying that power is available at the printer. Visually inspect
the control panel to verify that the power indicator (green LED) is lit. If
it is not, press the Set Page button and note if the power indicator lights
up. If it does, the power system is all right. If it does not, press the printer
reset button. If the power indicator still does not light, check the power
cable, by connecting it to a different printer. If the power indicator works
on the new printer, then the cable is all right, and the printer that was
originally connected is suspect. If it does not light, then the problem is
most likely the cable or the power source. Depending on the results,
either replace the cable or return the printer for service.
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Chapter 6 — Troubleshooting
Printer Verification
If the power indicator works properly and the printer still does not print,
then printer errors are noted. If any indicators light when you press the
Set Page button, or the printer beeps, refer to the Printer Failure
Indicators table on page 102 to determine the problem.
If none of the listed conditions are indicated by the beep codes and
LEDs, yet the printer does not perform properly, then perform a printer
self-test. Press and hold (for several seconds) both Form Feed and the
Set Page buttons at the same time, until the printer beeps and all
indicator lights come on. The lights change throughout the test, as it
progresses.
At the end of the self-test, the printer generates a report. This report
verifies the following: errors detected during self-test, the error history,
and the communication configuration. If the printer self-test report does
not print, then reset the printer. If the report does print after resetting,
then the printer is all right and the reason the printer does not respond to
PC print requests is probably communications or PC related. If the report
is partially completed, and a printer error occurs during the printing of
self-test, refer to the Printer Failure Indicators table on page 102 for the
cause of the printer failure.
Perform a power-on-self-test (POST) to test for errors either by resetting
the printer or powering it up. If errors occur, audible error codes, along
with indicator light status, are produced during POST (see the POST
Error Codes table on page 104).
If the POST completes without error, try the printer self-test again. If the
self-test prints correctly, but the printer does not respond to the PC, then
the problem may be related to communications or PC problems.
Communications / PC Verification
Use the self-test report to verify that the communications protocol
options, selected at the printer, match those expected by the host. If they
do not match the expected results, reconfigure the printer using the
control panel configuration modes described below in the Configuration
part of this chapter.
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Chapter 6 — Troubleshooting
If the protocol options match, then the communications cable may be
defective. To determine if the cable is working, substitute a new cable. If
the PC is suspect, substitute a different PC. A defective computer dock
might be another possibility.
Understanding Printer Errors
Printer Errors are divided into classes:
•
Runtime errors
•
POST errors,
•
Fatal errors (consisting of flash write errors and EEPROM block
errors).
Runtime Errors
Runtime errors can occur during the course of printing. These errors are
displayed on the LEDs, along with beep sequences. This causes the
printer to stop printing and enter an error state. Then beep sequences are
emitted, LED codes are displayed, the error status may be sent to the
host (depending on the protocol), and the printer goes into suspend
mode.
The printer exits from the suspend mode when the user presses one of
the keyboard keys or communications is resumed from the host. The
printer also places the printhead in its home position and attempts to
recover from the error condition. Until the error condition is corrected,
the error procedure does not end, and the error state is not removed.
For paper out errors, load paper and press the Set Page button before
printing begins. Press the Form Feed button to load the paper to the top
of form. The following table provides a listing of printer failure
indicators and describes what they mean.
Printer Failure Indicators
Sets of Beeps
Paper Out Head Jam Low Batt
Meaning
1 beep
1 set of 2 beeps
Off
Off
Off
Off
On
2 blinks
1 set of 3 beeps
Off
Off
3 blinks
12 V under voltage fault (Low Battery)
12 V over voltage fault (Input Voltage
too high)
24 V under voltage fault (internal
power supply failure)
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Chapter 6 — Troubleshooting
Printer Failure Indicators (continued)
Sets of Beeps
Paper Out Head Jam Low Batt
Meaning
1 set of 4 beeps
Off
Off
4 blinks
1 set of 13 beeps
2 sets of 2 beeps
2 sets of 3 beeps
2 sets of 4 beeps
5 sets of 2 beeps
Off
Off
On
Off
5 blinks
Off
2 blinks
Off
On
5 blinks
Off
2 blinks
Off
Off
5 blinks
3 sets of 2 beeps
3 blinks
Off
3 blinks
3 sets of 4 beeps
4 sets of 2 beeps
12 sets of 12 beeps
Off
4 blinks
Off
3 blinks
4 blinks
Off
Off
Off
Off
24 V over voltage fault (internal power
supply failure)
Configuration error
printhead over temperature
Paper Out
Head Jam
Paper feed current fault
(Possible paper jam or feed motor
failure)
printhead over current (printhead
failure)
Home switch failure
printhead short (printhead failure)
Operating System software failure
Note: The most common errors are Paper Out, Low Battery,
and Head Jam. Status indicators on the front panel alert you to
these errors. For a description see “Understanding the Status
Indicators” on page 3
Power-On-Self-Test (POST) Errors
When you reset the printer, a POST runs to determine why the printer
might be failing. Audible error codes, along with indicator light status,
are produced during POST if an error occurs. See on POST Error Codes
on page 104.
To perform a POST
1 Open the printer case.
2 Insert the printer diagnostic cable into the phone jack on the printer
and then connect the 9-pin D-Sub plug to your PC. The cable is used
during POST to configure the printer, access printer diagnostics,
update software, and install new fonts.
