PM4i Service Manual

Service Manual

EasyCoder® PM4i

Bar Code Label

Printer

ii EasyCoder PM4i Bar Code Label Printer Service Manual

Intermec Technologies Corporation

Worldwide Headquarters6001 36th Ave.W.Everett, WA 98203U.S.A.

www.intermec.com

Th e information contained herein 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 Technologies Corporation.

Information and specifi cations contained in this document are subject to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation.

© 2005-2007 Intermec Technologies Corporation. All rights reserved.

Th e word Intermec, the Intermec logo, Norand, ArciTech, Beverage Routebook, CrossBar, dcBrowser, Duratherm, EasyADC, EasyCoder, EasySet, Fingerprint, INCA (under license), i-gistics, Intellitag, Intellitag Gen2, JANUS, LabelShop, MobileLAN, Picolink, Ready-to-Work, RoutePower, Sabre, ScanPlus, ShopScan, Smart Mobile Computing, SmartSystems, TE 2000, Trakker Antares, and Vista Powered are either trademarks or registered trademarks of Intermec Technologies Corporation.

Th ere are U.S. and foreign patents pending.

Th e name Centronics is wholly owned by GENICOM Corporation.

Microsoft is a registered trademark of Microsoft Corporation.

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

TrueDoc is a registered trademark of Bitstream, Inc.

TrueType is a trademark of Apple Computer Inc.

Unicode is a trademark of Unicode Inc.

Windows is a trademark of Microsoft Corporation.

EasyCoder PM4i Bar Code Label Printer Service Manual iii

ContentsBefore You Begin .................................................................................................................vii

1 Models and Options

1.1 Identifi cation ..................................................................................................................21.2 EasyCoder PM4i Printer Specifi cations ..........................................................................71.3 EasyCoder PM4i Printer Dimensions ..............................................................................9

2 Front and Keyboard

2.1 Front..................... ........................................................................................................142.2 Keyboard ......................................................................................................................152.3 Console PCB ................................................................................................................16

3 Covers and Doors

3.1 Right-Hand Door .........................................................................................................203.2 Front and Left-Hand Cover ..........................................................................................213.3 Front Door ...................................................................................................................22

4 Chassis

4.1 Description........... ........................................................................................................244.2 Center Section ..............................................................................................................254.3 Bottom Plate .................................................................................................................25

5 Media Supply

5.1 Internal Supply .............................................................................................................285.2 Label Slack Absorber .....................................................................................................315.3 Print Mechanism Edge Guide .......................................................................................325.4 Internal Fan-Fold Guide ................................................................................................33

6 Transfer Ribbon Mechanism

6.1 Description........... ........................................................................................................366.2 Ribbon Supply Unit ......................................................................................................376.3 Ribbon Rewind Unit .....................................................................................................386.4 Ribbon Sensor ...............................................................................................................396.5 Ribbon Motor ...............................................................................................................416.6 Front Ribbon Break Shaft .............................................................................................426.7 Printhead Ribbon Break Shaft .......................................................................................43

7 Print Mechanism

7.1 Description............. ......................................................................................................467.2 Platen Roller ................................................................................................................497.3 Stepper Motor ...............................................................................................................517.4 Belts ..............................................................................................................................537.5 Label Stop Sensor ..........................................................................................................547.6 Printhead ......................................................................................................................607.7 Headlift Sensor .............................................................................................................667.8 Headlift Mechanism ......................................................................................................687.9 Media Feed Principles ..................................................................................................72

iv EasyCoder PM4i Bar Code Label Printer Service Manual

8 Liner Takeup Unit

8.1 Description........... ........................................................................................................768.2 Takeup Unit Parts .........................................................................................................778.3 Fitting a Liner Takeup Unit ...........................................................................................788.4 Replacing the Timing Belt .............................................................................................78

9 Label Taken Sensor

9.1 Description.. .................................................................................................................809.2 Replacement .................................................................................................................819.3 Activating the LTS ........................................................................................................819.4 Adjustment ...................................................................................................................82

10 Paper Cutter

10.1 Description .................................................................................................................8410.2 Installation ..................................................................................................................8510.3 Controlling the Cutter ................................................................................................8610.4 Media Load .................................................................................................................8610.5 Servicing .....................................................................................................................8710.6 Cutter PCB .................................................................................................................89

11 Electronics Compartment

11.1 Introduction ...............................................................................................................9411.2 Accessing the Electronics Compartment ......................................................................9411.3 Main Parts ..................................................................................................................95

12 Power Supply

12.1 Description .................................................................................................................9812.2 Replacing the Power Supply Unit ..............................................................................10012.3 Components .............................................................................................................10212.4 Schematics ................................................................................................................104

13 CPU Board

13.1 Description ...............................................................................................................10813.2 Circuits .....................................................................................................................10913.3 Connections ..............................................................................................................11413.4 Test Points .................................................................................................................11513.5 Startup ......................................................................................................................11613.6 Components .............................................................................................................11713.7 Schematics ................................................................................................................11913.8 Replacing the CPU board .........................................................................................128

14 Interfaces

14.1 Introduction .............................................................................................................13014.2 RS-232 Serial Communication Port ("uart1:") ..........................................................13114.3 USB Interface ("usb1:") ............................................................................................13214.4 Bar Code Wand Interface (wand:) .............................................................................13314.5 Installing an Optional Interface Board ......................................................................13414.6 Serial/Industrial Interface Board (not IPL) ................................................................13814.7 Double Serial Interface Board (not IPL) ....................................................................14814.8 RFID Serial Interface Board ......................................................................................158

EasyCoder PM4i Bar Code Label Printer Service Manual v

14.9 IEEE 1284 Parallel Interface Board ...........................................................................16614.10 EasyLAN Ethernet Interface Board .........................................................................17014.11 EasyLAN Wireless Interface Board ..........................................................................175

15 RFID

15.1 Key Components of Intermec RFID Kits ..................................................................18215.2 Verifying RFID functionality ....................................................................................187

16 Troubleshooting

16.1 Diagnosing.......... ......................................................................................................19016.2 No Reaction at Power Up ..........................................................................................19216.3 Printer Stops Working After Startup ..........................................................................19316.4 CPU Board Failures ..................................................................................................19416.5 Power Supply Unit Failures .......................................................................................19516.6 Console Errors ..........................................................................................................19616.7 Error Messages ..........................................................................................................19816.8 No Communication (general) ...................................................................................20016.9 No Serial Communication .......................................................................................20116.10 Network Communication Troubles .........................................................................20316.11 Sensor Malfunctions ...............................................................................................20716.12 Printing Troubles .....................................................................................................21016.13 Transfer Ribbon Troubles .......................................................................................21416.14 Liner Takeup Troubles .............................................................................................21616.15 Memory Card Troubles ...........................................................................................21716.16 Paper Cutter Troubles ..............................................................................................21816.17 RFID Troubles ........................................................................................................220

A Program Overviews

Intermec Shell v8.0 Overview ...........................................................................................226Setup Mode Overviews .....................................................................................................227

B Firmware Upgrading

Introduction............... ......................................................................................................244General Principles .............................................................................................................244Upgrading From a Memory Card .....................................................................................245Upgrading From the Host .................................................................................................247

vi EasyCoder PM4i Bar Code Label Printer Service Manual

EasyCoder PM4i Bar Code Label Printer Service Manual vii

Before You Begin

Th is section provides you with safety information, technical support infor-mation, and sources for additional product information.

Safety Summary

Your safety is extremely important. Read and follow all warnings and cau-tions in this document before handling and operating Intermec equipment. You can be seriously injured, and equipment and data can be damaged if you do not follow the safety warnings and cautions.

Do Not Repair or Adjust AloneDo not repair or adjust energized equipment alone under any circum-stances. Someone capable of providing fi rst aid must always be present for your safety.

First AidAlways obtain fi rst aid or medical attention immediately after an injury. Never neglect an injury, no matter how slight it seems.

ResuscitationBegin resuscitation immediately if someone is injured and stops breath-ing. Any delay could result in death. To work on or near high voltage, you should be familiar with approved industrial fi rst aid methods.

Energized EquipmentNever work on energized equipment unless authorized by a responsible authority. Energized electrical equipment is dangerous. Electrical shock from energized equipment can cause death. If you must perform autho-rized emergency work on energized equipment, be sure that you comply strictly with approved safety regulations.

Sicherheitsübersicht

Ihre Sicherheit ist äußerst wichtig. Lesen und befolgen Sie alle Warn- und Vorsichtshinweise in diesem Dokument, bevor Sie Intermec-Geräte ver-wenden und betreiben. Falls die Sicherheitswarnungen und Vorsichtshin-weise nicht befolgt werden, kann es zu ernsthaften Verletzungen sowie Geräteschäden und Datenverlusten kommen.

Nicht alleine Reparaturen oder Einstellungen durchführenReparieren oder justieren Sie niemals alleine stromführende Geräte. Aus Sicherheitsgründen muss eine zweite Person anwesend sein, die erste Hilfe leisten kann.

Erste HilfeNach einer Verletzung unverzüglich erste Hilfe oder medizinische Betreuung aufsuchen. Verletzungen dürfen nicht vernachlässigt werden, auch wenn sie noch so unbedeutend erscheinen.

WiederbelebungWiederbelebungsversuche müssen unverzüglich eingeleitet werden, falls jemand verletzt wird und die Atmung aussetzt. Verzögerungen können zum Tod führen. Bei Arbeiten an oder in der Nähe von Hochspannung müssen Ihnen die zugelassenen Erste-Hilfe-Methoden vertraut sein.

viii EasyCoder PM4i Bar Code Label Printer Service Manual

Stromführende GeräteNiemals an stromführenden Geräten arbeiten, es sei denn Sie wurden von einer verantwortlichen Stelle dazu berechtigt. Stromführende Geräte sind gefährlich. Stromschläge durch stromführende Geräte können zu tödlichen Verletzungen führen. Falls zugelassene Notreparaturen an stromführen-den Geräten vorgenommen werden müssen, ist darauf zu achten, dass die genehmigten Sicherheitsvorschriften strikt eingehalten werden.

Safety Information

Your safety is extremely important. Read and follow all warnings and cau-tions in this document before handling and operating Intermec equipment. You can be seriously injured, and equipment and data can be damaged if you do not follow the safety warnings and cautions.

Th is 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.

Warnung: Ein Warnhinweis macht Sie auf ein Betriebsverfahren, eine Praktik, einen Zustand oder eine Anweisung aufmerksam, die genauestens befolgt werden muss, um schwere oder tödliche Verletzungen der an den Maschinen arbeitenden Personen zu vermeiden.

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.

Vorsicht: Ein Vorsichtshinweis macht Sie auf ein Betriebsverfahren, eine Praktik, einen Zustand oder eine Anweisung aufmerksam, die genauestens befolgt werden muss, um Schäden oder eine Zerstörung der Maschine bzw. die Zerstörung oder den Verlust von Daten zu ver-meiden.

Th is icon appears at the beginning of any procedure in this manual that could cause you to touch components (such as printed circuit boards) that are susceptible to damage from electrostatic discharge (ESD). When you see this icon, you must follow standard ESD guide-lines to avoid damaging the equipment you are servicing.

Note: Notes either provide extra information about a topic or contain spe-cial instructions for handling a particular condition or set of circumstances.

Global Services and Support

Warranty InformationTo understand the warranty for your Intermec product, visit the Intermec web site at www.intermec.com and click Service & Support > Warranty.

Disclaimer of warranties: Th e sample code included in this document is presented for reference only. Th e code does not necessarily represent complete, tested programs. Th e code is provided “as is with all faults.” All

EasyCoder PM4i Bar Code Label Printer Service Manual ix

warranties are expressly disclaimed, including the implied warranties of merchantability and fi tness for a particular purpose.

Web SupportVisit the Intermec web site at www.intermec.com to download our cur-rent manuals (in PDF). To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor.

Visit the Intermec technical knowledge base (Knowledge Central) at intermec.custhelp.com to review technical information or to request tech-nical support for your Intermec product.

Telephone SupportTh ese services are available from Intermec:

Services Description

In the USA and Canada call 1-800-755-5505 and choose this option

Order Intermec prod-ucts

Place an order.

Ask about an existing order.

•

•

1 and then choose 2.

Order Intermec Media Order printer labels and rib-bons.

1 and then choose 1

Order spare parts Order spare parts. 1 or 2 and then choose 4

Technical Support Talk to technical support about your Intermec Product.

2 and then choose 2

Service Get a return authorization number for authorized service center repair.

Request an on-site repair technician.

•

•

2 and then choose 1

Service contracts Ask about an existing contract.

Renew a contract.

Inquire about repair billing or other service invoicing questions.

•

•

•

1 or 2 and then choose 3

Outside the U.S.A. and Canada, contact your local Intermec representa-tive. To search for your local representative, from the Intermec web site, click Contact.

Who Should Read This Document?

Th is Service Manual is for the person who is responsible for installing, maintaining and troubleshooting the EasyCoder PM4i printer.

Please note that the operations described in this manual should only be carried out by skilled and authorized personnel. Th e printers contain wires and circuits with up to 380V, which implies the risk of fatal 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 (Fin-gerprint and IPL) and their related standard application programs. Note that even if the printers are technically identical (with the exception of the keyboard overlay), Fingerprint and IPL make the printer work quite diff er-

x EasyCoder PM4i Bar Code Label Printer Service Manual

ently and certain devices and options are not supported by IPL. It is also assumed that the reader has access to the standard tools of an electronics workshop.

Related Documents

Th is table contains a list of related Intermec documents and their part numbers.

Document Title Part Number

EasyCoder PM4i User’s Guide (Fingerprint version) 1-960583-xx

EasyCoder PM4i User’s Guide (IPL version) 1-960584-xx

EasyCoder PM4i Spare Parts Catalog 1-960607-xx

Fingerprint Programmer’s Reference Manual 937-005-xxx

IPL Programmer’s Reference Manual 066396-xxx

In addition to the documents mentioned above, you may also fi nd use for Installation Instructions for various options.

Th e Intermec web site at www.intermec.com contains our documents (as PDF fi les) that you can download for free.

To download documentsVisit the Intermec web site at www.intermec.com.

Click Support > Manuals.

In the Select a Product fi eld, choose the product whose documentation you want to download.

To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor.

1

2

3

EasyCoder PM4i Bar Code Label Printer Service Manual 1

1 Models and Options

Th is chapter describes how to identify the various confi gurations of the EasyCoder PM4i printer, provides comprehensive technical specifi cations, and gives all important measurements.

2 EasyCoder PM4i Bar Code Label Printer Service Manual

Chapter 1—Models and Options

1.1 Identification

Main Model

Th e EasyCoder PM4i Printer comes in one main model, which can be modifi ed in regard of media handling, printhead density, interfaces, fi rm-ware, etc. As standard, the printer has an 8 dots/mm (203.2 dpi) printhead and is capable of both direct thermal and thermal transfer printing,

Th e printer runs either Intermec Fingerprint Programming Language (FP) v8.10 (or later) or Intermec Programming Language (IPL) v2.10 or later. Externally, the diff erence is visible on the keyboard overlay. Fingerprint printers have 23 keys and IPL printers have 8 keys (see Chapter 2).



Machine label

To identify the printer, start by reading the machine label attached to the rear of the printer. Th e machine label contains type, part number, serial number, and signs of approval.

Th e printer can use any 100 to 240 VAC, 50 to 60Hz voltage. Th ere is no manual voltage selector.



Options for EasyCoder PM4i Printer

Th e EasyCoder PM4i Printer can be fi tted with a number of options:

• Special Printheads (300 dpi and/or thick media) (see Chapter 7)

• Label Taken Sensor (see Chapter 9)

• Integral Liner Takeup Unit (see Chapter 8)

• Media Supply Hub (replaces supply post) (see Chapter 5)

• 3-inch Adapter (for media supply hub) (see Chapter 5)

• Media Roll Retainer (for media supply hub) (see Chapter 5)

• Paper Sensor (see Chapter 5)

• Fan-Fold Guides (see Chapter 5)

• Cutter with Tray (see Chapter 10)

• Side Door with Keylock (see Chapter 3)

• Real Time Clock Circuit (see Chapter 13)

• One or two interface boards of various types (only one parallel board with IPL) (see Chapter 14)

• EasyLAN interface (Ethernet or Wireless) (see Chapter 14)

Cutter

Cutter tray Special printheads Liner takeup unit

Rotating mediasupply hub

Fan-fold guide

Media rollretainer

3-inch adapter

Paper sensor

Cover(replaces liner takeup unit

Side door with keylock

Label taken sensor



Interfaces

As a standard, the printers are equipped with one serial RS-232 port, one serial USB port, and one wand interface. Th e USB port and the wand interface are not supported by IPL. In addition, one EasyLAN interface and one or two extra interface boards can be fi tted, see Chapter 14. IPL only supports the EasyLAN interface and one parallel interface board.

Serial Port (RS-232)

USB Port(not used with IPL)

Provision forone or two interface boards (only the left slot used with IPL)

Provision for Ether-net connector

Wand interface(not used with IPL)

Provision for Easy-LAN antenna



Checking Hardware and Firmware

Finally, you may want to inspect the electronics compartment. To do so, carefully follow the instructions in Chapter 11.

Th e electronic compartment contains wires and components with dangerous voltage (up to 380V). Always switch off the power and unplug the power cord before you remove the cover over the electronics compartment!

Im Elektronikfach gibt es Kabel und Komponenten, die hohe Spannungen (bis zu 380 V) führen. Immer die Stromversorgung abschalten und das Netzkabel abziehen, bevor die Abdeckung des Elektronikfachs abgenommen wird!

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 fi tted?

- Check type, straps, and optional circuits.

Refer to Chapters 13 and 14 for more information.

Th e PM4i printer comes with either Fingerprint v8.xx or IPL v2.xx fi rm-ware. Th e fi rmware type and version can be changed with a fi rmware card or special software. Th e keyboard overlay will also need to be changed. Th e current fi rmware type is indicated in the display window.

Fingerprint OnlyIf the printer is working and possible startup program can be interrupted, the type of program in the printer can be identifi ed. Connect printer and computer, open a suitable communication program, and start up the printer in Fingerprint’s immediate mode. Th e instructions FILES, FONTS, and IMAGES will return information about what fi les, fonts and images are stored in printer memory. Use the VERSION$ function to check ver-sion of the Intermec Fingerprint fi rmware.

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-fi le prevents access, lift the printhead and press and hold any key on the printer's keyboard (except the <Shift> key) while you turn on the power. When the Shell countdown begins, release the key and press <Enter> to start Shell. If you want to print test labels, lower the printhead. Refer to the User’s Guide and to Appendix A in this Service Manual for more information on Setup Mode and the Intermec Shell startup program.

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

IPL onlyTh e 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).



Printing

Print Technique Th ermal Transfer and Direct Th ermal

Printhead Resolution 8 dots/mm (203.2 dpi)11.81 dots/mm (300 dpi)

Standard Option

Print Speed (variable) 100 to 200 mm/sec. (approx. 4 to 8 in./sec.) 100 to 150 mm/sec. (approx. 4 to 6 in./sec.)

8 dots/mm (203.2 dpi)11.81 dots/mm (300 dpi)

Print Width (max) 104 mm (4.095 in.) = 832 dots105.7 mm (4.161 in.) = 1248 dots

8 dots/mm (203.2 dpi)11.81 dots/mm (300 dpi)

Print Length (max) 32767 dots = 409.5 cm (161.25 in.)1

Media Width (min/max) 25 to 114.3 mm (1.00 to 4.5 in.)

Media Roll Diameter (max) 213 mm (8.38 in.)

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

Ribbon Width (min/max) 25 to 110 mm (1 to 4.33 in.)

Ribbon Roll Diameter, Outer (max) 82 mm (3.2 in.) 450 m (1475 ft)2

Ribbor Roll Core Diameter, Inner 25.4 mm (1 in.)

Print Directions 4

Modes of Operation

Tear Off (Straight-through) Yes

Cut Off Option With paper cutter

Peel Off (Self-strip) Option With liner takeup unit

Firmware (Fingerprint)

Operating System Intermec Fingerprint v8.10 Incl. Direct Protocol

Smooth Fonts TrueDoc and TrueType fonts

Built-in scaleable fonts (std) 15 Unicode fonts3

Built-in bar code symbologies (std) 45

Startup Program (std) Intermec Shell v8.0

Firmware (IPL)

Operating System IPL v2.10

Built-in scaleable fonts (std) 13 scaleable + 21 simulated bitmap

Built-in bar code symbologies (std) 31

Startup Program (std) None

Physical Measures

Dimensions (W×L×H) 298×543×261 mm (11.7×21.4×10.3 in.)

Weight (excluding media) approx. 13.5 kg (30 pounds)

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

Humidity 20 to 80% non-condensing

Electronics

Microprocessor 32 bit RISC

On-board Flash SIMMs 2 sockets (for 4 or 8 MB each) Std. 1 × 4MB

On-board SDRAM SIMM 1 socket (for 8 or 16 MB) Std. 1 × 8MB

Power Supply

AC Voltage 90 to 265 VAC, 45 to 65Hz

PFC Regulation IEC 61000-3-2

Power Consumption Standby 15W; Peak 300W

1.2 EasyCoder PM4i Printer Specifications



Sensors

Label Gap/Black Mark/Out of Media Yes Variable position

Printhead Lifted Yes

Ribbon End/Ribbon Low Yes IPL only ribbon end

Paper Low Yes

Controls

Control Lamps 3

Display 2 × 16 character LCD with background light

Keyboard (Fingerprint) 22 keys membrane-switch type

Keyboard (IPL) 7 keys membrane-switch type

Print or Feed/Pause button 1

Beeper Yes

Data Interfaces

Serial 1×RS-232 + 1×USB

Bar Code Wand 1 Not supported by IPL

Connection for Interface Boards 1 + 2 1 EasyLAN + 2 other

Finisher Interface 1 For cutter etc.

Memory Card Adapter 1 CompactFlash cards

Accessories and Options

Special printheads 8 dots/mm: Th ick media11.81 dots/mm: Standard and Th ick media

203.2 dpi300 dpi

Paper Cutter Option For cut-off operation

Paper Cutter Tray Option For cut-off operation

Integral Self-strip Unit w. Liner Takeup Option For peel-off operation

Rotating Media Supply Hub Option Replaces supply post

3-inch Adapter Option For media supply hub

Media Roll Retainer Option For media supply hub

Internal Fan-fold Guide Option

Side Door with Keylock Option

Label Taken Sensor Option

Real Time Clock Option 10+ years life

RS-232 Interface Cable Option

Parallel Interface Cable Option

IEEE 1284 Parallel Interface Board Option

Double Serial Interface Board Option (not IPL)

Serial/Industrial Interface Board Option (not IPL)

EasyLAN Ethernet Interface Option Model EasyLAN100i2

EasyLAN Wireless Interface Option Model Wireless100i2

External Alphanumeric Keyboard Option (limited functionality in IPL)

CompactFlash Cards Option 8MB to 1GB. Not CF+

Compact Flash Card Protection Plate Option

1/. Th e max. print length is also restricted by the amount of free SDRAM memory.2/. Max. ribbon length depends on ribbon thickness.3/. Latin, Greek, and Cyrillic fonts according to Unicode standard are included.



1.3 EasyCoder PM4i Printer Dimensions

Front View

Rear View

101

mm

(3.9

8 in

.)

Media path114 mm (4.49 in.)

Edge of cover to dot #0:145 mm (5.71 in.)

539

mm

(21.

22 in

.)

Pape

r inp

ut: 2

6 m

m (1

.02

in.)

325

mm

(12.

80 in

.)

45 mm (1.77 in.)



At least 60 mm (2.3 inches) of free space behind the printer is required for the connectors, and for inserting and removing a memory card.

Side View26

1 m

m (1

0.28

in.)

69 m

m (2

.72

in.)

7 m

m (0

.28

in.)

18 mm (0.71 in.)543 mm (21.38 in.)

636 mm (25.04 in.)

23 mm (0.91 in.)

298

mm

(11.

73 in

.)

250 mm (9.84 in.)

430 mm (16.93 in.)60 mm (2.36 in.)

15 mm(0.59 in.)

25 m

m (0

.98

in.)

6 m

m (0

.24

in.) 24

5 m

m (9

.65

in.)

Ø 12 mm(0.47 in.)

Hole: Ø 7.1 mm (0.28 in.)Foot: Ø 16 mm (0.63 in.)

Dot #

0: 16

mm

(0.6

3 in

.)

Top View

Bottom View



Cutter with Tray, Side View15

0 m

m (5

.91

in.)

100

mm

(3.9

4 in

.)

593 mm (23.35 in.)

747 mm (29.41 in.)

154 mm (6.06 in.)

Cutter with Tray, Top View

136

mm

(5.3

5 in

.)



Open Cutter, Side View

644 mm (25.35 in.)

160

mm

(6.3

0 in

.)


2 Front and Keyboard

Th is chapter describes the keyboard and display fi tted at the front of the EasyCoder PM4i Printer.


Chapter 2—Front and Keyboard

2.1 Front

Th e front and left-hand moulding is made as a single integrated unit which covers the front of the printer and the electronics compartment. Th e entire moulding is illustrated in Chapter 3.

Th e front contains:

• Th e membrane-switch keyboard with overlay and print or feed/pause button.

• Th e console PCB (Printed Circuit Board)

Insert keyboard cables here

Console PCB

Print buttonlayer

Left-hand cover moulding

Self-adhesiveoverlay

Membrane-switch keyboard layer

Mounting plate

#T10 Torx screws (x3)

M3 nuts (x4)



2.2 Keyboard

Keyboard Overlay

Th e keyboard overlay is fi tted on the print button layer using a non-perma-nent adhesive to allow easy replacement. Custom-made overlays could also be printed and used to replace the standard overlays for customized appli-cations or in areas, where the English text is not acceptable. Th ere are two standard overlays; one for Fingerprint and one for IPL.

Print Button Layer

Th e print button layer is permanently glued to the the membrane-switch keyboard layer and contains a yellow print button dome that activates a switch on the membrane keyboard layer. Th e print button dome protrudes through a hole in the keyboard overlay.

Membrane Switch Keyboard Layer

Th e keyboard is of membrane switch type and is permanently glued to the mounting plate. Th ere are 23 switches including the print button switch. Th e keys have fi xed 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.

Two fl at cables connect the membrane-switch keyboard to P2 and P3 on the console pcb.

Mounting Plate

Th e mounting plate holds both the overlay/print button/membrane-switch keyboard assembly and the console pcb. It is fi tted to the left-hand cover moulding using four M3 nuts accessible from the inside.

Fingerprint overlay IPL overlay



2.3 Console PCB

Th e console PCB contains an LCD (Liquid Crystal Display) and three LED (Light Emitting Diode) control lamps. It also serves as a connec-tion point between the keyboard and the I2C bus on the CPU board. It is attached to the mounting plate using three #T10 Torx screws.

Th e display has 2 × 16 character with a 5 × 7 dots matrix and background light. 8 characters are programmable.

Th e left-hand LED control lamp (marked “Power”) shines green when the power is on. Power on is also indicated by the display’s background light.

Th e other two LEDs are programmable using the Fingerprint instructions LED ON and LED OFF. Th ere is no such facility in IPL. Th e center LED (marked “Ready”) is green and blinks when data is received. Th e right-hand LED (marked “Error”) is red.

Note: the console PCB is connected to J50 at the front of the CPU board via a permanently fi tted 10-p fl at cable. Th is cable must be disconnected from the CPU board before the cover can be entirely removed.



1-971651-26 Console PCB; Components

Component Side

Soldering Side



1-971651-26 Console PCB; Schematics

VC

CV

CC

VC

C

P

3

P

2

P4

KA

GN

DR

SEV

DIS

PR

/WV

CC

D7D6D5D4

D0D1D2D3

DIS

P1

DIS

PL

AY

IC1 P

IC16F

872

P1

R23

R24

R25

R26

R27

R28

R29

R30

R31

R32

R33

R17

R18

R19

R20

R21

R22

R15

R1

R2

R3

R10

R11

R12

R7

R8

R5

R14

R16

R13

R6

D2

D1

D3

C7

C8 C9

C10 C11

C12 C13

C14 C15

C16

C5

+C4

P5

T

R4

T3

T1

T2

C3

VC

C

C6

R34

VC

C

VC

C

VC

C

VC

C

VC

C

VC

C

VC

CV

CC

IN-C

IRC

UIT

SE

RIA

L P

RO

GR

AM

MIN

G

32

910

121314

20

1 2 3 4 5

VP

P

1 52 3 4 6 1 2 3 4 5 6 1 2

CO

L1

CO

L2

CO

L0

CO

L3

CO

L4

RO

W4

RO

W3

CO

LS

H21

22

23

24

25

26

28

27

11

RO

W2

RO

W1

RO

W0

R/W

SD

AS

CL

12

13

14

15

16

17

18

16

15

9 1

10

D4

D7

D5

D6

2 3 4 5 6E

7R

S

819

1

11

5 4 6

87

I2C

_N

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IFY

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D1

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D2

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A

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T321 4 5 6 7 8 9

SC

L10

RB

2R

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RB

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B5

RB

6R

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/RB

0

RC

0R

C1

RC

2

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4R

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7

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TIF

YR

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LR

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RA

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RE

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1

RA

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0C

KI

RA

5

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0

VC

C

GN

DG

ND

R35

D4


3 Covers and Doors

Th is chapter describes the covers and doors used on the EasyCoder PM4i printer. It covers the following topics:

• Th e right-hand doors, that is the doors that cover the print mechanism and media compartment.

• Th e front and left-hand cover that contains the console and protects the electronics compartment.

• Th e front door, that protects the front of the print mechanism.


Chapter 3—Covers and Doors

3.1 Right-Hand Door

Th e EasyCoder PM4i printer comes as standard with a large door that covers the print mechanism and the ribbon and media supplies. It has an inspection window that allows the operator to check the remaining amount of ribbon and media without having to open the door. Th e door swings upwards using two hinges fi tted between the center section and the door by means of four #T20 Torx screws each.

Th e rear part of the right-hand door has an inlet for external media sup-plies, such as fan-folded tickets and tags.

Th e standard door can be replaced by an optional door fi tted with a key-lock that engages the bottom plate. When replacing the right-hand door, remove the screws that hold the hinges to the door. Th is preserves the adjustment of the hinges.

Th e right-hand door is quite heavy. To avoid injury, make sure you keep your fi ngers out of the way when you close the door.

Die rechte Tür ist sehr schwer. Verletzungen vermeiden! Die Finger beim Schließen der Tür vom Türspalt fernhalten.

Optional keylock

Inspection window

Hinge (x2)




3.2 Front and Left-Hand Cover

Th e front/left-hand cover is fi tted with a number of user interface devices, see Chapter 2.

Removing the front/left-hand cover gives access to:

• Th e electronics including CPU board, AC connection, power supply, and any optional interface PCBs.

• Th e motor, belts, and pulleys of the media feed and the optional liner takeup unit and ribbon feed motor.

Th e left-hand cover plate is fi tted to the center section using eight #T20 Torx screws; four are accessible from the media compartment and the other four from the underside of the bottom plate.



#T20 Torx screw (x2)

To remove the coverDisconnect the power cord.



Tip the printer over so it rests on its left cover. Place it on a soft cloth or similar to avoid scratches.

Open the right-hand door.

Using a #T20 Torx screwdriver, remove the four screws that holds the cover along the lower left edge of the bottom plate and the four screws that hold the cover to the center section (see illustration).

Put the printer back on its feet and remove the cover while disconnecting the console cable from the CPU board.

Put the cover aside taking care to avoid scratches.

Install the cover like this:

• Put back the left-hand cover in reverse order. Route the cable from the console unit above the ribbon motor to prevent it from being entagled in the headlift mechanism. Connect the cable to connector J50 at the upper right corner of the CPU board. Make sure that the lower edge of the cover is pressed inwards as far as it goes before tightening the screws.

3.3 Front Door

Th e front door protects the print mechanism and is affi xed with two #T20 Torx screws to the upper side of the bottom plate. It cannot be used together with a cutter.

Th e door can be tilted down to facilitate media and ribbon load.

1

2

3

4

5

6


4 Chassis

Th is chapter describes the center section, bottom plate, and rubber feet, of the EasyCoder PM4i printers.


Chapter 4—Chassis

4.1 Description

Th e printer’s chassis consists of two main parts:

• Th e center section

• Th e bottom plate

Bottom plate

Center section

Rubber foot (x4) (enlarged)

#T20 Torx screws (x4) Plastic dampeners (x2)

Provision for cutter orfront door


Chapter 4—Chassis

4.2 Center Section

Th e center section is where most parts are fi tted, such as the print mecha-nism, the transfer ribbon mechanism, the liner takeup unit, and the media supply. Th e center section is fi tted to the bottom plate by a total of four #T20 Torx screws.

In the electronics compartment, the CPU board and power supply unit are fi tted to the center section. Th e power supply unit is also attached to the bottom plate using two screws.



4.3 Bottom Plate

Th e bottom plate is fi tted with four easily replaceable rubber feet. Th ese feet could be removed and the holes be used to bolt the printer to a frame, table or similar. Th e holes have a diameter of 7.1 mm (0.28 inches). To reduce noise, fi t rubber dampeners between the table and the printer if you bolt it in place.

When fi tting a replacement foot, insert it through the bottom plate and fi rmly press the pin so the rivet expands on the upper side of the plate.

Th e two keyholes should not be used to bolt the printer to a frame, or the bottom plate may be bent. Th ese holes are only used for fi xtures during manufacturing.


Chapter 4—Chassis

Th ere are two self-adhesive plastic dampeners attached to two tabs along the right edge of the bottom plate to reduce noice when the right-hand door is closed.


5 Media Supply

Th is chapter explains the media supply roll post and the two types of adjustable media edge guides. It also covers the rotating media supply hub with the 3-inch adapter, the media roll retainer, and the paper low sensor. Finally, it describes how an external media supply can be used in a standard EasyCoder PM4i printer and in a printer fi tted with an internal fan-fold guide.


Chapter 5—Media Supply

5.1 Internal Supply

Being of a modular design for maximum fl exibility, the EasyCoder PM4i printer can use either a media supply roll post or a rotating media supply hub inside the media compartment. Alternatively, an external media supply (for example a box of fan-folded tickets) behind the printer can be used, preferably in connection with an internal fan-fold guide.

Media Supply Roll Post Th e media supply roll post fi ts both 38 to 40 mm (1.5 inch) and 76 mm (3 inches) media roll cores because the post can be moved vertically in a slot in the center section. Th e bottom position is used for small cores and the top position is used for large cores. Th e post is locked by a straight-slot screw.

Th ere are two edge guides delivered with the EasyCoder PM4i printer; a low guide is fi tted as standard and a high guide is packed with the other accessories. Th e operator can switch between the two guides at will. Just pull out the guide as far as it goes and twist it carefully to release it from the post.

Both guides can be tilted down to a horizontal attitudes when they are in their extreme outer positions. In case of the low edge guide, this is not necessary when 76 mm (3 in.) media cores are used.

After the media roll has been loaded, it is important that the edge guide is adjusted so the roll becomes fl ush with the center section.

76 mm

(3 in.)

CORE

38-40 mm

(1.5 in.)

Straight-slot screw(hidden)

Low edge guide

Media supply roll post

High edge guide



Media Supply Hub Th e rotating media supply hub consists of four bobbin modules on threaded shaft that is fi tted to the center section. To remove the bobbins from the shaft, remove the #T20 Torx screw and washer and pull out the bobbin modules. When fi tting or removing the shaft, protect it using a piece of tape or similar to avoid dents and marks.

Th e hub is designed to fi t media roll cores with an internal diameter of 38 to 40 mm (1.5 inches). 76 mm (3 inches) cores can also be accepted by fi tting an optional 3-inch adapter on the hub. Secure the adapter on the hub using the locking screw. Make sure that the screw hits an even plastic surface on the hub (not a metal leaf-spring).

Some media rolls have a tendency to become unwound in an outward spiraling direction. Th us, Intermec off ers an optional media roll retainer, that can be pressed onto the media supply hub after the media has been loaded and keeps the media in place even if the printer is tilted sideways. Th e retainer restricts the media width to a maximum of 100 mm (3.94 inches).

3-inch adapter

Hub

Media roll retainer

Locking screw

Paper sensor cover

#T20 Torx screwand washer



Paper Sensor (Fingerprint Only)Th e paper sensor can only be used in connection with a media supply hub and allows the fi rmware to detect when the diameter of the remaining media becomes less than a value set in the Setup Mode (Media/Paper/Low Diameter). Th is aff ects SYSVAR(46) which switches from 0 to 1. Th us, 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.

Th e sensor detects a pattern of dark and light sectors at the back of the disk at the inner end of the media supply hub. By comparing the rotation speed of the hub and the print speed, the fi rmware can calculate the diameter of media roll.

