Documente Academic
Documente Profesional
Documente Cultură
EasyCoder PD4
Bar Code Label
Printer
Intermec Technologies Corporation
Corporate Headquarters
6001 36th Ave. W.
Everett, WA 98203
U.S.A.
www.intermec.com
The information contained herein is proprietary and is provided solely for the purpose of allowing
customers to operate and service Intermec-manufactured equipment and is not to be released, repro-
duced, or used for any other purpose without written permission of Intermec.
Information and specifications contained in this document are subject to change without prior notice
and do not represent a commitment on the part of Intermec Technologies Corporation.
© 2004 by Intermec Technologies Corporation. All rights reserved.
The word Intermec, the Intermec logo, Norand, ArciTech, CrossBar, Data Collection Browser,
dcBrowser, Duratherm, EasyCoder, EasyLAN, Enterprise Wireless LAN, EZBuilder, Fingerprint,
i-gistics, INCA (under license), InterDriver, Intermec Printer Network Manager, IRL, JANUS,
LabelShop, Mobile Framework, MobileLAN, Nor*Ware, Pen*Key, Precision Print, PrintSet, Route-
Power, TE 2000, Trakker Antares, UAP, Universal Access Point, and Virtual Wedge are either trade-
marks or registered trademarks of Intermec Technologies Corporation.
Throughout this manual, trademarked names may be used. Rather than put a trademark (™ or ®)
symbol in every occurrence of a trademarked name, we state that we are using the names only in an
editorial fashion, and to the benefit of the trademark owner, with no intention of infringement.
There are U.S. and foreign patents pending.
The name Centronics is wholly owned by GENICOM Corporation.
Windows is a trademark of Microsoft Corporation.
FCC Notice (United States of America)
WARNING
This equipment generates, uses, and can radiate radio frequency energy and if not installed and used
in accordance with the instructions manual, may cause interference to radio communications. It has
been tested and found to comply with the limits for a Class A computing device pursuant to Subpart
J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such inter-
ference when operated in a commercial environment. Operation of this equipment in a residential
area is likely to cause interference in which case the user at his own expense will be required to take
whatever measures may be required to correct the interference.
EMS and EMI Compliance Statement
This equipment has been tested and passed with the requirements relating to electromagnetic com-
patibility based on the standards EN50081-1 (EN55022 CLASS A) and EN61000-4-2/-3/-4/-5/-
6/-8/-11 (IEC Teil 2,3,4). The equipment also tested and passed in accordance with the European
Standard EN55022 for the both Radiated and Conducted emissions limits.
Contents
Before You Begin................................................................................................................. vii
Safety Summary ................................................................................................. vii
Safety Icons ......................................................................................................viii
Global Services and Support ................................................................................................ ix
Warranty Information......................................................................................... ix
Web Support ...................................................................................................... ix
Telephone Support ............................................................................................. ix
Related Documents .............................................................................................................. ix
About this Manual ................................................................................................................ x
2 Front Panels
2.1
2.2
Front Panel (no display)........... ..................................................................................8
Front Panel (with display) .........................................................................................9
2.3 Replacing the Front Panel ........................................................................................10
2.4 Bottom Right-Hand Panel .......................................................................................11
2.4 Console pcb. ............................................................................................................12
3 Side Panels
3.1
3.2
Right-Hand Door ....................................................................................................16
Left-Hand Panel .......................................................................................................17
4 Chassis
4.1
4.2
Chassis......................................................................................................................20
Rear Plate .................................................................................................................21
5 Media Supply
5.1 Media Supply Post ...................................................................................................24
7 Print Mechanism
7.1 Print Unit ................................................................................................................34
7.2 Motor, Pulleys, and Belts ..........................................................................................35
7.3 Platen Module..........................................................................................................37
7.4 Media Guides ...........................................................................................................38
7.5 Label Gap Sensor Module ........................................................................................39
8 Rewinder Module
8.1 Rewinder Module ....................................................................................................50
10 Cutter
10.1 Cutter....................................................................................................................... 58
12 Main Board
12.1 Description...............................................................................................................68
12.2 Replacement ............................................................................................................69
12.3 Connections .............................................................................................................70
12.4 Components ............................................................................................................73
12.5 Test Points................................................................................................................74
12.6 Schematics ...............................................................................................................75
12.7 Memory Expansion Card .........................................................................................83
13 Interfaces
13.1 RS-232 Serial Interface.............................................................................................86
13.2 USB Serial Interface .................................................................................................87
13.3 Centronics Parallel Interface .....................................................................................88
14 Troubleshooting
14.1 Error Handling ....................................................................................................... 90
14.2 Troubleshooting Check List .................................................................................... 91
14.3 No Reaction at Power Up ........................................................................................ 93
14.4 Error During Printing ............................................................................................. 95
14.5 No Printing ............................................................................................................. 96
14.6 Printing Partly Missing along the Feed Direction .................................................... 97
14.7 Printout not in Desired Position.............................................................................. 98
A Firmware Upgrading
Requirements.....................................................................................................................102
Instructions .......................................................................................................................102
Safety Icons
This section explains how to identify and understand dangers, warnings,
cautions, and notes that are in this document. You may also see icons that
tell you when to follow ESD procedures.
A warning alerts you of an operating procedure, practice, condition, or
statement that must be strictly observed to avoid death or serious injury
to the persons working on the equipment.
A caution alerts you to an operating procedure, practice, condition, or
statement that must be strictly observed to prevent equipment damage
or destruction, or corruption or loss of data.
This icon appears at the beginning of any procedure in this manual
that could cause you to touch components (such as printed circuit
boards) that are susceptible to damage from electrostatic discharge
(ESD). When you see this icon, you must follow standard ESD guide-
lines to avoid damaging the equipment you are servicing.
Note: Notes either provide extra information about a topic or contain spe-
cial instructions for handling a particular condition or set of circumstances.
Related Documents
This table contains a list of related Intermec documents and their part
numbers.
Document Title Part Number
EasyCoder PD4 User´s Guide 1-960614-00
Intermec ESim v5.00 Programmer´s Reference Manual 1-960615-00
EasyCoder PD4 Spare Parts Catalog 1-960617-00
This chapter describes the various models of the EasyCoder PD4 printer
family, describes the option, and provides technical specifications.
1.1 Models
The EasyCoder PD4 comes in three main models:
• Printer without display and 200 dpi printhead density
• Printer with display and 200 dpi printhead density
• Printer with display and 300 dpi printhead density
1.2 Options
The options for the EasyCoder PD4 depend on the printer model:
• External Keyboard/Display Unit (all models)
• EasyLAN 10 External Ethernet Adapter (all models)
• Memory Expansion Board 2MB (display models only)
• Cutter (display models only)
• Rewinder (display models only)
Keyboard/Display Unit
This chapter describes the front panels for various models of the Easy-
Coder PD4 printer family.