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Chapter 6 — Troubleshooting
3 Press the Reset button to start the POST. When the POST starts,
green Power LED will come on followed by a single beep indicating
that the printer is active.
Note: After the test is completed, all LEDs turn off and the
printhead moves to the home position. Only runtime errors or
fatal errors are reported until the next time the printer is reset
and POST is performed.
The printer emits beeps and flashes the LEDs to indicate the cause of any
POST errors. POST error codes are described in the following table.
POST Error Codes
Long
Beep
Short Paper Head
Beep Out
Jam
Low
Batt
Power Meaning
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
Off
On
Off
Off
On
On
Off
On
On
On
Off
Off
On
On
Off
Off
Off
Off
Off
On
Off
On
On
On
On
On
On
On
On
On
Off
On
On
On
Operational
No Power
Control program Initial Program Load (IPL)
successful
Invalid CRC on boot block
Invalid CRC on control program or program not
found
Upper 192K RAM failure
Upper 64K RAM failure
Diagnostic mode command check
Diagnostic flash memory check failed or is not
initialized
Diagnostic memory write failure
Control program IPL
Fatal Errors
There are two types of fatal errors, flash write errors and EEPROM
configuration block errors. These errors are extremely rare, but measures
are built into the printer diagnostics to track possible occurrences.
Flash Write Errors
Errors related to writing or erasing flash are critical errors. These errors
cause the printer to stop all processing and produce an LED code and a
sequence of beeps. The LED code indicates the address of the segment
where the error occurred in octal notation.
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Chapter 6 — Troubleshooting
The octal digit changes every four beeps until four octal digits are
output. Only four octal digits are output since blocks are 256 bytes in
size and flash can be addressed with a total of 0x7ff blocks. The segment
address output is the runtime address of the flash block and not the offset
of the block within flash.
To obtain the block offset within the flash
•
Subtract 0x800 from the address output to determine the block offset.
The printer suspends after the processing the error code. When the
printer resumes, an error again and the printer suspends again. Reset the
printer to correct the error. If a reset does not correct the error, have the
printer checked by a qualified service technician.
Note: Flash write errors may be unrecoverable.
EEPROM Configuration Block Errors
Errors related to an invalid configuration block (diagnostic block)
produce 13 beeps, and then the printer suspends. It continues to produce
this symptom until the configuration block error is corrected.
Configuration block errors may be caused by a flash write error or an
incorrect printer configuration. Reset the printer to correct the error. If a
reset does not correct the error, have the printer checked by a qualified
service technician.
Self-Test Function Descriptions
The self-test performs the following functions.
Boot Block Program Verification
A CRC (Cyclic Redundancy Check) is performed on the boot block
program. The calculated CRC is compared to the CRC embedded in the
program module.
Control Program Verification
A CRC is performed on the control program, which is loaded into
writable flash program memory. The calculated CRC is compared to the
CRC embedded in the program module. The results of this test are
printed on the self-test report.
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Chapter 6 — Troubleshooting
Font Module Verification
A CRC is performed on the font modules, which are loaded into writable
flash font memory. The calculated CRC is compared to the CRC
embedded in the program module. Results are printed on the self-test
report.
A2D Check
Current reading of the A2D sources are performed, and the results are
printed on the self-test report.
Nonvolatile Diagnostic Memory Verification
A CRC is performed on the area of the nonvolatile diagnostic memory
that has a CRC over it. Results are printed on the self-test report.
Nonvolatile Diagnostic Memory Update
The nonvolatile diagnostic memory is updated from the nonvolatile
diagnostic memory data shadowed in memory.
Detailed Printer Self-Test
Perform a self-test to verify printer functions, and provide reporting of
printer diagnostics. The self-test performs a series of internal diagnostics
and prints the results. When the self-test begins, the beeper sounds for
half a second and all LEDs turn on for half a second.
Initiating Self-Test
•
While the printer is idle or in Suspend mode, press the Line Feed and
Set Page buttons simultaneously to initiate a
self-test.
Terminating Self-Test
•
Press the Line Feed and Set Page buttons simultaneously to manually
terminate a self-test.
Self-Test Report
Note: This method is recommended to determine printer
functionality.
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6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
A self-test is equivalent to a warm start. Both are performed when you
simultaneously press Form Feed and Set Page buttons on the control
panel for a few seconds. Release the buttons when the printer beeps and
all indicators are lit. If you press the buttons for too long, the self-test
will not happen and the printer will form-feed one page.
As the self-test progresses, the indicator lights change. Internal tests are
performed and the two page report is printed. This report provides
helpful information in diagnosing and troubleshooting printer problems.
When you perform a self-test, the following actions occur:
•
All LEDs are turned on to verify the lights work
•
A 600 ms beep is emitted to verify the beeper works
•
LEDs flash individually to show progress during internal tests
•
Current voltage and ambient temperature are obtained
•
Validity of diagnostic block program is checked
•
Validity of boot block program is checked
•
Validity of control program is checked
•
Validity of loaded fonts is checked
•
LEDs turn off
•
Self-test report is printed
Printer capability is diagnosed by printing the report. Device errors are
displayed on the LEDs and emitted by the beeper. The printer then does
a warm reset (soft reboot) when an error is encountered or when the selftest report prints.
Understanding the Self-Test Report
The self-test report is divided into sections. Refer to page 110 and
page 111 for a sample printout. All other values are informational only.