Th e paper sensor assy is snap-locked to the center section below the media supply hub and is connected to J57 on the CPU board (see Section 13.3). Th e cover is always fi tted regardless whether it contains a sensor or not.

To adjust the paper sensorEnter Setup mode and navigate to Media > Paper > Paper Sensor.

In the Paper Sensor menu, press <Enter> to perform a Testfeed.

Th e printer will feed out a few labels and feed the ribbon accordingly.

While the media feed mechanism is operating, the paper sensor is autoadjusted and the resulting adjustment value is shown in the lower line of the menu (read-only).

1

2

3

Sensor inside

Cover

Snap-lock (x4)

Cable

Connect to J57 on CPU board



5.2 Label Slack Absorber

Th e EasyCoder PM4i printer is provided with a spring-loaded slack absorber between the media supply and the print mechanism. Th e slack absorber compensates for jerks in the media when the printing starts and stops in order to make the media feed as smoothly as possible. Th e label slack absorber body is snap-locked to a threaded shaft attached to the center section. One end of the spring is attached to the center section using a #T10 Torx screw and the other to the body of the absorber.

A green plastic edge guide is fi tted to the body of the label slack absorber and can be adjusted for various media widths.

To remove the slack absorber, disengage the snap-lock inside the body and pull it away from the shaft. Protect the shaft from scratches using for example insulating tape and remove it using a pair of pliers. Assemble in reverse order.

Body

Snap lockShaft

Spring

#T10 Torx screw

Edge guide



5.3 Print Mechanism Edge Guide

To the rear of the print mechanism is an adjustable edge guide. Th e guide is fi tted onto a shaft affi xed to the center section. Th e same shaft also holds the upper part of the media guide. Th e edge guide can be moved along the shaft to fi t various media widths and be locked using a knurled nut.

Before removing the edge guide, remove the upper media guide as described in Section 7.5.

Edge guide

Shaft

Upper media guide

Knurled nut



5.4 Internal Fan-Fold Guide

For temporary use of an external supply, the media can be routed through the slot in the rear part of the right-hand door and use the existing edge guides. However, for permanent use of an external supply of, for example, fan-folded tickets or tags, it is recommended to use the optional internal fan-fold guide.

Th e internal fan-fold guide is a factory-installed option. Th e fan-fold guide is fi tted to the bottom plate and center section. Th e S-shaped guide behind the print mechanism, the label slack absorber, the internal liner rewind unit, and the media supply roll post or hub are omitted.

Th e fan-fold guide can be adjusted from full media width down to 40 mm (1.57 in.) by untightening two knurled nuts and moving the outer guide inwards or outwards accoiding to the media width. Th en tighten the nuts.

Th e fan-fold guide cannot be used in connection with peel-off (self-strip) operation.

As the media will be not be fully protected by the printer cover, the user should take care to protect the exposed media supply from dust, dirt, and so on. Direct thermal media should also be protected from heat, direct sunlight, moisture, oil, plasticizers, and fat.

Outer guide(adjustable)

Knurled nut (x2)




6 Transfer Ribbon Mechanism

Th is chapter describes the mechanism that drives the thermal transfer ribbon in the EasyCoder PM4i printer. It covers the following topics:

• Description

• Ribbon supply unit

• Ribbon rewind unit

• Ribbon sensor

• Ribbon motor

• Front ribbon break shaft

• Printhead ribbon break shaft


Chapter 6—Transfer Ribbon Mechanism

6.1 Description

Th e thermal transfer ribbon mechanism is standard in EasyCoder PM4i printer. Th e mechanism consists of seven main parts:

• Ribbon supply unit (see Section 6.2)

• Ribbon rewind unit (see Section 6.3)

• Ribbon sensor (see Section 6.4)

• Ribbon motor assembly with gearbox (see Section 6.5)

• Adjustable front ribbon break shaft (see Section 6.6)

• Rear ribbon break shaft intergrated with the print mechanism

• Printhead ribbon break shaft (see Section 6.7)

Ribbon Motor assy. (hidden)

Ribbon Supply Unit

Ribbon Rewind Unit

Ribbon Sensor (hidden)

Front Ribbon Break Shaft

Rear Ribbon Break ShaftPrinthead Ribbon Break Shaft



6.2 Ribbon Supply Unit

Description

Th e ribbon supply unit accommodates the supply of thermal transfer ribbon. For troublefree printing, use ribbons recommended by Intermec.

Ribbon SpecificationsWidth: 25 to 110 mm (1 to 4.33 in.)Roll diameter (outer), max.: 82 mm (3.2 in.)Roll core diameter (inner): 25.4 mm (1.00 in.)Ribbon length, max.: approx. 450 m (1,475 ft)

Th e unit is designed to keep the ribbon tight all the time in order to avoid wrinkling and creases, which would ruin the printout. It consists of a shaft, screwed into the center section, on which a bobbin is snap-locked. Inside the bobbin is a hub with a tab that engages a hole in the center section and a spring clutch. Th e bobbin is fi tted with a plate that holds the cardboard core of the ribbon roll.

Inside the inner end of the bobbin is a pattern of refl ecting and non-refl ecting sectors by means of which the ribbon sensor can detect the rotation of the bobbin.

When the bobbin is rotated, the spring clutch is unwound and tries to pull the ribbon back onto the roll. As the pulling force increases, the clutch starts to slip and the ribbon can be unwound while still being kept tight. Th e bobbin can rotate in both directions. Th us, ribbons wound with the ink-coated side facing either inwards or outwards can be used.

Replacement

Pry the two legs of the snap-lock in the bobbin apart using a pair of fl at-tipped screwdrivers while pulling out the bobbin with the spring clutch and hub. Avoid removing the hub and spring clutch from the bobbin.

If the shaft needs to be removed, use a piece of insulating tape to protect the shaft from being scratched by the tool.

Reassemble in reverse order.

1

2

3

RibbonSensor

Hub

Tab

Spring Clutch

Bobbin Plate

Detection Pattern

Shaft

Bobbin



6.3 Ribbon Rewind Unit

Description

For logistic reasons, the ribbon rewind unit consists of the same parts as the ribbon supply unit (see Section 6.2) with the exception that there is no spring clutch.

Th e ribbon rewind bobbin winds up the used ribbon on its cardboard core after printing. It is driven via a gearbox by the ribbon motor. A gear wheel in the gearbox engages the cogs along the rim of the inner part of the bobbin. Th e bobbin rotates counterclockwise to wind up the ribbon during printing or clockwise to allow the ribbon to follow the media when it is pulled back.

Replacement

Pry the two legs of the snap-lock in the bobbin apart using a pair of slotted screwdrivers. At the same time, pull out the bobbin.

Remove the hub from the shaft, if necessary.

If the shaft needs to be removed, use a piece of insulating tape to protect the shaft from being scratched by the tool.

Reassemble in reverse order. Take care so the cogs along the rim of the bobbin engage the gear wheel in the gearbox properly.

1

2

3

4

Shaft

Hub

Tab

Bobbin Plate

Bobbin



6.4 Ribbon Sensor

Description

Th e ribbon sensor is snap-locked to the center section from the media compartment side and is completely enclosed by the ribbon supply unit (see Section 6.2). Th e sensor consists of a plastic housing with a LED and a photoelectric sensor.

Th e light from the LED is alternately refl ected or absorbed by black and silver-colored sectors on a label fi tted at the inner end of the ribbon supply bobbin. Th e signals from the sensor allow the fi rmware to detect the speed with which the bobbin rotates and compare it with the speed of the media feed.

If no bobbin rotation is detected during media feed, the Fingerprint fi rmware 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.

When the printer is set for direct thermal printing, the ribbon motor is switched off and the takeup will not work. If a ribbon is nevertheless loaded, it will be pulled out in front of the printer by the advancing media without any warning.

Th e ribbon sensor is connected to J56 on the CPU board (see Section 13.3).

Replacement

Open the media compartment door.

Remove the cover over the electronics compartment as described in Section 10.2, taking all precautions against electric shock.

Remove any transfer ribbon from the ribbon supply unit.

Remove the ribbon supply bobbin with hub and spring clutch as described in Section 6.2.

Disconnect the sensor’s cable from J56 on the CPU board.

From inside the electronics compartment, compress the snap-locks and pry out the sensor into the media compartment.

Install a replacement sensor unit in reverse order.

1

2

3

4

5

6

7

LED and Sensor

Housing

Snap-Locks



Adjustment (Fingerprint)

Low diameterIn the Setup Mode, it is possible to specify the diameter (in millimeters) of the ribbon supply roll, where a ribbon low condition should be detected. By default, this parameter (Media/Paper Type/Transfer/Low Diameter, see Appendix A) is set to 0, which disables the function. To enable it, enter the desired value.

By reading SYSVAR(26) in a Fingerprint application program, the status of the ribbon low sensor can be polled. 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.

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.

SensitivityEnter Setup Mode and navigate to Media > Paper Type > Transfer/Ribbon Sensor.

In the Ribbon Sensor menu, press <Enter> to perform a Testfeed.

Th e 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)

Th ere is no facility for adjusting either the low diameter or the sensitivity of the ribbon sensor in IPL.

1

2

3

4



6.5 Ribbon Motor

Description

Th e ribbon motor assembly consists of a 24 VDC motor with a gearbox. Th e gearbox engages the cogs along the rim of the ribbon rewind bobbin and rotates it in either direction according to the polarity of the power.

Th e power comes to the ribbon motor via a cable connected to P6 on the Power Supply Unit (see Section 12.3).

Th e ribbon motor assembly is a complete unit and should not be taken apart. It is fi tted to the electronics compartment side of the center section using three #T20 Torx screws.

DC Motor

Gearbox

#T20 Torx Screws (×3)



6.6 Front Ribbon Break Shaft

Description

Th e front ribbon break shaft serves two purposes: to keep the ribbon away from the print mechanism and to compensate for any lack of parallelity in the other parts of the ribbon mechanism. Th e shaft is screwed into a plate inside the center section. Th e shaft and the plate can be tilted using a straight-slot screw from the media compartment (also see last illustration in Section 7.1).

Before you attempt to adjust the break shaft, make sure that the ribbon wrinkling is not caused by something else (see Section 16.13).

Bevor versucht wird, die Bruchwelle einzustellen, sicherstellen, dass es keinen anderen Grund für das zerknitterte Band gibt (siehe Abschnitt 16.13).

• If the ribbon tends to slide outwards, turn the screw carefully clockwise (fw) to move the outer end of the break shaft forward.

• If the ribbon tends to slide inwards, turn the screw carefully counterclockwise (bw) to move the outer end of the break shaft backward.

Adjustment Screw

Front Ribbon Break Shaft



6.7 Printhead Ribbon Break Shaft

Description

Th e printhead ribbon break shaft keeps the ribbon away from the front edge of the printhead and minimizes the friction. Th e shaft is fi tted between the two gables of the printhead bracket. Th e inner gable has a D-shaped hole and the outer gable has a round hole. Th e shaft is held in place by a plastic clip inside the outer gable.

Replacement

Pry away the plastic clip, taking care not to lose it.

Pull the shaft in the direction towards the outer gable until it disengages from the inner gable.

Tilt out the inner end so it can bypass the inner gable and pull it out of the outer gable.

Reassemble in reverse order taking care so the D-plane on the shaft fi ts into the D-shaped hole in the inner gable.

1

2

3

4

D-plane

Inner Gable

Outer Gable

Break Shaft

Plastic Clip (hidden)




7 Print Mechanism

Th is chapter describes the print mechanism of the EasyCoder PM4i 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


Chapter 7—Print Mechanism

7.1 Description

Th e print mechanism is fully integrated with center section (see Section 4.2), the transfer ribbon mechanism (see Chapter 6), and optional liner takeup unit (see Chapter 8).

Th e main parts of the print mechanism are:

• Th e rubber-coated platen roller drives the media past the printhead and provides counter-pressure.

• Th e liner drive roller is used for peel-off operation and helps pulling the liner towards the takeup unit.

• Th e stepper motor drives the platen roller and the liner drive roller via two timing belts inside the electronics compartment. It also drives the optional liner takeup unit via a third belt running inside the center section. Th e liner drive roller and the takeup unit belt are always fi tted.

• Th e tear bar makes it easier to tear-off continuous stock. It also helps separate labels and liner during peel-off printing.

• Th e label stop sensor (LSS) controls the media feed and checks for out-of-media conditions.

• Th e printhead produces the heat that blackens the direct thermal media or melts the ink of the transfer ribbon in bitmap patterns that make up letters, graphics, or bar codes.

• Th e headlift mechanism presses the printhead against the direct thermal media or thermal transfer ribbon, or raises the printhead to allow media and ribbon replenishment.



Th e parts of the print mechanism, as seen from the media compartment side of the center section, are illustrated below.

Printhead

Printhead bracket

Upper media guide

Headlift leverPressure arm

Belts, and pulleys

Lower media guide assy with LSS adjustment screw

Headlift mechanism (partly hidden behind center section)

Guide

Tear bar

Platen roller (barely visible)

Liner drive rollerGuide link

Printhead cable (data)



Th e parts of the print mechanism fi tted inside the electronics compartment in an EasyCoder PM4i printer are illustrated below.

Stepper motor

Pulley & belt(platen roller)

Pulley & belt(liner drive roller)

Headlift sensor

Headlift Linkage

Ribbon motorand gear box



7.2 Platen Roller

Description

Th e platen roller is coated with silicon rubber. It is imperative that the roller is kept clean and is free from uneven wear or dents. Th e platen roller is identical to the liner drive roller, so these rollers could be switched. Th e 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. Th e roller is supported by two permanently lubricated plain bearings pressed into the center section.

Be careful not to rotate the platen roller manually when the power is switched on, as this may damage the stepper motor driver on the power supply unit (see Chapter 12). Always turn off the power to the printer before you remove labels or label residue that is stuck on the platen roller!

Darauf achten, dass die Druckwalze nicht von Hand gedreht wird, wenn die Stromversorgung eingeschaltet ist. Dadurch kann der Schrittmotorantrieb im Netzteilmodul beschädigt werden (siehe Kapitel 12). Immer die Stromversorgung des Druckers abschalten, bevor Etikette oder Etikettrückstände entfernt werden, die auf der Druckwalze festkleben!

Replacement

Th is procedure also applies to the liner drive roller.

Turn off the power and disconnect the power cord.

Remove the front/left-hand cover, see Section 3.2.

Raise the printhead to open position.

Remove the tear-off bar by pulling the plate upwards. Avoid bending the hooks, which will make it loose-fi tting.

Press down the snap-lock at the bottom of the guide link and pry the guide link away from the shafts of the platen roller and the liner drive roller.

Using a 1.5 mm hexagon key, loosen the grub screw in the pulley of the roller.

Hold the pulley and belt while pulling out the roller.

Reassemble in reverse order, making sure that the tear bar snaps at the inner end of the liner drive roller.

When fi tting back the pulley, check that the grub screw hits the fl at side of the D-shaped end of the roller shaft. Tighten fi rmly. Check that the belts are fi tted properly over the pulleys on both the two rollers and the stepper motor.

1

2

3

4

5

6

7

8



Tear bar

Platen roller

Liner drive roller

Guide link

Snap-lock

1.5 mm hexagon key



7.3 Stepper Motor

Description

Th e stepper motor drives the platen roller and the liner drive roller using a double-belt pulley and two timing belts inside the electronics compartment. It also drives the optional liner takeup unit using a pulley on the opposite side of the motor and a long belt that runs inside a recess in the center section. Th e pulleys are permanently fi tted and cannot be replaced.

Th e stepper motor is driven in micro-stepping mode with 8 steps/dot at 8 dots/mm (203.2 dpi), which means that the theoretical feed error will be negligible. However, mechanical conditions such as a worn platen roller or a slippery liner may adversely aff ect the accuracy.

Th e stepper motor is fi tted using four #T20 Torx screws and rubber noise dampeners inside a moulding protruding from the center section.

Replacement

Switch off the power and disconnect the power cord.


Disconnect the stepper motor cable from P10 on the Power Supply Unit.

Dismantle the stepper motor from the bracket by removing the four #T20 Torx screws.

If the printer has a liner takeup unit (see Chapter 8), remove the media guide assembly (see Section 7.5) to gain access to the belt running from the stepper motor to the liner takeup unit.

Remove the belts from the stepper motor pulleys. If no liner takeup unit is fi tted, you can leave its timing belt in the recess in the center section.

Loosen the 1.5 mm hexagonal grub screws that hold the pulleys of the platen roller and liner drive roller and remove the pulleys and belts.

Remove the stepper motor.

Replace the rubber dampeners with a fresh set.

Put back the stepper motor. If there is an optional liner takeup unit, start by fi tting its belt to the motor’s inner pulley. If no takeup unit is fi tted, make sure that the pulley does not engage the belt. Th en fi t the belt and pulley to the liner drive roller and fi nally the belt and pulley to the platen roller.

Fit the four screws that hold the fl ange of the stepper motor.

Connect the cable of the stepper motor to P10 on the Power Supply Unit.

Put back all remaining parts.

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Stepper motor

#T20 Torxscrews (×4)

Platen roller pulleyLiner drive roller pulley

Platen roller beltLiner drive roller belt

Rubberdampeners (×4)

Th e dampeners, the belts, and the pulleys are identical. Normally, there is no need to separate the fl anges and the pullies.

Flange

Flange



7.4 Belts

Description

Th e print mechanism has two timing belts, one that drives the platen roller and another that drives the liner drive roller. Th e belts are subject to wear and may need periodic replacement.

Replacement

Replace a worn out or broken belt using the same method as when replacing the stepper motor, see Section 7.3.

Adjustment

Th e tension of the belts cannot be adjusted.



7.5 Label Stop Sensor

Description

Th e label stop sensor (LSS) controls the media feed. It consists of two sets of sensors and diodes fi tted in a fork-shaped sensor housing. One part runs on top of the upper media guide and the other part runs inside the lower media guide assembly. Each part has one light-emitting diode and one photoelectrical receiver. Th e sensor housing slides along a shaft fi tted to the lower media guide when the straight-slot adjustment screw is rotated. Th e LSS can be moved laterally from the inner edge of the media and 57 mm (2.24 in.) outwards, which corresponds to the center of a full width media. Th e sensors are protected from the media by the two transparent media guides. Th e upper media guide can be removed to facilitate cleaning. Th e sensor are connected to the CPU board.

Upper media guide

Lower media guide

Adjustment screw

Shaft

Sensor housing

Connectors



Working Principles

Th e 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)/GapA beam of light is emitted from the diode in the lower part and received by the sensor in the upper part. Th e fi rmware 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-of-paper” condition is assumed.

Ticket (w mark)/MarkNormally, a beam of light is emitted from the diode in the lower part. Th e beam is refl ected back to the sensor in the lower part by the white media, or is absorbed by a black mark. Th e fi rmware 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-of-paper” 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)/GapTh e light is emitted from the diode in the lower part and received by the sensor in the upper part. Th e light will either pass uninterrupted through a detection gap in the media or be blocked by the non-transparent ticket. Th e fi rmware 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 “next-label-not-found” condition is assumed. If a renewed print operation gives the same result, an “out-of-paper” condition is assumed.

Var. Length Strip and Fix Length Strip/ContinuousTh e light is emitted from the diode in lower part and received by the sensor in the upper part. Th e beam will either be blocked by the media or be completely uninterrupted when the printer runs out of continuous stock. Th e fi rmware assumes an out-of-paper condition if the light has not been interrupted within a media feed corresponding to 150% of the set length.



GeneralTh e 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” fi le in the fl ash memory’s fi le operating system (see Section 12.2). However, if the printhead is raised, or if the power is interrupted during printing, this fi le may be cleared, which will aff ect any labels between the LSS and the dot line. In this case, readjust the LSS by a TESTFEED operation (Fingerprint) or by pressing the Feed/Pause button (IPL).

Note (Fingerprint only): It is possible to decide if the media feed data will be cleared or not when the printhead is raised by means of the Fingerprint instruction SYSVAR(28). By default, the media feed data are not cleared.

Th e 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.

Adjustment of the Sensitivity

Th e 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. Th is is especially the case with self-adhesive labels on liner, because the transparency of the liner may vary and the diff erence 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 OnlyAs 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.

Four values are displayed showing how the sensor has been adjusted.

1. A measured value lower than the displayed value is interpreted as

media detected.

2. A measured value higher than the displayed value is interpreted as no

media detected.

3. Gain, that is, the sensitivity of the sensor.

4. Drive, that is, the intensity of the light-emitting diode.

• Selecting the TESTFEED option in the Setup Mode.

• Executing a TESTFEED statement in a Fingerprint program.

Th e 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. Th e LSS is adjusted according to the result of the check and a full label is fed out according to the present feedadjust setup.

Th e label stop sensor/black mark sensor can be turned off for a specifi ed amount of media feed using the LBLCOND statement, see Intermec Fingerprint v8.xx Programmer’s Reference Manual.



IPL OnlyTh e sensitivity of the LSS is confi gured at startup. To force adjustment of the sensitivity (corresponding to a TESTFEED in Fingerprint), raise and close the printhead and then press the Feed/Pause key.

Adjustment of the LSS Lateral Position

Th e LSS can be moved continuously across the media path. Use a straight-slot screwdriver or a similar tool to turn the adjustment screw.

• Rotate the screw clockwise to move the detection point towards the center section. Th e extreme position is aligned with the inner edge of the media path.

• Rotate the screw counterclockwise to move the detection point outwards, away from the center section. Th e extreme position is 57 mm (2.24 in.) outward the inner edge of the media path (that is, at the center of a full width media).

When using irregularly shaped labels, align the LSS with the front tips of the labels.

INOUTOUT

Adjustment screw

Point of detection

Upper LSS



Cleaning the Media Guide

Th e upper part of the media guide assembly can be removed for occasional cleaning.

Raise the printhead.

Loosen the screw on the edge guide.

Pull both the upper media guide and the edge guide straight out along the shaft.

Clean both the upper and lower media guides where the LSS runs using a cleaning card or a soft cloth moistened with isopropyl alcohol.

Assemble in reverse order making sure that the LSS shaft fi ts into the holder on the upper media guide.

Isopropyl alcohol [(CH3)

2CHOH; CAS 67-63-0] is a highly fl ammable,

moderately toxic, and mildly irritating substance.

Isopropylalkohol [(CH3)

2CHOH; CAS 67-63-0] ist extrem brennbar,

moderat giftig und leicht reizend.

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Media guide(upper part)

Media guide(lower part)

Edge guide shaftClean here! Upper LSS

Edge guide

Holder

Clean underside here!



Replacing the Sensors

To replace the LSS sensors, proceed as follows:



Remove the tear bar and the guide link, see Section 7.2.

Pull out the S-shaped guide at the rear of the print mechanism.

Pull out the upper media guide and the edge guide, see “Cleaning the Media Guide” on the previous page.

Pry out the printhead lift lever, remove the two #T20 Torx screws that hold the housing, and remove the housing.

Disconnect the cables from connectors J54 and J55 on the CPU board.

Remove the three #T20 Torx screws that hold the lower media guide assembly and pull it out while carefully manipulating the cables and connectors through the slot in the center section. Release the snap-locks on the part that covers the timing belt to the liner takeup unit. Be careful not to lose the grounding spring.

Remove the E-ring that locks the LSS adjustment screw to the wall of the lower media guide (see the fi rst illustration in this chapter).

Replace the sensor assembly with a new set and lock it with the E-ring.

Connect the cable from the lower part (marked “BM”) to J54 on the CPU board and the one from the upper part (marked “GAP”) to J55. (Th e cables can be switched in order to detect black marks on top the media instead of at the back.)

Reassemble in reverse order making sure that the grounding spring is fi tted straight up. When pressing back the printhead lift lever, lower the printhead, lock the pressing arm and hold it forcefully so as to prevent the headlift mechanism from coming apart.

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Lower media guide assy.

#T20 Torx screws (×3)

Grounding spring

Edge guide

Guide

Printhead lift lever

LSS cables

Tear bar

#T20 Torx screws (×2)Guide link

HousingUpper media guide



7.6 Printhead

Description

Th e printing is produced by the thermal printhead, which consists of a line of very small, closely spaced resistors on a ceramic tile fi tted 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. Th e spots can be combined into bitmap patterns, which make up characters, bar codes, images, lines, and boxes.

Th e 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. Th e 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.

Th e 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, which is standard, each dot has a nominal size of 0.125 mm (4.92 mils). Th is 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, which is an Fingerprint-only option, each dot has a nominal size of 0.086 mm (3.33 mils). Th is 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 aff ect the calculation of distances, sizes, and positions.

At startup, the printer auto-detects the printhead density as well as the head resistance. Th e 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 <STX><ESC>H<ETX>.



Print Window

Th e EasyCoder PM4i printer has as standard an 8 dots/mm (203.2 dpi) printhead or as an Fingerprint-only option an 11.81 dots/mm (300 dpi) printhead. In addition to the normal printheads, which are designed for a media thickness up to 175 μm (7 mils), there are also 8 dots/mm and 11.81 dots/mm printheads for media thicknesses from 170 to 220 μm (6.6 to 8.7 mils).

8 dots/mm Printhead Density 8 dots/mm (203.2 dots per inch)Print width 104 mm (4.095 inches)Number of dots 832Dot size 0.125 mm (4.92 mils)

FEEDDIRECTIONDot #0

Dot-lineon printhead

Dot #831

10.3 mm (0.41 in.)

Print Widthmax. 104.0 mm (4.095 in.)

Media Width25-114.3 mm (1-4.5 in.)



FEEDDIRECTIONDot #0

Dot-lineon printhead

Dot #1247

8.6 mm (0.34 in.)

Print Widthmax. 105.7 mm (4.161 in.)

Media Width25-114.3 mm (1-4.5 in.)

11.81 dots/mm PrintheadDensity 11.81 dots/mm (300 dots per inch)Print width 105.7 mm (4.161 inches)Number of dots 1248Dot size 0.085 mm (3.33 mils)



Th e printhead is fi tted to a bracket using two screws. Th e printhead, the printhead ribbon break shaft, and the bracket are always delivered as a complete assembly. Two hooked fi ngers at the rear of the bracket are fi tted over the headlift shaft so as to hold the printhead in place. A U-shaped tab on the outer side of the bracket engages the guide link when the printhead is closed, making sure that the printhead becomes properly aligned with the platen roller. Th ere are no facilities for adjusting the position of the printhead relative the platen roller, neither longitudinally nor laterally.

Th ere are two cables from the printhead to the CPU board:

• Th e innermost cable is used for the power to the printhead and is connected to P5 at the front of the Power Supply Unit.

• Th e outermost cable is used for data to the printhead and is connected to J40 on the CPU board.

Printhead

Bracket

Cable from CPU board (J40)

Cable from power supply unit (P5)

“Finger”

“Finger”

Printhead ribbon break shaft



Replacing the Printhead

Th e printhead is a consumable part subject to wear from both the direct thermal media or the thermal transfer ribbon and from the rapid heating and cooling process during printing. Th us, it will require periodic replacement depending on print volume, type of media or ribbon, amount of energy to the printhead, print speed, ambient temperature, and several other factors.

Never use printheads that were designed for the EasyCoder F4 or F4 Compact Industrial. Using one of these printheads will cause a short circuit or even a blown fuse.

Niemals Druckköpfe benutzen, die für die Modelle EasyCoder F4 oder F4 Compact Industrial vorgesehen sind. Wenn einer dieser Druckköpfe benutzt wird, verursacht dies einen Kurzschluss oder eine durchgebrannte Sicherung.

To replace a defective or worn printheadSwitch off the power.


Turn the printhead lift lever clockwise to raise the printhead.

Remove any media and ribbon from the print mechanism.

Carefully pull the printhead bracket away from the magnet in the pressure arm.

Disconnect the printhead bracket from the print mechanism and pull out the printhead while twisting it outwards 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 two cables to the replacement printhead.

Put back the printhead in reverse order and check that the printhead cables run freely.

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Lower the printhead so the magnet engages the printhead bracket.

Switch on the power. Th e printer’s fi rmware automatically measures the printhead resistance and density at startup.

Load the media and ribbon again.

Precautions

Some simple measures can be taken by the user to prevent premature wear-out:

• 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 from dissipating 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. Th us, 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. Th e labels must not contain any aggressive substances such as chloride or grinding substances such as titanium dioxide.

• Only use transfer ribbons recommended by Intermec.

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7.7 Headlift Sensor

Description

Th e 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 cannot 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. Th us, it is important that the printhead is properly engaged and a suffi cient pressure is applied before the sensor detects a “Closed” condition.

Th e sensor is fi tted using a barbed shaft that is pressed into a hole in the center section. Th e sensor consists of a light-emitting diode and a photoelectric sensor with housing and cables. Th e headlift sensor is connected to J58 (marked “HEADLIFT”) on the CPU board.

A beam of light is constantly transmitted from the diode. When the printhead is in closed position, the light beam is interrupted by an angular plate at the end of the crank shaft. As soon as the headlift lever is activated, and even before the printhead starts to raise, the plate is moved out of the sensor gap and the sensor can detect the light beam. Th is condition is managed by the fi rmware. In Fingerprint, an error message (1022 “Head Lifted”) will be returned if you try to print a label. In IPL, the error message “Print Head UP/Press Feed” is displayed.

Plate on Crank Shaft(printhead lowered)

Headlift Sensor

Connect here!

J84

J58

HEA

DLI

FT



Sensor Replacement

Before deciding to replace the sensor, check that the sensor is free from dust, and other objects that can block the light.

To replace the sensorSwitch off the power, remove the power cord, and remove the front/left-hand cover.


Disconnect the sensor’s cable from the CPU board.

Pull the sensor straight out using a pair of pliers. Th e sensor has a barbed shaft inserted into a hole in the center section moulding and requires some force to come out.

Make sure the hole is clear from any remnants of the old sensor.

Reassemble in reverse order. Th e 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 (<STX>L<ETX>), see IPL Programming, Reference Manual.

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7.8 Headlift Mechanism

Description

Th e headlift mechanism is used to raise and lower the printhead to allow media and ribbon load and also to apply a proper printhead pressure against the media. See Section 7.1 and the next page for illustrations!

Th e headlift is operated by the green headlift lever in the print mechanism. Th e lever is snap-locked at the end of the crank shaft, which runs inside the pressure shaft. At the other end of the crank shaft and inside the electronics compartment is an angular plate, which is used by the headlift sensor to detect whether the printhead is lowered or raised (see Section 7.7).

A small eccentrically fi tted knob on the angular plate runs in a crescent-shaped slot in the lifting arm. A coil spring presses the knob down in the slot and helps lifting the printhead. Th e lifting arm is connected by a link to the pressure link, which pivots in extensions from the center section. Th ereby the rotating movement of the crankshaft is transformed into a lateral movement.

Th e upper part of the pressure link is spring-loaded in relation to the center section. Th us, when the lever is turned towards lowered printhead position, the pressure is increased. Th e pressure is factory-adjusted by means of two screws inside the electronics compartment and fi ne-adjusted by the operator using a straight-slot screw accessible through a hole in the center section.

Th e lifting arm is connected to the pressure shaft by a lever. Th e pressure shaft runs through the center section to the print mechanism, where the pressure arm is fi tted on the shaft. A magnet at the tip of the pressure arm holds the printhead bracket. Th e arm can be moved laterally to apply its pressure at the center of the media, regardless of media width.

Th e printhead bracket hangs loosely on the pressure shaft in two hooked “fi ngers.” When the printhead is lowered, semicircular guides at both sides of the bracket engage the inner part of the platen roller and a slot in the guide link, ensuring that the printhead will be properly aligned with the platen roller.

When the printhead lift lever is activated from lowered position, the printhead will not start to move immediately, but the angular plate on the crank shaft will start to rotate out of the gap in the headlift sensor, indicating a “printhead lifted” condition. When the lever has reached a more or less vertical position, a clicking noise will be heard and the printhead is raised from the platen roller. Now the coil spring between the angular plate and the lifting arm will help the operator fi nish the movement of the lever and hold the printhead fi rmly in raised position.



Coil springCrank shaftAngular plate

Link

Lifting arm

Pressurelink

Lever

Shoe

Fine-adjustment screw

Pressure spring

Pressure Shaft

Printheadlift lever

Pressure arm

Printheadwithbracket

#T10 Torx screws

Nut

When the printhead lift lever is turned from raised to lowered position, the operator has to overcome a slight pressure from the coil spring until the lever passes a vertical position. Th en the printhead snaps into place and the spiral spring applies its pressure. In the fi nal part of the movement, the angular plate is rotated into the gap of the headlift sensor indicating a “printhead closed” condition.

Th is exploded view shows the parts of the headlift mechanism. Also refer to illustrations in Section 7.1 for assembled views.

C

B

A

The transfer ribbon mechanism have been omitted in the illustration above to improve visibility.



Printhead Pressure Adjustment

A skilled service technician can use the procedure described below to adjust printhead pressure. Operators should only use the fi ne-adjustment screw accessible from the media compartment.

Slit a piece of plastic tube lengthwise and put it on the tear bar in order to minimize the friction. On the thermal transfer-capable printers, the tube must not interfere with the printhead ribbon break shaft.

Fit a 300 g (0.66 lb) weight at the end of a full width strip of liner.

Loosen the upper #T10 Torx screw (A) in the electronics compartment. Note: Th e designations “A”, “B”, and “C” refer to the illustration on the previous page.

Using a 5.5 mm spanner, loosen the nut on screw (B).

Loosen the lower #T10 Torx screw (B) in the electronics compartment until the nut almost comes off .

Tighten the fi ne-adjustment screw (C) until it comes as far into the shoe as possible and the spiral spring becomes compressed.

Lower the printhead.

Tighten screw B until it meets the end of screw C.

Raise the printhead and put the liner strip between the printhead and platen roller so the weight hangs freely over the tear bar. Lower the printhead.

Loosen screw B until the strip starts to slip and tighten it again until the strip stops to slip.

Tighten screw B two (2) full turns and lock it with the nut. Now the printhead has a pressure of approximately 4.2 kgs.

Loosen screw C four full turns to decrease the pressure (each turn represents approximately 0.5 kp of pressure).

Do not use a higher printhead pressure than necessary. High printhead pressure increases the wear on the printhead and shortens its life.

Keinen höheren Druckkopfdruck benutzen als erforderlich. Ein hoher Druckkopfdruck bedeutet mehr Druckkopfverschleiß und eine kürzere Lebensdauer des Druckkopfs.

Tighten screw A until it has a play of ±0.1 mm (4 mils) to the lifting link and lock it with blue Loctite. Th e tightness of this screw aff ects the resistance in the printhead lift lever.

Fine-adjust using screw C according to printout samples (preferably test labels). Diff erences in media thickness, stiff ness, width, etc. may require slightly higher or lower pressure. Generally, thicker and/or stiff er media requires more printhead pressure. However, a very high pressure setting on screw C may require readjustment of screw A or there will be no printhead pressure at all.

If necessary, lubricate moving parts with MolyKote P6 30 L Plastislip or a similar grease.

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Printhead Pressure Alignment Adjust

Th e printer is factory-adjusted for full media width. When using media less than full width, it is recommended to adjust the pressure arm so it becomes centered in relation to the media. Th ereby, an even pressure across the media is obtained.

A poorly adjusted pressure arm may be detected by a weaker printout on the inner part of a less than full width media. Similarly, when reverting to a wider media, the arm should be adjusted, or the printout on the outer part of the media could be weak.

To adjust the pressure armLoosen the straight-slot screw that holds the pressure arm. Move the arm inwards or outwards until the arrow on the tip of the arm becomes centered in relation to the media.

Note: While moving the arm, push at the part where the screw is situated, not at the tip. If the arm is hard to move, raise the printhead and pull the printhead bracket free from the magnet in the pressure arm.

After having centered the arm, lock it by tightening the screw.

Adjust all edge guides (print mechanism, label slack absorber, and media supply roll post.

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Center of media

Tip of pressure arm

Knurled nut

Edge guide



7.9 Media Feed Principles

Fingerprint onlyTh e 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 14.7 mm (0.58 inches) back from the tear bar, the printing will not start at the top of the label but further back along the media path.

Note: Due to several factors, media feed measurements are not exact and may vary somewhat between applications and individual printers. Th ere is inevitably a small amount of slippage between media and platen roller, which in its turn is aff ected by printhead pressure, type of media or liner, thickness of the media, roll size, type of media supply device, etc. Th e platen roller may be worn, giving it a slightly smaller diameter and/or less friction. Th ere is also a certain amount of inexactness in the media feed mechanics and belts and so on. Th erefore, 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 fi nd values that give the desired result.

Note: All calculations and feed adjust values in this chapter refer to 8 dots/mm (202.3 dpi) printheads.

Dot line on printhead

Tear bar

14.7 mm

(0.58 in.)

Default (tear-off):Start Adjust: 0

Stop Adjust: 0



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 -100 dots = 12.5 mm/0.49 inches). Be careful not to enter too large a value, or the media may come loose from platen roller.

