510391C

Allegro
Maintenance Manual
HP PCL-4, and HP Laser Jet II are Trademarks of Hewlett Packard Corporation
CG Triumvirate is a trademark of Agfa Corporation.
CG Times, based upon Times New Roman under license from The Monotype Corporation.
plc, is a product of Agfa Corporation.
Futura is a registered trademark of Fundición Tipográfica Neufville, S.A.
Allegro, SEAQ, and PC Batch are trademarks of Datamax Barcode Products Corporation.
As an Energy Star Partner, Datamax Corporation has determined that this product meets the Energy Star guidelines for
energy efficiency.
Firmware (Software) Agreement: The enclosed Firmware (Software) resident in the EPROM’s is owned by Licensor
or its suppliers and is licensed for used only on a single printer in the user’s Trade or Business. The User agrees not to,
and not to authorize or permit any other person or party to, duplicate or copy the EPROM’s or the information
contained in the EPROM’s. The firmware (Software) is protected by applicable copyright laws and Licensor retains all
rights not expressly granted. In no event will Licensor or its suppliers be liable for any damages or loss, including direct,
incidental, economic, special, or consequential damages, arising out of the use or inability to use the Firmware
(Software).
Information in this document is subject to change without notice and does not represent a commitment on the part of
Datamax Barcode Products Corporation. No part of this manual may be reproduced or transmitted in any form or by
any means, for any purpose other than the purchaser's personal use, without the expressed written permission of
Datamax Corporation.
© Copyright 1999 by Datamax Corporation
7500 Flying Cloud Drive • Suite 655 • Eden Prairie, Minnesota 55344 • (612) 946-0026
All rights reserved. Printed in the United States of America.
Part Number: 510391

Revision: C2
Agency Compliance and Approvals:
UL: UL1950 Information Technology Equipment

CSA: C22.2 No. 950-M93
TUV: EN60950, IEC950
VDE: Class B Vfg. 243/1991
1.Nur für Gebrauch innerhalb eines Gebäudes geeignet.

2.Bei Gefahr, Kabel aus der Steckdose herausziehen
3.Falls kein Kabel mitgeliefert wurde, bitte Folgendes bei der Anschaffung eines Kabels beachten:
Für 230 Volt (Europa): Benützen Sie ein Kabel, das mit "HAR" markiert ist, bestehend mindestens aus einem H05VV-
F Kabel, das mindestens 0,75 Quadratmillimeter Drahtdurchmesser hat; sowie eine IEC320 Steckdose und einen für
das Land geeigneten Stecker, 6A, 250 Volt.
1.This unit is intended for indoor use only.

2.Disconnect power supply cord in case of emergency.
3.When power supply cord is not provided; for proper power supply cord selection please see below:
For 230 Volt Operation (Europe): Use a cord set, marked "HAR," consisting of a min H05VV-F cord which has a
minimum 0.75 square mm diameter conductors, provided with an IEC 320 receptacle and a male plug for the country of
installation rated 6A, 250V
FCC: This device complies with Part 15 of FCC rules.
Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15
of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instructions in this manual, it may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.
Important Safety Instructions
This printer has been carefully designed to give you many years of safe, reliable performance. As with all electrical
equipment, however, there are a few basic precautions you should take to avoid hurting yourself or damaging the printer:
• Carefully read the installation and operating instructions provided with your printer.
• Read and follow all warning instruction labels on the printer.
• Place the printer on a flat, firm, solid surface.
• To protect your printer from overheating, make sure all openings on the printer are not blocked.
• Do not place the printer on or near a heat source.
• Do not use your printer near water, or spill liquid into it.
• Be certain that your power source matches the rating listed on your printer. If you are unsure, check with your
dealer or with your local power company.
• Do not place the power cord where it will be walked on. If the power cord becomes damaged or frayed replace it
immediately.
• Do not insert anything into the ventilation slots or openings on the printer.
• Only qualified, trained service technicians should attempt to repair your printer.
♦ Contents
♦ Introduction and Overview