Remember that these values are cleared after the self-test.
• The printer model number is given on line 1 (first line). This identifies
the printer type used, in this case the 6822.
• The 8-digit serial number of the printer is listed on line 4 under the
“Serial#” heading on line 3. The serial number is also on the inside of
the printer. In portable printers, raise the printer mechanism to look for
the number on the inside back wall.
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107
Chapter 6 — Troubleshooting
•
Battery Voltage, (line 13)
Indicates the input voltage sampled at the beginning of the self-test.
The input range must be between 7.5 and 15 V. The input voltage
must be greater than 10.5 V to charge the internal battery. At 7.5 V or
less, the Low Batt LED comes on and the printer enters Sleep mode.
At 10.5 V or less, the Low Batt comes on but the printer still prints.
•
Auto Feed (line 16)
Auto feed is a configurable item. Carriage Return (CR) means no
auto linefeed. This is the most common setting for applications using
NPCP CR+LF means a line feed will be added to each CR. This
setting can produce double-spacing of reports. See “Setting the
Autofeed” on page 29
•
Interface Mode (line 17)
Interface mode lists the interface protocol for the printer. The typical
setting is NPCP. Others include DTR with no, odd, or even parity,
and IrDA. See “Protocol Selection Mode” on page 29
•
Bit Rate (line 18)
Bit rate is commonly set to 19200 (19.2K) or 9600 bps. See
“Selecting the Bit Rate” on page 29
•
A2D History (lines 21 through 25)
Shows the recorded history for voltage measurements and
temperature measurements.
•
Head Jam History (lines 26 through 29)
Provides information on head jams. If the printer is having frequent
head jams, these lines can assist in determining the problem.
Head Jam History Information
Heading
Description
Home
Command
Err indicates the home position LED sensor has failed.
Indicates which printer command was executed when the
head jammed.
Indicates which way the head was moving, left is toward the
home position and right is away from the home position.
Home position is at the extreme left, toward the green thumb
wheel.
Indicates the acceleration speed of the printhead when the
jam occurred.
Direction
Speed
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Chapter 6 — Troubleshooting
Head Jam History Information (continued)
Heading
Description
Step
The acceleration step at the jam. 0 means no steps were
taken, 15 means all steps were taken. 1-14 indicates the
printer jammed during acceleration or deceleration.
The ambient temperature at the last head jam. The
temperature is listed in Celsius.
Position of carriage at the time of the jam in 1/720 in = 12 *
step position. Divide the number by 12 to get the step
position. There are 512 steps across the page. If it is jammed
at position 0, check the printer mechanism alignment. If it is
jamming in the middle, it is more likely a dirty ribbon or
obstruction in the printhead’s path.
Temp
Position
•
Head Dot Pattern (line 37)
Is used to verify the individual dot wires. There should be nine dots.
If some dots are missing, it could be a printhead failure or a circuit
board failure.
•
Error Log information appears on lines 38-43. This information is
cleared after every self-test.
Error Log Information
Heading
Description
PE
HJ
12Vu
12Vo
24Vu
24Vo
Home
Number of paper jams while feeding paper
Number of head jams while printhead is moving
Number of 12 V under-voltage
Number of 12 V over-voltage
Number of 24 V under-voltage (head/motor voltage)
Number of 24 V over-voltage
Number of home detect errors (typically caused by paper
scraps or circuit failures)
Unused
Number of head over-current errors (typically caused by a
bad printhead)
Number of head driver short errors (typically caused by
circuit failures)
Number of paper feed motor over current errors (excess
current in paper feed motor could indicate circuit failure)
Temp
OverC
HeadS
Fault
6822 Series 80-Column Printer User’s Manual
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Chapter 6 — Troubleshooting
Error Log Information (continued)
Heading
Description
ADErr
EEErr
Dlink
Number of A2D conversion failures
Number of EEPROM write failures to diagnostic block
Number of software memory errors (corruption in internal
memory)
Number of software memory errors
Llink
Sample First Page of the Self-Test
Note: Lines 15-18 are factory default printer settings. Take note
of these lines when reading the self-test report.
---------------------------------------------------------------------------------------------------------------------------------------- 1NP6822