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 -44 (= 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 -56 (= 7.0 mm/0.28 inches). Note that the sum of the Start and Stop Adjust values always is 100 dots (12.5 mm/0.49 inches), which corresponds to the distance between dot line and tear bar minus a margin for the gap between labels and certain slippage.

Dot line on printhead

Tear bar

14.7 mm

(0.58 in.)

Tear off (print at top of label):Start Adjust: -100

Stop Adjust: 0

Dot line on printheadTear bar

14.7 mm

(0.58 in.)

Peel off (print at top of label):Start Adjust: -56

Stop Adjust: -44



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.

IPL OnlyIn IPL, the media feed is aff ected by the mode of operation. Th ere are three such modes:

• Tear-off (straight-through) (default)

• Peel-off (self-strip) (enabled/disabled by <STX><SI>tn<ETX> command)

• Cut-off (activated/deactivated when the cutter is enabled/dispabled in the Setup

Mode or by <STX><SI>cn<ETX> command)

Each mode has a fi xed amount of media feed, which can be fi ne-adjusted using the Label Rest Point parameter in the Setup Mode (See Appendix A, Setup/Media/Lbl Rest Point) or an <STX><SI>fn<ETX> command.

Th e type of detection is decided by the Media Type parameter in the Setup Mode (See Appendix A, Setup/Media/Media Type).


8 Liner Takeup Unit

Th is chapter descibes the optional liner takeup unit and covers the follow-ing topics:

• Description

• Takeup unit parts

• Fitting a liner takeup unit

• Replacing the timing belt


Chapter 8—Liner Takeup Unit

8.1 Description

Th e liner takeup unit is a factory installed option that is used for peel-off (self-strip) operation. Peel-off means that self-adhesive labels are automati-cally separated from the liner (backing paper) after printing and the liner is wound up on a hub inside the printer’s media compartment. Peel-off operation cannot be combined with fan-fold guides. Th e rewind unit is made up by the following main parts:

• Th e takeup hub assy (see Section 8.2 for details)

• Th e timing belt (fi tted in all printers)

• Th e guide shaft

Th e takeup hub is driven by a pulley on the right side of the stepper motor via a timing belt, which runs in a recess in the center section behind the media guide assy. (To simplify manufacturing, the timing belt is fi tted in all printers, but when there is no takeup unit it does not engage the pulley of the stepper motor). Th e dimensions of the pulleys make the takeup hub rotate somewhat faster than the media is being fed out, thus providing a certain tension to the liner. A wrapped spring clutch inside the takeup hub allows it to slip so as to limit the tension. An extra guide shaft fi tted to the center section separates the liner from the media path.

Th e liner drive roller (standard) underneath the platen roller helps pulling the liner (see Section 7.1).

Th e tension of the timing belt cannot be adjusted.

Center section

Stepper motor

Pulley

PulleyBelt

Spring clutch

Takeup hub

Shaft

Guide shaft



8.2 Takeup Unit Parts

Th e liner takeup unit consists of the following parts:

• Timing belt pulley (with fl ange and bearing)

• Hub (with spring clutch, bearing, and brace)

• Shaft

Th e threaded shaft is screwed into the center section. Th e timing belt pulley is fi tted on the shaft and the timing belt is fi tted around the pulley. Th e spring brake is mounted inside the bobbin and fi ts around the outer end of the pulley. It provides the necessary friction to keep the liner tight without pulling it too hard.

Th e brace collapses when being pulled out. Th e plastic spring inside the brace returns and expands the brace when it is released. Th us, the wound up liner can easily be removed at media replenishment.

Th e bobbin is held on the shaft by a snap-lock of the same type as the ribbon supply and rewind hubs (see Sections 6.2 and 6.3).

When no rewind unit is fi tted, the recess in the center section is covered by a circular cover plate, which can be removed using a #T20 Torx screw-driver.

Bearing

Bearing

Pulley

Spring Clutch

Hub

Brace

Shaft

Return Spring



8.3 Fitting a Liner Takeup Unit

Even if the liner takeup unit is intended to be factory-fi tted, it is quite easy to upgrade a printer with such a device:

Remove the cover plate from the center section using a #T20 Torx screwdriver.

Pull out the rear part of the timing belt from inside the media guide assembly.

Fit the takeup pulley into the recess in the center section and wrap the timing belt around it. When you pull the timing belt, it will engage the pulley of the stepper motor.

Screw the takeup shaft through the rewind pulley and into the center section using a pair of pliers. Th en screw the takeup guide shaft into the center section. Use tape or similar to protect the shafts from being scratched by the tool.

While rotating it, press the takeup hub onto the shaft and the pulley. Press until the snap-lock engages the groove in the shaft.

8.4 Replacing the Timing Belt

To replace a broken or worn-out timing beltRemove the media guide assy. as described in Section 7.5, “Label Stop Sensor/Replacing the Sensors.”

Pull out the rewind bobbin from the shaft. You will need two straight-slot screwdrivers or a special tool to pry the two legs of the snap-lock out of the groove in the shaft.

Separate the pulley from the takeup hub while taking care so the spring clutch stays inside the hub.

Fit a new timing belt over the pulley of the stepper motor.

Put back the takeup pulley and rewind hub as described in Section 8.3.

Reassemble remaining parts in reverse order.

1

2

3

4

5

1

2

3

4

5

6


9 Label Taken Sensor

Th is chapter describes the optiona label taken sensor and covers the following topics:

• Description

• Replacement

• Activating the LTS

• Adjustment


Chapter 9—Label Taken Sensor

9.1 Description

Th e Label Taken Sensor (LTS) is a factory-installed or fi eld-installable optional device, which enables the printer’s fi rmware to detect if the latest printed label, ticket, tag, etc. has been removed before printing another copy. It cannot be used in conjuction with a paper cutter, see Chapter 10.

Th e label taken sensor consists of a photoelectric sensor with a connection cable. Th e sensor is fi tted to a lug at the front tip of the center section using a #T10 Torx screw and a washer. Th e cable is secured to the bottom plate inside the electronics compartment using two self-adhesive cable clips.

A LED (light-emitting diode) in the LTS emits a narrow beam of light, which will be refl ected back to a photoelectric sensor by any label, ticket, tag, piece of strip, or liner, that has not been removed from the outfeed area. A prerequisite is that the media is fed out along the center section of the printer.

Th e LTS is connected to J53 on the CPU board. Th e sensitivity is adjusted in the Setup Mode, see Section 9.3.

Th e theoretical point of detection of the LTS is situated 20.7 mm (0.81in.) outside the inner edge of the media path and immediately in front of the tear bar.

Cable to J53 on the CPU board

Sensor

#T10 Torx screwand washer

Mounting lug



9.2 Replacement

Th e LTS comes as a complete assembly of sensor and cable. To replace a faulty LTS, proceed as follows.


Remove the left-hand cover as described in Section 3.2.

Remove the front door as described in Section 3.3.

Disconnect the LTS cable from the CPU board.

Remove the #T10 Torx screw nad washer that hold the sensor.

Pull the LTS through the hole in the center section into the electronics compartment.

Fit a new LTS assembly in reverse order.

Start up the printer, enter the Setup Mode and adjust the sensitivity of the new LTS as described in Section 9.3.

9.3 Activating the LTS

In Fingerprint, the label taken sensor is enabled using the instruction LTS& ON.

In IPL, the self-strip mode must be enbled. Th is can also be done by executing the following commands:<STX>R<ETX> (Enter print/confi guration mode)<STX><SI>t1<ETX> (Enable self-strip)

1

2

3

4

5

6

7

8



9.4 Adjustment

Th e sensitivity of the Label Taken Sensor (LTS) may need to be adjusted according to the ambient light conditions and the refl ective characteristics of the back side of the media.

FingerprintTh e sensitivity can be adjusted in the Setup Mode (see Appendix 1), or by using setup fi les 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 <Enter>. A label is fed out. Remove the label and press <Enter>

again. A menu shows the sensitivity automatically selected by the fi rmware and the range in which the LTS will work. Press <Enter> again and you will proceed to the LTS Test menu.

• LTS Test: Press <Enter>. 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. Th en press <Enter> to stop and exit.

• LTS Value: Press <Enter>. 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.

IPLTh e sensitivity can be adjusted in the Setup Mode (see Appendix 1).

In Setup Mode, select the Confi guration option.

Select LTS Calibration and press the key.

Press <Enter>

A number of labels are fed out. Remove the labels and press <Enter>.

Th e sensor has now been automatically adjusted and the resulting sensitivity is displayed as a numeric value in the range of 8 to 14.

1

2

3

4

5


10 Paper Cutter

Th is chapter descibes the optional paper cutter for EasyCoder PM4i printer. Th e chapter covers the following topics:

• Description

• Installation

• Controlling the cutter

• Media load

• Servicing

• Cutter PCB


Chapter 10—Paper Cutter

10.1 Description

Th e cutter is a factory-installed or fi eld-installable option for the EasyCoder PM4i printer. Th e cutter automatically cuts off the media after printing according to instructions in the controlling fi rmware. Th e cut off portions of media are presented at the front of the cutter and can be collected on a removeable tray.

Th e cutter can be tilted forward to facilitate media load. As a safety measure, the cutter can only operate when being completely closed.

Th e cutter prevents an optional label taken sensor from working, even if it is not necessary to remove it before fi tting the cutter.

Th e cutter is primarily intended to cut paper-based media in the form of continuous stock. It is also possible to cut through the liner between labels, but be careful not to cut through the labels themselves, because the adhesive will stick to the cutting blade and may cause malfunction.

Avoid cutting soft plastic-based media.

Minimum media thickness: 78μm

Maximum media thickness: 175μm

For measures, refer to Sections 1.6 and 1.7.

Th e weight of the cutter is approximately 1.8 kg (4.0 lb).

Cutter

Outfeed Slot

Removable Tray



10.2 Installation

Th e cutter is easy to install and requires no modifi cation of the printer itself.

Th e installation kit contains:

• Cutter unit (1)

• Tray (1)

• #T20 Torx screws (3)

• Installation Instructions (1)

Th e only tool required is a #T20 Torx screwdriver.

To install the cutterTurn the printer upside down on a soft piece of cloth or similar.

Remove the front door, see Section 3.3.

Insert the cutter bracket between the printer’s bottom plate and print mechanism so the three thread bushings on the bracket fi ts into the corresponding holes in the printer’s bottom plate. Fit it using the three #T20 Torx screws included in the kit.

Turn the printer back on its feet.


Connect the cutter cable to the Finisher interface connector underneath the print mechanism.

Restart the printer.

1

2

3

4

5

6

7

Bracket

Connect to Finisher interface

#T20 Torx screws (×3)



10.3 Controlling the Cutter

FingerprintTh e cutter is activated by CUT or CUT ON statements, see the Fingerprint or Direct Protocol manuals. Application programs may have related facilities for operating the cutter.

Th e edge will cut through the media approx. 33 mm (1.3 inches) in front of the printer’s dot line. Th e following values are recommended for cutting:

Type of Cutting 8 dots/mm printhead 11.81 dots/mm printhead

Cut between labels w. gaps Start adjust: - 325 dots - 480 dotsStop adjust: + 240 dots + 354 dots

Cut fi x and variable length strip (no liner!)Start adjust: - 340 dots - 502 dotsStop adjust: + 340 dots + 502 dots

IPLTh e cutter can be enabled/disabled in the Confi guration part of the setup mode or using the command <STX><SI>cn<ETX>, 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 <STX><SO><ETX>.

Also see the IPL Programmer’s Reference Manual.

10.4 Media Load

Load media following the descriptions in the User’s Guide for Media Load/Cut-Off operation (optionally with Quick-Load guides). Th e 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.



10.5 Servicing

Th e cutter mechanism and the circuit board becomes accessible when the cover is removed. Th e cover is held by one #T20 Torx screw. It is not necessary to remove the entire cutter unit.

Th e 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). Th e extreme positions of the moving cutting shear (that is, the shear is in top or home/bottom position) is detected by a sensor at the tip of the circuit board and a microswitch at the right side of the cutter assembly.

FingerprintIf the following errors occur, clean the shears from adhesive residue and the sensor from dust.

• 1701 “Cutter error1” A cut has been performed but the shear has stopped on its way back to

home (bottom) position.

• 1702 “Cutter error2” Th e cutter has failed to cut after several attempt (3 is default) and the

shear has returned to home (bottom) position.

• 1703 “Cutter error3” Th e 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 Finisher interface, Error 37, “Cutter device not found” or Error 1059, “Cutter does not respond” will occur.

If the “cutter open/closed” microswitch on the cutter assy is faulty, Error 1704, “Cutter open” will occur, even if the cutter in fact is closed.

IPLIPL 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 the sensor from dust.



Tray

#T20 Torx screw

Circuit board

Bracket

Cover

Top position sensor S1

Cutter open/closed sensor S4

Cable

Cutter bottom (home) position sensor S2(hidden)

Lubricated PartsDo not use isolpropyl alcohol!

Cover fi tted/removedsensor S3

Media intake

Latch



10.6 Cutter PCB

1-971650-50 Cutter Circuit Board assembly



1-971650-25 Cutter Circuit Board; Components

Primary Side Secondary Side



1-971650-25 Cutter Circuit Board; Schematics




11 Electronics Compartment

Th is chapter describes how to access the electronics compartment and shows the main parts.

Th e electronics compartment contains wires and components with dangerous voltage (up to 380V). Always switch off the power and unplug the power cord before you remove the cover over the electronics compartment!



Chapter 11—Electronics Compartment

11.1 Introduction

Th e Electronics Compartment is off limits to the normal user, but for the authorized service technician, it contains a number of parts of great interest:

• Th e stepper motor and timing belts of the platen and liner drive rollers.

• Th e ribbon feed motor.

• Th e headlift mechanism and sensor.

• Th e CPU board.

• Th e power supply unit.

• Optionally one or two extra interface boards and/or one EasyLAN board.

11.2 Accessing the Electronics Compartment

To gain access to the electronics compartment, remove the front/left-hand cover as described in Section 3.2. To completely remove the cover, you will need to disconnect the cable to the console pcb from J50 on the CPU board.



CPU board

Connect console pcb here

Stepper motor Platen roller belt and pulley

Liner drive roller belt and pulley

Power supply (behind CPU board)

Headlift mechanism

11.3 Main Parts

Th is is what you may see when you remove the front/left-hand cover from an EasyCoder PM4i printer.

Ribbon motor

Optionalinterface board(s)

Optional EasyLAN board




12 Power Supply

Th is chapter describes the power supply unit (PSU) which is fi tted in the electronics compartment, see Chapter 11.



Double Pole/Neutral Fusing. Parts may remain live after fuse operation.

Zweipolige/Neutralsicherung. Teile können nach Ansprechen der Sicherung noch stromführend sein.

Th e chapter covers the following topics:

• Description

• Replacement

• Components

• Schematics


Chapter 12—Power Supply

Input Voltage:90 to 265 VAC45 to 65Hz

24 VDC 6A

P24 EnablePower Fail

Stepper MotorOutputPower Supply Board

15W standby(approx. 300W peak)

Input

Rectifier 24V

Stepper MotorController

Control Vout(24V)

ForwardConverter

BoosterConverter

Pulse WidthModulator

(w. Power Factor Contr.)

Pulse WidthModulatorForward

Temperature Control&

Power Fail Interrupt

I2C-bus

Stepper MotorController

12.1 Description

Th e Power Supply Unit (PSU) is identical in all EasyCoder PF2/4i- and PM4i-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.

Th e power supply unit is primary-switched with power correction factor controller so as to comply with the CE regulations, which require a sinus-shaped load curve. It is designed for input voltages in the range of 90 to 265 VAC, 45 to 65Hz. Th ere is no manual switch.

Th e unit requires 15W at standby and 300W peak. It produces 24VDC only; all other voltages are transformed from 24VDC by the CPU board. Th e CPU board controls the PSU over the I2C bus, where also identifi cation and error signals are transmitted to the CPU board. Voltage and temperature are monitored and the unit is over-current protected.

Th e PSU consists of the following main parts:



Power Factor Control

Th e 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. Th e booster is protected by two 4A fuses.

Forward Converter

Th e forward converter transforms 385 VDC to 24 VDC 0-6A. Th e 24VDC is the bulk voltage and is used for all parts of the printer. Other voltages needed for internal devices are locally transformed from 24VDC.

Connections

P1 24VDC to CPU board, control lines, and I2C bus communication between PSU and CPU board.

P5 24 VDC to printhead

P6 Ribbon motor

P7 Not used

P8 ISR connector (not used)

P10 Stepper motor

X1 Input voltage 90 to 265 VAC, 45 to 65Hz

Overheating Protection

Th e power supply unit is fi tted 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 supply units are generally diffi cult to troubleshoot and repair. If one component fails due to aging or overload, a number of other components will also break as a consequence. If a fuse blows, do not attempt to repair the PSU, but replace the entire unit!

Th e 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. Whenever a fuse blows, always replace the entire power supply unit.

Das Netzteilmodul enthält Kabel und Schaltkreise, die gefährliche Spannungen führen. Aus Sicherheitsgründen ist es streng untersagt, ein Netzteilmodul zu reparieren oder eine durchgebrannte Sicherung auszutauschen. Falls eine Sicherung durchbrennt, muss das gesamte Netzteilmodul ausgetauscht werden.



12.2 Replacing the Power Supply Unit

Th e PSU comes as a complete unit consisting of a large metal bracket to which the following parts are factory-fi tted:

• 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• Heatsink (attached to bracket using doublesided tape)

Th e bracket and heatsink are fi tted to the center section using six #T20 Torx screws.

Label Bracket

Protection Sheet

PSU Board

On/Off Switch

Power cord socket

#T10 Torx screws and washers (x4)

#T10 Torx screws and nuts (x2)

Power supply unit without heatsink (simplifi ed drawing)


Heatsink

Tape



Replacement Procedure

Take precautions to avoid any electrostatic discharge.

Switch off the printer and disconnect the power cord and all interface cables on the rear plate.

Remove the front/left-hand cover as described in Section 3.2.

Remove any interface bord connected or attached to the CPU board.

Disconnect all cables from the CPU board and remove it (see Section 13.3). Th e CPU board is held to the PSU bracket using four #T20 screws and one hexagonal spacer.

Remove the six #T20 Torx screws that hold the PSU bracket/heatsink assy to the center section.

Do not dismantle the PSU. Replace the entire unit!

Assemble in reverse order.

1

2

3

4

5

6

7

8



12.3 Components

1-971631-25 Power Supply Unit; Component side

TY

1

C3

C4 C6

C5

C32

C33

F1

F2

F10

P5

L3

T2

T1

U7

U6

U5

U15

L5

C98

C97

C84

C46

C12

SW

1

U11

X1

U8

C48

C94

C95

C70

C45

C31

C26

C28

C29

C22

C24

C19

C18

C51

C52

C27

C47

C71

C87

C76

C77

C75

C78

C90

C93 C91C92

C58

C36

C21

C20

C104

C102 C101

C100

D33

TR1

D32 D31

D30

D29

D28 D27

D26

D25

R13

1C

R13

1B

R13

1A

R13

0C

R13

0B

R13

0A

D17

Q3

Q1

Q2

C34

C15

C62

C56

C61

PT1

PT2

VAR1

C1

C2

C81

C44

D13

D12

D24

D8

D5 D4 D3

Q12

Q13

T4

T3

L4

RB

1

Q10

U12

P7

P6

U3

R93

PO

T1

CH

AS

SIE

D1

D11

D10

U2

U4

P10

P1

Z5

Z1

Z2

Z3

U1

R98

R99R94

R77

R78

R14

R15

R39

R40

R41

R42

R36

R37

R38

R30

R33 R31

R68

R70

R67

R69R71

R66

R64

R65

R51

R54

R52

R58R57

R76R62

R63

R55

R56

R53

R59

R60 R61

R95

R97

R80R81

R90

R87

R88

R92

R91

R84

R86

R85

R83

R89

R100

R82

R10

3

R101

R10

4

R105

R10

6R

102

R113R111

R112

R110

R11

4

R123

R122 R121

R11

7

R118

R11

5R119

R120

R11

6

R127 R125R124R126

THR1

THR2

U10

Q14

Q11

Q4

Q15

L2L1

L13

L12

L11

L10

D23

D18

D22

D16 D15

D14

D9

D2

P8

P4

C83

C68

U13

18 9

16

GS

D

GS

D

GS

D

GS

D

GS

D

GS

D

17

8 14

17

8 14

1 3.

KN

CA

KNC A

KN

CA

KN

CA

CEB

CE B

CE B

CE B

KNCA

KNC A

KN

CA

KNCA K

NC

A

KNCA

KN

CA

KN

CA

Z6K

NC A

C7

C8

D7

KN

CA

D6

R75

C9

C10

R79

CH

AS

SIE

S

C59



1-971631-25 Power Supply Unit; Soldering side

R13

R12

R11

R3 R2 R1

R10E

R10D

R10G

R10F

R10A

R10C

R10B

R16R17R18

R19R21 R20

R22 R24R23

R4

R5

R6

R48 R49 R50

R45 R46 R47

R44B

R44D

R44A

R44C

R74C

R74B

R74A

R73A

R73B

R73C

C57

C13

C11

C14

C35

C42

C55

C41

C23

C67

C66

C64

C65

C69

C60

C63

C54

C53

C40

C99

C96

C103

R35 R9

R43

R7

R32

R27

R25

R26

R129

R128

R8

R29

R28

R96

C25

C80

C88

C85

C43

C50

C30

C37

R10H

R10J

R10I



12.4 Schematics

24V

C55

15V

C31

C33

C32

R22

R19

R74B

R38

R23 R24

R20 R21

R25

R26

R27

C54

15V

C30

15V

C27

R36

R54

L4

C48

TY1

R56

R57

15V

R55

Q4

C53

R51

D15

D16

C29

R37 C28

C26

R35

R74C

C25

R63

15V

LM393M

U4

R62

R58

C47

R16

HV +

C15

C14

R14

D1

R17 R18

R28 C21

R29 R30

R15

D2

D3

Q1

R73B

C13 R13 R12 R11 R9

C12

C11

R10A

C52

R10B

R10D

R10C

R10H

R10I

R10J

R7

R4 R5

C20

C57

24VP

R33

C24

D5

R32

C23

R31

R73A

C18

C19

C22

15V +

C44

C43

D14

Z1

+

C46

C45

D13

D12

CONTROL

U3

TOP221G08A

D4

R8

R71

R6

128-46

T4

HV

TR1

RB1

Q2

L2

VARISTOR

L1

C6

C5

C4

R40

C2

T2 C3

T1

SW1

CHASSIE

F2

C1

R3

F1

R2

R1

X1

R76

C42

T3

84-14

L3

TL431CLP

U8

L5

R77

D18

D11

C58

R78

R73C

R74A

C41

R10E

R10F

R10G

R48

C40 R45

D10

R42

Q3

R44D

R44C

24VP

R44A

R44B

R68 R66

Z2

R67

+

C56

R70

C51

R69

C50

24VP

Z3

R64

R65

T

THR2

R50R49

R46 R47

15V

15V

T

THR1

R61

R52

15V

R59

R60

U4

LM393M

R53

R39

D7

D6

C35

+

C34

D9

R41

D8C36

R43

C37

U2

L6385

SURGE PROTECTOR

SURGE PROTECTOR

SECONDARY

PSU CTRL

OVERVOLTAGE

OVERHEATSHUT DOWN

80 DEG

SENSOR

SENSOR

TEMPERATURE

5-80 DEG

24V POWER OUT

5

4

34

21U5

34

21U7

34

21U6

43

21

C

REF

A

876

121110

98

2

14131211

10

1

PT23

2

13

2

1

4

3

2

1

4

3

2

1

PT1

VAR1

1 4

32

6 5

10 1

876321

C A

S

G

D

CA

57

6

3

20

19

791

13

2 11

144

17

8

16

18

10

12

65

15

U1

12

EC

B2

1

3

8 6 5

17

2 4

8

31

4

2

C AC A

3

21

POT1

S

G

D

C A

C A

S

G

D

DSG

D17

765

321

1K6

270K

B

B

UCC38503DW

AC2

GND

AC1A

B

+

AC

AC

-

A

A

HVG

GND

LVT817

OVP/ENBL

SHD

VERR

PFI_DET

5V

LVT817

LVT817

TEMP_MON

VAOUT

PFIV

5V

CT

ISENSE1

SS2

GT1

VFF

IAC

VREF

MOUT

PKLIMIT

2 31

GT2

ISENSE2

VSENSE

PFIV

CAOUT

PWRGND

OUT

LIN

GND

VCC

LVG

HIN

VB

RT

SHD

VCC

VGATE

4

3

C8

C7

CHASSIES

R75

R79

C10

C9

+

C59

1-971631-25 Power Supply Unit; AC to 24VDC



C96

C99

U11

5.0V

P7

+C83

24VS

+

C81

C80R93

Q15

R91

24VS

R92

C69

24V_PH

C63

+

C62

+

C61

24V

C60

P5

Q10

C71

D29

D22

R95R97

P10

F10

D28

C66 L13

L12

C67

5V

P8

5V

R90 D23

5V

R89

Q14

R88 R87

U10

PIC16F87204

C75

D27

C76

5V

C78

R83

C77

24VS

R86

D26

R85

R84

5V

R81

R80

5V

P1

R130C

P4

R82

5V

Z5

C70

R99

R130B

L10

L11

C65

C64

+

C68

24VS

R98

R96

R94

R131C

Z6

R131B

D25

R130A

C94

C95

R131A

C100

D32

5V

C101

C103

C102

R129

R128

5V

R114

AHCT14

D31

R113

A3977

U13

R127

C93

C92

R126

R124

R122

R118 R119

D30

R125

C91

C90

R123

R120 R121

R115

R116

AHCT14

AHCT14

R117

AHCT14

C87

C88

C85

D33

24VS

24VS

Q12

R106

P6

Q13

R102

R105

R104

C104

+C97

Q11

5V

R112

R111

R110

R103

R101

R100

+C98

5V

AHCT14

5V

AHCT14

D24

+

C84

PFI_DET

FAN DRIVER

ISR CONNECTOR

TPH 24V SWITCH

EXTERNAL DIODES

R129 MOUNTED IF

TT-MOTOR DRIVER

24 V TPH OUT

STEPPER MOTOR DRIVER

5V?

CPU

SCL

SDA

FAN+

STEPPER MOTOR CURRENT CONTROL

ELSE R128

FAN-

P24EN

PSU_NOT_N

CPU CON

24 V POWER IN

PSU_INT_N

PSU CTRL

VGATE

3

4

2

1

U15

21987654

34333231303

292827262524232221202

191817161514131211101

20

1817161514131211

2827262524232221

765432

198

109 1

EC

B

54321

S

G

D

87654321

EC

B

21

31

2

21

U12

12

13

U12

EC

B

S

G

D

21

S

G

D

43

U12

65

U12

89

U12

32

16

36

2543

31

26

42

21

3

27

14

1510

332423221312112

443534

1

9

28

18

40

6

19204

41 5

38

37

10

11

U12

4321

PSU_NOT_N

P24ON

C

P24ON

LVT817

TT_PWM

3A

SDA

VCC

STMC4

STMC3

STMC2

STMC1

PIC_RESET

DIR

STEP

STEPPER4

STEPPER5

STEPPER6

STEPPER7

STEPPER8

STEPPER9

P24EN

PSU_INT_N

SCL

MS2

MS1

RESET_N

DIR

CAD24V

STMC2

STMC3

STMC4

D B

RESET_N

PFI_DET

RB2

RC5

RB3

RB4

CLKOUT

RC7

RC6

RC4

RC3

RC2

RC1

RC0

RB7

RB6

RB5

RB1

RA5

GND

GND

10K

OUT1A

HOME_N

MS2

OUT2B

OUT1B

RC1

PGNDPGNDPGNDPGNDPGND

RESET_N

OUT2A

RC2

PFD

REF

DIR

STEP

MS1

ENABLE_N

SLEEP_N

CP1

VREG

VDD

SENSE2

SENSE1

PGND

PGNDPGND

PGNDPGND

PGND

SR_N

PGND

STEP

VBBVBB

VCP

TEMP_MON

VOUT

VIN GND/ADJ

TPHV

HOME_N

MS1

MS2

STEP

DIR

STEPPER3

HOME_N

MCLR/VPP

RA1

RA4/TOCKI

RA3/VREF

RA2

RA0

CLKIN

CP2

FAN_PWM

B

INT/RB0

STEPPER MOTOR

1-971631-25 Power Supply Unit; Driver and CPU Interfaces




13 CPU Board

Th is chapter describes the CPU board which is fi tted in the electronics compartment (see Chapter 11).



Before touching the CPU board, take precautions to avoid any electrostatic discharge.

Th e chapter covers the following topics:

• Description

• Circuits

• Connectors

• Test points

• Startup

• Components

• Schematics

Note: Devices and fi le systems, such as "/c:" or "uart1:", are only used in Fingerprint. Some may also exist in IPL, but are hidden to the user.


Chapter 13—CPU Board

13.1 Description

Th e CPU board is a four-layer board with most of its circuits surface-mounted. Inside the laminate are a combined VCC layer (5V/3.3V/2.5V) and a GND layer. Th e front and back sides are signal routing layers.

Th e hardware contains of the following main functions:

• Processor core

• Th ermal printhead driver

• Stepper motor control logic

• Sensor drivers

• Communication, such as UART, USB, etc.

• Flash memory SIMM for the fi rmware 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)

1-971630-25 CPU board; Block Diagram

(numbers refer to schematics in Section 13.7)

I2C bus

Power conversion5V

3.3V2.5V

24V In

Stepper control signals

(only one optionalboard in PF-series)

PSU/Motorinterface

Sensors

A/D converter

TPH

Console

FinisherClock

48 MHz

CLICSupport logic

Board idReset

Exp. interface

Optional board

(Optional board)

Flash memory Compact Flash USB

UART PCI bus(custom)

Networkcard

BeeperiButtonWand

CPURISC core

Memory controllerPCI interface

PSATPH logic

Stepper logicInterrupt

I2C master

Bus isolationCPU board

EEPROM

1

1

2

2 2 2

3

3

3

4

5

5

5

5 5

55

6 6

6

7

8

SDRAM1



13.2 Circuits

Components mentioned in this chapter are marked with gray in the drawing below.

Processor (U13)

Th e processor is a 32-bit RISC off ering about 125 MIPS at the internal clock speed 96MHz. Th e internal bus speed is twice the external bus speed at 48MHz. Th e processor has several features, such as integrated SDRAM controller, PCI bridge, DMA, UART, timers, etc.

Support Chip (U30)

Th e PSA (Processor Support ASIC) is a programmable logic device, which is programmed by the fi rmware at each startup. It contains most of the printer-specifi c 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, fi nisher, etc.

P35

J30

RTC & PROGRAM KEY

BOOT-FLASH

CO

MPA

CT

FLA

SHJ21 J20

J101-971630-00 PO2

U13Processor

U30Support

Chip



Flash Memory (J20 and J21)

Th ere are two sockets for Flash SIMMs (marked “BOOT FLASH” and “EXP FLASH”). A SIMM (Single Inline Memory Module) must always be fi tted in J20 since this bank is the Bootbank. As standard, a single 4MB fl ash SIMM is fi tted. It contains the following sectors:

1/. Devices are used in Fingerprint, but are hidden in IPL.2/. Th is sector can be used for the kernel or for the fi le system (/c). If it is used for the fi le system, the kernel is placed in the fi le system under the /c/boot directory, which is the normal confi guration, enabling the size diff erence 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 fi les stored in /c and /rom by default. Th e kernel includes Fingerprint or IPL fi rmware, bar codes, standard fonts, standard images, Intermec Shell, auxiliary programs, default setup values, and the EasyLAN home page fi les.

Th e fl ash 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. Th is is done automatically in the background. At power-up, the fl ash 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 fi le 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.

Th e Boot sector is necessary for Intermec Fingerprint or IPL to start. Th ere is a boot sector in all fl ash SIMMs at delivery, but the fi rmware will only accept the boot sector of a SIMM fi tted in J20 (marked “BOOT FLASH”). Th e boot sector is only protected when the fl ash SIMM is fi tted in socket J20 (”BOOT FLASH”). If you move fl ash SIMMs from one CPU board to another, make sure that the SIMM containing the boot sector is fi tted in J20 (“BOOT FLASH”) on the other board, or the boot sector will be overwritten.

Note: Th e Intermec Fingerprint fi rmware is either stored in the /c fi le system or in a dedicated area on the boot fl ash (2MB large). If it is stored in the fi le system, removing or exchanging an EXP FLASH in the J21 loca-tion may render the printer inoperable. To cure this condition, use a Com-pactFlash card containing an upgrade fi le (kernel) to reload the fi rmware.

As illustrated in the table above, a total nominal capacity of 3904K is used for the /c fi le system (MIFS, or FOS) and fonts. In Fingerprint, practically, around 2 MB are available to the user (about 200-400K less if the kernel is in the dedicated area).

Device1 Size Type Used for

– 128K Boot Startup

/c 2048K User fi le system or Kernel1 FP: Customer’s programs, fi les, images IPL: Formats, images, fonts

/c 1856K User fi le system FP: Customer’s programs, fi les, images IPL: Formats, images, fonts

– 32K TMP area Media feed info, odometer value, etc.

– 32K Parameters Media feed info, odometer value, etc.



Exactly which fonts, images, fi les, and programs are stored in the Fingerprint fi le system may vary between customers and applications.

Th e parameters sectors store the PFSVARs (see SETPFSVAR Fingerprint statement), odometer values, and a few other “invisible” fi les 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.

Th e printer’s permanent memory can be expanded by fi tting a second 4MB or 8MB fl ash memory SIMMs in sockets J21. 4MB and 8MB fl ash SIMMs can be mixed at will. Flash SIMMs are custom-made and can only be ordered from Intermec.

Note: Th e fi rst time the printer is started with a SIMM in J21 (“EXP FLASH”), the memory is not increased to enable cloning the fi rst SIMM. Th e 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 4 MB SIMM 1.8MB 4MB 5.8MB


8MB SIMM – 5.8MB – 5.8MB





SDRAM Memory (J10)

Th e 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. Th us, 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 fl ash memory. Th erefore, at startup the kernel is copied from the Flash memory to the SDRAM, where the various instructions are executed.

One SDRAM SIMM (standard size 8MB) must always be installed in socket J10 (SDRAM0-1).

Th e SDRAM is also used for the font cache and various buff ers. Th e remainder is used for the two print image buff ers where the bitmap patterns are stored prior to printing. One buff er 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 buff ers, batch printing without stopping between labels can be achieved.

Th e size of the buff ers depend on two factors:

• Number of physical dots on the printhead.

• Present label length setup value in dots.

Calculate the buff er size according to this formula:(No. of dots / 8 + 4) × (Media length in dots) = Buff er size in bytes(Buff er size in bytes) / 1024 = Buff er size in kbytesBuff er size in kbytes × 2 = Memory requirement in kbytes

Example:Th e number of dots on the 8 dots/mm printhead of an EasyCoder PM4i is 832.“Media; Length” is set to 1500 dots (= 187.5 mm/7.38 inches)[[(832 / 8) + 4) × (1500)] / 1024] × 2 = 316 kbyte total

If a longer print length or more storage space is required, the printer can be fi tted with a 16MB SDRAM instead of the standard 8MB. However, regardless of memory size there is an absolute print length limit of 32,767 dots (4,095 mm/161.2 inches).

Electronic Key Circuit (J30), Fingerprint-only option

Th e 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. Th e circuit also contains 4Kbits (500 bytes) of battery backed-up memory for the devices "lock:" and "storage:".

Th e Electronic Key Circuit (J30) contains an integrated lithium battery. Replace only with original Electronic Key Circuits from Intermec. Dispose of used Electronic Key Circuits in compliance with local regulations for lithium batteries.



Der elektronische Schlüsselschaltkreis (J30) ist mit einer integrierten Lithium-Batterie ausgerüstet. Dieser darf nur durch elektronische Original-Schlüsselschaltkreise von Intermec ersetzt werden. Benutzte elektronische Schlüsselschaltkreise müssen unter Einhaltung örtlicher behördlicher Vorschriften für Lithium-Batterien entsorgt werden.

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. Th us, there is a small risk that new data may be lost, before it has been saved back to the electronic key circuit. Th e original data in the electronic key circuit will not be damaged, if the read-back process should fail.

Memory Card Adapter (J22)

Th e 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 fi rmware at startup and must thus be inserted in the memory card adapter before the power is switched on or the printer is rebooted.

Switch off the power to the printer before you insert or remove any memory cards.

Die Stromversorgung des Druckers abschalten, bevor Speicherkarten eingesetzt oder entfernt werden.

Preprogrammed CompactFlash Memory CardsTh ere 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. Th ese fonts can be used

without the card being present.

• Firmware Cards Install a new fi rmware kernel in the printer including standard fonts. Used

for upgrading the fi rmware or switching between Fingerprint and IPL.