1.0 Introduction....................................................................................................................... 1
1.1 Overview............................................................................................................................. 2
1.2 Specifications ...................................................................................................................... 2
1.3 Location of Parts on the Printer ........................................................................................... 5
♦ Setting up the Printer

2.0 Set-up and Configuration.................................................................................................. 13
2.1 Printer Set-up .................................................................................................................... 13
2.2 Installing Options .............................................................................................................. 15
♦ Creating Labels Using Internal Batch Software

3.0 Introduction....................................................................................................................... 21
3.1 The Printer used with a LINK CRT ................................................................................... 22
3.2 Formatting and Printing Labels .......................................................................................... 25
3.3 Create/Modify Label Screen ............................................................................................. 30
3.4 Print Label Screen ............................................................................................................ 42
3.5 System Maintenance Screen .............................................................................................. 44
3.6 Quick Reference Listing ................................................................................................... 46
♦ Troubleshooting
4.0 Introduction....................................................................................................................... 49
4.1 Controlling print quality .................................................................................................... 50
4.2 Aligning the Printhead ....................................................................................................... 51
4.2.1 Printhead Alignment Procedure ............................................................................ 53
4.2.2 Adjusting Printhead Pressure/Support ................................................................... 55
4.3 Troubleshooting .................................................................................................................. 56
♦ Appendix A
ASCII Control Code Chart ...................................................................................................... A-1
♦ Appendix B
Switch Settings and Cable Interfacing...................................................................................... B-1
♦ Appendix C
Available Fonts and Barcodes.................................................................................................. C-1
♦ Appendix D
Cable Listings ......................................................................................................................... D-1
♦ Appendix E
Error Codes....................................................................................................................................E-1
♦ Appendix F
Specifications .................................................................................................................................F-1
♦ Appendix G
Warranty Information .................................................................................................................... G-1
ii
Introduction and Overview
1.0 Introduction
Figure 1-1 Allegro Printer
The Allegro Label Printer, hereafter referred to as the "Printer", incorporates high-performance/low
cost direct thermal and optional thermal-transfer label printing capabilities. The combination of
powerful capabilities, easy-to-use features, a contemporary look, and affordable pricing set a new
standard for direct-thermal and thermal-transfer label printers in retail, office and industrial
applications.
The Printer is factory installed with all standard bar codes and a variety of font styles and sizes
already stored in memory. The Printer is designed to work with any IBM compatible
personal computer, and may be modified to perform with Mainframe computers and other
work stations.
This manual is intended to provide the technician with all of the information needed to set-up,
adjust, and troubleshoot the Printer, and to perform any necessary maintenance. For additional
information on the day-to-day operation of the Printer, please refer to the Allegro Printer
Operations Manual.
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
1.1 Overview
The Printer can be divided into three main areas; the Media Path, the Printhead area, and the
Electronics and Power area. A description of each area is described below.
Media Path: Consists of the transport mechanism that moves print media through the
Printer, and includes the supply and take-up hubs, ribbon transport,
motors, drive belts, idler rollers and related mechanical parts.
The Printhead Area: Contains the printhead and printhead mounting assembly, printhead
adjustments, media edge sensor and latching mechanism.
Electronics and Power: Includes the main logic, front panel, options interfacing, sensor circuit
boards, and the power supply.
1.2 Specifications
Lights and Switches
Lights: Power, Paper/Ribbon, Pause
Switches: Power, Pause, Feed, Stop/Cancel, Thermal/Thermal Transfer, Baud Rate Selection
and Function Switch Bank Variable Head Temperature Control
Communications Interfacing
IEEE RS-232C +RS-422: 300, 600, 1200, 2400, 4800, or 9600 baud.
Character Set: ANSI ASCII character set
Word Length: Selectable 7-bit or 8-bit data format
Handshaking: Xon/Xoff (in receive mode only) and CTS/DTR
Input Buffer: Approximately 7000 bytes. Xoff is transmitted and DTR goes low
when 750 bytes are available in the buffer. Xon is transmitted and
DTR goes high when 750 bytes are left in the buffer. Characters are
transmitted with no parity from the Printer.
2
Electrical
Power Source: 115, 220/240 VAC, 50/60 Hz
Circuit Protection: 115 VAC: 1 amp time delay fuse; 230: 2 time delay fuses T 0.5 amp
Grounding: Unit must be connected to a properly-grounded receptacle
Environmental
Operating
Temperature: 40°F to 90°F (4°C to 32°C)
Storage
Temperature: 32°F to 120°F (0°C to 49°C)
Humidity: 10% to 95% non-condensing
Ventilation: Free air movement
Dust: Non-conducting, non-corrosive
Electromagnetic
Radiation: Moderate RF fields can be tolerated
Physical
Dimensions: 8.8"H x 16.6"W x 14.5"D (224mmH x 421mmW x 368 mmD)
Weight: 23 lbs. (10.4 kg)
3
Options
Front Rewind: 6" (152mm) maximum O.D. capacity (full supply roll)
8” (203mm) maximum O.D. capacity (full supply roll)
Cutter with Tray: Maximum thickness of 0.010" (.254mm)
Font Memory Cartridges: Pre-loaded from the manufacturer
256K Flash EEPROM