2 Copyright 1997, 1998, Intermec Technologies Corporation. All Rights Reserved.
3Serial#
MFG Date
Hardware
Check Repairs Svc Date
412345678 yy/mm/dd ddd-ddd-ddd/dddd (TOP)
GO/NG
00
yy/mm/dd
ddd-ddd-ddd/dddd (MLB)
ddd-ddd-ddd/dddd (PS)
ddd-ddd-ddd/dddd (IOB)
8Revisions:..........0000000000303100
9Bootblock:
NPBB6822.MOD - Version XX.XX XXXX XXXX GO/NG
10Control Program:
npfl6822.mod - Version XX.XX XXXX XXXX GO/NG
11Font Module:
nftxxxxx.mod - Version XX.XX XXXX XXXX GO/NG
12Font Module:
nftxxxxx.mod - Version XX.XX XXXX XXXX GO/NG
13Battery Voltage:
012.34
Low...../....High
14Total Pages:
123456
15Zero Font Style:
16Auto Feed:
CR
17Interface mode:
NPCP
18Bit Rate:
19200
19Cold Starts:
00024
20Warm Starts:
00050
21A2D History
22
Curr
Low
High
Min
Max
Error
Page
Count
2324v: 024.00
023.21
023.91
023.21
024.51
027.21
00401
00021
2412v: 012.55
010.91
013.51
010.90
014.50
8.71
00401
00021
25Temp:
023
-020
055
-021
060
000
00401
00021
26Head Jam History
27Total Head Jams:
00186
28Home Command Direction Speed
Step Temp Position Page
29
Print
Left
Const
010 -010
01440
12345
30NPCP History
31Disc
Addr
Parity IFTS
Seq
CRC
Frame
Bind
IPLDU
3212345
12345
12345
12345
12345
12345
12345
12345 12345
33IRDA History
34
FramesOk
BroadCasts CRC/TMO
DISCARD
35rx
1234567890 1234567890 0123456789 0000000000
36tx
1234567890 1234567890 0123456789 0000000000
37HEAD DOT PATTERN
38 Error Log
39PE
HJ
12Vu
40Dlink Llink
4112345 12345 12345
4212345 12345 12345
4312345 12345 12345
110
12Vo
24Vu
24Vo
Home
Temp
OverC HeadS Fault ADErr EEErr
12345 12345 12345 12345 12345 12345 12345 12345 12345 12345
12345 12345 12345 12345 12345 12345 12345 12345 12345 12345
12345 12345 12345 12345 12345 12345 12345
6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
Sample Second Page of the Self-Test
Page 2 of the self-test contains the print pattern used to diagnose printer
mechanical behavior. The pattern continuously prints the ASCII
characters between 33 and 126 decimal inclusive for the entire page, or
until you cancel the print by pressing a button on the printer. An example
of that rotating pattern is shown below.
!”#$%’()*+,–./
0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_’abcdefghijklmnopqrstuvwxyz{|}~!”#$%’
()*+,–./
0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_’abcdefghijklmnopqrstuvwxyz{|}~!”#$%’
()*+,–./
0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_’abcdefghijklmnopqrstuvwxyz{|}~!”#$%’
()*+,–./
0123456789:;<=>?@ABCDEFGHIJKL
Self-Test Failure
•
For help, see “Miscellaneous Troubleshooting Tips” on page 111.
•
Check the power source (internal battery, charge cable, or ac adaptor)
for a possible power failure.
Miscellaneous Troubleshooting Tips
The following table lists actual printing problems, possible causes, and
actions you should take to correct a problem.
Possible Printer Problems
Symptom
Test or Cause
Solution
Printer does not communicate Incorrect protocol selection.
with the mobile computer.
Bluetooth unable to connect.
Check lines 17 and 18 on the self-test
report for correct bit rate and protocol
selection. Change protocol settings
through configuration process.
Make sure you are in range
Make sure your device is
Make sure the Bluetooth shutdown
(10 cm to 10 m)
configured to be discoverable timer has not expired
and/or connectable. For help,
see “Bluetooth Configuration
Commands and
Specifications” on page 133.
Check line 16 on the self-test For help, see “Cleaning the Mask
Double-spacing on
application reports but single- report. CR+LF indicates an Spring” on page 22.
incorrect configuration for
spacing on
NPCP.
self-test.
Zero prints incorrectly (with Check line 15 on the self–test If incorrect, adjust the zero print
or without slash).
report for the Zero Font Style option, see “Cleaning the Mask
setting.
Spring” on page 22
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111
Chapter 6 — Troubleshooting
Possible Printer Problems (continued)
Symptom
Test or Cause
Solution
Does not print extended
Check line 11 or 12 on the
character set — missing font. self–test report to see if the
NFT0000.MOD file is listed
after Font Module.
Printer emits 1 or 2 beeps or Printer mechanism does not
blinking green light is the
have adequate power for
only indicator.
printing. The 12 V may be
under or over voltage fault.
(Note: Error lights do not
flash if voltage is too high)
If battery, recharge or replace If power supply, adjust supply
(see “Installing the Internal voltage to 7.5 to 15 V.
Battery” on page 10
Use the 6820 Printer Tool Kit to reload
the font file or send the printer in for
hardware repair.
Check battery or power supply.
Check the printer’s internal battery, if
installed. Check the vehicle charge
cable (see 6822 Printer Installation
Instructions P/N 931-052-001).
Printer emits 2 sets of 3 beeps Printer out of paper
Reload paper into printer mechanism.
For help, see “Loading the Paper Tray”
on page 13.
Printer works but some or all Gray ribbon cable connecting Call Customer Support
LEDs do not work.
control panel board to pivot (800-755-5505) or send printer for
frame assembly is loose.
hardware repair.
Printer does not print
No voltage
Voltage too high or low. Check line 13
on the self–test report, under the
Battery Voltage heading
No paper feed (paper jam or head jam)
No data input
Adjust supply voltage to
7.5-15 V
Tighten computer
connections.
Test: Pull paper toward roller. Paper tray too full
Cause: If paper is resistant:
Paper wrinkled, creased,
White ribbon cables
moist, or perforations missing obstructing paper
Torn paper perforation
Ensure fewer than 200 3-ply
sheets in the deep paper tray
and fewer than 50 3-ply
sheets in the shallow paper
tray.
112
Head Jams due to carriage alignment.
Check line 29 on self-test report, under
Position heading, for value.
Remove torn paper, load and center
new paper, readjust pinfeed holders.
6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
Possible Printer Problems (continued)
Symptom
Test or Cause
Replace the paper.