• Confi guration Cards Confi gures a CPU board for the type of printer in which it is installed, see

Section 13.8, or changes the printer’s EasyLAN setup.



13.3 Connections

Th e following connectors on the CPU board are used in the printer for communication with various devices and sensors.

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(s) (optional interface boards)

J57 Paper Sensor

J53 Label Taken Sensor (option)

J51 Finisher

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 PSU

J40 Data to printhead

J55 LSS (gap)

J54 LSS (black mark)

J58 Headlift sensor

J59

J61

J60

P35

RS2

32

USB

J57

J51 FINISHERPAPER J53 LTS

J62

EXP BOARD

WA

ND

J84

J50

PC

I

J56

J52

J40

J55

GA

PJ5

4B

MJ5

8H

EAD

LIFT

PR

INTH

EAD

PO

WER

CO

NSO

LE

RIB

BO

N

1-971630-00 PO2

J61



13.4 Test Points

Th e CPU board is provided with many test points. Only those of

immediate interest to the fi eld service technician are shown below. If

further testing or servicing is required, replace the CPU board and return

the faulty board to a service center.

Test Points

If available, use an oscilloscope to measure the various voltages. When using for example a multimeter, a fl uttering 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 F10 left side –> GND (allowed deviation, see Chapter 12) (If no voltage on the left side, check the right side. If voltage

there, fuse is blown, else cable or PSU trouble.)

DONE High level = U30 programmed, see Section 13.5

DEBUG Startup check, see Section 13.5

WAND Use an oscilloscope. OK if there is a pulse train when the wand is reading a bar code.

P35

WAND

F70

R718

3.3V

2.5V

GND

J23

DONE

DEBUG

1-971630-00 PO2



13.5 Startup

Th e prerequisite for the printer to start is that a fl ash memory SIMM with a boot sector is fi tted 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 file is recognized.- Th e fi rmware will be copied from the memory card to the internal

SDRAM.

- Th e processor will start to execute code from SDRAM.

- Th e fi rmware on the memory card will be copied to the internal fl ash memory.

2. A valid firmware is recognized in the internal flash memory.- Th e fi rmware will be copied to SDRAM and the processor will start

execute code from SDRAM.

If the printer is fi tted with an EasyLAN interface, there are also facilities for updating the fi rmware 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). Th e startup procedure can be followed on the printer’s display.

You can also follow the startup from the host provided a strap is temporarily fi tted 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 fi rmware.



13.6 Components

1-971630-25 CPU Board; Component Side

6835

341

ANC

K

1

ANC

K

ANC

KA

NCK

A NCK

BE

C

BE

C

BE

C

BE

C

B EC

B EC

B EC

B EC

B EC

B EC

B EC

B EC

J62

U25U24U23U22 U21U20

U42 U43U31

Y10

Y60

U11

U50

U32

U41

U52

U13

U30

J52 J40

J61J60

J10

MH

70M

H71

J59

THY

70

U26

U70

U91

U80

U90

B60

C70

8

C402

C50

8

C701

C70

9

C50

7

C92

1

C10

C62

C712

C93

8

C71

7

2.5V

3.3V

CC

LK

DO

NE

D0

GN

D

INIT

PP

30

PP31

PP

40

PP

50

PP

51

PP

52

PP53

PP54

PP

55

PP

56

PP

57P

P58

PP

59

PROGPSA_TDO

EXP

1_IN

T_N

EXP

2_IN

T_N

PP

32

PP

41

TCK

TDI

TMS

WA

ND

PSU_INT_N

USB

_IN

T_N

C71

0

C90

0

F70

J23

J83

J30

L50

L51

L52

L60

L61

L62

L63

L64

L65

L66

L67

L68

U40

U51

U81

U60

U61

U72

Z70

J20

J21

J51

J50

D72

L70

C70

0

RP

60

R71

8

J84

J81

J22

R714

R715

R320

R409

R319

R524

R724

R403

R712

R711

R713

D50

D71

D70

D40

R993

R966

R965

R959

R954

R970

R972

R985

R977

R999

R998

R996

R995

R992

R990

R989

R974

R969

R967

R963

R962

R960

R957

R955

R952

R951

R500

R912

R911

R206

R265

R925

R202

R924

R847

R300

R129

R921

R200

R920

R127R128R126

R125

R123R124

R339

R411

R404

R405

R913

R707

R703

R601

R600

R523

R522

R521

R520

R510 R509

R414

R413

R412

R406

R402

R401

R400

R327

R322

R314

R310

R306

R717

R303

R983

R981

R980

R978

R975

R973

R926

R923R922

R914

R898

R897

R896

R710

R709

R708

R526

R525

R424

R321

R313

R309

R305

R204

R203

R130

R100

R415

R318

R417

R423

R905

R103

R102

R101

R720

R719

R705

R702

R700

R323

R315

R311

R307

R722

R716

R407

R326

R304

R301

R615

R614

R613

R612

R611

R610

R410R422

R416

R605

R602

R704

R317

R915

R620

R619

R618

R408

R328

R324

R316

R312

R308

R421

R723

R721

R706

R701

R420

R419

R418

R325

R302

R110

R621

R604

R603

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

R232

R231

R230

R229

R228

R227

R226

R225

R224

R223

R222

R221

R220

R219

R218

R217

R216

R215

R629

R136

R623

R625

R624

R892

R89

3

R894R89

5

R430

R431

R432

R433

R434

R435

R436

R437

R438

R439

R440

R904

R137

R138

R139

R140

R141

R142

R143

R144

R145

R146

R147

R148

R149

R150

R151

R152

R153

R154

R155

R156

R157

R158

R159

R932

R934

T1

T80

T71

T70

T47 T46 T45T43T42 T41 T40

T44

C540

C716C96

4

C976

C972

C971

C967

C966

C96

5

C963 C961

C95

8

C95

7

C95

6

C95

5

C95

4

C95

3

C95

2

C951

C509

C403

C973

C705

C70

3

C40

6

C40

0

C974

C512

C405

C40

1

C66

C65

C64

C63

C11

C511

C404C70

2

C70

4

C61

C60

C975

C12

C510

C706

J24 U92

J53

J55

J56

J57

J54

J58

L71

L72

L402

L415

L400

T72

L74

U71



1-971630-25 CPU Board; Soldering Side

R899R899

R872R872

R111R111

R201R201

R516R516

R517R517

R544R544R545R545

R543R543

R542R542

R538R538

R539R539

R541R541

R540R540

R518R518

R519R519

R512R512

R513R513 R428R428R429R429

R426R426

R427R427

R531R531

R530R530

R533R533

R532R532 R535R535R534R534

R537R537R536R536

R515R515R514R514

R547R547R546R546

R549R549

R548R548

R910R910

R628R628R627R627R626R626

R329R329

R822R822

R802R802

R806R806

R819R819

R823R823

R803R803

R807R807

R833R833

R927R927

R816R816

R820R820

R804R804

R817R817

R818R818

R821R821

R801R801

R805R805

R800R800

R928R928

R864R864

R865R865

R871R871

R863R863

R862R862

R854R854

R861R861

R869R869

R868R868

R867R867

R866R866

R870R870

R873R873

R874R874

R881R881

R882R882

R884R884

R876R876

R875R875

R883R883

R856R856

R851R851

R858R858

R878R878

R887R887

R886R886

R885R885

R877R877

R848R848

R855R855

R849R849

R857R857

R850R850

R880R880

R879R879

R853R853

R860R860

R852R852

R859R859

R888R888

R815R815

R811R811

R831R831

R846R846

R841R841

R840R840

R839R839

R842R842

R843R843

R844R844

R845R845

R828R828

R808R808

R812R812

R825R825

R829R829

R809R809

R813R813

R826R826

R830R830

R810R810

R814R814

R827R827

R835R835

R838R838

R837R837

R834R834

R824R824

R336R336

R337R337R338R338

R334R334

R333R333

R335R335

R425R425

R725R725

R950R950

R991R991

R994R994

R997R997

R976R976

R979R979

R982R982

R984R984

R987R987

R988R988

R964R964

R968R968

R971R971

R953R953

R961R961

R958R958

R956R956

R986R986

R903 R903

R902 R902

R901R901

R900 R900

R209R209

R208R208

R210R210

R207R207

R889R889R890R890

R131R131R132R132R133R133R134R134R135R135R832R832

R929R929R930R930

R836R836

R931R931

R933R933

C718

C718

C715

C715

C711C711

C922C922

C939C939

C923C923

C940C940

C924C924

C941C941

C925

C925

C926

C926

C945

C945

C927

C927

C946

C946

C928

C928

C947

C947

C937C937

C950C950

C936C936

C949C949

C935C935

C948C948

C934C934 C933C933

C905C905 C904C904 C903C903 C902C902 C901 C901

C911

C911

C912

C912

C913

C913

C910

C910

C909

C909

C908

C908

C906

C906

C907

C907

C505C505

C506C506

C537C537

C536

C536

C534

C534

C535

C535

C513C513C501C501

C502C502

C409

C409

C408

C408

C532C532

C533

C533

C530C530

C531C531

C504C504C503C503

C538

C538

C539

C539

C929

C929

C942

C942

C930

C930

C943

C943

C931

C931

C944

C944

C932

C932

C920C920 C919C919 C918C918 C917C917 C916C916

C914

C914

C915

C915

C31C31

C30C30

C407

C407

C970C970 C969C969

C968C968

C707

C707

C713C713

C714C714

C33C33

C32C32

C991C991

C982

C982

C983

C983

C984

C984

C985

C985

C986

C986

C987

C987

C988C988C989C989

C990C990

C992

C992

C978

C978 C980C980

C977

C977

C979

C979

C981C981



13.7 Schematics

1-971630-25 CPU Board; Core (Schematics #1)

3.3

V

3.3

V

+C

10

C1

1

C1

2

R1

11

3.3

V

D

R8

47

R8

46

R8

45

R8

44

R8

43

R8

42

R8

41

R8

40

R8

39

R8

38

R8

37

R8

36

R8

35

R8

34

R8

33

R8

32

R1

35

R1

34

R1

33

R1

32

R1

31

R1

30

R1

29

R1

28

R1

27

R1

26

R1

25

R1

24

R1

23

R1

10

R1

03

R1

02

R1

01

D

DD

12

Mh

z

Y1

0

D

DR1

00

TD

I

R1

36

R1

54

R1

53

R1

52

R1

50R1

49

R1

48R1

47

R1

46

R1

45

R1

44

R1

57

R1

58 R1

59

R1

55

R1

56

R1

43

R1

42

R1

41R

13

8R

13

9R

14

0

R1

37

R1

51

3.3

V

3.3

VS

DR

AM

_S

IMM

J10

CLK

B

OE

/FS

VC

C

XT

ALI

N

XT

ALO

UT

GN

D

CLK

C

CLK

A

CY

20

71

A

U1

1

SD

_B

E1

_N

GN

D1

PC

I_B

E1

_N

RC

32

33

2

UART_RX0

UART_TX0

M_WE3_N

M_WE2_N

M_WE1_N

VCCO16

GND20

M_WE0_N

M_CS5_N

M_CS4_N

M_CS3_N

M_CS2_N

DMA_RDY0_N

M_CS1_N

M_CS0_N

M_OE_N

VCCO15

GND19

M_WAIT_N

M_245_OE_N

SPI_MOSI

SPI_MISO

SPI_SCK

SPI_SS_N

VCCI7

VCCI6

GND18

VCCI5

DB_CPU_DMA_N

DB_CPU_ACK_N

DB_CPU_ADS_N

DB_CPU_ID_N

EJTAG_DBOOT

EJTAG_DCLK

EJTAG_PCST2

VCCO14

GND17

EJATG_PCST1

EJATG_PCST0

JTAG_TRST_N

JTAG_TCK

EJTAG_TMS

JTAG_TMS

JTAG_TDO

JTAG_TDI

VCCO13

GND16

INT1_N

INT0_N

PCI_RST_N

PCI_GNT2_N

PCI_REQ2_N PC

I_G

NT

1_

N

PC

I_C

LK

PC

I_G

NT

0_

N

PC

I_R

EQ

0_

N

PC

I_A

D3

1

VC

CO

12

GN

D1

5

PC

I_A

D3

0

PC

I_A

D2

9

PC

I_A

D2

8

PC

I_A

D2

7

PC

I_A

D2

6

PC

I_A

D2

5

PC

I_A

D2

4

PC

I_B

E3

_N

VC

CO

11

GN

D1

4

PC

I_A

D2

3

PC

I_A

D2

2

PC

I_A

D2

1

PC

I_A

D2

0

PC

I_A

D1

9

PC

I_A

D1

8

PC

I_A

D1

7

PC

I_A

D1

6

VC

CI4

GN

D1

3

PC

I_B

E2

_N

PC

I_F

RA

ME

_N

PC

I_IR

DY

_N

PC

I_T

RD

Y_

N

PC

I_D

S_

N

PC

I_S

TO

P_

N

PC

I_LO

CK

_N

PC

I_P

ER

R_

N

VC

CO

10

GN

D1

2

PC

I_P

AR

PC

I_A

D1

5

PC

I_A

D1

4

PC

I_A

D1

3

PC

I_A

D1

2

PC

I_A

D1

1

VC

CO

9

GN

D1

1

PC

I_A

D1

0

PC

I_A

D9

PC

I_A

D8

PC

I_B

E0

_N

PC

I_A

D7

PCI_AD0

PCI_AD1

GND10

VCCO8

PCI_AD2

PCI_AD3

PCI_AD4

PCI_AD5

PCI_AD6

NMI_N

M_D21

M_D9

M_D22

M_D8

M_D23

VCCO7

GND9

M_D7

M_D24

M_D6

M_D25

245_DT_R_N

VCCI3

GND8

M_D5

M_D26

GNDP

VCCP

M_D4

M_D27

M_D3

M_D28

M_D2

M_D29

M_D1

VCCO6

GND7

M_D30

M_D0

M_D31

MAST_CLK

M_D15

VCCI2

M_D16

M_D17

VCCO5

GND6

M_D14

M_D18

M_D13

M_D19

M_D12

CO

LD_

RE

S_

N

M_

D2

0

M_

D1

1

M_

D1

0

M_

A2

2

VC

CO

4

GN

D5

M_

A2

1

M_

A2

0

SD

_C

S2

_N

M_

A1

9

M_

A1

8

M_

A1

7

M_

A1

6

M_

A1

5

M_

A1

4

VC

CO

3

GN

D4

M_

A1

3

SD

_B

E3

_N

SD

_B

E2

_N

SD

_C

S3

_N

SD

_C

KE

M_

A4

M_

A3

M_

A2

M_

A5

M_

A6

M_

A7

M_

A8

M_

A9

M_

A1

0

M_

A1

1

M_

A1

2

SD

_A

12

VC

CI1

GN

D3

OU

T_

CLK

VC

CO

2

GN

D2

SD

_S

1_

N

SD

_S

0_

N

SD

_R

AS

_N

SD

_C

S1

_N

SD

_C

S0

_N

VC

CO

1

SD

_C

AS

_N

SD

_B

E0

_N

SD

_W

E_

N

SD

_2

45

_O

E_

N

PC

I_S

ER

R_

N

U1

3

CP

U

(IN

CL

M_

A(2

2..1

7))

MO

DE

CLO

CK

DR

IVER

SDR

AM

SIM

M

57

SD

_A

12

58

181

185

PCI_RES_N

PCI_INT_N

PCST1

14

61

SD

_R

AS

_N

SD

_C

AS

_N

SD

_O

E_

N

72

202

50

71

31

1

20

SD

_B

E3

_N

M_RD_N

BUS_DIR_N

16

292

87

CLI

C_

CLK

CP

U_

CLK

VS

S1

14

SD

_P

D1

4

DQ

M3

SD

_P

D0

D1

5

D2

9

SD

A5

11

M_

D<

31

..0>

31

10

11

20

M_

A<

22

..1>

22

23

87

SD

_C

LK

D1

9

21

PC

ST

2

ID_

N

AC

K_

N

22

20

19

18

17

16

15

14

13

12

11

10

9 8 7 6 5 4 3 2 1

PC

ST

1

AD

S_

N

DM

A_

N

30

27

28

25

24

26

22

23

19

20

17

18

16

14

15

12

11

13

9 810

7

21922

654

23

10

823

724

256

526

274

328

1

0

15

1617

1418131912

CP

U_

CLK

PC

I_S

ER

R_

N

PC

I_C

BE

0_

N

PC

I_P

AR

PC

I_LO

CK

_N

PC

I_S

TO

P_

NP

CI_

DS

_N

PC

I_T

RD

Y_

N

PC

I_C

BE

2_

N

PC

I_C

BE

3_

N

PC

I_C

LK

PCI_GNT2_N

INT0_N

TDI

TMS

TCK

PCST2

EJ_DBOOTID_N

ACK_NDMA_N

PC

I_C

BE

1_

N

24

16

25

17

26

18

19

21

29

30

VC

C3

SD

A7

DQ

M2

VS

S7

D2

0

VS

S8

SD

A1

4

SD

A1

3

CS

1*

PD

0

PD

1

NC

3

VS

S9

NC

2

CS

0*

D3

0

CLK

0

VS

S6

D2

7

D2

6

D1

8

VC

C5

D1

7

D2

4

D1

6

VS

S5

DQ

M0

NC

1

SD

A1

2

VC

C4

SD

A1

1

SD

A9

SD

A8

VS

S4

D7

D1

4

D6

D1

3

D5

D1

2

D4

SD

A6

VC

C2

SD

A3

SD

A2

SD

A1

SD

A0

D1

1

D3

D1

0

D2

VC

C1

D9

D1

D8

D0

DQ

M1

VS

S3

80 1 9 2 10

3 12

5 13

14

6 15

2 3 4 5 76 8 9 10

11

13

SD

_B

E1

_N

SD

_A

12

SD

_B

E0

_N

15

D3

1

7

CK

E0

SD

A4

SD

A1

0

22

17

18

20

21

2

CA

S*

11

D2

5

1

SD

_B

E1

_N

SD

_C

S1

_N

SD

_C

S0

_N

VS

S2

D2

1

28

4 5 6 9 10

SD

_B

E0

_N

13

15

19

SD

_C

S1

_N

16

SD

_C

S0

_N

SD

_W

E_

N

NC

4

VC

C6

RA

S*

VC

C7

SD

_R

AS

_N

SD

_C

KE

3

27

SD

_W

E_

N

83178

180

177

189

176175

170171

174

167

6

98

11

0

13

0

15

0

162

172

182

26

36

46

68

81

88

78

160161

168

164165166

169

190

23

24

28

35

38

39

40

41

42

43

13

44

45

48

14

15

18

19

20

21

22

195196197198199

66

70

49

50

53

55

63

6160

56

72

51

94

92

90

86

84

79

75

7374

67

65

80

85

91

93

194

191

204205206

64

95

25

9697

10

9

11

21

13

11

41

15

13

21

33

13

41

35

100

13

61

37

13

81

39

14

31

44

14

51

46

14

71

48

101

14

9

102103104

10

5

10

71

08

10

6

11

7

12

9

14

2

15

5

12

5

12

8

15

4

15

6

158

12

3

11

8

12

2

15

3

157

159

12

4

12

6

1

294 5

33

343

308 9

31

32

10

11

122

187188

186

208207

27

62

82

13

1

183184

7

12

1

14

1

15

1

173

193

203

17

37

47

59

69

89

99

11

1

77

5 6 287 4

58

53

52

73

74

2 4 8

10

23

25

28

30

42

44

47

49

7

62

64

67

69

43

45

48

63

65

9

68

70

22

24

27

293 5

39

40

59

60

38

75

77

78

80

79

57

12

13

34

35

37

54

55

14

15

17

18

19

20

32

336

16

26

36

46

66

1

11

21

31

41

51

71

76

21

14

0

PC

I_P

ER

R_

N

12

7P

CI_

FR

AM

E_

N

TRST_NPCST0

PCI_REQ2_N

INT1_N

CPU_TDO

EJ_TMS

3

12

SD

_C

AS

_N

201

WE

*

D2

3

D2

2

D2

8

SD

_B

E2

_N

29

12

01

19

11

6

SD

_C

LK

RE

SE

T_

N

SD

_C

S3

_N

SD

_C

S2

_N

200

PS

A_

CLK

56

76

54

305

2

PC

I_A

D(3

1..0

)

31

PC

I_IR

DY

_N

PC

I_R

EQ

0_

NP

CI_

GN

T0

_N

163

ADS_N

PC

ST

01

52

UA

RT

<5

..0>

5

192

179

BUS_EN_NM_WAIT_N

CS0_NPSA_CS_N

CS2_NEXP1_CS_N

CF_CS_N

M_WR_N

DMA_DONE_N234

01



1-971630-25 CPU Board; Flash Interfaces (Schematics #2)

3.3

V3

.3V

3.3

V

2

G3

3E

N1

[BA

]

3E

N2

[AB

]

1

AH

C2

45

VC

C=

3.3

V;G

ND

=D

GN

D

J21

J20

2

G3

3E

N1

[BA

]

3E

N2

[AB

]

1

AH

C2

45

VC

C=

3.3

V;G

ND

=D

GN

D

DD

DD

3.3

V

D

3.3

VD

D

D

DM

UX

1 023

01G

3-0

VC

C=

3.3

V;G

ND

=D

GN

DA

HC

13

9

DM

UX

1 023

01G

3-0

VC

C=

3.3

V;G

ND

=D

GN

DA

HC

13

9

R2

57

R2

56

R2

55

R2

54

R2

53

R2

51

R2

52

R2

50

R2

49

R2

48

R2

46

R2

47

R2

45

R2

44

R2

43

R2

42

R2

41

R2

40

R2

38

R2

39

R2

37

R2

35

R2

36

R2

34

R2

33

R2

32

R2

31

R2

30

R889

R890

R892

R893

R894

R895

3.3

V

R2

29

R2

27

R2

28

R2

25

R2

26

R2

24

R2

23

R2

22

R2

21

R2

20

R2

19

R2

18

R2

17

R2

16

R2

15

J23

R200

R201

3.3

V

R2

02

3.3

V

R2

06

3.3

VR204

R203

3.3

VEN

&

AH

C5

41

VC

C=

3.3

V;G

ND

=D

GN

D

1

LVC

02

VC

C=

3.3

V;G

ND

=D

GN

D

U9

0

C_

2

CO

MP

AC

TF

LAS

H

J22

1

AH

C3

2V

CC

=3

.3V

;GN

D=

DG

ND

1

AH

C3

2V

CC

=3

.3V

;GN

D=

DG

ND

R2

65

U2

2

AH

C5

74

VC

C=

3.3

V;G

ND

=D

GN

D

U2

3

AH

C5

74

VC

C=

3.3

V;G

ND

=D

GN

D

U2

4

AH

C5

74

VC

C=

3.3

V;G

ND

=D

GN

D

XC

95

36

XL

U9

2

R207

D

3.3

V

D

3.3

V

J24

3.3

V D

R208

R209

R210

D

3.3

V

DEB

UG

PO

RT

PR

OG

RA

MM

ING

JTA

G VC

C

BO

OT

FLA

SH

MA

ST

ER

MO

DE

WH

EN

CS

EL*

=G

ND

GN

DC

LIC

_T

CK

CLI

C_

TD

OC

LIC

_T

DI

CLI

C_

TM

S

ISO

LAT

OR

/DR

IVE

R

CLI

C

BU

S/A

DD

RE

SS

CO

MP

AC

T F

LAS

HE

XP

FLA

SH

SD

_P

D1

SD

_P

D0

PC

I_R

ES

_N

7

D5

RE

SE

T*

PD

0

71

GN

D3

25

24

VP

P_

EN

A1

1

PC

I_D

ET

_N

NC

8

A1

9

A2

4

FL_

CS

2_

N6

19

D4

IO14

IO15

70

72

18

CLIC_CLK

IO6

IO1

6

VS

S7

1 2

FL_

B_

PD

0F

L_B

_P

D1

PS

A_

INIT

_N

PS

A_

PR

OG

_N

PS

A_

DO

NE

37

6D

2

VC

C5

A2

4

VCCINT1

CLI

C_

TC

KC

LIC

_T

MS

CLI

C_

TD

I

10

AD

S_

N

12

SD

_C

LK

D1

1

1

7 15

12

VS

S4

BU

S_

RD

_N

A6

A1

3

FL_

CS

3_

NB

US

_W

R_

NB

US

_R

D_

N

RE

SE

T_

N

FL_

CS

1_

NB

US

_W

R_

N

FL_

CS

0_

N

M_

D<

31

..0>

CF

_W

R_

NC

F_

RD

_N

NC

3

NC

4

1

A5

M_

A<

15

..1>

11

20

24

17

2 10

23

22

21

15

21

15

7

25

24

M_

WR

_N

31 2

4 5 6 710

9 12

14

23

22

20

98 4 5 6 7

24

25

17

18

321

11

12

13

14

15

10

4 5 68 9 12

13

14

1 2 3 4 5 6 78 9

10

11

12

13

14

16

22

21

25

0

15

19

11

8

M_

RD

_N

BU

S_

DIR

_N

BU

S_

EN

_N

16

13

EN 1DC

1

EN 1DC

1

EN 1DC

1

0

13

12

11

15

14

8 10

9

3 54 6 7

3 2 10 2

A5

PD

IAG

*

DA

SP

*

MTG2

MTG1

D3

D4

D6

CS

0*

D7

A1

0

AT

AS

EL*

A9

A7

A8

VC

C1

A6

A4

A3

A2

A1

A0

D0

D1

D2

CD

2*

IIOC

S1

6*

D1

1

CD

1*

D1

2

D1

3

D1

4

D1

5

CS

1*

IOW

R*

VS

1*

WE

*

INT

RQ

VC

C2

CS

EL*

VS

2*

RE

SE

T*

IOR

DY

INP

AC

K*

RE

G* D8

D9

D1

0

GN

D2

14

7 15

16

17

24

19

18

20

21

22

0 18 9 2 310

11

8 1 9 2 10

3 11

4

4 12

5 13

5 13

714

16

15

17

24

19

18

21

20

22

23

5 4

A1

D1

1

PD

0

D1

4

D7

D1

5

RE

SE

T*

VC

C3

D1

3

D5

D1

0

D3

A1

4

A7

A1

5

VS

S5

A1

6

NC

1

A1

7

A1

8

VS

S6

A2

0

A2

2

A2

1

VC

C6

NC

6

NC

7

VS

S7

NC

8

FCS

0*

FCS

1*

VP

P

NC

9

PD

1

VS

S1

D0

D8

D1

D9

VS

S2

A8

A9

A2

VC

C2

A3

A4

D1

2

D6

A1

2

SY

SW

R*

VC

C4

NC

2

VC

C1

VS

S3

A2

3

SY

SR

D*

VC

C7

0 8 1 9 2 10

3 11

1 2 3 11

4

4 12

13

6 14

7 15

12

5 613

D2

VS

S6

D1

0

D3

A1

4

A7

A1

6

NC

2

NC

1

NC

3

NC

4

A1

7

A2

0

A2

2

A2

1

VC

C6

NC

5

NC

6

NC

7

FCS

1*

VS

S1

D0

D9

VC

C1

A8

A1

A2

VC

C2

A3

A1

0

A1

1

VS

S3

D1

2

D1

3

VC

C3

D1

4

D6

D7

VS

S4

D1

5

A6

D8

D1

VS

S2

A1

3

A5

A1

8

A1

5

A9

A4

D4

D<

15

..0>

CF

_IO

RD

YR

ES

ET

_N

CF

_C

S1

_N

CF

_C

D1

_N

CF

_C

D2

_N

CF

_C

S0

_N

CF

_C

S1

_N

CF

_C

S0

_N

VS

S5

14

SY

SR

D*

SY

SW

R*

A<

25

..1>

23

CF

_C

S_

N

PD

1

VS

S8

6

3

19

VP

P

RE

SE

T_

N

9

BU

S_

WR

_N

BU

S_

RD

_N

18

10

A2

3

FL_

CS

0_

NF

L_C

S1

_N

FL_

CS

2_

NF

L_C

S3

_N

EX

P2

_C

S_

NU

SB

_C

S_

N

CS

0_

N

CS

2_

N

5

VC

C5

NC

5

NC

9

VS

S8

ID_

CS

_N

IO1

8

IO1

7

VC

CIO

GND2

IO10

IO_GTS1

VCCINT2

IO_GTS2

IO_

GS

R

IO23

IO24

IO26

IO28

IO_GCK1

TD

O

IO2

0

IO2

1

IO2

2

IO_

GC

K3

IO2

IO13

IO25

IO8

IO7

TM

S

TD

I

GN

D1

IO1

IO1

9IO

3

IO4

IO5

IO_GCK2

567

CLI

C_

TM

SC

LIC

_T

DI

CLI

C_

TC

K

RESET_NID_CS_NCF_CS_N

BUS_WR_N

CLI

C_

TD

O

CF

_R

D_

NC

F_

WR

_N

AR

ES

ET

_N

USB_RES_NBUS_RD_N

VPP_ENP24ENPSA_RES_N

1

D(1

5..0

)

310 2 4

VC

C4

A1

2

A1

0

VP

P_

EN

VC

C7

TC

K

IO11

IO27

EXP2_RES_NIO12

EXP1_RES_N

IO9

FL_

B_

PD

1

U2

0

23456789

18

17

16

15

14

13

12

11

1

19

13

17

32

34

37

39

40

48

49

50

15

52

53

54

55

47

18

20

33

35

38

12

142 4 8

10

23

25

28

307 9

22

24

27

293 5

62

63

42

43

44

45

57

58

59

60

72

69

70

67

65

64

16

26

36

46

56

66

68

1

11

21

31

41

51

61

71

13

17

19

32

34

39

40

48

49

50

15

52

54

55

47

20

33

35

38

12

142 4 8

10

23

25

28

307 9

22

24

27

293 5

62

63

42

43

44

45

57

58

59

60

69

67

65

64

6

16

26

36

46

56

66

68

1

11

21

31

41

61

U2

1

23456789

18

17

16

15

13

12

11

1

19

U2

6

15

14

13

12

11

9

U2

6

123

4567

U2

5

2345678911

9

18

17

16

15

14

13

11

2 31

20

198

18

17

16

15

14

12

11

109

26

257

32

39

21

22

49

27

28

29

30

31

232 4 5 6

47

48

45

1

50

24

43

37

34

42

35

46

44

41

13

38

33

40

36 U9

14 5

6

U9

19

10

8

11 9 8 7 6 5 4 3 21

12

14

15

16

17

18

19

11 9 8 7 6 5 4 3 21

12

13

14

15

16

17

18

19

11 9 8 7 6 5 4 3 21

12

13

14

15

16

17

18

19

4

17

2

16

1819202122

23

27

28

29

33

03

13

2

373839404142

5 6 8

121314

4344

13

3

36

34

119

10

15

35

26

1 2 3 4 5 6

8

FCS

0*

FL_

B_

PD

0

53

51

CF

_IN

TR

Q

D5

3

GN

D1

A1

9

IOR

D*

14

13



1-971630-25 CPU Board; PSA (Schematics #3)

3.3

V

DO

UT

_IO

10

6

CC

LK

IO108

IO109

IO110

IO111

IO112_NC

XC

2S3

0, X

C2

S50

, XC

2S1

00

, XC

2S1

50

&X

C2

S20

0

IO3

5

M1

VCCO4

IO3

4

VC

CO

1

VCCO16

VCCO14

VCCO13

VC

CO

12

VC

CO

11

VC

CO

10

VC

CO

9

VC

CO

8

VCCO7

VCCO6

VCCO5

PSA

M2

IO38

IO37

IO39

IO46

IO45

IO44

VCCINT4

IO43

IO42

IO41

GCK1

VCCINT5

IO51

IO50

IO49

IO48

IO47

IO59

IO58

IO57

IO56

IO55

IO54

IO53

IO52

GCK0

IO66

IO65

IO63

IO62

IO61

VCCINT6

IO60

IO67

DONE

IO69

IO68

PR

OG

RA

M_

N

INIT

_N

_IO

70

IO7

1

IO7

2

IO7

3

IO7

4

IO7

6

IO7

7

IO7

8

VC

CIN

T7

IO7

9

IO8

0

IO8

4

IO8

3

IO8

2

IO8

1

IO8

7

VC

CIN

T8

IO8

6

IO8

5

IO9

1

IO9

0

IO8

9

IO8

8

IO9

5

IO9

4

IO9

3

IO9

2

VC

CIN

T9

IO9

7

IO9

6

IO9

8

IO1

00

IO9

9

IO1

02

IO1

03

DIN

_IO

10

5

IO1

04

TCK

IO140

IO129

IO130

IO132

IO131

IO125

IO126

IO127

IO128

GCK2

GCK3

VCCINT11

IO121

IO122

IO123

IO124

IO116

IO117

IO118

IO119

IO120

IO114

IO115

VCCINT10

IO113

TDO

TDI

IO107

VC

CO

3

IO1

7

IO1

8

GN

D4

VC

CO

2

IO1

3

GN

D3

IO1

4

IO1

5

IO1

6

VC

CIN

T1

IO9

IO1

0

IO1

1

IO1

2

IO6

IO7

IO8

GN

D2

IO3

IO4

GN

D1

M0

IO3

3

IO3

2

IO2

9

IO2

8

GN

D6

VC

CIN

T3

IO2

7

IO2

6

IO2

5

IO2

4

IO2

3

GN

D5

IO2

2

IO2

1

IO2

0

VC

CIN

T2

IO1

9

GND8

GND9

GND10

GND11

GND12

GND13

GN

D1

4

GN

D1

5

GN

D1

6

GN

D1

7

GN

D1

8

GND19

GND20

GND21

GND22

GND23

GND24

IO3

6

GN

D7

NC1

NC2

VCCINT12

VCCO15

IO133

IO134

IO135

IO137

IO138

IO139

IO2

IO1

TM

S

IO3

0

IO5

_N

C

IO3

1_

NC

IO40_NC

IO64_NC

IO7

5_

NC

IO1

01

_N

C

IO136_NC

PIN

S W

ITH

_N

C N

OT

USE

D IN

XC

2S3

0

U3

0

5V

D

CH

0

CS

*

TLC

08

38C

LKS

AR

SD

OS

E*

RE

FA

GN

DG

ND

CO

MC

H7

CH

6C

H5

CH

4C

H3

CH

2C

H1

DI

NC

5V

U3

1

D

3.3

V R3

35

5V

U3

2

LM3

93

M

3.3

V R3

38

D

LM3

93

M

U3

2

2.5

V

R3

24

R3

23

R3

22

R3

21

2.5

V

R3

01

R3

02

R3

03

R3

04

R3

05

R3

06

R3

07

R3

08

R3

09

R3

10

R3

11

R3

12

R3

28

R3

26

R3

27

R3

25

R3

20

R3

18

R3

19

R3

17

R3

16

R3

15

R3

14

R3

13

R3

36

R3

33

R3

37

R3

34

R3

00

3.3

V

R3

39

PP

30

PP

31

INIT

PR

OG

DO

NE

CC

LK

D0

5V

R3

29

DA

TA

GN

D

J3

0 D

C3

0

C3

1

PS

A_

TD

OT

CK

TM

S

C3

2

C3

3D D

PP

32

D

3.3

V

SE

NS

OR

AD

JUS

T

IBU

TT

ON

A/D

-CO

NV

ER

TE

R

M_

D<

31

..0>

1

2

201

188

175

IBU

TT

ON

1

TP

H_

GA

IN1

EX

P2

_IN

T_

N

DM

A_

DO

NE

_N

57

6

8

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20

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11

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999897969594

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84838281

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13

1

12

4

11

6

103

93

85

79

1

185

182

77

80

104

15

3

15

5

CF

_IN

TR

Q

0

PS

A_

PR

OG

_N

PS

A_

INIT

_N

PS

A_

DO

NE

PS

U_

NO

T_

NP

SU

_IN

T_

N

CO

N_

NO

T_

N

CO

N_

IO2

RL_

INS

T

0

AD

_C

S_

NT

PH

_S

TR

B_

NT

PH

_LA

TC

H_

NT

PH

_C

LKHEADLIFT

PL_INST

PS

A_

CS

_N

PL_DIGRL_DIG

AD

_D

IA

D_

CLK

AD

_D

OT

T_

PW

M

P2

4E

N

M_RD_N

PSA_CS_N

PSA_CLK

ADS_N

CPU_TDO

PSA_TDO

BE

EP

US

B_

INT

_N

WA

ND

EX

P1

_IN

T_

N

INT

1_

N

PS

A_

RE

S_

N

CF

_IO

RD

Y

M_

WA

IT_

N

AC

K_

N

DM

A_

NM

_W

R_

N

FIN

_IO

2F

IN_

IO1

FIN

_IO

0

FIN

_N

OT

_N

TP

H_

CA

L0T

PH

_C

AL1

TP

H_

CA

L2

TP

H_

GA

IN0

TP

H_

GA

IN2

SD

A

SC

L

23 01

RL_

GA

IN(3

..0)