Memory Module : Used for permanent storage of custom fonts, graphics and formats.
256K and 512K RAM Used for temporary storage of fonts, formats and graphics; 512K
Memory modules: Module also extends label length to 20.25" (514mm).
Parallel Adapter: Converts Centronics Parallel type data to RS-232C
PC-Batch Software: Stand-alone label creation software package for IBM-PC or

compatible.
4
1.3 Location of Parts on the Printer
Figure 1-2 Front and Left Side View.
Figure 1-3 Front and Right Side View
5
Figure 1-4 Back view, 115 VAC model.
Figure 1-5 Back view, 230 VAC model.
6
Figure 1-6 Cover removed - Media Transport and Print Mechanism.
7
8
2.0 Set-up and Configuration
2.1 Printer Set-up

The following steps should be performed when the Printer is initially set up. Step 7 (Self-Test) should
be performed any time the Printer's switch settings have been changed.
1. Check the operating environment and power
• Ensure that the printer is placed on a firm, flat surface.
• Ensure that the work area conditions are within recommended environmental range, (See
Section 1.3)
• Ensure that the supply voltage is correct for the version of the printer (115V or 230V).
• Ensure that power is supplied from a properly-grounded outlet.
2. Determine the set-up requirements
• Determine the communications set-up (Serial or Parallel).

This selection will depend on the host computer or terminal's requirements. Most host
devices will provide a Serial interface. If the host's Parallel interface is to be used, a Parallel
Interface Converter cable (Part # 899516) will be needed.
• If Serial communication is chosen, complete the following steps:
1. Select the protocol (either RS-232c or RS-422);

2. Determine the type of cable needed, and;
3. Determine Baud Rate and Word Length.
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
Protocols: Most host devices will provide the RS-232c serial protocol. If the RS-422 protocol
is required, an optional RS-422 interface is available.
Cable Type: The following table is a list of Datamax cables available, with Part Numbers:
Part Number Description