Straighten the white ribbon
cables.
Solution
If “0,” realign mechanism in pivot tray.
See “Aligning the Printer
Mechanism” on page 98
No paper feed (paper jam or Move the printhead manually Remove ribbon cartridge, move
head jam)
from side to side.
printhead. If smooth, ribbon is
jammed.
Remove ribbon cartridge, move
printhead. If still resistant, mask spring
is bent or damaged.
Remove ribbon cartridge and
Cause: printhead gap
turn knob. If ribbon resists,
adjuster too tight.
replace ribbon cartridge (see
Cause: Paper scraps found in “Installing the Ribbon
printer mechanism or around Cartridge” on page 11
Replace the mask spring see
platen.
“Cleaning the Mask
Printer mechanism unlatched Spring” on page 22
(unlocked). (portable, fixed
Set the head gap adjuster to
mount printers)
the fifth notch away from the
paper see “Adjusting the
Printhead Gap” on page 12
If ribbon cartridge bumps
against inside of printer,
check white ribbon cable,
home position sensor, and
four screws.
Remove any paper scraps, do
a cleaning.
Latch (lock) the printer
mechanism into place.
Perform a self-test.
Note: In paper jams or head jams, press the Set Page button to
clear the printer before printing can resume.
6822 Series 80-Column Printer User’s Manual
113
Chapter 6 — Troubleshooting
Compatibility Issues
Use the following information to determine some compatibility issues
that come up relative to the 6822:I
Compatibility Issues and Conclusions
Issue
Conclusion
Does a 6820 ribbon work on the 6822?
Do 6820 applications work on the 6822?
Yes.
Yes. Applications that work on the 6820 also work on
the 6822.
Does the 6822 work with an application
Yes. The downloadable character set feature is the same
that downloads some custom characters to for both the 6820 and 6822.
the printer?
Can 6820 printers be replaced with 6822s? Yes. 6822s can be installed on existing 6820 mounting
brackets.
Understanding Diagnostic Information
Diagnostic information is stored in flash to support the hardware
configuration, both at time of manufacture and in the field. This includes
recording the initial configuration changes to hardware and software,
and various environmental statistics helpful in determining why failures
are occurring in the field. The flash is provided for storage of critical
data that must remain in the unit after power to the unit is lost. The data
in the flash is used for diagnostic information for a catastrophic failure,
or over the phone with a customer.
Diagnostic information is updated and maintained by the printer. All
diagnostic information is shadowed in RAM. At the end of every 50
forms, the flash information is updated from the RAM. The printer also
updates the diagnostic information for nonrecoverable error, printer
resets, printer self-test, and remote polling of diagnostic information.
Fields are stored with ID first, then length, then data. The details of the
data and the length of the entire field, including ID and Length bytes, are
shown in the “Diagnostic Information” table on page 115.
The amount of flash memory reserved for nonvolatile diagnostic
memory is 16 K bytes. Printer self-test prints most of the information
contained in the diagnostic memory for remote and end-user diagnostic
access.
114
6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
Diagnostic Information
Field
Id
01
08
Stored as
7 digit BCD set at MFG 39 bytes
6 digit BCD set at MFG
52 digit BCD set at
MFG
09
10
20
30
Total
Length
Length Description
Serial Number
Date of Manufacture, yy/mm/dd
Hardware Configuration
ddd-ddd-ddd/ddd (top level P/N)
ddd-ddd-ddd/ddd (control board)
ddd-ddd-ddd/ddd (power supply)
ddd-ddd-ddd/ddd (I/O board)
CRC of preceding fields
Hardware Revisions: ECNs. applied. 64
ECNs can record separately by number 1-64.
Service Repairs: a two-digit field indicating
number of times serviced
Date of last repair, yy/mm/dd
Cold starts since MFG or last repair
Warm starts since last cold start
Pages printed over life
Last high and low voltage extremes on 24 V
input over last 50 reports. Extremes stored as
8-bit A2D conversions
Voltage extreme history stores min/max 24 V
A2D conversions over printer life
24 V voltage error. Voltages greater than 10%
considered errors. A2D error count
Form number at last voltage error
24 V error count
Last high and low voltage extremes on 12 V
input over last 50 reports. Extremes stored as
8-bit A2D conversions
Voltage extreme stores min/max 12 V A2D
conversions over printer life
12 V error. Voltages less than 10.5 V and
greater than 14.5 V are considered errors.