Flat cable
Console pcb
LEDs (green-green-red)
Control keys
(Feed-Pause-Cancel)
Label E-ring
Overlay
Clear window
Console pcb
LEDs (green-green-red)
LCD display
Control keys
(Feed-Pause-Cancel)
Screw (x2)
Label E-ring
Dust protection
Overlay
Strip sensor housing
Clear window
Q3
R36
R24
R35 R10 R22 R17 R19 R18 Q2 Q1
R6 R1 C6 R20 R2 R4
+5V R16 R5 R9
CN2 R42 Q4
D5 C15
U1
LS08
C16
C7 C8 C9 C10 C11 C12 C13 C14 C5
+5V U3
A LS32
K C17
U2
HC14 200−000103−02
C18
D4 R40
R41
C4 R14 R13 C3 R12 C2 R15 R38
C1 VR2
R25 R7 R23
BZ1
VCC
D1 D2 D3
Y_LED R_LED G_LED
VCC R7
2
R4 R5 R6 R1 R2 R3 C1 + R35 R36 BZ1
Schematics
Q1 Q2 Q3 CN1
R8 LEDG 2 1 D0
4 3
1
LEDR D1
LEDY 6 5 D2 VC C
R9 8 7 D3
10 9 D4
12 11 D5 R10
CS1_ 14 13
R11 D6
CS2_ 16 15
R12 FEED D7
VCC R13 PAUSE 18 17
R14 STOP 20 19
VCC 22 21
R15 R16 R2 0 24 23
26 25 RD_
CN9
8
7
6
5
8
7
6
5
2
4
3
19 R4 2 R21
S1 C2VCC 18 VCC CN2
(with G9) 17 E3A_
16 1
1
2
3
4
1
2
3
4
RW_ VCC
15 2
1
1
2
W_
12 CS1A 15
EMPTY
4
3
11 14
S2 C3 10 13
(with G10) 9 12
VCC 8 11
7 10
3 6 9
5 8
1
2
R25
4 E1A_ 7
3 E2A_ 6
2 E1A_ RS 5
4
3
1 4
S3 C4 3
(with G11) 2
1
C7 C8 C9 C1 0 C1 1 C1 2 C13 C1 4
C5 C6 C15 +
1
2
R37 VCC
1
VCC
9
8
7
6
5
4
3
2
1
C16 C17 C18
14
13
12
11
10
C5-C14 EMPTY
CN4
U2 C U1C
RESET EM PTY U1B
9
RESET CIRCUIT E3A_ 6 5 8 4
C19 10 6 W_
5 RD_
R41
VR2 U2D U3B
E MPT Y
EMPTY 4
E2A_ 8 9 6
5
U2B
CS2 A 4 3 CS2_
13
Chapter 2—Front Panels
Chapter 2—Front Panels
This chapter describes the right-hand door assembly that covers the media
compartment and the left-hand side panel that covers the electronics com-
partment.
Window
Label
Right-hand door
Top/right panel
Screw
Leaf-springs
Screw
Panel
Leaf-springs
Removal
The electronics compartment is only to be accessed by skilled service
technicians. It contains high voltages wires and circuitry. Disconnect
the power cord to eliminate the risk of electric shock and short circuits
before removing the left-hand panel.
Never run the printer without the left-hand panel installed because of
the risk of radio interference. Approvals are only valid when the cover is
installed.
Take standard precautions against ESD (Electrostatic Discharges)
before touching any electronics components inside the electronics com-
partment.
1 Disconnect the power cord.
2 Open the right-hand door.
3 Remove the screws in front of the front hinge and to the rear of the rear
hinge.
4 Close the right-hand door.
5 Using for example a flat-tipped screwdriver, pry the panel upwards until
it comes free. Protect the paint by inserting for example a thin piece of
cardboard or similar between the plate and the screwdriver.
6 Put the panel aside on a soft piece of cloth or similar to avoid scratches.
Installation
1 Making sure that the leaf springs along the rear edge of the panel
embrace the edge of the rear plate, push down the panel. Check that the
leaf springs along the bottom edge fit the bottom plate.
2 Open the right-hand door.
3 Secure the panel using two screws inserted from the media compart-
ment.
4 Reconnect the power cord.
This chapter describes chassis, which consists of the center section, the
bottom plate, and the rear plate.
4.1 Chassis
Description
The chassis is the printer’s main frame to which various modules are
attached, such as the panels and doors, the print mechanism, the transfer
ribbon mechanism, the electronics, and the media supply post. It consists
of three main parts:
• Bottom plate with four rubber feet and two dampeners for the right-
hand door
• Center section (two different; the displayless model has no hole for the
rewinder and no cover plate)
• Rear plate
Rear plate
Center section
Dampeners (x2)
Bottom plate
Serial port
USB port
Parallel port
On/Off
switch
AC power
cord socket
Serial port
connector
(cable not shown)
This chapter describes the media supply post with its two types of edge
guide.
Screws (x3)
Hook
Washer
Spring
Post
Screws (x3)
Guide plate
Center section
Hook
Washer
Coil spring
Post
Note: The high edge guide is hinged to allow media load. Before remov-
ing an empty core or loading a roll of media, the guide must be flipped
down to a horizontal attitude. Likewise, after loading the media it must
be flipped back so it points straight up. Like the low edge guide, it can be
adjusted along the post to fit different media widths.
Edge guide
Hook
Washer
Coil spring
Post
Be careful to flip the high edge guide straight up before closing the side
door, or the guide could be damaged.
Bracket
Screws (x6)
Belt
Replacement
The ribbon module has three replaceable parts—the belt and the bobbin
plates on the ribbon supply and rewind units. The ribbon out sensor and
the ink position knob are also replaceable.
To replace the entire ribbon module, follow these instructions:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Slip the belt that drives the platen from its pulley (also see Chapter 7.2).
3 Use a pair of narrow pliers to disconnect the spring between the ribbon
supply and the ink position knob.
4 Remove the six screws that hold the ribbon module to the center section
from the media compartment side.
5 Tilt the ribbon module so you can remove the belt from the pulley on
the platen roller shaft.
6 Do not dismantle the module any further, unless you need to replace the
belt (See Chapter 6.2). Reassemble in reverse order
One-way clutch
E-ring
Washer
Belt
Bobbin plate
Cable
(connector not shown)
Screw
Washer Sensor assy.
Isolating sheet
Ink outside the roll Ink inside the roll Remove knob in this
position
Replacement
To remove the ink position knob, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Disconnect the spring from the ink position knob inside the electronics
compartment using tweezers or a pair of narrow-tipped pliers.
3 Move the knob to the center of the slot, rotate it a quarter of a turn, and
pull it out into the media compartment.
4 Install the ink position knob in reverse order. Do not forget to move it
to either end of the slot before closing the right-hand door.
Slot
Spring
This chapter describes the print mechanism and the stepper motor that
drives both the platen roller and the transfer ribbon takeup unit.
Printhead module
203.2 or 300 dpi)
(Pulley;
for belt to Headlift sensor
ribbon unit)
Pulley
(motor belt;
203.2 or 300 dpi)
Media guide Platen module Media guide
Belt
Motor
Pulley
Replacement
Stepper Motor Module
To remove the stepper motor, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Disconnect the cable from CN7 on the main board and free the cable
from the spiral bindings and the cable clip.
3 Remove the four screws that hold the stepper motor module to the
bottom plate. A screwdriver with a magnetic tip is highly recommended.
4 Disconnect the belt(s) from the motor’s pulley and pull out the motor.
5 Install the motor in reverse order. In case of a printer prepared for a
rewinder, fit the platen roller belt on the inner pulley (that is, the pulley
closest to the motor housing) and the rewinder belt to the outer pulley.