GA

P_

GA

IN(3

..0)

BM

_G

AIN

(3..0

)

BM

_D

RIV

E(3

..0)

TM

S

TP

H_

DA

TA

(8..1

)

TCK

76

345

2

10

3

210

32

32

01

3

10

210

87

56

2 3 41

101120

1912

13

181417

1516

31301

292283

27426

255

6247

823

22921

13

11

12

024 36 59 8 7

AD

_C

S_

NA

D_

DI

AD

_C

LK

AD

_D

OT

HE

RM

PL_

SE

NR

L_S

EN

LTS

_IN

ST

TP

H_

RE

S

IBU

TT

ON

BM

_S

EN

GA

P_

SE

N

10

ST

EP

PE

R(1

3..0

)

CO

N_

IO0

CO

N_

IO1

INT

0_

N

TP

H_

ME

AS

_E

N

192193

LTS_DIG

7 6 5 4 3 2 01

LTS

_S

EN

LTS

_G

AIN

(7..0

)

0 21 3 0 1 2 3 0 1 2 3 0 1 2 3 0 1 2 3

PL_

GA

IN(3

..0)

RL_

GA

IN(3

..0)

BM

_D

RIV

E(3

..0)

BM

_G

AIN

(3..0

)

GA

P_

GA

IN(3

..0)

PL_

PR

E

RL_

PR

E

BM

_D

IOD

E

BM

_P

RE

GA

P_

PR

E

11

0

PL_

SE

N

RL_

SE

NR

L_D

IG

PL_

DIG



1-971630-25 CPU Board; Thermal Printhead Interface (Schematics #4)

5V

R4

25

DD

DD

D

LM3

58

M

U4

1

EN& A

HC

T54

1

VC

C=

5V

;GN

D=

DG

ND

EN& A

HC

T54

1

VC

C=

5V

;GN

D=

DG

ND

R4

09

R4

06

R4

07

R4

08

R4

00

R4

01

R4

23

R4

22

R4

02

R4

12

R4

13

R4

14

TP

HV

D

C4

04

R4

03

R4

04

R4

05

R4

10

R4

11

R4

18

R4

19

R4

15

R4

16

R4

17

R4

20

R4

21

R4

24

D

C4

07

D

R4

27

R4

26

R4

28

R4

29

C4

08

C4

09

D

PP

40

D4

0

L4

00

L4

02

L4

15

PP

41

R4

30

T4

2

R4

31

R4

32

R4

33

R4

34

R4

35

R4

36

R4

37

R4

38

R4

39

R4

40

D

24

V_

S

D

J40

C4

05

C4

06

D

U4

0

D C4

03

T4

1

D

T4

0

T4

4

T4

3

C4

01

+C4

02

U4

1

LM3

58

M

T4

7 C4

00

DD

T4

6T

45

C_

1

D

DD

DA

TA

8

DA

TA

7

DA

TA

6

DA

TA

5

DO

T R

ESIS

TA

NC

E T

EST

CIR

CU

IT

SA

ME

TY

PE

VC

C

STR

OB

E2

GN

D

VC

CLA

TC

H

STR

OB

E1T

HER

M2

I2C

CLK

GN

D

GN

D

GN

D

GN

DD

AT

A2

DA

TA

3

I2C

DA

TA

GN

D

GN

D

DA

TA

1

CLO

CK

TH

ERM

1

DA

TA

4G

ND

BO

AR

D M

US

T B

Y O

F

TH

E C

OR

RE

SP

ON

DIN

GD

IOD

E O

N P

SU

TH

ERM

AL

PR

INT

HEA

D (

TP

H)

TP

H_

ME

AS

_E

N

26

24

22

20

18

16

14

12

10

987654321 11

13

15

17

19

21

23

25

TP

H_

RE

S

15

TP

H_

DA

TA

<8

..1>

B

TP

H_

GA

IN2

TP

H_

GA

IN1

TP

H_

GA

IN0

B

C E

C E

B

C E

TH

ER

M

2

OU

TIN

AD

J

TP

H_

ST

RB

_N

SD

A

875431T

PH

_C

LK

SC

L

TP

H_

CA

L1T

PH

_C

AL0

TP

H_

CA

L2

TP

H_

LAT

CH

_N

5V

_T

PH

GN

D_

TP

H

6

B

C E

1

32

B

C E

B

C E

BCE

B

C E

2

4

13

8

67

5

U4

2

9876543211

9

11

12

13

14

15

16

17

18

U4

3

4325678911

9

16

17

18

14

13

12

11



1-971630-25 CPU Board; Internal Interfaces (Schematics #5)

R5

00

SCL

SDAWP

VC

C

A2

GN

D

A1

A02

4C

02

A

U5

0

5V

D

24

IGN

D

J53

5V

R5

24

R5

25

5V

J55

J56

5V

R5

21

5V

T1

R5

22

R5

23

D

R5

20

+

C5

08

C5

09

C511

C510

+

C5

07

J57

5V

5V

R5

15

D R5

17

D

J58

D

R5

19

5V

R5

18

D

R5

14

R5

16

C5

03

C5

05

D D

C5

04

C5

06

R5

13

C5

02

D

R5

12

C5

13

D

J50

J51

TIM

E C

AP

TO

NE

IN

IN F

ILT

ER

OU

T F

ILT

ER

OU

T

TO

NE

VC

C

GN

D

LM5

67

U5

2

R5

26

C5

12

L5

0

C_

2

L5

1

L5

2

R5

43

C537

R5

44

R5

45

R5

42

C536

C535

C534

R5

38

R5

39

R5

40

R5

41

D

R5

35

R5

34

R5

36

R5

37

C533

C532

C531

R5

30

R5

31

C530

R5

32

R5

33

D

R5

49

R5

46

C539

C538

R5

47

R5

48

D

PP

52

PP

53

PP

55

PP

56

PP

57

PP

58

PP

54

PP

59

J59

D C5

01

PP

50

PP

51

D

+C

70

0

5V

R6

21

BU

ZZ

ER

B6

0

D

D

=1

VC

C=

5V

;GN

D=

DG

ND

AH

C8

6

=1

VC

C=

5V

;GN

D=

DG

ND

AH

C8

6

=1

VC

C=

5V

;GN

D=

DG

ND

AH

C8

6

D

C5

40

D5

0

WA

ND

PS

U_

INT

_N

DD

F70

24

V_

I

24

V_

S

J54

5V

5V

J52

TP

HV

5V

R5

10

R5

09

5V

VC

C

N/C

GN

D

SM

BU

S1

SM

BU

S2

LTC

16

94

U5

15

V

D

5V

D

SEN

SOR

SB

LAC

KM

AR

K

I2C

INT

ERFA

CES FI

NIS

HER

LTS

WA

ND

PS

U/

RIB

BB

ON

LO

W

BEE

PER

CO

NS

OLE

GA

PM

OT

OR

DR

IVER

S

MT

G1

MT

G2

BM

_P

RE

BM

_S

EN

41 2 3B

M_

DIO

DE

321 4

PS

U_

NO

T_

N2

9

FIN

_IO

1

FIN

_IO

2

14

LTS

_IN

ST

2 4 6 8

34

RL_

SE

N

PL_

PR

E

GA

P_

PR

E

321 4 321 4 5321 4 321 4

1 241 2 3 65

9876543 33

32

31

30

2 28

27

26

25

24

23

22

21

20

1 19

18

17

16

15

13

12

11

10

61 2 3 4 5 7 8 9 10

61 2 3 4 5 7 8 9 10

FIN

_N

OT

_N

FIN

_IO

0

45

3 6

8 7

1 2

TT

_P

WM

WA

ND

LTS

_D

IG

12

11

10

13

0 1 3 5 7 9

HE

AD

LIF

T

GA

P_

SE

N

RL_

PR

E

RL_

INS

T

PL_

INS

T

SD

A

PL_

SE

N

PS

U_

INT

_N

CO

N_

NO

T_

N

CO

N_

IO1

BE

EP

SC

L

CO

N_

IO2

CO

N_

IO0

23

5 4

11 2 3 4

6 58 7

B

C E

U8

01

21

31

1

U8

09

10

8

U8

04 5

6

P2

4E

N

ST

EP

PE

R<

13

..0>

LTS

_S

EN

PA

PE

R L

OW

HE

AD

LIFT



1-971630-25 CPU Board; External Interfaces (Schematics #6)

D

3.3

V

C_

2D

R6

20

D

R6

19

D

R6

18

R6

02

R6

03

R6

04

R610

R611

R612

R613

R614

R615

24

Mh

z

Y6

0

R605

C61

C60

L6

1

L6

2

L6

3

L6

4

L6

5

L6

6

L6

7

J61

C_

2

L6

8

RP

60

5V

EX

P2

_IN

T_

N

EX

P1

_IN

T_

N

US

B_

INT

_N

R6

23

R6

24

R6

25

R6

29

3.3

V

24

V_

S5

V

3.3

V

J62

R6

28

R6

27

C6

6

R6

26

C6

5

D

J6

0

3.3

V

+

C6

2

L6

0

DC

_2

3.3

V

C6

4

SH

DN

*E

N*

C2

-C

2+

C1

-C

1+

GN

D

V-

V+

VC

C

R1

INR

1O

UT

BR

1O

UT

T1

IN

T3

INT

4IN

T5

IN

T1

OU

TT

2O

UT

T3

OU

TT

4O

UT

T5

OU

T

T2

IN

R2

OU

TR

3O

UT

R2

INR

3IN

MB

AU

D

MA

X3

23

7E

U6

1

C6

3

D

R601

3.3

V

R600

U6

0

USB

N9

60

4

EXP

BU

S

RS2

32 D

CD

- D

AT

A C

AR

RIE

R D

ET

EC

T

5

- P

CI_

GN

T1

_N

- D

TR

3

- S

PI_

MIS

O

- R

TS

2

- S

PI_

MO

SI

- C

TS

1

- U

AR

T_

TX

0

- T

XD

0

- U

AR

T_

RX

0

- R

XD

BU

S N

O.

CP

U P

INS

R

S2

32

CS

INT

DR

EQD

AC

KD

AC

KD

REQ

CS

SCL

SPA

RE

SLO

T 2

INT

SLO

T 1

SPA

RE

SDA

RT

S -

RE

QU

ES

T T

O S

EN

DD

SR -

DA

TA

SET

REA

DY

DT

R -

DA

TA

TE

RM

INA

L R

EA

DY

RX

D

DT

R RI -

RIN

G IN

DIC

AT

OR

CT

S -

CLE

AR

TO

SE

ND

RD

- R

EC

EIV

E D

AT

AS

D -

TR

AN

SM

IT D

AT

A

SG

- S

IGN

AL

GR

OU

ND

1 532 4 6 7 8 9

RES

ET

DSR

RES

ET

SA1

SA1

4

- S

PI_

SC

K

- D

SR

D+

NC

GN

D

RE

FE

RE

NC

E -

IBM

ST

AN

DA

RD

DB

9

RT

SC

TS

GN

D

TX

D

NC

NC

USB

VD

DD

-

3

CS*

MT

G1

MT

G2

9854321 76

XO

UT

MT

G1

DA

CK

*321 4 M

TG

2

US

B_

CS

_N

6A

0_

ALE

_SI

VC

C

5

1

1

UA

RT

<5

..0>

4

28

12

D4

RES

ET*

US

B_

RE

S_

N

4

BU

S_

RD

_N

A<

24

..1>

4

763 54D

3

D7

WR

_SK

RD

*

MO

DE0

V3

.3A

GN

D

D-

D0

_SO

D5

D6

D1

D2

INT

RD

RQ

GN

D

GN

D

D+

XIN

CLK

OU

T

MO

DE1

27

26

22

18

16

2

24

25

4

23

21

5

19

20

15

14

13

11

10981

17

7

10 2

3

2

0

6

5

1 2 3 5 7 8 9 10

11

12

13

14

15

1 2 3 4 5 7 8 9 10

11

12

0 4

BU

S_

WR

_N

6

BU

S_

RD

_N

M_

WA

IT_

N

1 39

6 40

7 41

8 42

9 43

10

35

44

11

45

12

46

13

47

14

48

15

2 49

16

50

17

51

18

52

19

53

20

36

54

21

55

22

56

23

57

24

58

25

3 59

26

60

27

61

28

62

29

63

30

37

64

31

65

32

66

33

67

34

68

4 38

5

25

28 3

132

15

82

11

6

92

01

11

8

14

24

23

62

27

19

10

17

12

27

26

SD

A

SC

L

EX

P1

_R

ES

_N

EX

P1

_C

S_

NE

XP

1_

INT

_N

EX

P2

_R

ES

_N

EX

P2

_C

S_

NE

XP

2_

INT

_N

US

B_

INT

_N

D<

15

..0>

BU

S_

WR

_N



1-971630-25 CPU Board; Power (Schematics #7)

+C

70

9+

C7

12

+C

71

7

C7

18

C7

16

DD

L72

L71

24

IGN

D

D

24

V_

S

L74

MH

70

2.5

V3

.3V

+C

71

0

D

U

72

5V

C7

11

DD

5V

D

GN

D

2.5

V3

.3V

U7

1

+C

70

1

TL5

94

U7

0

R7

00

R7

01

R7

02

R7

05

R7

03

R7

04

R7

06

C7

02

R7

08

R7

07

C7

04

L70

R7

10

T7

0

R7

11

R7

12

T7

1

D7

0

D7

1

R7

13

C7

05

T7

2

C7

06

R7

14

R7

15

D7

2

R7

18

R7

16

R7

20

R7

19

R7

21

R7

17

R7

22

R7

23

R7

24

R7

25

C7

07

+C

70

8

Z7

0T

HY

70

5V

R7

09

C7

03

C_

1

MH

71 C

_2

C7

13

C7

14

C7

15

24

V_

I

MO

UN

TH

OLE

CLO

SEST

TO

24

V S

OU

RC

E

SHO

RT

CIR

CU

IT D

IGIT

AL

GR

OU

ND

(D

)LO

WER

LEF

T O

N P

CB

MO

UN

TH

OLE

AT

WIT

H M

H7

0 IN

TH

IS P

OIN

T A

ND

INT

HIS

PO

INT

ON

LY!

5V

TO

3.3

V5

V T

O 2

.5V

24

V T

O 5

V C

ON

VER

TER

3

12

C A

S

G

D

EC

B

EC

B

23

1

23

4

1

VIN

VO

UT

GN

D/A

DJ

VIN

TA

B

VO

UT

2IN

-

1IN

-1

IN+

2IN

+

CT

OC

E2

FB

C2

DT

C

GN

D

VC

C

RT

C1

E1

RE

F

12

6

14

7

3

10

9

4 51

1

8

15

1621

13

GN

D/A

DJ



1-971630-25 CPU Board; Pull-ups (Schematics #8)

3.3

V

R8

24

R879

R878

R877

R876

R875

R874

R873

R872

R871

R870

R869

R868

R867

R866

R865

R864

R863

R862

R861

R860

R859

R858

R857

R856

R855

R854

R853

R852

R851

R850

R849

3.3

V

R848

3.3

V

R8

96

R8

97

R8

98

R8

99

R8

00

R9

20

R9

21

R9

22

R9

23

3.3

V

R9

24

R9

25

R9

30

R9

29

R9

28

R9

27

R9

26

R9503.3

V

R8

16

R8

01

R951

R952

R954

R953

R956

R8

02

R955

R958

R957

R960

R959

R8

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13.8 Replacing the CPU board

To replace the CPU boardSwitch off the power.


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.

Th e same CPU-board can be used for a range of EasyCoder printers. However, the fi rmware 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 reconfi gured after being installed in an EasyCoder PM4i printer.

If the printer feeds out labels in a peculiar way, the CPU board may be confi gured for the wrong type of printer (there is a diff erence in the distance between the dot line and the LSS position). You can easily check if the CPU board is correctly confi gured by printing the “Hardware Info” or “HW” test label in the Setup Mode or sending the Fingerprint instruction PRINT VERSION$(1).

To reconfigure the CPU boardSwitch off the power.

Insert a confi guration 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.

1

2

3

4

5

6

7

1

2

3

4

5

6

7


14 Interfaces

Th is chapter describes the various communication interfaces for the EasyCoder PM4i printers. However, some interfaces are not supported by the Intermec Programming Language (IPL) even though the connectors are present.

Th e chapter describes three categories:

• Standard built-in interfaces

RS-232 interface

USB interface

Bar code wand interface (not supported by IPL)

• Optional interface boards

Serial/Industrial interface board (not supported by IPL)

Double Serial interface board (not supported by IPL)

RFID Serial interface board

IEEE 1284 Parallel interface board

• EasyLAN interface boards

EasyLAN Ethernet interface

EasyLAN Wireless interface

Th e EasyCoder PM4i printer can—in addition to the standard built-in interfaces—also be fi tted with one or two optional interface boards and one EasyLAN interface board.

Note: Device designations, such as "uart1:", "usb1:", or "net1:", apply only to Fingerprint, not to IPL.


Chapter 14—Interfaces

14.1 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 specifi c 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). Th is 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. Th e settings for the selected communication channel will appear in the display window when pressing the <info> key on the printer’s keyboard.

In IPL, all communication channels are always scanned for incoming data and the fi rmware automatically switches to the same channel for output too. Th e settings for the active communication channel will appear in the display window when pressing the <info> key on the printer’s keyboard.

Th e standard interfaces (RS-232, USB, and Wand) are fi tted directly on the rear of the CPU board with connectors protruding through slots in the printer’s rear plate. USB and Wand are not supported by IPL.

All optional interface boards, except the EasyLAN boards, are fi tted in a slot on the printer’s standard rear plate and connected to the CPU board via a fl at cable. If no interface board is fi tted, the slot is closed by a cover plate.

Th e EasyLAN boards are fi tted directly to the front of the CPU board and connected by wire to a connector or antenna. Th ere 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.



14.2 RS-232 Serial Communication Port ("uart1:")

Th e EasyCoder PM4i printers are always fi tted with one RS-232 communication port. In Intermec Fingerprint, this port is designated "uart1:" (uart = Universal Asynchronous Receiver and Transmitter.) Th e circuitry is fi tted on the CPU board (see Chapter 13) and has a fi xed set of signals in a DB-9pin female connector which protrudes through a slot in the printer’s rear plate.

ProtocolDefault setupBaud rate: 9600Char length: 8 bitsParity: NoneStop bits: 1RTS/CTS: DisabledENQ/ACK: DisabledXON/XOFF: Disabled in both directionsNew line: CR/LF

Signals on serial port ("uart1:")

DB-9 socket Signal Meaning

1 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

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14.3 USB Interface ("usb1:")

Th e EasyCoder PM4i printers are, as standard, fi tted with a USB (Universal Serial Bus) interface connector on the CPU board.

Th e 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. Th e 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).

Th e EasyCoder PM4i 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 diff erent 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.

USB Class B connector.

Connect to USB port on printer’s rear plate.

USB("usb1:")



14.4 Bar Code Wand Interface (wand:)

Th e printer has a socket (J59) on the CPU board for connecting a bar code wand or scanner. Th e socket is accessible through a slot in the printer’s rear plate. Th e 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.

Th e 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 buff er which could be read by specifying the "wand:" device. Th e buff er is small, so it is recommended to use short bar code data (max. 36 characters) and read the buff er regularly to avoid overfl ow.

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:")



14.5 Installing an Optional Interface Board

To install an optional interface board

Note: Th is chapter does not apply to installation of any type of EasyLAN interface board, which instead is described in Section 14.9. Th e general description DOES however apply to the installation of RFID interface boards, and RFID-specifi c information has been marked in the text.

Open the electronics compartment, see Section 11.2.



Before you install driver circuits and straps on the interface board, make sure that the circuit is not installed upside down (see front end markings in the illustrations). Also make sure that the circuit pins fi t into the slots in the socket and are not bent. Take precautions to protect the board and circuits from electrostatic discharge.

Vor der Installation von Treiberschaltkreisen und Kabelbändern auf der Schnittstellenkarte muss sichergestellt werden, dass der Schaltkreis nicht verkehrt eingebaut ist (die Vorderkantenmarkierungen in den Abbildungen beachten). Außerdem muss sichergestellt werden, dass die Schaltkreisstifte in die Schlitze in der Buchse passen und nicht verbogen werden. Vorsichtsmaßnahmen treff en, um die Karte und die Schaltkreise vor elektrostatischer Entladung zu schützen.

Remove the two #T10 Torx screws that hold the inner interface cover plate. Remove the cover plate.

1

2

#T10 Torx screw

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#T10 Torx screw

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Save the cover plate for possible later use. Keep the screws.

Remove the #T20 Torx screw fi tted on the hexagonal spacer at the center of the CPU board. Keep the screw.

If necessary, fi t or remove circuits and straps on the interface board according to the descriptions of each board later in this chapter.

RFID only: If the interface board has been designed to hold an RFID radio module, slide the module into its designated slot. Note: Jumpers J5-J9 must be set to comply with the type of radio module installed. See Section 14.8.

Attach the fl at 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.

Attach the interface board to the printer’s rear plate using the two screws left over when you removed the original cover plate.

3

4

5

6

7

8

9

Interface board

Component side

#T10 Torx screw

#T10 Torx screw



Using the #T20 Torx screw you previously removed, attach the interface board to the hexagonal spacer at the center of the CPU board.

Th e kit contains two fl at 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 fl at cable to connector P1 on the interface board, also see the next page.

Th e fl at cable should run as illustrated below.

Put back the cover over the electronics compartment.

Connect the communication cables to the connectors on the printer’s rear plate.

RFID only: Apply the RFID label to the rear plate of the interface board. Make sure the specifi cations printed on the label correspond to those of the board and radio module.

Connect the power cord and switch on the power.

10

11

12

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C50

1-971643-01 P01

C67

RS232: IC11, J2A

RS422: IC12, J3, J4

RS485: IC13, J1, J4*

* IF END OF CABLE

UARTA

C40

C51

C34C36

C60

C21

C22

C65

R26

R27

R35

R34

R33

R32

R31

R41

R42

R51

R52

R36

R37

R38

IC20

C61

R21

R22

R23

R24

R25

R28

IC21

IC27

IC28

C33

C35

C66IC3

IC22

C32

C56

C57

R10

R18

R5

R8

R9

C55

C64

C23

C24

C25

C26

C27

C28

R43

R44

R45

R46

R47

R53

R54

R55

R56

R57

IC24

IC23

IC26C62

REL3

REL4

REL1

REL2

C63

R48

R58

P3

F2

F3

F4

F5

F8

F7

F1

F6

R12

R13

R14

R15

R17

R16

J3

J2

J4

C54

IC9

C3C4

C1C2

IC12IC11

IC13

IC10

C31

C52

IC6

IC5

IC4

IC1

C53

R1

R6

R7

C30

J1R11

R2

R3

R4

P1

IC2

IC25

P1

Flat cable(two types)

Hexagonal spacer

CPU Board

Inner Interface Board

(Outer Interface Board)

Cable



In case the interface board provides additional serial communication ports, enter the Setup Mode to set the proper communication parameters for these ports.

If you need to install two interface boards, fi rst install the inner board, then the outer one using the same fl at cable from one of the kits. Put the hexagonal spacer included in the kit between the inner and the outer interface board. Th e list below shows which combinations are allowed in Fingerprint and IPL respectively and how the ports will be designated in Fingerprint.

Allowed interface combinations (Fingerprint)

Left-hand slot Ports Right-hand slot Ports

Double Serial uart2: + uart3: – –

Double Serial uart2: + uart3: IEEE 1284 centronics:

Double Serial uart2: + uart3: Double Serial uart4: + uart5:

Double Serial uart2: + uart3: RFID uart4:

Serial/Industrial uart2: – –

Serial/Industrial uart2: Serial/Industrial uart3:

Serial/Industrial uart2: IEEE 1284 centronics:

Serial/Industrial uart2: RFID uart3:

IEEE 1284 centronics – –

IEEE 1284 centronics Double Serial uart2: + uart3:

IEEE 1284 centronics Serial/Industrial uart2:

IEEE 1284 centronics RFID uart2:

RFID uart2: Double Serial uart4: + uart5:

RFID uart2: IEEE 1284 centronics

RFID uart2: Serial/Industrial uart4:

Allowed interface combinations (IPL)

Left-hand slot Ports Right-hand slot Ports

IEEE 1284 parallel RFID serial*

RFID serial* IEEE 1284 parallel

Remarks:• Th e left-hand slot is the slot closest to the center section.• Always start by fi tting an interface board in the left-hand slot.• RS-485 is only supported by "uart2:"• Th e serial port (*) refers to the RFID interface. Th e 9-pin contact on the

back plate of the interface board is not functional on IPL printers.

17



14.6 Serial/Industrial Interface Board (not IPL)

Description

Th e Serial/Industrial Interface Board is a Fingerprint-only optional device for EasyCoder PM4i. It provides these printers with two extra interfaces.

Th e Serial/Industrial Interface kit contains:• One Industrial Interface Board fi tted with straps and circuits for RS-232• One hexagonal spacer• Two fl at cables• One Installation Instruction booklet

Serial Interface ("uart2:" or "uart3:")Th is interface contains one serial communication port ("uart2:" or "uart3:") which can be confi gured for one of the following alternatives:• RS-232 non-isolated • RS-422 isolated, full duplex (reconfi guration required)• RS-485 isolated, half duplex (reconfi guration required)

Selection of type of serial interface is decided by fi tting various types of socket-mounted driver circuits and straps.

Industrial InterfaceTh is interface contains eight digital IN and eight digital OUT ports with optocouplers, plus four OUT ports with relays.

Th e 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).Th us, 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. Th e 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)



Serial Port Configuration

Th e serial communication port "uart2:" or "uart3:" is as standard confi gured for RS-232 but can be reconfi gured for two other types of serial communication by fi tting certain driver circuits and straps. Th e circuits can be ordered separately from Intermec:

• RS-422 isolated, full duplex• RS-485 isolated, half duplex

RS-232 Non-Isolated (standard)

P2

B A

C50

1-971643-01 P01

C67

RS232: IC11, J2A

RS422: IC12, J3, J4

RS485: IC13, J1, J4*

* IF END OF CABLE

UARTA

C40

C51

C34C36

C60

C21

C22

C65

R26

R27

R35

R34

R33

R32

R31

R41

R42

R51

R52

R36

R37

R38

IC20

C61

R21

R22

R23

R24

R25

R28

IC21

IC27

IC28

C33

C35

C66IC3

IC22

C32

C56

C57

R10

R18

R5

R8

R9

C55

C64

C23

C24

C25

C26

C27

C28

R43

R44

R45

R46

R47

R53

R54

R55

R56

R57

IC24

IC23

IC26C62

REL3

REL4

REL1

REL2

C63

R48

R58

P3

F2

F3

F4

F5

F8

F7

F1

F6

R12

R13

R14

R15

R17

R16

J3

J2

J4

C54

IC9

C3C4

C1C2

IC12IC11

IC13

IC10C

31

C52

IC6

IC5

IC4

IC1

C53

R1

R6

R7

C30

J1R11

R2

R3

R4

P1

IC2

IC25

Strap fi tted on J2 A

RS-232 circuit fi tted on IC11

Connector Configuration (RS-232 on "uart2:" or "uart3:")



2 TXD Transmit data

3 RXD Receive data


5 GND Ground


7 CTS Clear to send


9 – Not used

4

5

3

2

1

8

9

7

6TXD out+5V DC

RXD inDSR inGND

MTG

MTG

DTR outCTS in

RTS out



RS-422 Isolated, Full Duplex (Reconfiguration required)

Fit straps on J3 and J4

P2

B A

C50

1-971643-01 P01

C67

RS232: IC11, J2A

RS422: IC12, J3, J4

RS485: IC13, J1, J4*

* IF END OF CABLE

UARTA

C40

C51

C34C36

C60

C21

C22

C65

R26

R27

R35

R34

R33

R32

R31

R41

R42

R51

R52

R36

R37

R38

IC20

C61

R21

R22

R23

R24

R25

R28

IC21

IC27

IC28

C33

C35

C66IC3

IC22

C32

C56

C57

R10

R18

R5

R8

R9

C55

C64

C23

C24

C25

C26

C27

C28

R43

R44

R45

R46

R47

R53

R54

R55

R56

R57

IC24

IC23

IC26C62

REL3

REL4

REL1

REL2C

63

R48

R58

P3

F2

F3

F4

F5

F8

F7

F1

F6

R12

R13

R14

R15

R17

R16

J3

J2

J4

C54

IC9

C3C4

C1C2

IC12IC11

IC13

IC10

C31

C52

IC6

IC5

IC4

IC1

C53

R1

R6

R7

C30

J1R11

R2

R3

R4

P1

IC2

IC25

Remove RS-232 circuiton IC11Fit RS-422 circuit on IC12

Connector Configuration (RS-422 Isolated on "uart2:" or "uart3:")


1 External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) provided strap is fi tted on J2:A which spoils the galvanical isolation

2 +TXD +Transmit data

3 +RXD +Receive data

4 –

5 GNDE Ground

6 –

7 -RXD -Receive data

8 -TXD -Transmit data

9 –

4

5

3

2

1

8

9

7

6+TXD+5V DCif GND strapfitted

+RXD

GNDE

MTG

MTG

-RXD-TXD

Remove strap on J2 A



Connector Configuration (RS-485 Isolated on "uart2:" or "uart3:")



2 +DATA

3 –

4 –

5 GNDE Ground

6 –

7 –

8 -DATA

9 –

4

5

3

2

1

8

9

7

6+DATA+5V DCif GND strap fitted

GNDE

MTG

MTG

-DATA

RS-485 Isolated, Half Duplex (Reconfiguration required)

P2

B A

C50

1-971643-01 P01

C67

RS232: IC11, J2A

RS422: IC12, J3, J4

RS485: IC13, J1, J4*

* IF END OF CABLE

UARTA

C40

C51

C34C36

C60

C21

C22

C65

R26

R27

R35

R34

R33

R32

R31

R41

R42

R51

R52

R36

R37

R38

IC20

C61

R21

R22

R23

R24

R25

R28

IC21

IC27

IC28

C33

C35

C66IC3

IC22

C32

C56

C57

R10

R18

R5

R8

R9

C55

C64

C23

C24

C25

C26

C27

C28

R43

R44

R45

R46

R47

R53

R54

R55

R56

R57

IC24

IC23

IC26C62

REL3

REL4

REL1

REL2

C63

R48

R58

P3

F2

F3

F4

F5

F8

F7

F1

F6

R12

R13

R14

R15

R17

R16

J3

J2

J4

C54

IC9

C3C4

C1C2

IC12IC11

IC13

IC10

C31

C52

IC6

IC5

IC4

IC1

C53

R1

R6

R7

C30

J1R11

R2

R3

R4

P1

IC2

IC25

Fit strap on J4 if end of cable(terminator)

Remove RS-232 circuiton IC11Fit RS-485 driver circuiton IC13

Fit strap on J1


Note: Th e 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 advise the customer to consider a LAN network solution for new applications.



Industrial Interface Configuration

Th e 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)

Th e Industrial Interface has no straps or circuits to be fi tted 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 InTh e 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 Description Min. Typical Max.

Vin [High] Input Voltage High 10V 24V 40V

Vin [Low] Input Voltage Low -1V 0V 1V

Connector Configuration

Th e Fingerprint reference numbers inside the parentheses refer to a second Serial/Industrial interface board.

Simplifi ed schematics of a digital IN port.

Pin Signal Name Description Fingerprint Ref. No.

10 IN1A Anode Opto In Channel 1 + 101 (301)

40 IN1K Cathode Opto In Channel 1 -















GND

INA

INK



Digital Opto Out

Th e current to each optocoupler of the digital OUT ports can be turned on and off using PORTOUT ON/OFF statements.

Th e 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 Description Max.

Vceo Collector-Emitter breakdown voltage 35V

Veco Emitter-Collector breakdown voltage 6V

Collector Current 15 mA

Vog Output to ground (optocoupler) 100V


Th e Fingerprint reference numbers inside the parentheses refer to a second Serial/Industrial interface board .

Simplifi ed schematics of a digital OUT port.

VCC

OUTa

OUTc


20 Out1c Collector Opto Out Channel 1 221 (421)

5 Out1e Emitter Opto Out Channel 1

















Simplifi ed schematics of a relay OUT port.

1

0.5

0.110 20 30 40 50 100

DC Voltage (VDC)a: resistive loadb: inductive load L/R=20 ms

DC cu

rrent

(A)

ab

VCC

REL comREL ncREL no

Relay Out

Th e relays of the OUT ports can be individually activated using PORT-OUT ON/OFF statements.

Th e 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 Description Max.

I Current 1A

Psw AC Switching power 100VA AC

Usw AC Switching voltage 100V AC

Max DC Load Breaking Capacity


Th e Fingerprint reference numbers inside the parentheses refer to a second Serial/Industrial interface board.


16 REL1nc Relay 1 Normally Closed 201 (401)

1 REL1no Relay 1 Normally Open

31 REL1com Relay 1 Common












Components

RS232: IC11, J2A

RS422: IC12, J3, J4

RS485: IC13, J1, J4*

*: IF END OF CABLE

B AB AUARTA

C4

0

C51

IC2

351

P1

C50

C34C36

C31

68

34

C5

2

C60C21

C22

C6

5

R26R27

R35R34R33R32R31

R4

1

R4

2

R5

1

R5

2

R36R37R38

IC20

C61

C67

R21R22R23R24R25

R2

8

IC21

IC27

IC28

C33

C35

C66

IC3

IC22

C32

C5

3

C56

C57 IC4IC6

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C3

0

C55

IC1IC5

J1

R11

R2

R3

R4

C6

4

C23

C2

4

C2

5

C2

6

C2

7

C2

8

R4

3

R44

R4

5

R4

6

R4

7

R5

3

R5

4

R55

R5

6

R5

7

IC23IC24

C6

2

REL3

REL4

IC25 IC26

C3C4

REL1

REL2

C1C2

R12

R13

R14

R15

IC11

R17

R16

IC13

IC12

C6

3

R4

8R

58

P2

F2

F3

F4

F5

F8

F7

J3

J4

J2

C54

F1

F6

IC9

P3

1-971643-26 Serial/Industrial Interface Board; Component side



Schematics; Serial Port

P1

C5

4

C5

5

C5

7

C3

0

C3

1

C3

2

C3

3

C3

4

C3

5

C3

6

5V

LD

11

17

IC2

R1

R2

R3

5V

3.3

V

16C

550

MR

RT

S*

DT

R*

NC

OU

T1

*

OU

T2

*

INT

RP

T A0

A1

A2

RX

RD

Y*

RC

LK

D5

SIN

D7

D6

NC

BA

UD

OU

T*

CS

2*

SO

UT

CS

1C

S0

RD2

TXRDY*DDIS

RD1*

ADS*

NC

XIN

VSSWR2

XOUTWR1*

VCCRI*

DCD*DSR*CTS*

NC

D1D0

D2D3D4

IC10

1

AH

C3

2

VC

C=

3.3

V

1

AH

C3

2

VC

C=

3.3

V

1

AH

C3

2

VC

C=

3.3

V

3.3

V

3.3

V

P2

9P

IN D

SU

B

C

F1

F2

F3

F4

F5

F6

F7

F8

5V

5V

R17

R13

R14

R12

J4J3R

16

R11

R10R

9

R18

R8

MA

X1480

MA

X1490

=1

VC

C=

3.3

V

AH

C8

6

=1

VC

C=

3.3

V

AH

C8

6

=1

VC

C=

3.3

V

AH

C8

6

=1

VC

C=

5V

AH

CT

86

=1

VC

C=

5V

AH

CT

86

=1

VC

C=

5V

AH

CT

86

=1

VC

C=

5V

AH

CT

86

3.3

V

5V

J13.3

V

MA

X2

38

5V

5V

J2

PO

WE

R_S

WIT

CH

C5

3

C5

2

C5

1

C5

6

R5

R6

R7

R4

R15

+C

1

+C

50

+C

2

+C

3

+C

4

1.8

432M

HZ

IC3

1

AH

C3

2

VC

C=

3.3

V

=1

VC

C=

3.3

V

AH

C8

6

VC

CA

0A

1

GN

DA

2W

P

SD

AS

CL

IC1

5V

3.3

V

5V

DT

R

*: I

F E

ND

OF

CA

BL

E

BA

RS

485

RT

S

RS

485

TX

D+

5V

RS

422

RS

485

GN

DD

SR

RX

D+

TX

D+

RX

D

GN

DE

-RX

D-T

XD

-DA

TA

GN

DE

TE

RM

.RE

C.

RS

422

TE

RM

.TR

A.