A2D value is recorded
Page number at last 12 V error
12 V error count
Temperature, maximum and minimum over
last 50 reports. Set A2D value
6822 Series 80-Column Printer User’s Manual
2 byte binary set at MFG
8 byte bit field
11 bytes
2 BCD digits
6 BCD digits
binary digits
binary digits
binary digits
2 bytes
8 bytes
11 bytes
2 bytes
1 byte
2 bytes
2 bytes
2 bytes
11 bytes
2 bytes
1 byte
2 bytes
2 bytes
2 bytes
11 bytes
115
Chapter 6 — Troubleshooting
Diagnostic Information (continued)
Field
Id
Length Description
Stored as
Temperature, min/max over printer life. Set
A2D value
Temperature error. Last A2D conversion
below -10 or above 60°C recorded
Page number at last temperature error
Total number of temperature errors
Total number of head jams
Command
0 = Stop
2 = Print
4 = Print/LF
6 = Seek
8 = Slow Seek
10 = Change Speed
12 = Feed
14 = Wait
2 bytes
Speed
00 = Init
01 = Low
10 = High
bits 4-5
Direction
1 = Left
0 = Right
bit 6
Home Switch
0 = No Error
1 = High Error
Acceleration or deceleration stop motor value
when jam occurred
Ambient temperature when had jam
occurred. Set A2D value
Form number where head jam occurred
Carriage position where head jam occurred
bit 7
40
60
116
IrDA rxFramesOK – total frames received
OK
Total
Length
1 byte
2 bytes
2 bytes
2 bytes binary
bits 0-3
11 bytes
1 byte binary
1 byte
2 bytes binary
2 bytes binary in 1/720
in
4 bytes
46 bytes
6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
Diagnostic Information (continued)
Field
Id
Length Description
Stored as
4 bytes
70
IrDA rxFrameCrcErr – total frames received
with CRC error
IrDA rxTotalBytes – total bytes received OK
IrDA rxFramesDiscardBuf – total frames
discarded due to no buffer space
IrDA rxBroadcastFrames – total broadcast
frames received OK
IrDA rxFramesDiscardHwErr – total
received frames discarded due to hardware
error
IrDA txFramesOK – total frames transmitted
OK
IrDA txTotalBytes – total bytes transmitted
OK
IrDA txBroadcastFrames – total broadcast
frames transmitted OK
IrDA txFramesNotTxTimeout – total frames
not transmitted due to time out
IrDA txFramesNotTxHwErr – total frames
not transmitted due to a hardware error
Paper out count
Head jam count
12 V low count
12 V high count
24 V low count
24 V high count
Home switch error count
Unused
Over current error count
Head short error count
Paper fault error count
A2D conv. error count
EEPROM write error count
Double link error count
Lost link error count
6822 Series 80-Column Printer User’s Manual
Total
Length
4 bytes
4 bytes
4 bytes
4 bytes
4 bytes
4 bytes
4 bytes
4 bytes
4 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
2 bytes
74 bytes
117
Chapter 6 — Troubleshooting
Diagnostic Information (continued)
Field
Id
118
Length Description
Stored as
2 bytes
20 * 2 bytes
Out of buffers error count
Unused
Total
Length
6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
Communications Pin-Out Configurations
This section shows common cable configurations between a mobile
computer or a dock and the printer.
Wall Mount Printer or
Remote Mount Terminal Holder
Mobile Computer
Signal Name
Pin #
Chassis Ground
Charge Input
SG (Signal Ground)
DSR (Data Set Ready)
DTR (Data Terminal Ready)
CTS (Clear To Send)
RTS (Ready To Send)
RXD (Receive Data)
TXD (Transmit Data)
Dock_A/B_SW
shell
NC
Pin #
Signal Name
20
12
NC (No Connection)
HHC_CHARGE
GND
DTR
NC
RTS
CTS
TXD
RXD
Term A/B
shield
13
25
15
14
15-Pin DSUB Male
15-Pin to 25-Pin Cable (P/N 216-605-1XX)
25-Pin DSUB Male
15-Pin to 25-Pin Cable (P/N 216-605-1XX)
6822 Series 80-Column Printer User’s Manual
119
Chapter 6 — Troubleshooting
Wall Mount Printer
PC
Signal Name
Pin #
Pin #
Signal Name
DTR (Data Terminal Ready)*
RC (Receive Carrier)
TC (Transmit Carrier)
DCD (Data Carrier Detect)
SG (Signal Ground)
DSR (Data Set Ready)*
CTS (Clear to Send)
RTS (Ready to Send)
RXD (Receive Data)
TXD (Transmit Data)
20
17
15
20
17
15
NC (No Connection)
NC
NC
NC
GND
DTR
RTS
CTS
TXD
RXD
* Signals are not available on the 6100 Dock
14
13
25
13
25
14
25-Pin DSUB Male
25-Pin DSUB Female
25-Pin to 25-Pin Cable (P/N 216-771-XXX)
25-Pin to 25-Pin Cable (P/N 216-771-XXX)
120
6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
Printer
PC
Signal Name
Pin #
Pin #
Signal Name
TXD (Transmit Data)
RXD (Receive Data)
RTS (Ready to Send)
CTS (Clear to Send)
DSR (Data Set Ready)
SG (Signal Ground)
RCT
TXD
CTS
RTS
DTR (Data Terminal Ready)
GND
Chassis Ground
shell
shell
Chassis Ground
Terminal Charge out to computer
shield
15
9-Pin DSUB Female
9-Pin to 15-Pin Cable (P/N 226-016-XXX)
15-Pin DSUB Female
9-Pin to 15-Pin Cable (P/N 226-016-XXX)
6822 Series 80-Column Printer User’s Manual
121