Belt
To remove the belt, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Disconnect the cable from CN7 on the main board and free the cable
from the spiral bindings and the cable clip.
3 Remove the four screws that hold the stepper motor module to the
bottom plate.
4 Disconnect the belt(s) from the motor’s pulley and pull out the motor.
5 Install belt and motor in reverse order. Make sure the belt is intended for
the type of printhead (203.2 or 300 dpi) installed in the printer. In case
of a printer prepared for a rewinder, fit the platen roller belt on the inner
pulley (that is, the pulley closest to the motor housing) and the rewinder
belt to the outer pulley.
Note: If the printer is not prepared for a rewinder, that is, it has only one
belt, you do not have to remove the motor. Just pull the belt of the platen
roller pulley and then off the motor pulley. Fit the new belt in reverse
order. Temporarily disconnecting the tension adjuster spring makes the
process easier.
Replacement
To remove the platen, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
2 Remove the front panel as described in Chapter 2.3 (this step can be
omitted)
3 Remove the E-ring from the inner end of the platen roller shaft and
remove the motor belt and pulley.
4 Remove the ribbon rewinder belt and pulley.
5 Remove the E-rings and washers from either end of the platen roller
shaft.
6 Remove the bearings.
7 Pull out the platen roller.
8 Install the platen roller, bearings, washers, E-rings, pulleys, and front
panel in reverse order.
Inner gable
Shafts
Adjustments
Lateral Position
The label gap sensor’s point of detection can be moved manually across
the media path from 0 to 57 mm (0 to 2.24 in) from the inner edge of the
media. The point of detection is indicated by a narrow white triangle vis-
ible from the front of the print mechanism when the printhead is open.
Sensitivity
The sensitivity of the sensor can be adjusted in the Setup Mode (printers
with display only) or using ESim commands, see the EasyCoder PD4 User’s
Guide and the Intermec ESim v5.xx, Programmer’s Reference Manual.
Replacement
Before replacing the module, check that there is no dirt, dust, adhesive resi-
due, or stuck labels that blocks the light between the two sensors. To clean
the sensors, it may be necessary to take out the module as described below.
To remove the label gap sensor module, follow these steps:
1 Disconnect the power cord and remove the left-hand panel as described
in Chapter 3.2. Carefully read the safety instructions in Chapter 3.2!
Open the right-hand door and remove the bottom right-hand panel, see
Chapter 2.4.
2 Remove the E-ring, washer, and bearing from the outer end of the platen
roller, that is, the end in the media compartment.
3 Remove six screws that hold the outer gable of the printhead.
4 Fold the outer gable aside, taking care not to damage the headlift sensor
and its cable (see Chapter 7.6).
5 Remove the single screw that holds the label gap sensor module in the
electronics compartment. It is situated immediately to the rear of the
black sensor module.
6 Disconnect the cables from CN8 (“BLACK”) and CN9 (“SEE”) on the
main board. Free the cables from the spiral bindings and the cable clip.
7 Pull out the entire label gap sensor module into the media compartment.
8 Do not dismantle the module. The entire module is available as a
replacement part.
9 Install the label gap sensor module in reverse order.
Outer gable
Bearing
Washer
E-ring
Screw (x6)
Bearing
Washer
Headlift sensor E-ring
Screw (x6)
Outer gable
Adjustments
Printhead Balance
The printer is factory-adjusted for full-size media width. When using
media less than full width, it is recommended that you adjust the position
of the printhead balance boxes so the printhead gets an even pressure across
the media.
A poorly adjusted printhead pressure may be detected by a weaker printout
on either side of the media path.
To adjust the pressure, proceed as follows:
1 Open the top cover.
2 Remove the ribbon.
3 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.
4 Move the balance box on the right side (outer) outward (to the right) for
wider media and inwards (to the left) for more narrow media.
Balance box
Note: Before readjusting the pressure, try to fix the problem by moving the
outer balance box as described earlier in this chapter.
4 Use a straight-slot screwdriver to turn the screw at the top of the balance
boxes clockwise to increase the pressure or counterclockwise to decrease
the pressure. To set the pressure to factory default value, turn the screws
down completely and then 9 turns up (counterclockwise).
Adjustment screws
4 Lift the printhead by pulling out the printhead lever and flipping it
counterclockwise a quarter of a turn.
5 Turn both screws at the front of the printhead carefully clockwise a
quarter of a turn at a time (a full turn corresponds to 0.5 mm which
is a lot). The adjustment range is ±2 mm (0.08 in). Make sure to make
identical adjustments on both the screws! If you get lost, tighten both
screws by turning them counterclockwise as far as they go and start all
over again.
6 Important step! Engage the printhead and lock the printhead by tight-
ening the two screws at the top of the printhead bracket, that is, the
reverse action of step #3.
7 Load the ribbon (only in case of thermal transfer printing).
8 Test the print quality and readjust if necessary. (Hint! If you use direct
thermal media you will not have to load and remove the ribbon over and
over again.)
Replacement
The printhead is subject to wear both from the direct thermal media (or
ribbon) and from the rapid heating and cooling process during printing.
Thus, the printhead will require periodic replacement.
Time between printhead replacements depends on the print images, the
type of direct thermal media (or ribbon) in use, the amount of energy to
the printhead, the print speed, the ambient temperature, and several other
factors.
While replacing the printhead, the power must be off. The firmware
will not detect the new printhead resistance until the printer has been
restarted.
Take precautions against electrostatic discharges by touching a
grounded object, for example the chassis of the printer (assuming the
printer is connected to a grounded wall socket).
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 to dissipate through the media.
• Use as low density setting as possible. Too much energy to the printhead
will wear it out rapidly.
• Do not use higher speed setting than necessary.
• Low ambient temperature requires more energy to the printhead dots
than room temperatures and will therefore cause more wear to the
printhead. High print speed accelerates the wear. Thus, at low tempera-
tures, select as low a print speed as acceptable.
• 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 balance so there is an even pressure across the media. Not only
will an uneven pressure impair the printout quality, but it may also pre-
vent the dots from being properly cooled. Moreover, a sharp outer media
edge in direct contact with the printhead may cause excessive mechanical
wear on some dots, which may be visible when printing on wider media
later.
• When using preprinted labels or labels with some type of varnish or
non-standard top coating for direct thermal printing, use original
Intermec labels or inks recommended by leading manufacturers of direct
thermal media. The labels must not contain any aggressive substances
such as chloride or grinding substances such as titanium dioxide.
• Only use transfer ribbons recommended by Intermec.
This chapter describes the optional internal liner rewinder required for
peel-off (self-strip) operation. The rewinder can only be fitted on Easy-
Coder PD4 printers with a display.
Cover plate
Gear
Rewinder connector
Cutter connector
Gear/pulley
Washer
E-ring
The rewinder module consists of the following parts. Only the liner reten-
tion clip and the liner takeup full sensor are available as spare parts. The
cable from the takeup full sensor is not shown in this drawing.
Installation
The rewinder module can easily be fitted by the operator following these
steps.
1 Remove the screw that holds the front cover. Remove the front cover.
Front cover
Screw
2 Open the side door and remove the rewinder option cover plate, which
is held by two screws.