556000 Printer to CRT Terminal (DB25P) RS-232
556001 Printer to PC 9 Pin (DB9S) RS-232
556002 Printer to PC 25 Pin (DB25S) RS-232
899516 Printer to PC Parallel Port (DB25P)
Table 2-1 Cable Types
Note: The pin connections for all of the usable cable types, as well as installation instructions for the
Centronics Parallel Interface Converter cable, are listed in the Appendix.
Handshaking: The Printer is DTE equipment and supports both CTS/DTR and XON/XOFF
handshaking. (Note - in RS-422 protocol, only XON/XOFF handshaking is used).
Baud Rate: These settings are also determined by the host device requirements. They are
selected by setting switches on DIP Switch SW1, (see Figure 1-4 for DIP Switch
locations).
The Printer can accept either 7 or 8 bit data words, and at least one Stop Bit is
required. If ASCII characters 128-255 (foreign language characters) are to be
used, the 8 Data Bit, 1 Stop Bit option must be selected.
10
3. Install the Options
If the cutter option, internal batch mode, or prodigy emulation are to be used, they must be selected
by setting the appropriate DIP switch. Section 2-2 describes in detail installing the various options.
Table 2-2 lists the correct DIP switch settings.
Fig. 2-1. Printer rear view - Connector and Switch locations
11
4. Set the Switches
DIP Switch SW-1, located on the back of the Printer, is used to select the baud rate, word length,
prodigy printer emulation, and to enable the Cutter and Internal Batch options.
Baud Rate
Baud 9600 4800 2400 1200 600 300 Test
SW-1 OFF OFF OFF OFF ON ON ON
SW-2 OFF OFF ON ON OFF OFF ON
SW-3 OFF ON OFF ON OFF ON ON
Word Length
SW-4 Data Bits Parity Stop Bits
ON 7 NONE 2
OFF 8 NONE 1
Printer Options
SW-5 SW-6 SW-7 SW-8
FUNCTIO Compatibili Not used Batch Cutter
N ty
ON Prodigy N/A Enabled Enable
d
OFF Allegro N/A Disabled Disabl
ed
Table 2-2 DIP Switch settings
Step 5 Plug in the Printer

Plug the Printer's power cord into the receptacle on the back of the Printer. Connect the power cord to
the proper supply voltage. The Printer requires either a 115V or 230V grounded receptacle.
Step 6 Load Media and Ribbon

See Section 3.2.2, Media, for detailed loading instructions.
Step 7 Perform a Self Test

Section 4.1 describes the Self Test.
12
2.2 Installing Options
2.2.1 The Cutter Option

The Cutter may be installed and removed by the Operator. The Cutter option is shipped with complete
installation instructions. Section 3.3.3 describes the Cutter Option in greater detail.
2.2.2 Memory Modules

Three different types of Memory Module are available, FLASH, RAM and FONT. FLASH and RAM
modules are used for storing font, label format or graphic image data in the printer. Data contained in these
modules may be re-written or erased. FONT modules are pre-programmed Read Only Memory - the data
contained in the module cannot be re-written. The Printer's internal 48K of RAM memory is called Memory
Bank A. When modules are installed, they are addressed as Memory Bank B.
Table 2-3 lists the available modules and their Part Numbers.
Name Part Number