GN

D-S

HIE

LD

CT

S

+D

AT

A

RS

232

EX

TE

RN

AL 5

VS

WIT

CH

FO

R

INT

ER

FA

CE

CO

NF

IGU

RA

TIO

NR

S2

32

: IC

11

, J2

AR

S4

22

: IC

12

, J3

, J4

RS

485: IC

13, J1

, J4

*

RS

232

485_DIR

0 10

81

09IC

5

11

1312

IC4

4

31

2

8 7 6 5321 4

IC9

321

9 15

11

20

21

24

19

118

25

17

16

22

23

43

678

14

13

12

10

IC11

21

11

13

12

IC6

321

IC6

654

IC6

8109

IC6

654

IC5

11

1312

IC5

321

IC5

18

17

10821 7

11

1422

13

21

15

16

125 6 943

19

23

24

20

IC12

14

10821 7

13

18

26

15

24

22

19

21

17

16

20

125 6 9

1143

25

27

28

23

IC13

21 21

MT

G2

MT

G1

987654321

81

09IC

4

654

IC4

321

IC4

1918

2120

22

44

27

13

11

32

36

43 2524

10

35

38

34

23

12

1

39

33

37

412642

987

65432

40

16

15

14

17

28

29

30

31

23

1

78 564321

5384

68

34

67

33

66

32

65

31

64

37

30

63

29

62

28

61

27

60

26

593

25

58

24

57

23

56

22

55

21

54

36

20

53

19

52

18

51

17

50

16

492

15

48

14

47

13

46

12

45

11

44

35

10

439

428

417

406

391

SC

L

SD

A

RE

SE

T_N

CLK

T1O

UT

INT

A

RX

DA

Z

IRC

DR

V

+24V

I

GN

D

INT

_N

RE

SE

T_N

RD_N

A<

12..1>

OC

_N

OU

TO

UT

OU

TIN E

N_

NING

ND

5V

_E

XT

_E

N_N

VC

C3

1

VC

C

GN

DO

UT

NC

/EN

_N

5V

_E

XT

SA

1

CS

_N

INT

_N

9 10

11

VIN

GN

D

VO

UT

GN

D1

AC

2

12

1

6

12

87

15

652 3 4

13

11

9873

GN

D2

RO

DI

SD

VC

C2

VC

C1

D1

D2

IRLE

DIV

CC

2

ICO

M1YBA

AC

1

VC

C5

RO

_N

GN

D2

VC

C4

DE

DI

SD

FS

D2

D1

VC

C2

IRLE

DIC

OM

2ID

ED

RV

AC

1

IVC

C2

IDID

RVB A

FS

VC

C1

IRC

DR

V

IVC

C1

AC

2

GN

D1

ICO

M1

IDE

INID

IIN

VC

C3

VC

C4

32

10

23

5 6 7

WR_N

RE

SE

T

4

IDID

RV

IVC

C1

2

DC

DA

_N

12

TX

DA

OV

ER

CU

RR

EN

T_N

D<

15..0>

1 14

54

WR

_N

WR

B_N

WA

IT_N

RD

_N

WR

_N

11

CS

A_N

RE

SE

T

RT

SA

_N

C1

-C

1+

T2

INT

1IN

C2

-

R2O

UT

R3O

UT

R4O

UT

V-

V+

T2O

UT

T3O

UT

T4O

UT

R2

INR

1IN

R3

INR

4IN

C2

+

VC

C

DT

RA

_N

R1O

UT

T4

INT

3IN

DS

RA

_N

INT

A

CS

B_N

CT

SA

_N

1-971643-26 Serial/Industrial Interface Board; Schematics 1



Schematics; Industrial Interface

R34

C6

0

C6

1

C6

2

C6

3

C6

4

C6

5

C6

6

C6

7

5V

3.3

VO

PT

O_C

OU

PLE

R

OP

TO

_C

OU

PLE

R

OP

TO

_C

OU

PLE

R

OP

TO

_C

OU

PLE

R

C21

C2

2

C23

C24

C25

C26

C27

C28

R32

R31

5V

R21

R22

R23

R24

R25

R26

R27

R28

RE

SE

T

CLK

DA

HC

T273

VC

C=

5V

RE

SE

T

CLK

DA

HC

T273

VC

C=

5V

ULN

2003A

IC28

ULN

2003A

IC27

ULN

2003A

IC27

ULN

2003A

IC27

ULN

2003A

IC27

ULN

2003A

IC27

ULN

2003A

IC27

ULN

2003A

IC27

ULN

2003A

IC28

ULN

2003A

IC28

ULN

2003A

IC28

ULN

2003A

IC28

ULN

2003A

IC28

ULN

2003A

IC28

R33

P3

R41

R51

EN

&

AH

C541

VC

C=

3.3

V

R52

R42

R53

R43

R54

R44

R55

R38

R45

R56

R46

R57

R47

R58

R37

R48

5V

R36

R35

C

C4

0

IN5K

IN3A

OU

T3E

SIG

NA

LS

RE

L3N

CR

EL3N

O

RE

L4C

OM

RE

L1N

O

IN1K

IN1A

IN2K

IN2A

IN3K

IN4K

IN4A

IN5A

IN6K

IN6A

IN7K

IN7A

IN8K

IN8A

OU

T8E

OU

T8C

OU

T7E

OU

T7C

OU

T6E

OU

T6C

OU

T5E

OU

T5C

OU

T4E

OU

T4C

OU

T3C

OU

T2E

OU

T2C

OU

T1E

OU

T1C

RE

L4N

OR

EL4N

CR

EL3C

OM

RE

L2C

OM

RE

L2N

OR

EL2N

CR

EL1C

OM

RE

L1N

C

910

11

12

13

14

15

16

87654321

IC26

910

11

12

13

14

15

16

87654321

IC25

9

10

11

12

13

14

15

16

87654321

IC24

9

10

11

12

13

14

15

16

87654321

IC23

14

12

11

A2

A1

RE

L1

14

12

11

A2

A1

RE

L2

14

12

11

A2

A1

RE

L3

14

12

11

A2

A1

RE

L4

MT

G2

MT

G1

98765 44

43

42

41

404 39

38

37

36

35

34

33

32

31

303 29

28

27

26

25

24

23

22

21

202 19

18

17

16

15

14

13

12

11

101

11

6

10

7

15

2

14

3

13

4

12

5

16

1

15

2

14

3

13

4

12

5

11

6

10

7

16

1

2 5 6 9 12

15

16

19

111 3 4 7 8

13

14

17

18

IC22

2 5 6 9 12

15

16

19

111 3 4 7 8

13

14

17

18

IC21

11

12

13

14

15

16

17

18

19

1 9 8 7 6 5 4 3 2

IC20

CO

M

VC

C=

5V

VC

C=

5V

7

A1

A2 NO

CO

M

NC

RE

SE

T_N

WR

B_N

11

10

98 0123456

RD

_N

CS

B_N

NC

CO

M

NO

A2

A1

NC

CO

M

NO

A2

A1

NO

A1

A2 NC

D<

15..0>

1234567

DS

UB

44

0

1-971643-26 Serial/Industrial Interface Board; Schematics 2



14.7 Double Serial Interface Board (not IPL)

Description

Th e Double Serial Interface Board (DUART) is a Fingerprint-only optional device for EasyCoder PM4i printers. It provides these printers with two extra serial interfaces.

"uart2:"Th is interface can be fi tted with straps and circuits for one of the following alternatives:• RS-232 non-isolated • RS-422 isolated, full duplex• RS-485 isolated, half duplex

"uart3:"Th is interface can be fi tted with straps and circuits for one of the following alternatives:• RS-232 non-isolated • RS-422 non isolated, full duplex• 20 mA Current Loop.

Th e Double Serial Interface Kit contains:• One interface board fi tted for RS-232 on both ports.• Two fl at 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:" Configuration

Th e serial communication port "uart2:" can be confi gured for three diff erent types of serial communication by fi tting or removing certain driver circuits and straps:

• RS-232 non-isolated• RS-422 isolated, full duplex• RS-485 isolated, half duplex

RS-232 Non-isolated (standard)

A

B

C

C

B

A

UARTBB A

A

B

C

C

B

A

B A

UARTA

A

B

C

C

B

A

B A

RS232: IC21, J6ARS422: IC22, J6B, J7, J820MACL: IC23, IC24, J5 J9*, J10**: TRANSM.=J9, RECEIV.=J10

RS232: IC11, J2ARS422: IC12, J3, J4RS485: IC13, J1, J4**: IF END OF CABLE

PASSIVE=B, ACTIVE=A+C

B A

P1

C50

C42

C51

C31

C52

C10 C12

C61

IC8

J5

IC7

IC6

IC5

IC4

IC1

R23R24

C36

C60

C40

R20

R21

R22

IC20

IC21

C33

C34

C35

C41

IC2

C32

C53

C56

C57

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C30

C55 J1R

11

R2

R3

R4

C11

C13

R27

C63

R30

R34

R33

R35

AN

CK

Z2

IC23

IC24IC

22

C62

C64

AN

CK

D1

R26

R28 R29

R19

AN

CK

Z1

C3C4

IC3

C1C2

R12

R13

R14

R15

R17

R16

IC12IC11

IC13

F13J6

J7J10

J9

P3

F1

4F

10

F1

5F

11

F1

6F

12

F9

R32

R31

P2

F2

F3

F4

F5

F8

F7

J3

J2

J4

C54

F1

F6

IC9

AN

CK

AN

CK

R25

AN

CK

1-971642-01 P01

J8



Connector Configuration (RS-232 on "uart2:")



2 TXD Transmit data

3 RXD Receive data


5 GND Ground


7 CTS Clear to send


9 – Not used

4

5

3

2

1

8

9

7

6TXD out+5V DC

RXD inDSR inGND

MTG

MTG

DTR outCTS in

RTS out



RS-422 Isolated, Full Duplex (reconfiguration required)


A

B

C

C

B

A

UARTBB A

A

B

C

C

B

A

B A

UARTA

A

B

C

C

B

A

B A




B A

P1

C50

C42

C51

C31

C52

C10 C12

C61

IC8

J5

IC7

IC6

IC5

IC4

IC1

R23R24

C36

C60

C40

R20

R21

R22

IC20

IC21

C33

C34

C35

C41

IC2

C32

C53

C56

C57

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C30

C55 J1R

11

R2

R3

R4

C11

C13

R27

C63

R30

R34

R33

R35

AN

CK

Z2

IC23

IC24

IC22

C62

C64

AN

CK

D1

R26

R28 R29

R19

AN

CK

Z1

C3C4

IC3

C1C2

R12

R13

R14

R15

R17

R16

IC12IC11

IC13

F13J6

J7J10

J9

P3

F1

4F

10

F1

5F

11

F1

6F

12

F9

R32

R31

P2

F2

F3

F4

F5

F8

F7

J3

J2

J4

C54

F1

F6

IC9

AN

CK

AN

CK

R25

AN

CK

1-971642-01 P01

J8

Fit RS-422 circuit on IC12

Connector Configuration (RS-422 Isolated on "uart2:")





4 –

5 GNDE Ground

6 -



9 –

4

5

3

2

1

8

9

7

6+TXD+5V (0.5 A)if GND strapfitted

+RXD

GNDE

-RXD-TXD


Remove RS-232 circuit on IC11



A

B

C

C

B

A

UARTBB A

A

B

C

C

B

A

B A

UARTA

A

B

C

C

B

A

B A




B A

P1

C50

C42

C51

C31

C52

C10 C12

C61

IC8

J5

IC7

IC6

IC5

IC4

IC1

R23R24

C36

C60

C40

R20

R21

R22

IC20

IC21

C33

C34

C35

C41

IC2

C32

C53

C56

C57

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C30

C55 J1R

11

R2

R3

R4

C11

C13

R27

C63

R30

R34

R33

R35

AN

CK

Z2

IC23

IC24

IC22

C62

C64

AN

CK

D1R26

R28 R29

R19

AN

CK

Z1

C3C4

IC3

C1C2

R12

R13

R14

R15

R17

R16

IC12IC11

IC13

F13J6

J7J10

J9

P3

F14

F10

F15

F11

F16

F12

F9

R32

R31

P2

F2F3

F4F5

F8F7

J3

J2

J4

C54

F1F6

IC9

AN

CK

AN

CK

R25

AN

CK

1-971642-01 P01

J8

RS-485 Isolated, Half Duplex (reconfiguration required)


Fit RS-485 driver circuit on IC13

Fit strap on J1




2 +DATA

3 –

4 –

5 GNDE Ground

6 –

7 –

8 -DATA

9 –

4

5

3

2

1

8

9

7

6+DATA+5V (0.5 A)if GND strapfitted

GNDE

-DATA







Th e serial communication port uart3: can be confi gured for three diff erent types of serial communication by fi tting 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)

A

B

C

C

B

A

UARTBB A

A

B

C

C

B

A

B A

UARTA

A

B

C

C

B

A

B A




B A

P1

C50

C42

C51

C31

C52

C10 C12

C61

IC8

J5

IC7

IC6

IC5

IC4

IC1

R23R24

C36

C60

C40

R20

R21

R22

IC20

IC21

C33

C34

C35

C41

IC2

C32

C53

C56

C57

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C30

C55 J1R

11

R2

R3

R4

C11

C13

R27

C63

R30

R34

R33

R35

AN

CK

Z2

IC23

IC24

IC22

C62

C64A

NC

K

D1

R26

R28 R29

R19

AN

CK

Z1

C3C4

IC3

C1C2

R12

R13

R14

R15

R17

R16

IC12IC11

IC13

F13J6

J7J10

J9

P3

F1

4F

10

F1

5F

11

F1

6F

12

F9

R32

R31

P2

F2

F3

F4

F5

F8

F7

J3

J2

J4

C54

F1

F6

IC9

AN

CK

AN

CK

R25

AN

CK

1-971642-01 P01

J8


RS-232 driver circuit fi tted on IC21




2 TXD Transmit data

3 RXD Receive data


5 GND Ground


7 CTS Clear to send


9 – Not used

4

5

3

2

1

8

9

7

6TXD out+5V DC

RXD inDSR inGND

MTG

MTG

DTR outCTS in

RTS out



"uart3:" RS-422 Non Isolated, Full Duplex (Reconfiguration Required)

A

B

C

C

B

A

UARTBB A

A

B

C

C

B

A

B A

UARTA

A

B

C

C

B

A

B A




B A

P1

C50

C42

C51

C31

C52

C10 C12

C61

IC8

J5

IC7

IC6

IC5

IC4

IC1

R23R24

C36

C60

C40

R20

R21

R22

IC20

IC21

C33

C34

C35

C41

IC2

C32

C53

C56

C57

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C30

C55 J1R

11

R2

R3

R4

C11

C13

R27

C63

R30

R34

R33

R35

AN

CK

Z2

IC23

IC24

IC22

C62

C64

AN

CK

D1

R26

R28 R29

R19

AN

CK

Z1

C3C4

IC3

C1C2

R12

R13

R14

R15

R17

R16

IC12IC11

IC13

F13J6

J7J10

J9

P3

F1

4F

10

F1

5F

11

F1

6F

12

F9

R32

R31

P2

F2

F3

F4

F5

F8

F7

J3

J2

J4

C54

F1

F6

IC9

AN

CK

AN

CK

R25

AN

CK

1-971642-01 P01

J8


Move strap from J6 A to J6 B

Fit straps onJ7 and J8

Connector Configuration (RS-422 Non-isolated on "uart3:")


1 External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) if strap is moved from J6 B to J6 A.



4 –

5 GNDE Ground

6 -



9 –

4

5

3

2

1

8

9

7

6+TXD+5V (0.5 A)

+RXD

GND

-RXD-TXD

Remove RS-232 driver circuit from IC21



"uart3:" 20 mA Current Loop (Reconfiguration Required)

A

B

C

C

B

A

UARTBB A

A

B

C

C

B

A

B A

UARTA

A

B

C

C

B

A

B A




B A

P1

C50

C42

C51

C31

C52

C10 C12

C61

IC8

J5

IC7

IC6

IC5

IC4

IC1

R23R24

C36

C60

C40

R20

R21

R22

IC20

IC21

C33

C34

C35

C41

IC2

C32

C53

C56

C57

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C30

C55 J1R

11

R2

R3

R4

C11

C13

R27

C63

R30

R34

R33

R35

AN

CK

Z2

IC23

IC24

IC22

C62

C64

AN

CK

D1

R26

R28 R29

R19

AN

CK

Z1

C3C4

IC3

C1C2

R12

R13

R14

R15

R17

R16

IC12IC11

IC13

F13J6

J7J10

J9

P3

F1

4F

10

F1

5F

11

F1

6F

12

F9

R32

R31

P2

F2

F3

F4

F5

F8

F7

J3

J2

J4

C54

F1

F6

IC9

AN

CK

AN

CK

R25

AN

CK

1-971642-01 P01

J8

Fit optocouplers on IC23 and IC24

Fit strap on J5

Fit strap on J10 if printer is receiver:A + C = activeB = passive

Fit strap on J9 if printer is transmitter:A + C = activeB = passive

Connector Configuration (20 mA Current Loop on "uart3:")


1 External +5VDC max 500 mA (automatic switch-off at overload, short-circuit protected) provided a strap is fi tted on J6 A which spoils the galvanic isolation.



4 –

5 GNDE Ground

6 -



9 –

4

5

3

2

1

8

9

7

6+TXD+5V DCif GND strapfitted

+RXD

MTG

MTG

-RXD-TXD

Remove RS-232 driver circuit from IC21

Remove strap from J6 A

Note: Th e maximum recommended baud rate is 9600.



Components

A

B

C

C

B

A

UARTBB A




UARTAB A

A

B

C

C

B

A

UARTBB A




UARTAB A

A

B

C

C

B

A

UARTBB A




UARTAB A

351

P1

C50

C42

C51

C31

6834

C52

C10 C12

C61

IC8

R23

R24

C36 C40

C60

IC7

J5

R20

R21

R22

IC20

IC21

C33

C34

C35

C41

IC2

C32

C53

C56

C57 IC4IC6

R1

R10

R18

R5

R6

R7

R8

R9

IC10

C30

C55

IC1IC5

J1

R11 R2R3R4

C11

C13

C63

J10

R27

R30

R34

R35

ANC

K

Z2

IC23

C62

C64

ANC

K

D1

J9

R26

R28 R29R19

R33

ANC

K

Z1

IC22

IC24

C3C4IC3

C1C2

R12

R13

R14

R15

R17

R16

IC11

IC13

IC12

F11

F12

F13

F16

J7

J6

P3

F10

F14

F15

F9

J8R3

2R3

1

P2

F2F3

F4F5

F8F7

J3J4

J2

C54

F1F6

IC9

ANC

K

ANC

K

R25

ANC

K

1-971642-26 Serial/Industrial Interface Board; Component side



Schematics "uart2:"

C54

C55

C57

C30

C31

C32

C33

C34

C35

C36

R1

R2

R3

5V

3.3V

1

AH

C32

VC

C=3

.3V 1

AH

C32

VC

C=3

.3V 1

AH

C32

VC

C=3

.3V

3.3V

3.3V

P2

9PIN

DS

UB

C

F1

F2

F3

F4

F5

F6

F7

F8

5V

5V

R17

R13

R14R12

J4J3R

16

R11

R10

R9

R18

R8

MA

X14

80

MA

X14

90

=1V

CC

=3.3

V

AH

C86

=1V

CC

=3.3

V

AH

C86

=1V

CC

=3.3

V

AH

C86

=1V

CC

=5V

AH

CT

86

=1V

CC

=5V

AH

CT

86

=1V

CC

=5V

AH

CT

86

=1V

CC

=5V

AH

CT

86

3.3V

5V

J13.

3V

MA

X23

8

5V

5V

J2

PO

WE

R_S

WIT

CH

C53

C52

C51

R5

R6

R7

R4

R15

+C

1

+C

50

+C

2

+C

3

+C

4

1

AH

C32

VC

C=3

.3V

=1V

CC

=3.3

V

AH

C86

5V

5V

3.3V

16C

550

MR

RT

S*

DT

R*

NC

OU

T1*

OU

T2*

INT

RP

T A0

A1

A2

RX

RD

Y*

RC

LK

D5

SIN

D7

D6

NC

BA

UD

OU

T*

CS

2*

SO

UT

CS

1C

S0

RD2

TXRDY*DDIS

RD1*

ADS*

NC

XIN

VSSWR2

XOUTWR1*

VCCRI*

DCD*DSR*CTS*

NC

D1D0

D2D3D4

IC10

C565V

1.84

32M

HZ

IC3

P1

3.3V

IC2

VC

CA

0A

1

GN

DA

2W

P

SD

AS

CL

IC1

BAR

S42

2G

ND

-SH

IELD

RS

232

RS

485

SW

ITC

H F

OR

EX

TE

RN

AL

5V

RS

485

RT

S

DT

R

TX

D+5

VR

S42

2R

S48

5

GN

DD

SR

+TX

D

GN

DE

-RX

D-T

XD

-DA

TA

TE

RM

.RE

C.

CT

S

+DA

TA

TE

RM

.TR

A.

*: IF

EN

D O

F C

AB

LE

RS

485:

IC13

, J1,

J4*

RS

422:

IC12

, J3,

J4

RS

232:

IC11

, J2A

UA

RT

A C

ON

FIG

UR

AT

ION

RS

232

GN

DE

+RX

DR

XD

33

11

IC4

D<1

5..0

>

810

9IC

5

111312

IC4

4

31

2

8 7 6 5321 4

IC9

321

9 1511 2021

2419

118

25

1716

2223

4367

814131210

IC11

21

111312

IC6

321

IC6

654

IC6

810

9IC

6

654

IC5

111312

IC5

321

IC5

18 17

10

821 7

111422 1321 1516

12

5 6 943

192324 20

IC12

1410

821 7

13

1826 1524 22 1921 17 1620

12

5 6 9

11

43252728 23

IC13

21 21

MT

G2

MT

G1

987654321

810

9

654

IC4

321

IC4

1918

2120

22

44

27

133236

43 2524

103538 34

23

12

1

39 3337

412642

987

65432

40

161514 17

28

293031

23

1

78 564321

538

4

683467663265316437 30632962286127602659

3

2558245723562255215436 20531952185117501649

2

1548144713461245114435 10439

428

417

406

39

1

RD

_N

9

+24V

I

WA

IT_N

SC

L

SD

A

SA

1

CS

_NIN

T_N

CT

SA

_N

C2-

DE

IVC

C2

RE

SE

T

INT

A

WR

_N

INT

BIN

TA

INT

_N

RE

SE

T_N

CS

B_N

EN

_N

RT

SA

_ND

TR

A_N

T3I

NT

4IN

R2O

UT

R3O

UT

R4O

UT

R3I

NR

4IN

T4O

UT

T3O

UT

T2O

UT

DS

RA

_N

VIN

GN

DN

C/E

N_NVC

C

OV

ER

CU

RR

EN

T_N

5V_E

XT

_EN

_N

VC

C1

T1I

N

C2+

C1-

CS

A_N

T2I

N

R1O

UT

R2I

NR

1IN

GN

D1

IN INO

C_N

C1+

V-

T1O

UT

RX

DA

D2

GN

D1

IDIIN

IDE

IN

GN

D2

RO

_NV

CC

5

IDE

DR

V

IRLE

D

VC

C3

VC

C2

D1

D2

ICO

M1

IDID

RV

IRLE

D

IVC

C1

SD

VC

C4

RD_N

RE

SE

T

A<1

2..1

>

12

2

RO

TX

DA

DC

DA

_N

V+

GN

D

485_DIR

4

WR_N

765

32

01

2 3

VC

C3

ICO

M1

AC

2IV

CC

1

IRC

DR

V

VC

C1

FS

AB

IDID

RV

AC

1

ICO

M2

VC

C2

D1

FS

SD

DI

VC

C4

AC

1

IRC

DR

V A B Z Y

IVC

C2

DI

GN

D2

1 3 5 7 8 10 11 13

432 5 6

14 15

7 8 12

4 6

1

12

11

AC

2

VC

C

CLK

VO

UT

GN

D

11109

RE

SE

T_N

5V_E

XT

OU

T

1

0

GN

DO

UT

OU

TO

UT

1-971642-26 Double Serial Interface Board; Schematics 1



Schematics "uart3:"

P3

9PIN

DS

UB

J9 J10

=1V

CC

=3.3

V

AH

C86

C60

C61

C62

C63

C64

C40

C41

C42

5V3.

3V

R21

R22

R20

R23 R27

R28

R26

R25

+C

10

+C

11

+C

12

+C

13

5V

C

J7

F9

J8R

32

R31

R24

F10

5V

MA

X23

8

=1V

CC

=3.3

V

AH

C86

=1V

CC

=3.3

V

AH

C86

F11

3.3V

J5

5V

F12

=1V

CC

=3.3

V

AH

C86

F13

3.3V

16C

550

MR

RT

S*

DT

R*

NC

OU

T1*

OU

T2*

INT

RP

T A0

A1

A2

RX

RD

Y*

RC

LK

D5

SIN

D7

D6

NC

BA

UD

OU

T*

CS

2*

SO

UT

CS

1C

S0

RD2

TXRDY*DDIS

RD1*

ADS*

NC

XIN

VSSWR2

XOUTWR1*

VCCRI*

DCD*DSR*CTS*

NC

D1D0

D2D3D4

IC20

F14

3.3V

J6

DS

2981

6N13

9

6N13

9

F15

5V

5V

1

AH

CT

32

VC

C=5

V 1

AH

CT

32

VC

C=5

V 1

AH

CT

32

VC

C=5

V1

AH

CT

32

VC

C=5

V

F16

R30

R29

R33

R19

R34

R35

D1

Z2

Z1

GN

D-S

HIE

LD

20M

AC

L: IC

23, I

C24

, J5,

J9*

, J10

*

UA

RT

B C

ON

FIG

UR

AT

ION

RS

232:

IC21

, J6A

RS

422:

IC22

, J6B

, J7,

J8

*: T

RA

NS

M.=

J9, R

EC

EIV

.=J1

0P

AS

SIV

E=B

, AC

TIV

E=A

+C

CU

RR

-FE

ED

RE

CE

IVE

R

BA CCB BAA

TE

RM

.RE

C.

TE

RM

.TR

A.

GN

DG

ND

ED

TR

CT

SR

TS

-TX

DT

XD

OU

T

TX

D+T

XD

+RX

DR

XD

TX

DIN

RX

DIN

20M

AC

L+5

V

-RX

D

DS

R

RS

422

CU

RR

-FE

ED

TR

AN

SM

.RS

232

RS

232

RS

422

20M

AC

L

RX

DO

UT

20M

AC

L11

1312IC

7

43214321

C A C A

321

IC8

111312

IC8

810

9IC

8

654

IC8

8 57 632

IC24

8 57 632

IC23

1 27 8

4

5 63

IC22

321

1918

2120

22

44

27

1311

3236

43 2524

103538 34

23

12

1

39 3337

412642

987

65432

40

161514 17

28

293031

8109

IC721

654

IC7

321

IC7

9 1511 2021

2419

118

25

1716

2223

4367

814131210

IC21

2121

MT

G2

MT

G1

987654321

TX

DB

+24V

I

R4I

N

T3I

N

C2-

D<1

5..0

>

C1+

C1-

T2I

NT

1IN

C2+

T1O

UT

VC

C

RE

SE

T

CS

B_N

5V_E

XT

WR

_N

CLK

RD

_N

765

32

234

10

10V

10V

RI-

RI+

DO

+D

O-

VC

C

R3I

N

R1I

NR

2IN

T4O

UT

T3O

UT

T2O

UT

GN

D

V+

V-

R3O

UT

R2O

UT

R1O

UT

T4I

N

DC

DB

_N

CT

SB

_N

DT

RB

_NR

TS

B_N

R4O

UT

GN

DD

IR

OR

XD

B

1

A<1

2..1

>

INT

B

DS

RB

_N

CL_EN_N

1-971642-26 Double Serial Interface Board; Schematics 2



14.8 RFID Serial Interface Board

Description

Th e RFID Serial Interface Board is an optional device for EasyCoder PM4i printers. It provides these printers with one serial interface port and RFID functionality. It is supported by both Fingerpint and IPL.

Th e RFID Serial Interface Board is available as part of various RFID Kits that typically contain:

• One RFID Serial Interface Board• One Radio Module• One Dual Slot / Single Slot I/O Bus Cable (Flat Cable)• One RFID Antenna• Two MRT 4x8 Screws• One MRT 3x5 Screw• One Spacer Screw• One RFID label• One Quick Start Guide or User’s Guide booklet• One Installations Instructions booklet

"uart2:"Th is interface can be fi tted with straps and circuits for one of the following alternatives:• RS-232 non-isolated • RS-422 isolated, full duplex• RS-485 isolated, half duplex

"uart3:"Jumpers J5-J9 can be fi tted with straps to provide support for two diff erent types of RFID modules.


1RBR1

13434

356868

P4

P4

3PP3

R16

R16

R17

R17

IC2

IC2

11CIIC11

21CIIC1231CIIC13

02CIIC20

01CIIC10

3CIIC3

9J98JJ87JJ76J65J5

2J2

02RR20

91RR19

9RR9

8RR8

R7R7

R6R6

R5R5

R4R4 R3R3 R2R2

81RR1851R15

41R14

31RR13

21R12

R11

R11

01R10

R1R1

4JJ4

3JJ3

1J1

8CIIC8 7CIIC7IC

6IC

6IC

5IC

5

IC4

IC4

IC9

IC9

IC1

IC1

F7F7F8F8

F6F6F5F5

F4F4F3F3

F2F2F1F1

C61

C61

06C60

75CC57

65CC56

C55

C5545C54

C53

C53

C52

C52

15CC51

24CC42

C41

C41

04CC40

63CC36

53CC35

43CC34C

33C

33

C32

C32

C31

C31

C30

C30

05CC50

4CC4 3CC3

2CC2 1CC1

2PP2

1PP1

13434

35356868

B9J-B5J :0006RPMMPR6000: J5B-J9BA9J-A5J :4MI/3MIIM3/IM4: J5A-J9A

AB

ELBAC FO DNE FI :*: IF END OF CABLE*4J ,1J ,31CI :584SRRS485: IC13, J1, J4*

4J ,3J ,21CI :224SRS422: IC12, J3, J4A2J ,11CI :232SRRS232: IC11, J2A

ATRAUARTA

PC

B N

UM

BE

R




Th e serial communication port "uart2:" can be confi gured for three diff erent types of serial communication by fi tting or removing certain driver circuits and straps:

• RS-232 non-isolated• RS-422 isolated, full duplex• RS-485 isolated, half duplex

RS-232 Non-Isolated (Standard)






2 TXD Transmit data

3 RXD Receive data


5 GND Ground


7 CTS Clear to send


9 – Not used

4

5

3

2

1

8

9

7

6TXD out+5V DC

RXD inDSR inGND

MTG

MTG

DTR outCTS in

RTS out

1RBR1

13434

356868

P4

P4

3PP3

R16

R16

R17

R17

IC2

IC2

11CIIC11

21CIIC1231CIIC13

02CIIC20

01CIIC10

3CIIC3

9J98JJ87JJ76J65J5

2J2

02RR20

91RR19

9RR9

8RR8

R7R7

R6R6

R5R5

R4R4 R3R3 R2R2

81RR1851R15

41R14

31RR13

21R12

R11

R11

01R10

R1R1

4JJ4

3JJ3

1J1

8CIIC8 7CIIC7

IC6

IC6

IC5

IC5

IC4

IC4

IC9

IC9

IC1

IC1

F7F7F8F8

F6F6F5F5

F4F4F3F3

F2F2F1F1

C61

C61

06C60

75CC57

65CC56

C55

C5545C54

C53

C53

C52

C52

15CC51

24CC42

C41

C41

04CC40

63CC36

53CC35

43CC34

C33

C33

C32

C32

C31

C31

C30

C30

05CC50

4CC4 3CC3

2CC2 1CC1

2PP2

1PP1

13434

35356868


AB



ATRAUARTA

PC

B N

UM

BE

R



RS-422 Isolated, Full Duplex (reconfiguration required)


Fit RS-422 circuit on IC12






4 –

5 GNDE Ground

6 -



9 –

4

5

3

2

1

8

9

7

6+TXD+5V (0.5 A)if GND strapfitted

+RXD

GNDE

-RXD-TXD



1RBR1

13434

356868

P4

P4

3PP3

R16

R16

R17

R17

IC2

IC2

11CIIC11

21CIIC1231CIIC13

02CIIC20

01CIIC10

3CIIC3

9J98JJ87JJ76J65J5

2J2

02RR20

91RR19

9RR9

8RR8

R7R7

R6R6

R5R5

R4R4 R3R3 R2R2

81RR1851R15

41R14

31RR13

21R12

R11

R11

01R10

R1R1

4JJ4

3JJ3

1J1

8CIIC8 7CIIC7

IC6

IC6

IC5

IC5

IC4

IC4

IC9

IC9

IC1

IC1

F7F7F8F8

F6F6F5F5

F4F4F3F3

F2F2F1F1

C61

C61

06C60

75CC57

65CC56C

55C

5545C54

C53

C53

C52

C52

15CC51

24CC42

C41

C41

04CC40

63CC36

53CC35

43CC34

C33

C33

C32

C32

C31

C31

C30

C30

05CC50

4CC4 3CC3

2CC2 1CC1

2PP2

1PP1

13434

35356868


AB



ATRAUARTA

PC

B N

UM

BE

R



RS-485 Isolated, Half Duplex (reconfiguration required)



Fit strap on J1




2 +DATA

3 –

4 –

5 GNDE Ground

6 –

7 –

8 -DATA

9 –

4

5

3

2

1

8

9

7

6+DATA+5V (0.5 A)if GND strapfitted

GNDE

-DATA




1RBBR1

13434

35356868

P4

3PP3

R16

R16

R17

R17

IC2

11CIIC11

21CIIC1231CIIC13

02CIIC20

01CIIC10

3CIIC3

9JJ98JJ87JJ76JJ65JJ5

2J2

02RR20

91RR19

9RR9

8RR8

R7

R6R6

R5R5

R4R4 R3R3 R2R2

81RR1851R15

41R14

31RR13

21R12

R11

R11

01R10

R1R1

4JJ4

3JJ3

1J1

8CIIC8 7CIIC7

IC6

IC5

IC4

IC4

IC9

IC9

IC1

IC1

F7F7F8F8

F6F6F5F5

F4F4F3F3

F2F2F1F1

C61

C61

06CC60

75CC57

65CC56

C55

C5545C54

C53

C53

C52

C52

15CC51

24CC42

C41

C41

04CC40

63CC36

53CC35

43CC34

C33

C33

C32

C32

C31

C31

C30

C30

05CC50

4CC4 3CC3

2CC2 1CC1

2PP2

1PP1

13434

35356868


AB



ATRAUUARTA

PC

B N

UM

BE

R

1RBBR1

13434

35356868

P4

3PP3

R16

R16

R17

R17

IC2

11CIIC11

21CIIC1231CIIC13

02CIIC20

01CIIC10

3CIIC3

9JJ98JJ87JJ76JJ65JJ5

2J2

02RR20

91RR19

9RR9

8RR8

R7

R6R6

R5R5

R4R4 R3R3 R2R2

81RR1851R15

41R14

31RR13

21R12

R11

R11

01R10

R1R1

4JJ4

3JJ3

1J1

8CIIC8 7CIIC7

IC6

IC5

IC4

IC4

IC9

IC9

IC1

IC1

F7F7F8F8

F6F6F5F5

F4F4F3F3

F2F2F1F1

C61

C61

06CC60

75CC57

65CC56

C55

C5545C54

C53

C53

C52

C52

15CC51

24CC42

C41

C41

04CC40

63CC36

53CC35

43CC34

C33

C33

C32

C32

C31

C31

C30

C30

05CC50

4CC4 3CC3

2CC2 1CC1

2PP2

1PP1

13434

35356868


AB



ATRAUUARTA

PC

B N

UM

BE

R



"Module Select" Configuration

Straps can be fi tted to jumpers J5-J9 to provide support for two diff erent types of RFID radio modules:

IM3/IM4

MPR6100

Fit straps on J5-J9, in "upper" position

Fit straps on J5-J9, in "lower" position

BR1BR11

4353

86

4P

P3P3

61R

71R

2CI

IC11IC11 IC12IC12

IC13IC13

IC20IC20

IC10IC10

IC3IC3

J9J9J8J8J7J7J6J6J5J5

J2J2

R20R20

R19R19

R9R9

R8R8

7R

6R

5R

4R

3R 2R

R18R18R15R15

R14R14

R13R13

R12R12

11R

R10R10

1R

J4J4

J3J3

J1J1

IC8IC8 IC7IC7

6CI

5CI

4CI

9CI

1CI

7F8F

6F5F

4F3F

2F1F

16C

C60C60

C57C57

C56C56

55C

C54C54

35C

25C

C51C51

C42C42

14C

C40C40

C36C36

C35C35

C34C34

33C

23C

13C

03C

C50C50

C4C4 C3C3

C2C2 C1C1

P2P2

P1P1

143

5386

MPR6000: J5B-J9BMPR6000: J5B-J9B

IM3/IM4: J5A-J9AIM3/IM4: J5A-J9A

AB

*: IF END OF CABLE*: IF END OF CABLE

RS485: IC13, J1, J4*RS485: IC13, J1, J4*

RS422: IC12, J3, J4RS422: IC12, J3, J4

RS232: IC11, J2ARS232: IC11, J2A

UARTAUARTA



Components

1-971644-53 RFID Serial Interface Board; Component side

V5

LA

NR

ET

XE

ROF

HCT

IWS

NOIT

ARUG

IFN

OC

ECA

FR

ETNI

A2J

,11C

I:232S

R4J

,3J

,21CI

:22

4S

R

ELB

AC

FO

DN

EFI

:*

*4

J,

1J

,31C

I:58

4SR

58

4SR

DLEI

HS-

DN

G

.C

ER

.M

RET

.A

RT

.MR

ET

DN

G

DX

R-

ATAD-

B

584S

R

AT

AD+

ST

C

22

4S

R

ED

NG

DXT-

EDN

G

DXR

+D

XT

+DX

RR

SD

224S

R

DX

T

RT

D

ST

R

584

SR

A

V5+

232S

R

23

2S

R

91

3R

2CI

71

11

DL

N_

TN

ERR

UCR

EVO

1

8R

2C1C

4C

3C

05

C

1R

B

8019

5C

I

113121

4CI

4

31

2

3C

I

51R

4R

7R

6R

5R

65

C15C

35

C2

5C

8 7 6 532 4

9CI

3212

J

9

5111 02

1242

911

812

5

6 17 1

32

224

36

7841312101

11

CI

21

1J

113121

6C

I

321

6C

I

654

6CI

8019

6C

I

56

45

CI

113121

5C

I

321

5C

I

81 71

01

821 7 11412

2

3112

5161

21

5 6 943

91324

2

02

21

CI

4101

821 7 31

8162

5142

22

9112

71 6102

21

5 6 9 1 1

435

2

7282

32

31

CI

81

R

9R 0

1R

11

R

61R

213

J

214J

21

R

41

R

31

R

71

R

8F

7F

6F

5F

4F

3F

2F1F

2G

TM

1G

TM987654321

2P

80 19

4CI

654

4C

I

321

4CI

1918

2120

22

44

27

3111

2363

43 2524

015383 43

23

21

1

93 3373

412642

987

65432

40

615141 71

28

920313

01

CI

2R

1R

23

1

63

C5

3C

43

C33

C23C

13

C03

C75

C5

5C

45C

78 564321

1CI

5834 8

6437

6336

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Schematics "uart2:"

1-971644-53 RFID Serial Interface Board; Schematics 1

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Schematics "Module Select"

1-971644-53 RFID Serial Interface Board; Schematics 2



14.9 IEEE 1284 Parallel Interface Board

Description

Th e IEEE 1284 Parallel Interface Board is an optional device for EasyCoder PM4i printers. It provides these printers with one parallel interface port and is supported by both Fingerpint and IPL.