Cover plate
Y
Z X
3 Remove the U-shaped clip and attach the rewinder unit to the center
section using the four screws included in the kit.
4 Plug in the cable from the rewinder switch into the front one of the two
connectors in the center section.
Switch
Rewinder cable
This chapter describes the strip module (also called “label taken sensor”)
which is a standard feature on EasyCoder PD4 printers with a display. It
cannot be fitted on printers without a display.
Strip module
Replacement
Before replacing the strip module, check
• that the sensor is in its horizontal position,
• that nothing blocks the LED and the sensor, for example dust or stuck
labels,
• that the back side of the media is able to reflect the light,
• and that the cables of the sensor are visibly undamaged and properly
connected to CN12 on the main board.
Replace the strip module this way:
1 Remove the left side panel (see Chapter 3.2).
The electronics compartment contains high voltages wires and circuitry.
Disconnect the power cord to eliminate the risk of electric shock and
short circuits.
Take standard precautions against ESD (Electrostatic Discharges)
before touching any electronics components.
2 Disconnect the flat cable from the main board.
3 Remove the front panel module as described in Chapter 2.3.
4 Disconnect the strip module cable from the main board and remove it
from the clips, ties, and plastic spiral binding.
5 Remove the E-ring that holds the strip module and pull it away. The
strip module is only available as a complete unit.
6 Assemble in reverse order.
E-ring
H
PUS
Strip module
Front panel
This chapter describes the cutter which is an option for EasyCoder PD4
printers with a display. It cannot be fitted on printers without a display.
Never use the cutter to cut through any kind of adhesive, which will get
stuck on the shears and render the cutter inoperable or even damage
it. If you need to cut self-adhesive labels, be careful to cut the liner
between labels.
10.1 Cutter
Description
The cutter cuts off portions of continuous media after printing and collects
them on a tray. It is an option for EasyCoder PD4 printers with an LCD
display, but cannot be used on printer models without a display. When a
cutter is installed, the strip module (see Chapter 9) cannot be used. The
cutter can cut non-adhesive media 64 to 118 mm (2.52 to 4.65 in) wide
and with a thickness of 60 to 250 µm (2.3 to 9.8 mils).
The cutter comes in three main parts:
• Cutter mechanism including cable
• Cutter front panel
• Tray
Control
The cutter is controlled in the Setup Mode, see the EasyCoder PD4 User’s
Guide, or using an O command, see ESim v5.xx for EasyCoder PD4, Pro-
grammer’s Reference Manual.
Replacement Parts
In addition to the complete cutter module, the following replacement parts
are available:
• Cutter pcb
• Cutter front panel
• Tray
Cutter pcb
Screws (x6)
Bracket
Cutter
mechanism
Bracket
Front Panel
Tray
Installation
1 Remove the screw that holds the front cover. Remove the front cover.
Front cover
Screw
2 Open the side door and remove the tear bar, which is held by two Phil-
lips screws.
3 Attach the cutter mechanism to the printer using the two Phillips screws
and washers included in the kit.
4 Plug in the cable from the cutter into the rear one of the two connectors
in the center section and fasten the cable to the bottom plate using the
two cable clips included in the kit.
Cutter
connector
Cutter cable
Cable clips
5 Attach the cutter cover onto the cutter mechanism by first connecting
the hooks on the back side of the cover over the cutter mechanism and
then locking the cover with the screw at the bottom.
This chapter describes the switching power module and its connections
from the power switch unit and to the main board.
CN1
90-260
VAC In
CN2
24 VDC
to main
board
Replacement
To replace the power module, follow these steps:
1 Remove the left side panel (see Chapter 3.2).
The electronics compartment contains high voltages wires and circuitry.
Disconnect the power cord to eliminate the risk of electric shock and
short circuits.
Take standard precautions against ESD (Electrostatic Discharges)
before touching any electronics components.
2 Disconnect the two cable harnesses at the rear of the power module.
3 Remove the two screws at the front of the power module that hold it to
the bottom plate.
4 Push the module forward so as to disengage the tab at the rear and lift
out the entire unit.
5 Install the power module in reverse order.
Components
MADE IN TAIWAN D3 CN4 FAN
HS2 +
R3
C10 C11
−
C6
L2 C15 CN3 LED
+
R4
D1
− CN2
R13
R19
R14
+V
C9
R20
R12
HS1
Q1 C12 C13
R5
R2
GND
AUTEC UPS 110−1001
L1
R18 C14
REV−B
C7
R7
R8
R17
+V
T1
SCR1
R6
R9
D2
C16
R10 VR1
R11
R15
R16
ZD1
D4
ZD2
C17
JP1
C8 CONT1
C5 C4
G
TR1 C1
N
1
C2 C3
L
LF1
BO1
R1
CN1
VDR1
F1 5A−250V
3
Schematics
CN1
+HV
F1
L LF1
+ BD1
C1 R1 VDR1 + C5
N
TR1
−
C2 C3 -HV
FC
C4
+HV
R4 R2 C6 R3 CN3
D1 LED
R12 C9
R14
CN2
CONT1
R7 Q1+HS1 +24V
3 D3+HS2 L2
SCR1 ZD1
1
R5 + C10 + C11 + C12 + C13 + C14
2 D2
7 6 5 4 R8 R6 R18 R19 R16
+
C8 GND
L1
C17
R9
+24V
R10
R11
VR1
This chapter describes the three different main boards including connec-
tions, test points, component placement, and schematics.
12.1 Description
Models
There are three different main boards for the EasyCoder PD4 depending
on printer model:
• EasyCoder PD4 No display 203.2 dpi
• EasyCoder PD4 LCD display 203.2 dpi
• EasyCoder PD4 LCD display 300 dpi
The printer must be fitted with the correct type of main board or it will
not work.
All types of main board are based on the same circuit board but the com-
plement of circuits differ. They are all designed to work with ESim v5.xx
for EasyCoder PD4 or later versions.
The main boards are delivered as complete units. Do not attempt to repair
or modify a main board.
The main board has a 16 bit microprocessor and, as standard, a memory of
2MB flash and 2MB DRAM.
The models with an LCD display has a real-time clock and the memory
can be expanded using a 2MB flash memory module.
Block Diagram
FEED Flash
Flash (1) Flash (2) EDO Memory
EEPROM
PAUSE
Memory Memory RAM Extension
Input Console
Buzzer
LEDs
System Buss
IEEE 1284
A/D line
IO Ports
RS-232 port
Virtual pot
USB Drivers
GAP sensor
BM sensor
Sensors
Stepper Motor
Rewinder unit
Printhead
Power
Power detection
TPH temp
Cutter
Ribbon End
Power Input
TPH open
Power Temp
termistor
supply
Sensor
24 VDC
Sensors
12.2 Replacement
To replace the main board, follow these steps:
1 Remove the left side panel (see Chapter 3.2).
The electronics compartment contains high voltages wires and circuitry.
Disconnect the power cord to eliminate the risk of electric shock and
short circuits.
Take standard precautions against ESD (Electrostatic Discharges)
before touching any electronics components.
2 Disconnect all cables from the main board. It may be a good idea to
mark them up first.
3 In case there is a memory expansion board installed, remove it (see
Chapter 12.7.
4 Remove the five screws and washers that hold the main board. (In case
of a memory expansion board, there are four sets of screws and washers
plus one hexagonal spacer.)