Chapter 6 — Troubleshooting
Printer w/6210 Terminal Holder
Dock
Signal Name
Pin #
Pin #
Signal Name
TXD (Transmit Data)
DTR (Data Terminal Ready)
RTS (Ready to Send)
RXD (Receive Data)
CTS (Clear to Send)
DSR (Data Set Ready)*
SG (Signal Ground)
20
RXD
NC (No Connection)
CTS
TXD
RTS
DTR
GND
open
shield
shell
* Signal is not available on the 6100 Dock
13
25
14
15
15-Pin DSUB Female
25-Pin DSUB Male
25-Pin to 15-Pin Cable (P/N 226-162-XXX)
25-Pin to 15-Pin Cable (P/N 226-162-XXX)
122
6822 Series 80-Column Printer User’s Manual
Chapter 6 — Troubleshooting
Printer
PC
Pin #
Pin #
RJ-11 Jack
9-Pin DSUB Male
Data Communications Cable (P/N 226-270-XXX)
Data Communications Cable (P/N 226-270-XXX)
The printer has a 25-pin connector with the following pinout
designations and signal mnemonics:
Printer Communications Connector
15-Pin 25–Pin
D–Sub D–Sub Signal Name
Type
I/O
Description
–––
RS-232
RS-232
RS-232
RS-232
RS-232
–––
IN
IN
IN
OUT
OUT
NC (No Connection)
Printer’s DSR
Wake up
Printer’s RxD
Printer’s TxD
Printer’s RTS
NC
20
NC
DSR (Data Set Ready)
CTS (Clear To Send)
RXD (Receive Data)
TXD (Transmit Data)
RTS (Ready To Send)
6822 Series 80-Column Printer User’s Manual
123
Chapter 6 — Troubleshooting
Printer Communications Connector (continued)
15-Pin 25–Pin
D–Sub D–Sub Signal Name
Type
I/O
Description
RS-232
OUT
Printer’s DTR
POWER
POWER
OUT
11-13 V, 2 A maximum
SG (Signal Ground)
124
DTR (Data Terminal
Ready)
HHC_CHARGE
GND
6822 Series 80-Column Printer User’s Manual
A
Specifications
This appendix provides physical specifications for the 6822
printer models as well as specifications for the media used with
the printers.
6822 Series 80-Column Printer User’s Manual
125
Appendix A — Specifications
Specifications
Print Speed
230 cps
Note: Various print fonts do affect the print speed.
Weight
Fixed Mount Printers6.55 kg (14.41 lbs)
Portable Printers
w/ 4000 or 61XX terminal holder5.80 kg (12.75 lbs)
w/ 62XX, 600 series, 700 series, or CK60 holder5.67 kg (12.25 lbs)
Mounting plate1.93 kg (4.25 lbs)
Flat paper tray2.45 kg (5.40 lbs)
Compact paper tray2.05 kg (4.50 lbs)
Temperature
DC Operating -20°C to 60°C (-4°F to 140°F)
AC Operating -20°C to 45°C (-4°F to 113°F)
Storage -30°C to 70°C (-22°F to 158°F)
Humidity
Operating10 to 85% noncondensing
Storage5 to 95% noncondensing
Altitude
Operating–100 to 5000 m
Storage15,000 m
Electrical
Voltage13.8 VDC (nominal)
Current10 mA (idle, sleep mode not charging batteries);
3.5 A (average while printing);
450 mA (charging internal battery);
Up to 1.5 A (charging computer battery)
Vibration
12 g RMS for 4 hours
126
6822 Series 80-Column Printer User’s Manual
Appendix A — Specifications
ESD
15 kV noncontact and 8 kV contact
Battery Shelf Life
1 year at 25°C (77° F)
2.3 Ah
12 V sealed lead-acid)
Note: The battery goes dead within two weeks when connected
to the printer and with no external charge source.
Note: A printer and a computer, using the supplied serial cable,
can operate up to 9 m (30 ft) apart.
Printer Dimensions
Listed below are the dimensions of the fixed mount and portable
printers.
Fixed Mount Printer
The base of the fixed mount printer is 32.5 cm (12.75 in) wide by
35.5 cm (14.0 in) front to back. The upper portion varies according to the
configurations shown in the following table.
Fixed Mount Printer Dimensions
Configuration
(with deep paper tray)
with 61XX Holder Side Mount
with 4000 Series, 62XX, 600 Series, 700 Series, or CK60
Holder Side Mount
with 61XX Holder Top Mount
with 4000 Series, 62XX, 600 Series, 700 Series, or CK60
Holder Top Mount
6822 Series 80-Column Printer User’s Manual
Width
Length
Depth
51.4 cm
(20.25 in)
47.0 cm
(18.5 in)
42.5 cm
(16.75 in)
38.1 cm
(15.0 in)
36.8 cm
(14.5 in)
36.8 cm
(14.5 in)
42.6 cm
(16.75 in)
42.6 cm
(16.75 in)
19.1 cm
(7.5 in)
20.3 cm
(8.0 in)
19.1 cm
(7.5 in)
20.3 cm
(8.0 in)
127
Appendix A — Specifications
Portable Printer
The portable printer may come with a handle, an AC foot, or with a
terminal holder top mount.
Portable Printer Dimensions
Configuration
Width
with handle, 61XX Holder Top Mount, and Deep Paper
41.9 cm
Tray
(16.5 in)
with handle, 61XX Holder Top Mount, Shallow Paper Tray 42.5 cm
(16.8 in)
with handle, 4000 Series, 62XX, 600 Series, 700 Series, or 38.1 cm
CK60 Holder Top Mount, and Deep Paper Tray
(15.0 in)
with handle, 4000 Series, 62XX, 600 Series, or 700 Series, 41.9 cm
or CK60 Holder Top Mount or Fill Plate, and Shallow Paper (16.5 in)
Tray
Length
Depth
42.6 cm
(16.8 in)
42.6 cm
(16.8 in)
42.6 cm
(16.8 in)
38.1 cm
(15.0 in)
20.3 cm
(8.0 in)
19.1 cm
(7.5 in)
20.3 cm
(8.0 in)
13.0 cm
(5.1 in)
Note: The AC foot adds 6.35 cm (2.5 in) to the length of the
printer.