Th e parallel communication port is addressed in Intermec Fingerprint as device centronics: (communication channel 4). Th e board is IEEE1284-I compatible. Nibble, byte, ECP, and EPP modes from printer to host are not presently supported.

Th e IEEE 1284 Parallel Interface kit contains:

• One Parallel Interface Board• Two fl at cables• One hexagonal spacer• One Installations Instructions booklet.

Th ere are neither any straps nor any other types of physical confi guration on this interface board, nor any options in the Setup Mode.

IEEE 1284 interface("centronics:")




Th e IEEE 1284 board has a standard 36pin IEEE 1284 B socket with the following confi guration:

Pin Signal Remark

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


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



Components

C14

C2

C12

C13

C11

C9

C8

C3

C1

IC3

IC2

IC5

R19

R18

IC6

C10

C7C6

C5

C4

IC1

R20

R22

R21

R17

R16

R15

R14

R13

R12

R8

R10

R11

F12

F11

F10

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F16

F15

F14

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F8

F7

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R7

R6

R5

R4

R9

R2

R1

F19

F1

F2

F3

F9D1

F6

F5

F4

IC4

P3

P1

1-971641-02 P01

1-971641-27 IEEE 1284 Parallel Interface Board; Component side



Schematics

5V

C11

C12

C13

C1

C2

C3

C4

C5

C6

C8

5V

P3

5V

3.3V

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2 14

1-971641-27 IEEE 1284 Parallel Interface Board; Schematics



14.10 EasyLAN Ethernet Interface Board

Description

Th is section describes how to install an EasyLAN Ethernet network interface in an EasyCoder PM4i printer and how to connect it to a 100base TX Fast LAN, WAN, Intranet, or Internet network via a wired connection.

Th e installation instructions describes how to physically install the interface board in a printer. Confi guration and setup are described in the EasyLAN Interface Kit, Installation Instructions and the Intermec EasyLAN, User’s Guide on the attached CD-ROM.

Printer Firmware

Th e printer must be running either Intermec Fingerprint v8.00 (or later) or IPL v2.00 (or later). In Intermec Fingerprint, the network port is addressed as device "net1:" (communication channel #5).

Installation Kit

Th e 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

Th e only tool required for the installation is a #T20 Torx screwdriver.



Installation Instructions

Also see illustration on the next page.

Switch off the printer and disconnect the power cord.

Disconnect all communication cables.


Remove the LAN connector plug, which is snap-locked at the top of the rear plate.

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 snaplock.

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 below the RJ-45 socket and to the right of the memory card slot.

Put back the front/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.


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.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

LAN connector plug



Network extension cable

EasyLAN Ethernet interface board

Light guideCable tie

Screw and spacer

Optional interface board(Serial/Industrial,Double serial, orIEEE 1284 Parallel)

CPU board

RJ-45 Ethernet connector("net1:")

Serial number label



Components

1

J1

IC1

M1

C1

C10

C11

C13

C14C15

C16

C17

C18

C19

C2

C20

C21

C22

C23

C24

C26

C27C28

C29

C30

C31

C32

C34

C35C

36

C37

C5

C7 C4

C6

C38

C12

C25

C3

C39

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L3L2

L1

IC3

Y1

R9

R5R6

R7

R12R13

R4 R11

R8

R1

R2

R3

J2

D1

C33

Y2

1-971645-26 EasyLAN Interface Board; Soldering side

1-971645-26 EasyLAN Interface Board; Component side



3.3V

R4

5V

R5

R6

R7

R8

C30

C29

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L3

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C2

C17

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C16

C18

3.3V

3.3V

C15

C14

C19

C21

C22

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C4

C5

3.3V

C6

C7

C10

C11

C20

C24

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C32

C31

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C34

C

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C36

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948

41

1

79

76

80

TPTDM

PCI_CBE1_N

PCI_AD(31..0)

PIN19

RXD3/MA9

PCI_PAR

PCI_AD19

AD31

VSS_77

AD25AD24

AD19

AD10

PCI_TRDY_N

PCI_AD28

PCI_AD1

PCI_CBE1_N

RXD0/MA6

PCI_CBE0_N

AD2

6

REGEN

22

RESERVED_41

3VAUX

REGEN

TPTDM

PCICLK

RXAVDD

PCI_REQ_N

PCI_GNT_N

PCI_RST_N

PCI_CLK2

PCI_INT_N

TPTDP

TPRDP

TPRDM

RXAVDD

PCI_SERR_NPCI_PERR_NPCI_STOP_NPCI_DEVS_N

PCI_IRDY_NPCI_FRAME_N

PCI_CBE2_N

PCI_CBE3_N

AUXVDD_47

REGEN

AD9

CBEN0

AD8

AD7

AD6

VSS_114

AD4

AD5

PCIVDD_117

AD3

AD1

PWRGOOD

MACVSS2/NC83816

SUBGND3/NC83816

RESERVED_127

MCS_N

EESEL

MWR_N

MD0

MRD_N

MD2

MD1/CFGDIS_N

MD3

AUXVDD_137

VSS_136

MD4/EEDO

MD5

MD6

MD7

MA0/LEDACT_N

MA1/LED10_N

MA2/LED100_N

AD26

AD27

AD30

AD29

PCIVDD_69

VSS_65

REQ_N

GNT_N

RST_N

INTA_N

TPTDP

VSS_55

AUXVDD_56

VSS_52

TPTDM

RESERVED_50

VSS_49

VSS_51

VSS_44

TPRDP

TPRDM

NC_42

NC_43

AUXVDD_39

VREF

VSS_38

MA3/EEDI

MA5MDIOMDC

RXCLK

VSS_8AUXVDD_9RXD1/MA7RXD2/MA8

RXOERXER/MA10RXDV/MA11

VSS_16X1

C1X2

AD11AD12

PCIVDD_107

AD13VSS_103AD14

CBEN1AD15

PARSERR_N

STOP_N

IRDY_NFRAME_NVSS_90CBEN2VSS_20

TXD0/MA12AUXVDD_21

TXD1/MA13TXD2/MA14

VSS_26AUXVDD_27

CRSCOL/MA16

TXENTXCLKVSS_32

NC_34AUXVDD_33

VSS_35FXVDD/NC83816

AD16AD17

VSSIO4/NC83816

AD20AD21

AD23

IDSELCBEN3

RXAVDD

TPRDM

PCI_SERR_N

PCI_AD13

PCI_CBE_N0

PCI_AD7

PCI_CBE_N1

PCI_DEVS_N

PCI_AD2

PCI_FRAME_N

VSS2

16

EN/NCVCC

GND

OUT

PCI_RST_N

PCI_CLK1

PCI_INT_N

PCI_GNT_N

PCI_REQ_N

PCI_CBE3_N

PCI_TRDY_N

PCI_STOP_N

PCI_CBE0_N

PCI_PERR_N

PCI_SERR_N

29

2627

PCI_CLK

PCI_AD21

VSS3

PCI_AD4

PCI_AD6

VCC2

PCI_FRAME_N

PCI_AD17

PCI_AD20

PCI_AD3

PCI_AD8

PCI_AD9

PCI_AD11

PCI_PAR

PCI_AD14

PCI_AD15

VSS4

PCI_STOP_N

PCI_AD16

VSS6

PCI_LOCK_N

VSS7

VSS8

TCK

PCI_AD5

PCI_PERR_N

PCI_AD23

VCC6

VCC5

VCC4

PCI_IRDY_N

PCI_AD24

SDA

SCL

VCC7

NC1

VCC9

PCI_AD0

PCI_AD12

VCC3

PCI_AD31

VCC1

VSS10

TDO

TMS

VSS1

PCI_CBE_N2

VSS5

PCI_TRDY_N

PCI_AD27

TRST_N

TDI

PCI_AD29

PCI_AD26

PCI_CBE_N3

PCI_DET_N

PCI_AD10

22

1816

1514

11

98

31

2524

1920

17

131210

40 3 67

521

TX+

10

VIN GNDVOUT

31

24

11

23

2021

19

2726

28

2930

1514

1211

8 954 710 2 3

25

13

TD-

RX+

RXCT

TXCT

TX-

RD+

RDCT

NC2

NC1

RD-

NC4

TX+

RX- RX+

TD+

TDCT

RX-

TX-

TPTDP

TPRDP

CS

VCC

SKDI

DO

NC

21

30

1817

PCI_AD18

23

PCI_REQ_N2

24V

PCI_CLK1

PCI_GNT_N0

PCI_REQ_N0

PCI_CBE2_N

PCI_AD25

28

PCI_CLK2

MA4/EECLK

TXD3/MA15

PERR_N

DEVSEL_N

TRDY_N

AD18

AD22

AD28

PCI_INT_N

VSS9

VDDIO4/NC83816

AD0

PCI_DEVSEL_N

NC3

GND

ORG/NC

MACVDD2/NC83816

VCC8

PCI_RST_N

PIN19

RXAVDD

PCIVDD_94

PMEN/CLKRUN_N

AUXVDD_58

VSS_57

PCI_AD22

PCI_AD30

PCIVDD_80

SUBGND1/NC83816

Schematics

1-971645-26 EasyLAN Interface Board; Schematics



14.11 EasyLAN Wireless Interface Board

Description

Th is section describes how to install an EasyLAN Wireless network interface in an EasyCoder PM4i printer and how to connect it to a LAN, WAN, Intranet, or Internet network via a wireless connection.

Th e installation instructions describes how to physically install the interface board in a printer. Confi guration and setup are described in the EasyLAN Wireless Kit, Installation Instructions and the Intermec EasyLAN, User’s Guide on the attached CD-ROM.

Th is device is country/region specifi c and must be ordered for the correct country/region. Use of this device in other regions than shown on the device home page/test label may violate applicable law.

Dieses Gerät ist für ein bestimmtes Land bzw. eine bestimmte Region vorgesehen und muss daher für das korrekte Land bzw. die korrekte Region bestellt werden. Wenn dieses Gerät in anderen Regionen benutzt wird (nicht in den Regionen, die auf der Startseite bzw. dem Prüfetikett des Geräts angeführt sind), können die geltenden Gesetze gebrochen werden.

Printer Firmware

Th e printer must either be fi tted with Intermec Fingerprint v8.10 (or later) or IPL v2.10 (or later). In Intermec Fingerprint, the network port is addressed as device "net1:" (communication channel #5).

Installation Kit

Th e EasyLAN Interface Kit contains:• One EasyLAN adapter board complete with radio module fi tted• Rear plate (for EasyCoder PF2/4i-series printers only)• RJ-45 plug (for EasyCoder PM4i 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

Th e only tools required for the installation are #T10 and #T20 Torx screwdrivers and a small wrench.



Installation Instructions

Switch off the printer and disconnect the power cord.

Disconnect all communication cables.


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-fi tted on the EasyLAN adapter board, as illustrated below. Support the upper edge of the radio module with a fi nger while connecting the cable.

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-fi tted on the EasyLAN adapter board and the other should be fi tted 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.

1

2

3

4

5

6

7

8

9

10

Connect antennacable here

Radio module

Adapter board



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 front/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.


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. Th ere are several methods:

- Connect the printer and a PC and run the EasyLAN Network Setup

wizard, which can be found on the attched CD-ROM. Requires a PC

running Windows 98 or later.

- Insert a CompactFlash Card containing a confi guration fi le in the

printer and start it up. Confi guration 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 fi les. 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 RS-

232 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. Th is requires a server that supports DHCP

and/or BOOTP. See EasyLAN Wireless Kit, Installation Instructions.

11

12

13

14

15

16



Antenna

EasyLAN adapter board

Light guideCable clips #T20 Torx screw and spacerAntenna

cable

Cable tie

Antenna(packed separately when the EasyLAN Wireless interface is factory-installed)



Components

1-971646-26 Adapter Board

Primary Side Secondary Side

J1

1

J2J2

IC2IC2

D1D1

R30

R30

R29

R29

R28R28

R27R27 R26R26

R25

R25

R24

R24

R23

R23

R22

R22

R21

R21

R20

R20

R19

R19

R18

R18

R17R17

R16R16R15R15R14R14

R2R2R1R1

R8

R8

R11R11

R4

R4

R13R13

R12R12

R7

R7 R6

R6 R5

R5 R9

R9

Y1Y1IC1IC1

L1L1

C11C11

C1C1

C4C4

C12C12

C9C9C10C10

C8C8

C3C3

C6C6

C7C7

C5C5

C2C2

1 3 123123

1241242 4



Schematics

1-971646-26 Adapter Board

CROSSING 5V TO 3.3VFOR PCI SIGNALS

ONLYR26 OR R27

COLOR SWITCH

POPULATEDIF IC2POPULATED

DECOUPLING IC2

DO NOT POPULATE

PRINTER PCI INTERFACE

RESISTORS

LED BLINK ONE-SHOT CIRCUIT

BOUNDARY

ONLY IC2 OR

SOURCE SIDE

UNUSED PART

COLOR SWITCH

POPULATEDR29 OR R30

TERMINATION OF UNUSEDMINI-PCI SIGNALS

AC RETURN PATHS

MINI-PCI INTERFACE

RESISTORS

SINK SIDE

61

3.3V

CBE1_NSERR_NPERR_N

DEVSEL_N

13

10

14

22

AC_SDATA_OUTAC_CODEC_ID0_NAC_BIT_CLK

AC_CODEC_ID1_N

LED2_YELP

AHCT123

3.3V

VCC=5V;GND=GND

11

5V

32.768MHZ

3.3V

LED2_YELN

3.3V

CBE3_N

CBE2_N

PERR_N

AC_RESET_N

27

LED2_YELN

LED1_GRNP

5V

AC_RESET_N

LED_LINKN

STOP_N

CBE2_N

PAR

21

16

GNT_N

AC_CODEC_ID0_N

24

5V

AC_BIT_CLK

AC_SDATA_OUT

AC_SYNC

CLKRUN_N

AC_CODEC_ID1_N

PCI_AD(31..0)

INT_N

VCC=5V;GND=GNDLED1_GRNN

CBE1_N

FRAME_NTRDY_N

CBE0_N

17

5V

LED_ACTN

28

30

3.3V

LED_ACTP

LED_LINKP

5V

15

3

26

1124

20

1618

13

9

6

0

42

3.3V1

5

2

7

5V

0

43

6

8

3129

2725

23

2119

17

14

1210

8

12

1920

23

25

3031

7

5

1

9

15

18

22

29

3.3V

CLK1

CLK2

CLK2

SERR_N

GNT_N

LED1_GRNN

AC_SYNC

LED1_GRNP

IRDY_N

DEVSEL_N

FRAME_N

CBE0_N

PAR

STOP_NTRDY_N

INT_N

REQ_N

CLK1

CBE3_N

2628

AHCT123

REQ_N

GREEN/YELLOW

LED_LINKN

RST_N

RST_N

11

LED2_YELP

J1

80

76

79

1 41

9 4950

1112

20 6021

42

622324 64

6566

2728 6829

3

6970

4 445 45

78

46

52

19

25

72

56

58

3233

57

15

1354

31

7374

53

1617

7778

35

39

3736

40

43

47

51

55

59

63

67

71

75

2

38

6

10

14

18

22

26

30

34

IC1

1

3 2

Y1

2

1 3

4

R1

R2

C4C2 C3C1

J21

10

100101 102103 104105 106107 108109

11

110111 112113 114115 116117 118119

12

120121 122123 124

13 1415 1617 1819

2

2021 2223 2425 2627 2829

3

3031 3233 3435 3637 3839

4

4041 4243 4445 4647 4849

5

5051 5253 5455 5657 5859

6

6061 6263 6465 6667 6869

7

7071 7273 7475 7677 7879

8

8081 8283 8485 8687 8889

9

9091 9293 9495 9697 9899

MTG1MTG2

R11

R12

R13

R14

R15

R16

R17

R25

R22

R21

R18

R6

R5

R8

R7

L1

C5

C6

C7

C8

C9 C10

IC2

14

15

3

2

1 13

4

R28

C11R19

R23

R24

R26

R29

R30

R4

R9

IC2

6

7

11

10

9 5

12

D1

1 2

3 4

C12

48

IRDY_N

CLKRUN_N

5V

LED_ACTN

LED_ACTP

LED_LINKP

R27

R20

VSS6

VCC9

PCI_RST_N

PCI_REQ_N2

PCI_CLK

PCI_CBE_N2

PCI_AD18

PCI_AD23

PCI_AD24

TRST_N

TDI

VSS10

TDO

TMS

TCK

VSS9

PCI_INT_N

PCI_GNT_N0

PCI_REQ_N0

VSS8

PCI_AD29

PCI_AD27

PCI_AD26

VSS7

PCI_CBE_N3

PCI_AD22

PCI_AD21

PCI_AD16

VSS5

PCI_TRDY_N

PCI_STOP_N

VSS4

PCI_LOCK_N

PCI_AD15

PCI_AD14

PCI_PAR

VSS3

VSS2

PCI_AD4

PCI_AD3

VSS1

PCI_AD0

PCI_AD10

PCI_CBE_N0

VCC2

24V

PCI_DET_N

SDA

SCL

NC1

VCC8

PCI_AD31

PCI_AD30

PCI_AD28

VCC7

PCI_AD25

VCC6

PCI_AD20

PCI_AD19

PCI_AD17

VCC5

PCI_FRAME_N

PCI_IRDY_N

PCI_DEVSEL_N

VCC4

PCI_PERR_N

PCI_SERR_N

PCI_CBE_N1

VCC3

PCI_AD13

PCI_AD12

PCI_AD7

PCI_AD5

VCC1

PCI_AD2

PCI_AD1

PCI_AD11

PCI_AD9

PCI_AD8

PCI_AD6

++

C

C

C

A

REXT/CEXT

QB

CEXT

CLR

Q

+

A

REXT/CEXT

QB

CEXT

CLR

Q

VIN

GND

VOUT

EN/NC OUTGND

VCC


Th is chapter describes the various components included in Intermec RFID kits for the EasyCoder PM4i printer.

15 RFID


Chapter 15—RFID

15.1 Key Components of Intermec RFID Kits

Th e various RFID kits available for the PM4i printer all contain the following basic components:

• An antenna used to transmit RF signals between the RFID tag and the reader module. Th e antenna is mounted in close vicinity to the printhead, and is connected to the reader with a cable that runs from the media compartment to the electronics compartment via a cavity in the center deck.

• A reader module with RF transceiver that generates radio frequency signals and receives RF transmissions from the RFID tag. Depending on which reader type is used in the kit, the reader is mounted either directly on the I/O board or on a separate bracket assembly in the electronics compartment.

• An RFID I/O board which handles communication between the RFID reader module and the main board. Th e RFID interface board occupies one of the slots for optional interfaces at the back of the printer and features an extra RS-232 serial interface.

Note: Th e RS-232 interface on the RFID I/O board can only be utilized in printers running Fingerprint fi rmware. Th e interface is referred to as “uart2:”, “uart3:”, etc. depending on which slot is used and what other optional interfaces are installed.

Main Components of an RFID Kit

Th e following sections describe how to replace and service the individual parts of the RFID kits. For more detailed information and illustrations of the diff erent steps involved, refer to the documents listed in the next table.

Antenna

Antenna Cable

RFID Reader Module

RFID I/O

Board


Chapter 15—RFID

RFID related documentation

Document Title Part Number

RFID Kit for the EasyCoder PM4i Installation Instructions 931-041-xxx

RFID Kit for the EasyCoder PM4i User’s Guide 934-008-xxx

RFID Kit (Class 1, 915 MHz) Installation Instructions 1-960650-xx

RFID Kit (Gen 2, 869&915 MHz) Installation Instructions 1-960654-xx

Replacing the Antenna

To prevent damage, handle the radio module delicately and be careful when attaching or detaching the antenna cable.

Zur Vermeidung von Schäden das Funkmodul sorgsam behandeln und das Antennenkabel nur vorsichtig anbringen bzw. abtrennen.

Th ere are currently two types of RFID antenna installations:

• Type 1: Antenna is fi tted underneath the lower media guide.

Antenna installed under lower media guide.

• Type 2: Antenna is installed as part of a replacement upper media guide.

RFID Antenna


Chapter 15—RFID

To replace the antenna (Type 1)

Disconnect the power cord and open the electronics compartment, see Section 3.2.

Detach the antenna cable from the radio module.

Th e antenna is fi tted underneath the lower media guide in the media compartment.

Remove the screw which holds the antenna to the center deck.

Pry the antenna loose, and proceed by carefully pulling the antenna cable out of the electronics compartment through the hole in the center deck.

Take the cable end of your replacement antenna, and feed it through the opening in the center deck. Th is operation can be facilitated by laying the printer down on its left side (to prevent damage to electrical components, be sure to put back the metal chassis prior to this).

In the electronics compartment, connect the antenna to the upper contact on the radio module.

Put back the cover over the electronics compartment. Follow the procedure as described in Section 3.2.

To replace the antenna (Type 2)


Detach the antenna cable from the radio module.

Th e antenna is fi tted in a slot in the upper media guide.

Carefully slide the upper media guide out along the support shaft. Loosen the edge guide and remove both items from the shaft.

Carefully pull the antenna cable out of the electronics compartment through the hole in the center deck.

Take out your replacement upper media guide (with antenna).

Route the antenna connection cable through the opening in the center deck. Slide the antenna assembly and the edge guide onto the shaft.

In the electronics compartment, connect the antenna to the upper contact on the radio module.

Put back the cover over the electronics compartment. Follow the procedure as described in Section 3.2.

Replacing the Dual Slot I/O Bus Cable (“Flat Cable”)

Th is procedure is described in section 14.5 (“Installing an Optional Interface Board”).

1

2

3

4

5

6

7

1

2

3

4

5

6

7


Chapter 15—RFID

Replacing the Radio Module

Th ere are currently two types of radio module installations:

• Type 1: Radio module is the “PC-Card” type installed directly on the RFID I/O board.

Radio module installed directly on I/O board.

• Type 2: Radio module is installed on a bracket assembly in the middle of the electronics compartment.

Radio module installed on brackets.

To replace the radio module (type 1)


1


Chapter 15—RFID

Remove the old radio module, and slide the new one in place. Th e label should be facing outward.

Make sure jumpers J5-J9 are set to their correct position (modifying jumper positions is not necessary if, for example, a faulty unit is replaced with a unit of the same model). Refer to section 14.8 for more information on this issue.


To replace the radio module (type 2)


Disconnect all cables (adapter, data and power) from the radio module.

Remove the three screws that hold the module to the horizontal and vertical brackets. Lift the module off the brackets.

Put the new module in place, connect the cables and attach the screws.


Upgrading the Radio Module’s Firmware

Note: Th is procedure applies only to PC Card RFID modules (described as Type 1 in preceding section).

To upgrade the fi rmware

Remove the radio module from the RFID serial interface board as described above.

Download the latest fi rmware version from the Intermec Global Services & Support web site to a computer equipped with a PCMCIA slot. Insert the Radio Module in the slot and install the new fi rmware.

2

3

4

1

2

3

4

5

1

2

RFID

Card

Jumpers J5-J9 in

“upper” or “lower”

position


Chapter 15—RFID

Replacing the RFID Serial Interface Board

Please refer to section 14.5 (“Installing an Optional Interface Board”) for information on how to replace this part.

15.2 Verifying RFID functionality

Once a part (or parts) have been replaced, it is important to verify that the RFID-equipped printer works properly before put into active use.

Recommendations for Printers Running Fingerprint

Turn on the printer and set RFID > ENABLE either via the Setup menu, the web page or by using the command SETUP “RFID,MODE,ENABLE”. Print an RFID test label to make sure the printer can communicate with the RFID tag.

To print an RFID test label

Load the printer with RFID media.

Press Setup.

Navigate to PRINT DEFS > TESTPRINT > RFID TEST LABEL.

Press Enter. Th e test label prints.

Recommendations for Printers Running IPL

Turn on the printer and set RFID > ENABLE either via the Setup menu, the web page or by using the command <STX><SI>J1<ETX>. Raise and lower the printhead, and then perform a Tagread operation. If successful, the printer will return the contents of the current RFID tag.

To perform a Tagread

Load the printer with RFID media.

Press Setup.

Navigate to RFID > TAGREAD.

Press Enter. Th e printer reads and returns the content of the current RFID tag.

1

2

3

4

1

2

3

4


Chapter 15—RFID


Th is chapter explains how to diagnose and fi x problems that may occur in an EasyCoder PM4i printer, even if great eff ort has been made to ensure problem-free 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).

Th is 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.

16 Troubleshooting


Chapter 16—Troubleshooting

16.1 Diagnosing

To diagnose the printer for faults, take steps in the following order:

In case the printer is running the Intermec Fingerprint fi rmware, use Intermec Shell to check printer’s setup and functions. Intermec Shell can be accessed regardless of any running autoexec.bat fi les as described below.

Browse through the remainder of this chapter to fi nd symptoms that apply to the faulty printer.

Refer to the Printer Technical Bulletins for updated information.

Fingerprint onlyTh e keyboard, display messages, sounds, and other functions will be custom-confi gured, if a custom-made program is running in the printer. Normally, such a program is started at power-on using an autoexec.bat fi le.

Th e procedure of starting up Intermec Shell, bypassing any other autoexec.bat fi les 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.

To enter Intermec Shell in Test modeSwitch off the power.


Press any key on the printer’s built-in keyboard, with the exception of <Shift>, and keep on pressing it.

Switch on the power.

Th e printer will start the initialization procedure.

Release the key.

Th e printer will start up Intermec Shell.

Press <Enter> 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 fi les the printer’s memory contains or to list fi les.

1

2

3

1

2

3

4

5

6

7

8



• Restart the printer and exit 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.

Fingerprint and IPLUse this list to fi nd the symptom that applies to the printer:

Symptom See Section

• No reaction at power up 16.2

• Printer stops working after startup 16.3

• CPU board failures 16.4

• Power supply unit failures 16.5

• Console errors 16.6

• Error messages 16.7

• No communication (general) 16.8

• No serial communication 16.9

• Network communication troubles 16.10

• Sensor malfunctions 16.11

- Label stop sensor

- Headlift sensor

- Label taken sensor

- Ribbon end sensor

• Printing troubles 16.12

- 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 fi rst part of label printed

- Media feed does not work properly

- Printing is slow and halted inbetween labels

• Ribbon troubles 16.13

- Transfer ribbon breaks

- Transfer ribbon wrinkles

- No transfer printout

• Liner takeup troubles 16.14

• Memory card troubles 16.15

• Paper cutter troubles 16.16

• RFID troubles 16.17



16.2 No Reaction at Power Up

Description:

Th ere is no visible reaction when the power to the printer is switched on.

• Th e Power LED does not light up.

• Th ere 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 fi rmly connect both ends of power cord. Try again.

• Faulty power cord.

- Replace and try again.

• Cable between CPU board and power supply not properly connected.

- Test as described in Section 16.5 using test points on CPU board (see

Section 13.5).

• 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 Section 16.5.

• Faulty power supply unit.

- Refer to Section 16.5.

• Faulty console unit.


• Wrong type of printhead fi tted (designed for EasyCoder F-series) causing a short-circuits because of diff erent cablings.

- Check part number and label on printhead. If wrong type, replace

with a correct one.

- If the printer still refuses to start up, check if fuse F70 on the CPU

board has blown. Normally, this condition is very unlikely to

happen and no harm should be done to either the electronics or the

printhead.



16.3 Printer Stops Working After Startup

Description:

Th e printer stops working after a successful startup.

• Th e Power LED is lit.

• Th e <Feed>, <Setup>, and <Print> keys, work properly.


• Communication problems?

- Refer to Sections 16.8-16.10.

• Printer malfunction?

- Check if the printer can print test labels in the Test Mode.

Description:


• Th e Power LED is lit.

• Th ere is no reaction on software commands.

• Th ere is no reaction on any keys on the printer’s keyboard.


• Th e printer’s main program has halted due to high external disturbances from other electrical sources.

- Restart the printer and fi nd out if there are disturbances coming via

the 115/230 VAC supply, via a communication channel, or from

other electrical appliances.

• CPU board failures.


• Power Supply Unit failures.


• Console errors.


Description:


• Th e Power LED is not lit.


• Error in the supply of AC power to the printer.


• Faulty console, faulty power LED, or faulty cabling between CPU board and console.




16.4 CPU Board Failures

Description:

Th e power LED is lit, but the printer has one of the following faults:

• Th e printer refuses to start.

• Th e program execution is halted.

• Th e stepper motor does not work.

• At startup, the message “Starting” is displayed followed by the message “Timed Out.”


• Flash or SDRAM SIMMs not properly fi tted.

- A SIMM is not fully inserted in its socket. Remove all SIMMs and fi t

them back again, making sure they are being fi rmly held by the snap-

locks.

• No Boot Flash SIMM in socket J20.

- A Flash SIMM containing a boot sector must be fi tted in socket J20,

or the printer will not start.

• Fluttering voltages.

- Check voltages on the CPU board test points, see Section 13.4. If a

voltage fl utters 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, see Section 16.5.

• Startup error.

- Execution of the initial boot sequence can be checked as described

in Section 13.5. 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.



16.5 Power Supply Unit Failures

Description:

Th e printer refuses to print.

• Th e message “Temperature high please wait”(FP) or “Printhead hot” (IPL) appears in the display window.

Th e 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. Whenever a fuse blows, always replace the entire power supply unit.

Das Netzteilmodul enthält Kabel und Schaltkreise, die gefährliche Spannungen führen. Aus Sicherheitsgründen ist es streng untersagt, ein Netzteilmodul zu reparieren oder eine durchgebrannte Sicherung auszutauschen. Falls eine Sicherung durchbrennt, muss das gesamte Netzteilmodul ausgetauscht werden.


• Power Failure Interrupt signal activated because of a Power Supply overload.

- Th e power supply unit is overheated, due to 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), which 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 12).

Description:

Th e printer stops working or functions are unstable.

• Th e power LED is unstable, weak or not lit.

• Stepper motor does not run.

• No or very weak printout.


• Wrong or missing voltages from power supply.

- Check voltages using the test points on the CPU board (see Section

13.4).

- Check the cable between the power supply unit and the CPU board.

If the cable is OK, replace the power supply unit.

- Blown fuse in power supply. Replace the entire power supply unit (see

“Warning” notice).

- Stepper motor driver damaged because the platen roller has been

manually rotated while power was on. Replace PSU.



16.6 Console Errors

Description:

Th e complete console is “dead”.

• Power LED is not lit.

• Green background lighting in display window is not lit.

• Th e 5V on the CPU board is OK (see Section 13.4).


• Defective cable.

- Th e 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.


• Bad connection between keypad and console pcb.

- Check connections on the two fl at 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 fl uids, may

cause short-circuits. Let it dry, replace if necessary.



Description:

No messages appear in the display window after power-up.

• Power LED is lit.

• Green background lighting in display window is lit.


• 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.



16.7 Error Messages

Description:

An error message appears in the display window or is returned via a serial port.

• Th e printer stops functioning.

• Th e 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 diff erent error codes and use that information to correct the error.

Depending on the fi rmware, printer’s mode, or running program, there are diff erent ways of giving the error message.

Immediate Mode (Fingerprint only)

• Th e fi rmware 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. Th e 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. Th e execution stops and an error message is transmitted. It is recommended to include some kind of error handler in any custom-made application program, for example ERRHAND.PRG.

Intermec Direct Protocol (Fingerprint only)

• Six error conditions can be detected. Note that by default verbosity is off in the Intermec Direct Protocol.

- Error 1005 (“Out of paper”) - Error 1006 (“No fi eld to print”) - Error 1022 (“Head lifted”) - Error 1027 (“Out of transfer ribbon”) - Error 1031 (“Next label not found”) - Error 1606 (“Testfeed not done”)

Th e Intermec Direct Protocol has a programmable error-handler. Refer to the Intermec Direct Protocol v8.xx, Programmer’s Reference Manual.



IPL only

• Six possible errors are indicated by messages in the display window:

- Printhead hot (Printhead over-temperature)

- Paused (Empty/paused)

- Paper out (Out of media)

- Ribbon out (Out of transfer ribbon

- Print head UP/Press Feed (Printhead lifted) - Open&shut cutter (Cutter error)

Some additional errors can be returned to the host as an ASCII number by the <BEL> 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.



16.8 No Communication (general)

Description:

Th e following actions are valid for all communication interfaces installed in the printer.


• 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 confi gured.

- 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. Th is does not apply to the serial port ("uart1:"), the USB port, or any EasyLAN board which all are fi tted 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).



16.9 No Serial Communication

Description:

Th e following actions are valid for the standard serial interface ("uart1:") fi tted on the CPU board and to some extent also to any other serial interfaces on optional interface boards. Also see Section 16.8.


• Communication setup mismatch.

- Press the <i/F5> 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 stongly 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 (“break-out box”), verify that the interface signals to and from the CPU board are correct. Th e 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 insuffi cient cable screening, or the electrical environment being too noisy.

• Circuits or straps on an optional interface board missing or fi tted incorrectly.

- See confi guration instructions in Chapter 14.

• No supply voltage.

- Verify that the +3.3VDC and +5VDC voltages are present (see

Section 13.4).

• No external +5VDC.

- Th e printer supplies max. 500 mA. Th e current is automatically

switched off at higher loads. Check the consumption of the

connected device.

- Th e 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. 10-15 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).

• Input buff er on host overfl ow.



- Th e input buff er should normally be handled by the software of the

host. Increase the receive buff er in the printer to a large value, restart

the host to empty its input buff er and try again.

• No response from printer when a custom-made program is run (Fingerprint only).

- Th e 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 aff ect the verbosity.

- Verify that the correct communication port is selected as standard

IN/OUT channel.



16.10 Network Communication Troubles

Th is 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:

Th e printer cannot communicate with the network after the network interface has been installed.


• 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. Th ere

should be a green light fl ashing 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.



- 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. Th ere

should be a green light fl ashing occasionally showing network activity,

or a solid yellow background light if the network card is associated

with an access point, or fl ashing yellow light if the network card is

searching for an access point.

- Press the <i> key on the printer’s front panel and browse to the

network information. Th ere 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 off ers 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:

Th e printer cannot communicate with the network.


• Bad IP Settings in printer

- Use a PC connected to the same network as the printer. First of all

verify the network confi guration of the printer as described in the

Installation Instructions provided with the kit.