5 Install the main board in reverse order.
12.3 Connections
EasyCoder PD4, no display, 203.2 dpi
CN23 CN11 CN14 CN8 CN9
RS-232 Ribbon out Headlift Black See
mark through
JP4
USB
CN21 CN3 & CN4 CN19 CN7 CNA1 & CNB1 CN28
Centronics Memory Cutter Motor Printhead Power
expansion card
CN31
CN1
CN23
UART1
L12
FB1 R181
REWIND EXTDRAM R180
L UART2 CN10 CN11 CN13 CN12 CN17 CN14 CN20 CN8 CN9
R151 R6 R7 U37A
R52
C93 R166 C152 R182 JP3 R152
CN26
SEE
JP2 R53 CN22
DOOR
U37 1
STRIP
Q1 C46
COVER
R51
JP5
BLACK
R56
R57
C59
R84
R78
R50
R147
C51
R68
R65
C52
R67
C55
R73
R72
C44
SPSTMP
C45
R55
R54
C48
R61
R59
C49
R62
R60
R165
R58
R148
C5
C140
R153
R162
R150
REWINDFUL
R85
R167 R183
RIBBONOUT
RIBBONEND
C19
C18 R69
C153
R168
C146
R164
R173 C109
Q4 R8
C112
U43 R174
C141 U3
R2 R1
U7
C134
R177 U2
C133
C17
R172
C149
R115 U40
R171
PS2 C95 Y3 R10
R86 R91 U25 Y2 C138 Y1
12.4 Components
RT3 RT4
Q5 C132 U11 U9
R184 C128
C147
R170
R169
C151
R4
LCD PANNEL
C13
C14
R141 C139 R143
C154
C137
C131
R140 U6
R163
R128
R139 X1
U35 U34
R9
U27 Y2A C4 C3
R176
R28
R129
R127
R131
R132
USB L11 R3
C127
C111
CN21 R126 U4
R11
C11
U27A
R12
R185
C115 R175
R186
C129
C8 C79 C80 C108 U1 C110
C81 C82
CN4 CN3
R83
R82
R80
R155 C117
R26
R23
R18
R17
R144
CN29
C114
U12
R88
C148 R92
R157
U28
R79
R187
R188
C66 R90
C64 Q7 Q6 LX1 DC-JACK
C65 R87 U24 C12 U5 R30 CN28
C57
C62
R95 R134
MEMORY CADR
C69 C7 L5
MEMORY CADR
R96 C30
C68 U39 L7
R29 C125
R75 U33
C142
1
C126
C31
R39
R33
C83 D45 R34 R35 R37 R34 R38 C124
R136
C10
C23 R106
R15
C20
R13
U20 C28
R135
U21 U18
C120
R14
C22
D3 D2 C123
C113
C121
FX1
C29
D16 U13
D40 POWER
L9 L8
D22 D7 CN27
R31
R32
C27
U13A
C41
C40
R44
C42
D44 C24
R47
R41
R40
C32
R36
R43
R42
R46 L6 GNDS
C38
C37
C36
C35
C43
C77 R98 C33 C86 VDD
C76 R99 RP1 D39 U16 R45 C118
C75 R100 D32 D11 GND
C74 R101 D28 R49 U22
C73 R102 5V
D41 D14 D20 D15 D21 D25 D29 D26 D30 D37 D35
R64
R71
C72 R103 D31 C87 D1
C71 R104 D27 D10 POWER
R20
C56
R24
R22
R19
C70 R105
C26
A D24 D9 R81 C58
D18 CN19 D5 D4
C157
R77
P1 D23 CUTER C39
R63
Q2 D8 ZD2
D17 R66 CN7 L4 C85 C25
C47
C53
D43
MOTOR
200-000102-03
R70
MOTOR
73
Chapter 12—Main Board
Chapter 12—Main Board
D0
D1
D2
D3
D4
D5
D6
D7
D8
A20 2 23 D[0..15]
PWRTM I1 I/O9 FLASH0
C1 C2 A21 3 22
BLACK I2 I/O8 FLASH1
SEE A22 4 21
I3 I/O7 FLASH2
D9
D8
R3 A23
D15
D14
D13
D12
D11
D10
A19
A18
A17
A16
A15
A14
5 I4/PD I/O6 20 FLASH3
RDDW 6 19
I5 I/O5 EXTMEM0 WRCASL
WRCASL 7 18 PORTS
I6 I/O4 WRCASH
EEPDO PDAT 8 I7 I/O3 17 RD_
R4 9 16
PCLK I8 I/O2 WR_
U2 10 15
144
143
142
141
140
139
138
137
136
135
134
133
132
131
130
129
128
127
126
125
124
123
122
121
120
119
118
117
116
115
114
113
112
111
110
109
DO I9 I/O1 DI
11 14 R154
HCTL I10 I/O0 PHDI
R5 12 13
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
GND I11 SW
U3
Vcc
Vss
Vref
AVcc
AVss
P150
P151
P152
P153
P154
P155
P156
P157
P110
P111
P112
P113
P114
P00/D0
P01/D1
P02/D2
P03/D3
P04/D4
P05/D5
P06/D6
P07/D7
P10/D8
A9
A8
A7
A6
A5
A4
NC
VCC
Vss
Vss
Vss
OE-
I/O9
I/O8
P100/AN0
P101/AN1
P102/AN2
P103/AN3
I/O15
I/O14
I/O13
I/O12
I/O11
I/O10
Y1
CASL-
R6 R7 VCC
P104/AN4/KI0
P105/AN5/KI1
P106/AN6/KI2
P107/AN7/KI3
2 1 10K 10K
Vcc
I/O0
I/O1
I/O2
I/O3
Vcc
I/O4
I/O5
I/O6
I/O7
NC
NC
WE- CASH-
RAS-
NC
NC
A0
A1
A2
A3
Vcc
RAS_
R8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
RAS1_
JP2 RDDW
C3 C4 RAS0_ WRCASL RDDW
P97/ADtrg-/RxD4/SCL4/STxD4
WRCASH WRCASL VCC
12.6 Schematics
WRCASH RAS0_
1 108 D9
EEPDI P96/ANEX1/TxD4/SD4/SRxD4 P11/D9
2 107 D10 RDDW
EEPCLK P95/ANEX0/CLK4 P12/D10
1
2
3
D0
D1
D2
D3
D4
D5
D6
D7
A10
A11
A12
PHDI 3 P94/DA1/TB4in/CTS4/RTS4/SS4 P13/D11 106 D11 CN1 A13
4 105 D 12
LCDLIGHT P93/DA0/TB3in/CTS3/RTS3/SS3 P14/D12 D13
5 104
Processor and Memory
RS P92/TB2in/TxD3/SDA3/SRxD3 P15/D13/INT3-
PDAT 6 103 D14 A[1..23]
P91/B1in/RxD3/SCL3/STxD3 P16/D14/INT4- D15
7 P90/TB0in/CLK3 P17/D15/INT5- 102
VCC PCLK VCC D[0..15]
PHLTH 8 P146 P20/A0(/D0) 101
9 100 A1 U5
HCTL P145 P21/A1(/D1)
10 99 A2 A18 1 15
SCTL P144 P22/A2(/D2) A Y0 SRAM SRAM