Media Specifications
Using paper that matches the following specifications
ensures optimum 6822 performance. Variation from these
specifications, use of aged paper, or use of paper exposed to
elements such as dirt or humidity may cause printing
problems.
The printer works with 1-3 ply carbonless paper that is single-edge glued
and designed for sprocket feed. Standard paper size is 8.5 x 11 in or 241
x 305 mm international (8.5 x 12 in). Use 3-ply forms up to a maximum
of 0.23 mm (0.009 in) thick.
A soft, flexible, rubber type cement applied to one perforation strip only
is preferred. The paper should wrap around a 1 1/4 in diameter roll
without curl or wrinkle.
128
6822 Series 80-Column Printer User’s Manual
Appendix A — Specifications
Material Breakdown
The following tables show the material broken down per ply:
14# CBF (Carbonless Back and Front)
Target
Under
Over
Basis Weight
14 lb
13.3 lb
14.7 lb
Caliper
2.9
2.6
3.2
Moisture
5.0
4.0
6.0
Smoothness (RS)
165
110
230
Smoothness (CB)
270
220
320
Brightness (Wht)
88
86
90
Colors available: White, Canary, Pink, Goldenrod, Blue, Green
15# CF (Carbonless Front)
Target
Under
Over
Basis Weight
15 lb
14.43 lb
15.8 lb
Caliper
3.0
2.5
3.2
Moisture
5.0
4.0
6.0
Smoothness (RS)
140
100
180
Smoothness (CB)
140
100
180
Brightness (Wht)
85
84
86
Colors available: White, Canary, Pink, Goldenrod, Blue, Green
16# CB (Carbonless Back)
Target
Under
Over
Basis Weight
16 lb
15.2 lb
16.8 lb
Caliper
3.3
2.8
3.8
Moisture
5.7
4.2
6.7
Smoothness (RS)
180
120
270
Smoothness (CB)
270
220
320
Brightness (Wht)
86
84
88
Opacity (Wht)
81
78.5
82
Colors available: White, Canary, Pink, Goldenrod, Blue, Green
6822 Series 80-Column Printer User’s Manual
129
Appendix A — Specifications
20# OCR Laser Bond
Basis Weight
Caliper
Moisture
Smoothness
Brightness (Wht)
Opacity (Wht)
Target
Under
Over
20 lb
4.0
3.8
140
94
85
15.2 lb
3.8
4.7
100
82
84
16.8 lb
4.2
5.0
170
N/A
N/A
Caliper Breakdown
The following table shows the caliper of forms broken down by ply:
Caliper Breakdown
1-Ply (20 lb)
2-Ply (15 lb and 16 lb)
3-Ply (14 lb, 15 lb, and 16 lb)
130
Target
Maximum
4.0
6.3
9.2
4.2
7.0
10.2
6822 Series 80-Column Printer User’s Manual
Appendix A — Specifications
Understanding the Fanfold Paper Page Layout
The following illustration shows the printable area of the lower section
of a page of fanfold paper and the upper section of the next page. The
Assured Print Area is the best area to use for printing.
Page width
Assured Print Area
8 inches Max.
(area 2)
0.75 inch
(or more)
Assured Print Area
55 lines max
(at 1/16” line spacing)
(area 2)
0.75 inch
(or more)
Paper End
Detection Position
Abcdef...
1 inch
...Xyz
(area 3)
1.833 inches
(11 lines)
(area 1)
Perforation
1 inch
(area 1)
Abcdef...
...Xyz
Printable Area of Fanfold Page
You should leave a 1 in margin at both the top and the bottom of the
page. This provides for a margin of six lines at 1/6 in line spacing. Even
though printing in Area 1 (before or after the perforation) may be
possible, you should keep in mind that paper feed precision is reliable
only within the Assured Print Area.
6822 Series 80-Column Printer User’s Manual
131
Appendix A — Specifications
•
The top and bottom margins are represented by Area 1, as shown in
the previous illustration. The top margin is defined as the distance
between the top edge of the paper and the first row of printed
characters. The bottom margin is defined as the distance between the
last row of printed characters and the bottom edge of the paper.
•
There is a possibility that printing can start within one line below the
perforation and printing could continue beyond the Assured Print
Area, however paper feed precision is only reliable with top and
bottom margins of approximately one inch. Basically, you should
consider there are only 55 lines available for reliable printing.
•
The left and right margins are represented by Area 2. For reliable
printing, use a margin of at least 0.75 in for the left and right margins.
The Paper End Detection line indicates the point where the Paper Out
sensor detects the bottom edge of the paper.
Area 3 represents the distance between the Paper End Detection position
and the bottom edge of the page.
Once the last page of the fanfold paper stack is in the printer, and the
printhead has advanced past this Paper End Detection line, printing is no
longer reliable.
When the bottom end of the last page has advanced through the printer,
past the spring plate along the front of the platen, the paper should not
reverse back through the printer, because the printer could jam and cause
paper feed problems.
132
6822 Series 80-Column Printer User’s Manual

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