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.

Th e PC will show a table with its confi guration containing the

settings for IP-address, Subnet Mask and Default Gateway. Verify

these settings to be sure that the computer is correctly confi gured to

access your network.

Printer Settings

Check the IP address of the printer. Press the <i> 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 <Setup> key, on the printer’s internal keyboard, and step

your way to “NETWORK” using the < > key.

By pressing <Enter> on the printer, you can step through the

confi guration to verify the settings.

Press <Setup> to exit the Setup Mode.

More information about confi guration settings can be obtained by

printing a test label.

Also check on the printer’s home page (Confi guration [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 fi nd information on how

to print test labels in the chapter “Setting Up the Printer”. Print the

network test label and fi nd the IP Address fi eld. 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 <Same>.<Same >.<Same >.<Any >

255.255.0.0 <Same>.<Same >.<Any >.<Any >

255.0.0.0 <Same>.<Any >.<Any >.<Any >

Other subnet masks Contact the network administrator



In case the addresses are not in the same network segment, the printer may not be reachable from the LAN side. Check the confi gu-ration with the administrator.

Pinging the Printer

Start the Command Prompt. In the Command Prompt, type Ping

<printer IP-Address> and then click OK.

Th is command sends an echo command to the EasyLAN to check

if the PC and the printer can reach each other through the network.

Th e following fi gure shows a correct response to the Ping command.

Th e fi rst reply to the fi rst Ping command often takes more time than

the following. Th is is a normal behavior. Th e fi rst time the Ping

command is executed, the PC needs some extra time to perform

a “discovery” of the network address (ARP request). Th e Ping

command makes the printer’s network LED fl ash 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:

Th e performance of a Wireless network connection ceases to work or the performance deteriorates after having worked properly for some time after installation.


• 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. Th ere 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 fi tting a higher gain antenna.

• Slow response.

- Too many devices associated with the same access point.



16.11 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.


• 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 <Shift> and <Feed> 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 Section 7.5.

- Check that both parts of the LSS are adjusted to the same lateral

position, see Section 7.5.

• Light path obstructed.

- Check that both the upper and lower sensors as well as the windows

in the upper and lower guide plates are clean and free from dust,

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 more or less continuously. Th us.

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 Section 13.3.

• Faulty sensor or diode.

- Replace LSS as described in Section 7.5.

• CPU board not confi gured for the right type of printer.

- Reconfi gure the CPU board as described in Section 13.8.



Headlift Sensor

Description:

• Th e 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.


• 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 Section 7.7.

Label Taken Sensor (LTS)

Description:

Th e label taken sensor (LTS) is not working properly.


• Intermec Fingerprint instruction missing.

- Th e 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.

- Th e self-strip mode must be enabled using the commands

<STX>R<ETX> and <STX><SI>t1<ETX>.

• 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.

- Th e sensitivity of the sensor’s receiver and the light intensity of the

sensor’s emitter are adjustable, see Section 9.3.

• Interference from sunlight or lamps.

- Shield the sensor from interfering light source.

• Defective sensor.

- If still no reaction, the sensor is probably defective. Replace.



Ribbon Sensor

Description:

Th e ribbon sensor is not working properly.


• Bad sensor adjustment (Fingerprint only).

- Adjust the sensor in the Setup Mode as described in Section 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 material? 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 (Fingerprint Only)

Description:

Th e ribbon sensor is not working properly.


• 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.



16.12 Printing Troubles

Th e 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.


• Bad connection.

- Is the cable between the printhead and P5 on the Power Supply Unit

fi tted correctly and not broken or otherwise damaged?

- Is the cable between the printhead and J40 on the CPU board fi tted

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 laoded 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 Section 16.13

• Wrong printhead voltage.

- Check that the printhead voltage +24VDC ±2V (see Section 13.4).

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 (see Section 12.4, connector P5 for schematics).



• Wrong printhead pressure.

- Check that the printhead is pressing against the media with a

suffi cient force, see Section 7.8.

• Headlift sensor out of order.

- Check the headlift sensor as described in Section 16.11.

Description:

Overall weak printout.


• 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.


- Measure the +24VDC on the CPU board, see Section 13.4.

• Printhead pressure too low.

- Adjust as described in Section 7.8.

Description:

Weaker printout on either inner or outer part of label.


• Bad printhead pressure alignment.

- Adjust the position of the headlift arm as described in Section 7.8.

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.


• 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 combi-

nation of transfer ribbon and media.


- Measure the +24VDC on the CPU board, see Section 13.4.



Description:

Weak or missing printout of some dots.


• 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. Th is 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.

- Th e internal IC circuit of the printhead is probably damaged. Replace

the printhead.

Description:

Unexpected black printout (completely or partially).



- 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 that the printhead voltage +24VDC ±2V

(see Section 13.4). 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 (see Section 12.4, connector

P5 for schematics). If too high, in the range of 40 to 50V during

printing, replace the power supply unit.

- Th e printhead is most certainly damaged too and will also need to be

replaced.



Description:

Media feed does not work properly.


• Faulty stepper motor.

- Connect a replacement stepper motor to P10 on the Power Supply

Unit (see Chapter 12) and perform a print or feed operation. If this

motor runs, the original stepper motor is probably damaged and

needs to be replaced (see Section 7.3).

• Dirty or worn platen roller.

- Inspect the platen roller for visible wear. Replace if necessary (see

Section 7.2).

- 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.

- Th e stepper motor could be incorrectly connected to P10 on the

PSU, or its drive circuit (U13) on the PSU could be damaged.

- Check that all pins in the connector of the stepper motor’s cable are

fully inserted.

- Measure the +24VDC on the CPU board, see Section 13.4. If there is no power, when an attempt to print is made, the power supply unit is probably faulty.

Description:

Excessive wear of printhead.


• Various reasons.

- Refer to Section 7.6 “Printhead/Precautions” for advices on how to

reduce the wear of the printhead.

Description:

Printing is slow and halted inbetween labels.


• RFID mode is ON

- Th e printer is trying to access an RFID label that is not there. Turn it

off with the following commands:

SETUP “RFID,OFF” (Fingerprint)

<SI>J0 (IPL)



16.13 Transfer Ribbon Troubles

Description:

Th e thermal transfer ribbon breaks.


• 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 fi tted).

• 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.


- Check printhead voltage, see Section 13.4.

Description:

Th e thermal transfer ribbon wrinkles.


• Media misalignment.

- Is the edge guide positioned so as to guide the media closely along the

printer’s center section?

- Is the media supply roll as far in on the post or 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 Section 7.8.

- Check the printhead pressure, see Section 7.8. 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

eff ect.

• Bad ribbon break shaft adjustment.

- Check the adjustment of the front ribbon break shaft, see Section 6.6.

Do not change the adjustment before you have performed all other

checks mentioned above.



Description:

No transfer printout.


• Refer to Section 16.12 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.


• 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 rewind motor does not run.

- Cable between ribbon motor and P6 on the Power Supply Unit

broken or not correctly connected?

- Faulty ribbon sensor? See Section 16.11.

- Faulty ribbon motor? Replace.

- Faulty CPU board? Replace.

- Faulty Power Supply Unit? Replace.



16.14 Liner Takeup Troubles

Description:

Th e internal liner takeup unit does not work properly.


• 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 Section 8.2.

• 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 Section 16.12.

- Check if both the belts from the stepper motor are broken or have

come off the pulleys, see Section 8.2.



16.15 Memory Card Troubles

Description:

Th e printer cannot read a memory card. Note that in IPL, memory cards are not used to expand the printer’s memory.


• Memory card not inserted at startup.

- Th e 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.

- Th e 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 fi les are stored in the memory card and their sizes with the aid

of Intermec Fingerprint command FILES "card1:".

- 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.



16.16 Paper Cutter Troubles

Description:

Th e 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 fi tted properly.

- Check that the cable has not come loose from the cutter pcb and is

fi tted so all the slack is between the cable cover and the cutter, see

Section 10.2.

• Faulty cable, cutter pcb, or CPU board.

- Replace one at the time, reboot, and check.

Description:

Th e cutter does not cut.


• Error 1704, “Cutter open” occurs in Fingerprint.

- Check that the cutter is positively in closed position.

- Th e microswitch on the cutter assembly may be defect. Replace the

cutter assembly.

- Faulty cable, cutter pcb, or CPU board. Replace one at the time,

reboot, and check.

• Errors 1701-1703 occurs in Fingerprint.

- Check the “cutter top position” sensor on the cutter pcb for dust and

similar. Clean if necessary.

- 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.



Description:

Th e cutter cuts at the wrong place.


• 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<nnn> instructions (Fingerprint

only).



16.17 RFID Troubles

Description:

"No tag found" is displayed when a TESTFEED is attempted.


• Th e inlay could be broken.

- Replace the inlay or use an entirely new label.

• You are not currently using RFID media.

- Load the printer with RFID media.

• Th e current TAGADJUST value is incorrect.

- Align the label with the edge of the tear bar (Fingerprint) or

dot line (IPL). Leave the lid open and measure the distance between

the middle of the inlay and a point orthogonally right above the

antenna. Convert the distance to dots.

TAGADJUST = Distance * TPHresolution

(mm)

Enter the TAGADJUST value in the SETUP menu with the com-

mand:

SETUP “RFID,ON,TAGADJUST,<value>” (Fingerprint)

<SI>J1,<value> (IPL)

Example:

TPH resolution 203 dpi

DISTANCE 15 mm

TAGADJUST = 15 * 203 / 25.4 = 120 dots

Description:

An application writing to Class 1 RFID tags produces a large number of VOID labels.


• Verify that the TAGADJUST value is set correctly.

- Follow the procedure as described above

• Th e output power to the antenna could need adjusting.

- Th is can be done with a run command, setting the output power to a

value between 15 and 27 dBm, where 27 dBm is 0.5 W and every 3

dBm decrease means half the output power.

run “wjsetpower read|write <value>”

(Fingerprint)

<STX><ESC>.x,wjsetpower read|write <value><ETX>

(IPL)



Th e current setting can be read with the command (Answer is in

dBm):

run “wjgetpower read|write” (Fingerprint)

<STX><ESC>.x,wjgetpower read|write<ETX> (IPL)

Example:

run “wjsetpower read 24” run “wjgetpower read” > 24

Description:

None of the RFID commands work. Th e message "RFID inactive" is displayed.


• Th e RFID mode has been switched OFF.

- Turn it on with the following commands:

SETUP “RFID,ON” (Fingerprint)

<SI>J1 (IPL)

Description:

Printing on non-RFID media is slow and printing is halted inbetween labels.


• RFID mode is ON

- Turn it off with the following commands:

SETUP “RFID,OFF” (Fingerprint)

<SI>J0 (IPL)

Description:

After the printer has been loaded with a new roll of RFID media, it is unable to write to the tags.


• Th e printer has not yet identifi ed the RFID media type.

- If RFID media is changed without the printer having been turned

OFF, it resets the inlay type and waits for a TESTFEED to identify

the new RFID media. A TESTFEED should take care of this

problem.



Description:

RFID operations yield "Not supported by tag type" error messages.


• A command tries to access a tag data segment that is not available on the current RFID media.

- Example: Performing TAGWRITE or TAGREAD operations on the

”@DATA” segment for Class 1 RFID media.

• A command is referring to a tag format that is not available on the current RFID media.

- Example: using TAGFORMAT "NUM" for Class 1 media, or trying

to write an EPC-96 format to a 64-bit tag.

• A command is used together with a "level" that is not allowed for a particular tag type.

- Example: using TAGPROTECT ”UNLOCKP” on Class 1 media or

TAGPROTECT ”ON” for Gen 2 tags.

Description:

Data can be written unlawfully to a write-protected ISO 18000-6B tag.


• For some ISO 18000-6B tag chips the functionality to protect the tag memory from being rewritten has not been implemented.

- Switch to tags with a diff erent chip that have this functionality

implemented.

Description:

TAGWRITE commands yield "Invalid parameter" error messages.


• Th e user is trying to store an excessive amount of data in the tag's memory.

• An invalid value has been entered, e.g. an uneven number of characters for one of the "HEX" formats or an incorrect number of digits for a parameter defi ning an EPC-format.

Description:

TAGREAD commands yield "Wrong number of parameters" error messages.


• Th e number of required parameters depend on what TAGFORMAT has been defi ned for the read operation.

- See the manual for Fingerprint v8.60 or later. Additional information

can be found in the EPC Tag Data Standard (v1.1, revision 1.27)

document available via http://www.epcglobalinc.org/standards_

technology/specifi cations.html.



Description:

Th e message "Error in fi lename" is displayed when RFID mode is set to ON.


• No RFID kit is installed in the printer.

Description:

ISO 18000-6B tags work fi ne, but reading Class 1 tags yield a "No tag found" error message.


• ISO 18000-6B tags are addressed with the IM3 or IM5 RFID reader. For these modules, Class 1 support has not been implemented yet. Class 1 tags require an MPR6100 RFID Radio Module.

- An MPR6100 can be ordered from Intermec Sales as part of an

upgrade kit ("RFID Kit (Class 1, 915 MHz").

Description:

"RFID" does not show up in the SETUP tree.


• Th e printer does not communicate properly with the RFID hardware.

- Check that the RFID kit has been installed in accordance with the installation instructions. Check that the jumpers on the RFID option board are set to the correct position (see section 14.8).

- Print a hardware test label to see what hardware the printer has

recognized, confi rm that the RFID option board is present on

the label (this rules out potential errors in the board or I/O cable).

- Test the RFID radio module by downloading and installing the latest

fi rmware. If the module proves faulty, replace it.




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 printer user’s guides for information on the various parameters and instructions for navigation.


Appendix A—Program Overviews

Intermec Shell v8.0 Overview

Note: To enter Intermec Shell if a custom-made autoexec-file prevents access, lift the printhead and press any key on the printer's keyboard (except the <Shift> key), then turn on the power while continuing to press the key. When the Shell countdown begins, release the key and press <Enter> to start Shell. Do not forget to lower the printhead if you want to print for example test labels.

SHELL

TEST LABEL

SHELL

TESTFEED

SHELL

DEFAULT SETUP

Performs a Testfeed (feeds out a number of blank copieswhile autoadjusting the label stop sensor).

Prints test labels “Diamonds”, “Chess”, “Bar Codes #1”, and “Bar Codes #2” in a loop. Press Enter for each new label.

SHELL

REBOOT

Restarts the printer (same as power off/on)Printer rebooted automatically.

STD I/O CHANNEL

uart2:

STD I/O CHANNEL

uart3:

SEL. APPLICATION

Fingerprint 8.10

SHELL

SETUPSee the chapter “Setup Mode”

Prints a list of current setup values (test label “Setup Info”).

Note: Dotted channels are only shown if the corresponding optional interface pcb is fitted.

SHELL

PRINT SETUP

ENTER=SHELL

5 sec. v.8.0

ENTER=SHELL

4 sec. v.8.0

ENTER=SHELL

3 sec. v.8.0

ENTER=SHELL

2 sec. v.8.0

ENTER=SHELL

1 sec. v.8.0

Last selectedapplication is started

Default: Fingerprint 8.10 w. std I/O = "auto"

Last selected application is started

The s

elect

ed ap

plica

tion

is st

arte

d

POWER ON

Return to previous menu.

Proceed to next menu.

Accept displayed optionand proceed, or

execute displayed option.

Perform a Testfeedanywhere in Intermec Shell.

Enter the Setup Modefrom anywhere

in Intermec Shell.

Legend:

SHELL

SEL. APPLICATION

SEL. APPLICATION

Direct Protocol

SEL.APPL rom:

LINE_AXP.PRG

Optional application

programs

SETUP:

SER-COM,UART1

SEL. APPLICATION

CURRENT APPL.

ARE YOU SURE?

YES=ENTER/NO=ESC

DEFAULT SETUP

PERFORMED

SHELL

SOFTWARE UPDATE

UPDATE:

COMPACT FLASH?

UPDATE:

FIRMWARE?

TRANSFER

COMPLETED

TRANSFER FILE

USING ZMODEM

STD I/O CHANNEL

centronics:

STD I/O CHANNEL

net1:

STD I/O CHANNEL

usb1:

STD I/O CHANNEL

auto

STD I/O CHANNEL

uart1:

TRANSFER FILE

USING ZMODEM


Appendix A— Program Overviews

Setup Mode Overview (FP v8.70) Ser-Com, uart1:

NEW LINE:CR

NEW LINE:LF

DATA TO HOST:ENABLE

DATA FROM HOST:ENABLE

BAUDRATE;4800

BAUDRATE;2400

BAUDRATE;1200

BAUDRATE;600

BAUDRATE;300

BAUDRATE;115200

BAUDRATE;57500

BAUDRATE;38400

BAUDRATE;19200

PARITY:SPACE

PARITY:MARK

PARITY:ODD

PARITY:EVEN

CHAR LENGTH7

STOP BITS:2

ENQ/ACK:ENABLE

SETUP:SER-COM, UART1



SETUP:NET-COM, NET1

SER-COM, UART1:BAUDRATE

SER-COM, UART1:CHAR LENGTH

SER-COM, UART1:PARITY

SER-COM, UART1:STOP BITS

SER-COM, UART1:FLOWCONTROL

BAUDRATE;9600

CHAR LENGTH8

PARITY:NONE

STOP BITS:1

FLOW CONTROL:RTS/CTS

FLOW CONTROL:ENQ/ACK

ENQ-ACK:DISABLEENQ/ACK:

ENABLE

RTS/CTS:DISABLE

FLOW CONTROL:XON/XOFF

SER-COM, UART1:NEW LINE

NEW LINE:CR/LF

XON/XOFF:DATA TO HOST

XON/XOFF:DATA FROM HOST

DATA TO HOST:DISABLE

DATA FROM HOST:DISABLE

SER-COM, UART1:REC BUF

REC BUF:[1024]:

SER-COM, UART1:TRANS BUF

TRANS BUF:[1024]:

See separate overview See separate overview See separate overview

SETUP:NETWORK

See separate overview

next

Scroll forwardScroll back








SETUP:RFID

See separate overviewpage



Setup Mode Overview (FP v8.70) Feed Adjust

SETUP:FEEDADJ

FEEDADJ:STARTADJ

FEEDADJ:STOPADJ:

STARTADJ:[0]:

STOPADJ:[0]:

Continued on the next page

Continued from theprevious page



Setup Mode Overview (FP v8.70) Media

TESTFEED MODE:SLOW

CONTRAST:-2%

CONTRAST:-4%

CONTRAST:-6%

CONTRAST:-8%

CONTRAST:-10%

CONTRAST:+10%

CONTRAST:+8%

CONTRAST:+6%

CONTRAST:+4%

CONTRAST:+2%

MEDIA TYPE:VAR LENGTH STRIP

MEDIA TYPE:FIX LENGTH STRIP

MEDIA TYPE:TICKET (w GAPS)

MEDIA TYPE:TICKET (w MARK)

SETUP:MEDIA

MEDIA:MEDIA SIZE

MEDIA:MEDIA TYPE

MEDIA SIZE:XSTART

MEDIA SIZE:WIDTH

MEDIA SIZE:LENGTH

MEDIA TYPE:LABEL (w GAPS)

XSTART:[24]:

WIDTH:[832]:

LENGTH:[1200]:

MEDIA:PAPER TYPE

PAPER TYPE:TRANSFER

TRANSFER:RIBBON CONSTANT

TRANSFER:RIBBON FACTOR

TRANSFER:LABEL OFFSET

TRANSFER:RIBBON SENSOR

TRANSFER:LOW DIAMETER

RIBBON CONSTANT:[90]:

RIBBON FACTOR:[25]:

LABEL OFFSET:[0]:

RIBBON SENSOR:[14]:

LOW DIAMETER:[0]:

MEDIA:CONTRAST

MEDIA:PAPER

PAPER TYPE:DIRECT THERMAL

CONTRAST:+0%

PAPER:PAPER SENSOR

DIRECT THERMAL:LABEL CONSTANT

DIRECT THERMAL:LABEL FACTOR

LABEL CONSTANT[85]:

LABEL FACTOR:[40]:

PAPER SENSOR:[10]:

PAPER:LOW DIAMETER

LOW DIAMETER:[0]:

Continued from the previous page

Continued onthe next page

MEDIA:TESTFEED

TESTFEED:[26 28 0 10]

Press <Enter> to per-form a testfeed. Values are read-only.

Only displayed if a paper sensor is installed.



MEDIA:TESTFEED MODE

TESTFEED MODE:FAST


MEDIA:LEN (SLOW MODE)

LEN (SLOW MODE):[0]:



Setup Mode Overview (FP v8.70) Print Defs

TESTPRINT:NETWORK INFO

Only displayed if anoptional EasyLAN boardis installed.


<Enter> to print<?> for error info

TESTPRINT:RFID TEST LABEL

TESTPRINT:HARDWARE INFO

TESTPRINT:SETUP INFO

TESTPRINT:BAR CODES #2

TESTPRINT:BAR CODES #1

TESTPRINT:CHESS

SETUP:PRINT DEFS

PRINT DEFS:HEAD RESIST

PRINT DEFS:TESTPRINT

PRINT DEFS:PRINT SPEED

HEAD RESIST:[nnn]:

PRINT SPEED:[100]:

PRINT DEFS:LTS

LTS:LTS ADJUST

LTS:LTS TEST

LTS:LTS VALUE

REMOVE LABEL AND PRESS ENTER

REMOVE LABEL ENTER TO STOP

LTS VALUE:[10]:

SENSITIVITY 10OUT OF 9-10

PRINT DEFS:LSS TEST

LSS TEST:LSS AUTO

LSS TEST:LSS MANUAL

LSS AUTO: �

LSS [G: 2]D: 6 �


Return to the start of the Setup Mode loop (SETUP/SER-COM, UART1) or press <Setup> to exit the Setup Mode.

Read-only

Toggle betweengain (G) and drive(D)

Decrease/increasevalue insidebrackets

Only displayed if an optional LTS (Label TakenSensor) is installed in the printer.

TESTPRINT:DIAMONDS



Setup Mode Overview (FP v8.70) Ser-Com, uart2

BAUDRATE;4800

BAUDRATE;2400

BAUDRATE;1200

BAUDRATE;600

BAUDRATE;300

BAUDRATE;115200

BAUDRATE;57500

BAUDRATE;38400

BAUDRATE;19200

SETUP:SETUP:SER-COM, UART2

SER-COM, UART2:BAUDRATE

BAUDRATE;9600












Setup Mode Overview (FP v8.70) Network Communication

BAUDRATE;CR

BAUDRATE;LF

PARITY:BOOTP

PARITY:DHCP

PARITY:MANUAL

SETUP:NET-COM, NET1

SETUP:NETWORK

NET-COM, NET1:NEW LINE

NETWORK:IP SELECTION

NETWORK:IP ADDRESS

NETWORK:NETMASK

NETWORK:DEFAULT ROUTER

NETWORK:NAME SERVER

NEW LINECR/LF

IP SELECTION:DHCP+BOOTP

IP ADDRESS:192.168.1.79

NETMASK:255.255.255.0

DEFAULT ROUTER:192.168.1.1

NAME SERVER:192.168.1.7

NETWORK:MAC ADDRESS

MAC ADDRESS:00104017b80e

Read-only if DCHP and/or BOOTPis selected.

These menus will only be displayed when an optional EasyLAN interface board is installed.



Setup Mode Overview (FP v8.70) RFID

MODE:DISABLE

SETUP:RFID

RFID:MODE

RFID:VOIDTEXT

RFID:RETRIES

MODE:ENABLE

These menus will only be displayed when an RFID module is installed.

VOIDTEXT:[VOID]:

RETRIES:[1]:

TAGADJUST:[0]:

Read-Only

RFID:TAGADJUST

RFID:FIELDSTRENGTH

FIELDSTRENGTH:[100]:



Setup Mode Overview (IPL v2.70) Serial Communication

STANDARD


BAUDRATE;4800

BAUDRATE;2400

BAUDRATE;1200

BAUDRATE;115200

BAUDRATE;57500

BAUDRATE;38400

BAUDRATE;19200

PARITY:SPACE

PARITY:ODD

PARITY:EVEN

CHAR LENGTH7

STOP BITS:2

SETUP:SER-COM

SER-COM:BAUDRATE

SER-COM:DATA BITS

SER-COM:PARITY

SER-COM:STOP BITS

SER-COM:PROTOCOL

BAUDRATE:9600

DATA BITS:8

PARITY:NONE

STOP BITS:1 ENQ/ACK:

XON/XOFF+STATUS

PROTOCOL:XON_XOFF

Continued on the next page






Setup Mode Overview (IPL v2.70) Network (option)

PARITY:BOOTP

PARITY:DHCP

PARITY:MANUAL

SETUP:NETWORK

NETWORK:IP SELECTION

NETWORK:IP ADDRESS

NETWORK:NETMASK

NETWORK:DEFAULT ROUTER

NETWORK:NAMESERVER

IP SELECTION:DHCP+BOOTP

IP ADDRESS:192.168.1.79

NETMASK:255.255.255.0

DEFAULT ROUTER:192.168.1.1

NAMESERVER:192.168.1.7

NETWORK:MAC ADDRESS

MAC ADDRESS:00104017b80e

Read-only

These menus will only be displayed when an optional EasyLAN interface board is installed.



Setup Mode Overview (IPL v2.70) RFID

MODE:DISABLE

SETUP:RFID

RFID:MODE

RFID:VOIDTEXT

RFID:RETRIES

MODE:ENABLE

These menus will only be displayed when an RFID module is installed.

VOIDTEXT:[VOID]:

RETRIES:[1]:

TAGADJUST:[0]:

Read-Only

RFID:TAGADJUST

RFID:FIELDSTRENGTH

FIELDSTRENGTH:[100]:



Setup Mode Overview (IPL v2.70) Test/Service

CONFIG:NETWORK

CONFIG:HW

SETUP:TEST/SERVICE

TEST/SERVICE:TESTPRINT

TESTPRINT:CONFIG

TESTPRINT:FORMAT

CONFIG:SW

FORMAT:ALL

ALL:PRINT FORMATS

TESTPRINT:PAGE

PAGE:ALL

ALL:PRINT PAGES

TESTPRINT:UDC

UDC:ALL

ALL:PRINT UDC

TESTPRINT:FONT

FONT:ALL

ALL:PRINT UDFs




CONFIG:YES

TEST/SERVICE:DATA DUMP

DATA DUMP:NO


CONFIG:CONFIGURATION

TEST/SERVICE:MEMORY RESET

MEMORY RESET:ALL


TEST/SERVICE:LSS TEST

LSS TESTLSS AUTO



Setup Mode Overview (IPL v2.70) Media

MEDIA :SLOWCONFIG:

CONTINUOUS

CONFIG:MARK

SETUP:MEDIA

MEDIA :MEDIA TYPE

MEDIA TYPE:GAP

MEDIA :PAPER TYPE




CONFIG:TTR

PAPER TYPE:DT

MEDIA :LBL LENGTH DOTS

LBL LENGTH DOTS:1200




MEDIA :SENSITIVITY

SENSITIVITY:420


MEDIA :DARKNESS

DARKNESS:0


MEDIA :LBL REST POINT

LBL REST POINT:0

MEDIA :FORM ADJ DOTS X

FORM ADJ DOTS X:0

MEDIA :FORM ADJ DOTS Y

FORM ADJ DOTS Y:0

100/200/400/800/1200/1600/2000/2500/3000/3600/4200/4800

130/140/160/180/366/420/440/450/470/480/513/527/567/627/677/687/864

0/1/2/3/4/5/6/7/8/9/10/-10/-9/-8/-7/-6/-5/-4/-3/-2/-1

0/2/4/6/8/10/15/20/25/30/-30/-25/-20/-15/-10/-8/-6/-4/-2


0/2/4/6/8/10/15/20/25/30/-30/-25/-20/-15/-10/-8/-6/-4/-2


0/2/4/6/8/10/15/20/25/30/-30/-25/-20/-15/-10/-8/-6/-4/-2

MEDIA :TESTFEED MODE

TESTFEED MODE:FAST



Setup Mode Overview (IPL v2.70) Configuration

PRINT SPPED:8 IN/SEC




SETUP:CONFIGURATION

CONFIGURATION:LTS CALIBRATION

LTS CALIBRATION:PRESS <ENTER>

REMOVE LABEL AND PRESS ENTER

CONFIGURATION:PWRUP EMULATION


Return tothe start of the loop

CONFIG:DISABLE

CONFIG:ENABLE

CUTTER:NOT INSTALLED


Labels are fed out

SENSITIVITY 9OUT OF 8-14

<Enter>

Read only, press<Enter>

CONFIG:86XX-15MIL

CONFIG:86XX-10MIL

EMULATION:NONE


CONFIGURATION:PRINT SPEED

PRINT SPEED:4 IN/SEC


CONFIGURATION:CUTTER


B Firmware Upgrading

Th is appendix describes various methods for upgrading the printer’s fi rmware and for switching between Intermec Fingerprint and IPL.


Appendix B—Firmware Upgrading

Introduction

All EasyCoder PM4i printers can use both Fingerprint v8.xx and IPL v2.xx fi rmware. Th ere are many ways to upgrade or exchange the printer’s fi rmware. Use the most convenient way. You can either do it from host by sending the fi le to the printer or by inserting a CompactFlash card in the memory card slot at the printer’s rear plate. Th ere are 3 diff erent fi le types containing the fi rmware. Th e fi le types are related to the way of upgrade procedure. Th e fi les can be obtained from Intermec.

File Description

File name Type of fi le

1-972020-xx.bin (for FP) 1-972105-xx.bin (for IPL)

Th ese .bin fi les contain the fi rmware kernel fi le only. Th e .bin fi les can be sent to the printer with a serial con-nection using a communication program, for example HyperTerminal or Printset, or via FTP. Th ey can also be stored on a CompactFlash card, which is inserted in the back of the printer.

1-972021-xx.bin (for FP) 1-972106-xx.bin (for IPL)

Th ese .bin fi les contain the fi rmware kernel fi le and the factory default setup parameter values. Th ey can be stored on a CompactFlash card.

Note: If you run these .bin fi les, they will remove all fi les stored on the printer except the fi rmware fi les, so it is recommended you backup before running such a fi le. Th e main purpose of the factory default .bin fi les is to allow the user to reset login information (user name and password will be reset to default setting).

Another format is .uff fi les, which are created by, for instance, NetPrintSet. Th ey 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 you change fi rmware from IPL to Fingerprint, it is recommended you reset the printer memory to factory default 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. Th is just means that there was an instruction that erased "/c" [FORMAT "/c",A]. Th is is a normal condition! Th e error shows that no setup fi le [.setup.saved] is detected on "/c". Th e "/rom" setup fi le 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.



Upgrading From a Memory Card

Th is chapter describes how to upgrade the printer from a CompactFlash card.

Insert the card and switch on the printer. Th e printer’s display will automatically show ongoing steps. Th e procedure ends with a normal startup of the printer.

Switch off the printer and remove the card. Printer is ready for use.

CompactFlash cards with fi rmware (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 fi rmware fi les on the memory card, it is not forseeable which one will be selected. However, by renaming the desired fi le to FIRMWARE.BIN, you can make sure that the fi le will be selected.

How to Create a Firmware Upgrade Card

Th ere 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-sideUse a computer fi tted with a PCMCIA slot and a CompactFlash adapter and insert the CompactFlash card.

Copy the upgrade .bin or .uff fi le to the CompactFlash card.

At the Printer Side (Fingerprint only)Insert the CompactFlash card in the slot at the printer’s rear plate.

Start up the printer and select Intermec Shell.

Press <Enter> to go to the “Sel. Application” menu.

Press <⇒> repeatedly to browse to ”SOFTWARE UPDATE”.

Press <Enter> to go to ”UPDATE: COMPACT FLASH?”

Press <Enter>.

Start sending the fi le using a communication program, for example HyperTerminal. Th e communication program must use zmodem. (Th ere is a one-minute time-out on the printer side.) Shell will automatically rename the fi le to FIRMWARE.BIN to make sure that this fi le will upgrade the printer.

Switch off the printer and remove the card.

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Note: A special case is if the CompactFlash card already has a Fingerprint fi rmware. Inserting such a card will always install fi rmware in the printer according to CompactFlash card. However, perhaps you like to install a later fi rmware version picked from the web. If so, proceed like this:

Insert the CompactFlash card with a upgrade fi rmware on. Switch on and wait for a completed upgrade and the normal startup of the printer so you are in Fingerprint mode.

Activate the Shell program from "/rom" like this:

LOAD "/rom/SHELLXP.PRG"

MERGE "/rom/ERRHAND.PRG"

RUN

In Shell, select the option “UPDATE: COMPACT FLASH?” and press <Enter>.

Send the .bin or .uff fi le from the host using zmodem.

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Upgrading From the Host

Software Suggestions

1. Intermec PrintSet (IPL and Fingerprint)Install Intermec PrintSet software and a serial cable. Intermec PrintSet is included on the PrinterCompanion CD. It can also be obtained from the Intermec web site.

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 FTPUse command prompt in Windows 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 CableDB-9pin female -> DB-9pin male (see Spare Parts Catalog)

Ethernet CableIntermec does not provide any Ethernet cable.Th e cables are normally provideed locally. At a straight connection between a host and printer, a cross RJ45 cable is needed.

Parallel Cable(see Spare Parts Catalog)

How to Use Intermec PrintSet and Serial Cable

Connect a serial cable between host and printer

Start up the printer and select Fingerprint via Shell and to listen on serial port "uart1:" on for example baud rate 115200.

Start PrintSet. Th e program will automatically set the communication parameters and is ready for use.

Select ”DataXfer\Change fi rmware”. Depending on settings, PrintSet may ask for the admin’s password.

Send one of the following fi les:

1-972020-xx.bin (Fingerprint)

1-972105-xx.bin (IPL)

After fi le is received in printer, it will automatically replace the fi rmware

and boot up with the new one. Th e printer’s display will automatically show ongoing steps. Th e procedure ends with a normal startup of the printer.

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How to Use MS HyperTerminal and a Serial Cable (Fingerprint Only)

Connect a serial cable between host and printer.

Start the HyperTerminal or a similar terminal program. Select port com1. Use a high communication speed (baudrate 115200).

Start up the printer and select Fingerprint via Intermec Shell1 to listen on serial port "uart1:".

Make sure that your are in contact with printer by typing for example FONTS and the printer will respond showing fonts.

Type a download command2 so printer is ready for receiving data:

RUN "dlk"

Select .bin upgrade fi le. Now printer waits for about 1 minute to get the fi le sent using zmodem as protocol.

Go to “Send fi le” and send it.

After fi le is received in printer, it will automatically replace the fi rmware

and the printer will boot up with the new version. Th e printer’s display

will automatically show ongoing steps. Th e 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 fi le.) Also check the printer’s baud rate in the Setup Mode. Continue with items 6-8. If the printer is fi tted 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.

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How to Use Command Prompt FTP and Ethernet

Connect a printer on Ethernet LAN or by a cross cable between host and printer

Open an FTP session to the printer typing this command from your Windows command prompt: FTP <ip address of the printer>

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: Th e user you log in as must be allowed to upgrade.

After some answers on your screen you will see the prompt FTP>. At this point type bin + <Enter>, then type hash + <Enter>.

Now send the fi rmware to the printer with the command:

put <fi lename.bin> FLASH

Some ###### will appear on your screen showing the ongoing transfer.

Th e printer’s display will automatically show ongoing steps. Th e procedure ends with a normal startup of the printer.

Close FTP session typing bye + <Enter>.

After fi le is received in printer it will automatically replace the fi rmware

and the printer will boot up with the new version. Th e 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 confi guration utility for Intermec printers that allows you to upgrade or confi gure the printer. Makes font upgrades and other maintenance a child’s play. Available both as Netscape plugin and standalone executable.

• Th e Netprintset can merge printer’s necessary fi le to one fi le either using a CompactFlash card or download direct to printer. Necessary fi les are for example Images, Fonts, Firmware, or other custom-made fi les.

• User instructions are embedded in the software.

If Upgrading Directly Via NetPrintSet and PrinterStart up the printer and select Shell. Press <Enter> to go to the “SEL. APPLICATION” menu. Use <⇒> to browse to “SOFTWARE UPDATE”. Press <Enter> to go to the “UPDATE: COMPACT FLASH?” menu. Use <⇒> to go to “UPDATE: FIRMWARE?”. Finally, press <Enter>.

User might not be allowed to update.

Start to send the fi le from the software. (Th ere is a one-minute timeout before the printer exits the receive mode.)

After fi le is received in printer, it will automatically replace the fi rmware and the printer will boot up with the new version.

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Worldwide Headquarters

6001 36th Avenue West

Everett, Washington 98203

U.S.A.

tel 425.348.2600

fax 425.355.9551

www.intermec.com

P/N 1-960588-04

EasyCoder PM4i Bar Code Label Printer Service Manual

*1-960588-04*