R9 R10 11 98 A3 A1 9 2 14
BLACK/_EN P143 P23/A3(/D3) B Y1 RTC
12 97 A4 A20 3 13 RDDW
CUT1 P142 P24/A4(D4) C Y2 POE0
CUT2 13 96 A5 12 WRCASH W R C ASL
P141 P25/A5(D5) Y3 USBCS_
14 95 A6 11
CUT_SW P140 P26/A6(D6) Y4 LCDE0
A7
A9
A9
15 94 6 10
D7
D6
D5
D4
D3
A12
A16
A14
A10
A11
A16
A14
A10
A11
A12
D15
D14
D13
D12
D11
VCC
16 CNVss Vss 93 4 G2A Y6 9 RTC_ALE
XIN 17 92 A8 5 7
P87/Xcin P30/A8(MA0)(D8) G2B Y7
XOUT 18 P86/Xcout Vcc 91
JP1 19 90
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
W
W
S2
A8
A9
S1
S2
A8
A9
S1
OE
OE
A15
A13
A11
A10
A15
A13
A11
A10
22 87
DO8
DO7
DO6
DO5
DO4
DO8
DO7
DO6
DO5
DO4
VCC
VCC
NC
A16
A14
A12
A7
A6
A5
A4
A3
A2
A1
A0
DO1
DO2
DO3
GND
NC
A16
A14
A12
A7
A6
A5
A4
A3
A2
A1
A0
DO1
DO2
DO3
GND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
30 79 A15
RIBBONOUT P77/TA3in P37/A15(MA7)(D15) A16
BUZZER 31 P76/TA3out P40/A16/(MA8) 78
32 77 A17
LEDG P75/TA2in/W- P41/A17/(MA9)
LEDR 33 P74/TA2out/W Vss 76
A18
A7
A5
A4
A2
A8
A6
A4
A3
A1
A8
A6
A3
A1
A7
A5
A2
34 75
D8
D9
D0
D1
D2
A17
A18
A15
D10
D[0..15] D[0..15]
XIN XOUT
VCC C5
FLASH0
R143
CN3 + RDDW
Y2 EMPTY
A1 WRCASL
EMPTY A2 1 2 D0
A9
A9
D7
D6
D5
D4
D3
A18
A15
A12
A15
A14
A10
A11
3 4
A14
A10
A11
A18
A12
D15
D14
D13
D12
D11
2 1 A3 D1
A4 5 6 D2 VCC VC C
A5 7 8 D3
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
C138 C139 A6 9 10 D4
A7 11 12 D5
P70/TxD2/SDA2/TA0out
P67/TxD1
Vcc
P66/RxD1
Vss
P65/CLK1
P64/CTS1-/RTS1-/CTS0-/CLKS1
P63/TxD0
P62/RxD0
P61/CLK0
P60/CTS0-/RTS0-
P137
P136
P135
P134
P57/RDY-
P56/ALE/RAS-
P55/HOLD-
P54/HLDA-/ALE
P133
Vss
P132
Vcc
P131
P130
P53/BCLK/ALE/CLKout
P52/RD-/DW-
P51/WRH-/BHE-/CASH-
P50/WRL-/WR-/CASL-
P127
P126
P125
P147/CS0-/A23
P46/CS1-/A22
P45/CS2-/A21
P44/CS3-/A20(M12)
13 14
A8
A9
A8
A9
D7
D6
D5
D4
D3
D7
D6
D5
D4
D3
CE
CE
NC
OE
NC
OE
EMPTY EMPTY
WE
WE
A8 D6
A14
A13
A11
A10
A14
A13
A11
A10
VCC
VCC
15 16 D7
RDDW 17 18
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
FLASH2 19 20 WRCASL
U8 U9
FLASH3 21 22 EXTMEM0
EEPCS
23 24
NC
A16
A15
A12
A7
A6
A5
A4
A3
A2
A1
A0
D0
D1
D2
GND
NC
A16
A15
A12
A7
A6
A5
A4
A3
A2
A1
A0
D0
D1
D2
GND
TXD1
RXD1
A23
A22
A21
A20
DTR1 VCC C6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DSR1
TXD0
RXD0 +
A7
A5
A4
A2
A8
A6
A4
A3
A1
A[1..23] CN4
A8
A6
A3
A1
A7
A5
A2
D8
D9
D0
D1
D2
A19
A16
A13
A17
A13
DSR0
A17
A19
A16
D10
A9
DTR0 A10 1 2 D8 A[1..23]
WRCASL A11 3 4 D9
REWIND 5 6
PRGRST WRCASH A12 D10 D[0..15]
R DD W A13 7 8 D11
USBTXE RAS_ A14 9 10 D12
A15 11 12 D13
POT_CS 13 14 FLASH1
A16 D14
POT_RS SELIN0 15 16 RDDW
A18 D15
POT_CK SW_ROM 17 18 WRCASL
A17
POT_DI LCDRW_ 19 20 WRCASH
A19
A9
A9
D7
D6
D5
D4
D3
TPH_ON 21 22
A18
A15
A12
A15
A14
A10
A11
A14
A10
A11
A18
A12
D15
D14
D13
D12
D11
R11 R12
U 10 U11
A8
A9
A8
A9
D7
D6
D5
D4
D3
D7
D6
D5
D4
D3
CE
CE
VCC VCC
NC
OE
NC
OE
WE
WE
VCC
A14
A13
A11
A10
A14
A13
A11
A10
VCC
VCC
VCC VCC
VCC U12A
1
Q
CL
R13 D45
CLK 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
R146 5 2
PR
SW Q D SW_ROM
D8
D9
A7
A5
A4
A2
A8
A6
A4
A3
A1
A8
A6
A3
A1
A7
A5
A2
A19
A16
A13
A17
A13
A17
A19
A16
D10
R14 D12
D0
D1
D2
VCC
EMPTY U13 A[1..23]
RESET_
2 VIN
1 U15A D[0..15]
OUT
3 GND 14 CEXT
C13 C14 C15 C16 C17 C18 C19 VCC
+ C20
C22 C23 + R1 5 U16A
C155 15
EMPTY REXT/CEXT
1
PRGRST 1 A Q 13 3 CPURST
2 B 2
3 C LR Q 4
VCC
75
Chapter 12—Main Board
Chapter 12—Main Board
Motor Driver
2 1
VDD1
D3 D2
1 2
V CC
C29
820pF\50V R32 1 16
56K MB E
2 T MA 15
3 VMM VMM 14
4 13 R33
GND GND 1K
5 GND GND 12
6 11 R34
VCC VR 0.5 1W
7 I1 C 10
C30 + 8 9 DIP
47uF\35V PHASE I0 C31
DIP U20 820pF\50V
TEA3718/3770
VDD1 DIP
VCC
CN6
MT4 D4
1 D5 VDD1 DIP 2 R35
2 1
MT3 DIP 0
3 MT2
4 1 2
5 MT1 VCC VR
6
DIP:2.5 C32
MOTOR 820pF\50V R36 1 16 R37
EMPTY 56K MB E [560]
2 T MA 15
3 VMM VMM 14
4 13 R38
GND GND 1K
5 GND GND 12
6 VCC VR 11
7 10 R39
I1 C 0.5 1W
8 PHASE I0 9
+ C34 DIP
C33 U21 820pF\50V
47uF\35V DIP TEA3718/3770
DIP
U22
[SLA7026M]
CN7 DI P R40
VCC VCC
R44
C40 C41 [56K] R45
[2200pF] R46 R47 [2200pF] EMPTY 56K
EMPTY [2.4K] [2.4K] EMPTY EMPTY
R48 EMPTY EMPTY
[0.5 2W] R49
EMPTY
DIP [0.5 2W]
DIP C43
820pF\50V
C42 EMPTY
[820pF\50V]
EMPTY
+
Printhead
VCC + C 24
15 C85
14 CN5
VCC U23 13 U 4B
12 R19 2 1
11 4 3
10 R22 6 5
Q6 9 8 7 4 3 PHSTB2
C28 VDD2 8 10 9
VHH 7 12 11
6 14 13 U4C
R29 5 16 15
4 D1 18 17
3 20 19
2 22 21 6 5 PHSTB1
1 24 23
26 25
+ EMPTY R20
R30
PCLK
C25
DI
CNA1
R74
Q7
TPH_ON 15 PHTM
U18C
R176
9
8 PHSTB1
STB1 10
PHSTB2
VCC STB2 U18D
PHSTB3
STB3
12
VCC R175 11
U18B 13
U17C U16D VCC
R163
3
4 U18A
DELAY
9 + 6 12 R17
3
14 5 11 U17A 10K
8 - 13 1 LM339 7
C27 3 +
1
6 CEXT 2 6
12
VCC -
R28 R18
R31
12
10K
7 REXT/CEXT
SCTL 9 A Q 5 VCC
10 B
RESET_ 11 CLR Q 12
U 17B R 23
3
R26
12
10K
77
Chapter 12—Main Board
78
VDD2
VCC VDD1 VCC
Power
CN27
R126
1
R127 EMPTY 2
3
R128 U17D 4
ZD1
3
11 EMPTY
+
13
Chapter 12—Main Board
POWERLO
- 10
12
R129
6 VDD1 L4
5
4
1
3
2 2 1 2 VDD2
1 3 4
CN29 LX1 L5
3
+ C117 FX1 + C118
FUSE 5A
R134 L6 L7
VCC
8 DC SC 1
7 IS SE 2
6 VCC TC 3
5 CI GND 4
D7 + C119 + C1 2 0 + C1 2 1 C124
U33 C122 C123
C125 +
R135 R136
VCC
+5V VCC VDD L10
1 2
L9
1 2 C126
L12 L8
1 2 1 2
Connectors
VCC
VCC
R180
REWINDER
BLACK MARK R72
CN17
BLACK1 R73 REWINDFUL
EMPTY
SEN_TX0 Rewindful
1
R50 2
R147 CN8
C55
BLACK
R51
SEN_TX1 1
2
BLACK 3
4
Q1
BLACK/_EN
R53 C44 VCC
R52
EMPTY COVER
R78
VCC
(not used) R84
CN20
COVER
EMPTY
COVER 1
SEE THROUGH R181
R5 K C59
2
VCC CN9
R56 R148 SEE
EMPTY R57
1
SEE 2
3
VCC
R58
EMPTY
C4 6
SPSTMP
VCC
(not used) R54
CN10
CN11 R55 SPSTMP
EMPTY
R59 RIBBONOUT
VCC
RIBBON R61
1
PWRTM 1
2
2
3 C45
VCC 4
C48
U37
5 1 OUT
VDD A END
B 2
RIBBONOUT 4 Y VSS 3
V CC
CN13
RIBBONEND
R67 VCC
R69 1 VCC
2
3 REWIND
4
C52 (not used) R150 R151 R152
JP 5
R162
EMPTY CN31
REWIND
REWIND EMPTY
Q4
1
2
VDD1 3
R153
EMPTY
CN30
(not used) D8 C47 FAN
U16B
1
D10 R63 2
Q2
FAN 4
6
5
VCC
R64
CUTTER VCC VDD1
R66
VDD1
VCC R77 CN19
DELAY HEADER 5
CUTTER
+
C50 1
D9 CN15 CUT1 2
C53 DCMOTOR CUT2 3
C5 6 C57
EMPTY EMPTY CUT_SW 4
U16C 5
1 R81
D11 R70 2
Q3 C58
DCMOT 9
8
10
EMPTY
DRIVERS
80
C67 + Ports 1
VCC CN22
U25 D0 1 2
3 4 LEDG
R85 24 1 D1
VCC MOT 5 6 LEDR
23 2 D2
SQW X1 7 8 L EDY
22 3 D3
NC X2 9 10 RS
21 4 D0 D4
RCLR AD0 11 12 WRCASL
20 5 D1 D5
VBAT AD1 13 14 LCDE0
19 6 D2 D6
IRQ AD2 15 16 LCDE1
18 7 D3 D7
RESET_ RESET AD3 17 18 FEED
RD_ 17 DS AD4 8 D4 BUZZER 19 20 PAUSE
Chapter 12—Main Board
VCC
RTC
C79 U27
FB1 VCC
1 16 C80
CN23 1 16
+
+
3 3 2 2
C81 4 15
4 15
+
5 6 C82
TXD0a 5 6
+
D[0..7]
D0
D0
D1
D1
D2
D2
D3 CN24
D3
D4
D4 TXD1 2 1 SHTD#
D5 VCC
D5 DTR1 4 3 RXD1
VCC D6
D6 DSR1 6 5
D7
D7 8 7 E_MD
R115
10 9 E_RST
R114
12 11
SERIAL
RT3
PS2CLOCK TO USB
C93 + RT4 EMPTY
PS2DATA
3
1
2
4
5 6 C136 C108 C109 C110 C111 C112 C113 C114 C115
CN26
EMPTY
10
9
8
7
6
5
4
3
2
1
10 A CK-
27
9 R9 7
PBUSY0
26
8 R98
R105 U14E
RESET_
PINT0
U19B
6 VCC U12B VCC
CEXT
10
C8 3
R106 9 12
Q D
PR
REXT/CEXT 7
CL K 11
5 Q A 9 POE0
10 8
CL
B Q
12 Q CLR 11
13
VCC VC C V CC VCC VCC VCC VCC V CC VCC VCC VCC VCC VCC VCC VCC VCC
D33 D13 D14 D15 D35 D19 D20 D21 D3 7 D38 D2 5 D26 D41 D42 D2 9 D30
EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY
Paper error Selectin PD0 PD2 BUSY+ Autolf PD1 PD3 ACK- Error P D4 PD6 st b Select PD5 PD7
D34 D16 D17 D18 D36 D2 2 D2 3 D24 D39 D40 D27 D28 D43 D44 D31 D32
EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY
81
Chapter 12—Main Board
VCC VCC
82
VCC R164
USB
L11
U40
R165 C152 C153
EMPTY
30
3
13
26
JP4
R166
1 7 25
VCC
VCC
VCC
USBDP D0 D0
AVCC
2
R167
3 8 USBDM D1 24 D1
4
Chapter 12—Main Board
D2 23 D2
6 3V3OUT D3 22 D3
C154
5
TO USB D4 21 D4
C144
27 XTIN D5 20 D5
VCC 19
D6 D6
Y3 18
D7 D7
C145
R168 28 U24A
XTOUT
2 USBCS_
VCC 16 3
RD#
1 RD_
31 RCCLK WR 15
AGND
GND
GND
R183
29
9
17
DECOUPLING CAPS
VCC
VCC
R172 VCC
VCC
U43
1 CS VCC 8
2 SK NC 7
3 DIN NC 6
C148 C149 C150 C151 4 5
DOUT GND
R173
GND
R174
Description
The memory expansion card can only be installed in EasyCoder PD4
printers with and LCD display. It provides an additional 2MB of flash
memory.
Installation
To install a memory expansion card, follow these steps:
1 Remove the left side panel (see Chapter 3.2).
The electronics compartment contains high voltages wires and circuitry.
Disconnect the power cord to eliminate the risk of electric shock and
short circuits.
Take standard precautions against ESD (Electrostatic Discharges)
before touching any electronics components.
2 Remove the screw and washer at the center of the main board and
replace it with the hexagonal spacer delivered with the expansion card.
3 Connect the expansion card to CN3 and CN4 on the main board,
making sure that the hole at the center of the card corresponds to the
threaded hole in the spacer.
If the expansion card is fitted upside down (that is, the hole is not
aligned with the spacer), the card will blow when the power is switched
on.
4 Secure the card by fitting the screw and washer you previously removed
through the hole in the expansion card and into the spacer.
5 Put back the left side panel and connect the power cord.
Signals
Pin Signal Meaning Remark
1 External +5 VDC Max. 500mA, permanently enabled
2 TXD Transmit data
3 RXD Receive data
4 Not used
5 GND Ground
6 Not used
7 CTS Clear to send
8 RTS Request to send
9 Not used
Pinout Description
Pin Function Transmitter Comment
1 /Strobe host
2-9 Data 0-7 host
10 /Acknowledge printer
11 Busy printer
12 /Paper empty printer
13 /Select printer
14-16 Not connected
17 Chassis ground
18 External +5 VDC Max 500mA, permanently enabled
19-30 Signal ground
31 Not connected
32 /ERROR printer
33 Signal ground
34-36 Not connected
When all errors have been cleared, the Error LED goes off, the beeper
emits a single beep, and the printer returns to the same mode as when the
error occurred, which is indicated in the display window.
The printer’s error-handler can manage the following errors:
Description/Display Message Action
01: Syntax error Press the Feed key
02: Object exceeds image buffer border Press the Feed key
03: Data length error Press the Feed key
04: Insufficient memory to store data Press the Feed key
05: Memory configuration error Press the Feed key
07: Out of media Load new supply of media
08: Form or image name duplicate Press the Feed key
09: Form or image not found Press the Feed key
11: Print head lifted Close the printhead
13: Label taken sensor waiting Remove label
15: Rewinder is full Remove wound-up liner
16: No form was retrieved before ‘?’ Press the Feed key
17: Out of ribbon Load new supply of ribbon
50: Does not fit in area specified Press the Feed key
51: Data length too long Press the Feed key
62: High print head temperature (WAIT) Wait for printhead to cool off
71: Default Setup retrieved (RESET) Switch power off/on or send ^@ cmd
72: Flashing not completed (RESET) Switch power off/on or send ^@ cmd
73: Download error (RESET) Switch power off/on or send ^@ cmd
81: Cutter jammed or not installed Clear media from cutter or disable cutter
When printing, page skipping occurs Check label height setting (Q command) Programmer’s Ref-
erence Manual
Check if label gap sensor is disturbed by media or dust Chapter 14.7
Weak printout Check density setting User’s Guide
Check if thermal printhead needs cleaning User’s Guide
Check printhead pressure Chapter 7.7
Check printhead dot line position Chapter 7.7
Uneven darkness across media path Check printhead balance Chapter 7.7
When using cutter, label was not cut Check if media is loaded correctly User’s Guide
straight
When using cutter, label was not cut Check if media is loaded correctly User’s Guide
successfully Check that media thickness does not exceed 250 µm (9.8
mils)
When using cutter, label could not Check if cutter is installed properly Chapter 10.1
feed or abnormal cutting occurs Check if paper feed rods are sticky. Clean if necessary
using isopropyl alcohol.
When using stripper, abnormal func- Check if stripper full sensor is working Chapter 9.1
tion occurs Check if media is loaded properly User’s Guide
14.5 No Printing
Description:
Printing is started but nothing is printed.
Possible Causes and Suggested Remedies:
• Incorrectly loaded supplies.
- Check if direct thermal media is loaded with the heat-sensitive side
facing down. If so, reload the media.
- Check if the ink-coated side of the thermal transfer ribbon faces the
media. If not, reload the ribbon.
• Wrong printer driver.
- Check that the correct printer driver is specified in the host computer.
• Wrong Media Type, Paper Type, and Option setup.
- Check that the printer is set for correct media type, paper type, and
print method, either using the Setup mode or program commands
depending on whether the printer has a display or not (see User’s
Guide).
• Bad connection between printhead and main board.
- Check that the printhead is properly inserted into the print mecha-
nism, see Chapter 7.7.
- Check that the cables running from the print mechanism to the main
board are not visibly damaged and that they are properly connected to
the main board, see Chapter 12.3.
- Try installing a replacement printhead (must have the same density!).
• Faulty main board
- Use an oscilloscope to examine the printhead signals on the main
board while trying to print for example a test label (see Chapter 12.5
“Test Points”).
• Label taken sensor active and label not removed.
- Check if the label taken sensor is folded out and enabled and if there
is a label left in the outfeed slot or the ambient light disturbs the label
taken sensor.
- In case of tickets with black marks, consider if the black marks have
sufficient blackness or if there is some kind of printing on the back of
the media that may interfere with the label gap sensor.
• Bad friction between platen roller and media.
- Check if the platen roller is slippery, worn out, or dry and hard. Clean
or replace if necessary (see Chapter 7.3).
This appendix describes how to upgrade the printer with a new firmware
version.
Requirements
To upgrade the printer’s firmware via a cable connection from a PC run-
ning MS Windows, you will need the following:
• The Intermec EasyCoder PD4 Config Tool. This is a free software
running under Microsoft Windows1. It makes it possible to download
various firmware version either directly to the printer or to a memory
cartridge. It also supports font downloading and memory partitioning.
The Config Tool supports seven languages and comes with a compre-
hensive on-line help in English.
• An upgrading file (.ufz). The Intermec EasyCoder PD4 Config Tool
comes with a collection of firmware upgrading files. New files can be
downloaded from the Intermec Web site (http://www.intermec.com)
and should be located in the subfolder “Firmware.”
• A host computer running Microsoft Windows with a parallel, USB, or
RS-232 connection to the EasyCoder PD4. (Parallel or USB connec-
tions are recommended.)
Instructions
1 Install the Intermec EasyCoder PD4 Config Tool in your PC.
2 Run the PD4Conf.exe program.
3 Set up the parameters for the firmware download. Use the on-line help
for instructions.
4 Start the Firmware download wizard and follow the instructions on the
screen.
1
/. Supported versions of MS Windows: Windows 95, Windows 98, Windows Me, Win-
dows 2000, and Windows XP.
*1-960618-00*
*1-960618-00*