256K FLASH EEPROM 899506
256K RAM 899517
512K RAM 899505
CG Triumvirate Italic 899510
CG Triumvirate Bold 899511
CG Times 899512
CG Times Bold 899513
Futura Extra Bold Condensed 899514
Plantin 899515
Table 2-3 Font Modules
NOTE - Install all modules label forward, as shown in Figure 1-2.
13
2.2.2.1 RAM Modules
RAM Modules are available in both 256K and 512K capacity. Both size modules will add 256K of memory
space for storing soft font, graphics, and label format data storage. The 512K RAM module also provides an
additional 256K for the label format buffer, which increases the maximum label length from 8.25 in. to 20 in.
RAM memory is volatile, that is, it requires power in order to retain data. When the Printer is turned off, all
data stored in RAM will be lost.
2.2.2.2 FLASH Modules
The 256K FLASH module provides the same storage function as the 256K RAM module, with the added
advantage that the FLASH module is non-volatile, that is, data will be held until erased or overwritten, even
without power.
NOTE - When using the Internal Batch program, a 256K FLASH module is required.
2.2.2.3 FONT Modules
Six 512K FONT modules are available. They are listed, along with other module types, in Table 2-3.
14
2.2.2.4 Main Logic Board Connectors and Test Points
The following is a list of the connector sockets on the Printer Main PC Board.
Fig. 2-2 shows the location of these connectors (J1 - J9) and of Test Points TP1 - TP3
Items indicated in Fig. 2-2.
J1 - Options Board Connector - Connects the Options P.C. Board to the Main Logic Board
J2 - Front Panel Connector - Connects the Front Panel P.C. Board to the Main Logic Board.
J3 - Power Connector - Supplies power from the Power Supply to the Main Logic Board.
J4 - Serial Port - Capable of either RS-232 or RS-422 communications protocols.
J5 - Label Sensor - Provides connection for the Label (Media Edge) Sensor.
J6 - Ribbon Sensor - Provides connection for the Ribbon Sensor
J7 - Printhead - Provides connection for power and control signals for the Printhead.
J8 - Memory Module I/O - Provides connection for data signals to and from the external memory
modules.
J9 - Motor - Provides connection for power and control signals to the Printer's Line Feed Stepper Motor.
Test Points TP1-TP3 may be monitored for specific voltages during test procedures.
15
Fig. 2-2 Main Logic Board Connectors and Test Points
16
Fig. 2-3 Front Panel P.C. Board
17
18
3. Basic Operations
♦ The Control Panel
♦ Loading Media
♦ Changing Ribbons
♦ Maintenance
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
20
3.0 Basic Operations
This section briefly reviews the basic operation of the Printer, including the use of the Control Panel
and buttons, loading label stock, installing ribbons and using the Printer’s self test function.
3.1 Front Panel Controls
Fig. 3-1. Control Buttons, LEDs and LCD.
3.1.1 Push Button Controls
• Pause The Pause button allows a print job to be interrupted and then re-started. Pushing the
switch causes the Printer to (1) stop printing upon completion of the current label, (2) turn
on the Pause indicator, and (3) stop the label counter while holding the count balance. All
data is retained in memory.
Pressing Pause a second time will (1) turn off the Pause indicator, and (2) re-start the
Printer and cause it to continue with the current print job.
21
• Feed The Feed button allows the operator to control the feeding of labels through the
Printer. The button works in different ways, depending on whether the Printer is
currently On Line or on Pause.
When on Pause, pressing Feed will immediately feed one label.
When On Line, the Printer will first finish printing the current job, and then feed one
label.
• Stop/Cancel Pushing the Stop/Cancel button cancels the current print job. If another print job has
been sent to the Printer, it will begin to print the next job. If there is no other job, the
Printer stops.
3.1.2 LED Status Lights
Located above the Control Buttons are LEDs that provide information on machine status. The LED’s
are labeled On Line/Pause, Ribbon/Media, and Power.
• On Line/Pause The LED is on when the Printer is Paused, and off when the Printer is On Line.
• Paper/Ribbon This LED is normally off. It comes on only to indicate a fault in the Media or Ribbon
path.
• Power This LED comes on when the Printer is powered up, and stays on as long as the
Printer is receiving power.
3.1.3 Other Controls
• Darkness Adjusts the darkness or lightness of the print image.
• Transfer Switch Sets the Printer for either Thermal Transfer or Direct Thermal media.
Must be in the ON position when printing with a ribbon installed.
22
3.2 Media and Ribbons

The following section describes print modes, how to load the stock, the stock sizes that can be used,
and how to install and remove ribbons.
3.2.1 Print Modes
The Printer can use either of two printing methods, called Direct Thermal and Thermal Transfer.
Both methods use heat to produce the printed image - they differ in the way in which the heat is
applied.
In Thermal Transfer printing, the individual dot elements of the Printhead apply heat to a ribbon. The
“ink” on the ribbon is a specially formulated material that is literally melted into the print media,
bonding with it to produce the black dots that form an image.
Direct Thermal printing dispenses with a ribbon and instead applies heat directly to the print media.
This media is formulated to react to the heat by turning black. Direct Thermal printing requires the use
of a special Direct Thermal print media. It also requires that if a ribbon is already installed it must be
removed.
NOTE - When Printing with the Thermal Transfer method, the Transfer Switch must be set to ON (See
Figure 3-1 for Transfer Switch Location). For Direct Thermal, the switch must be set to OFF.
NOTE - Using Direct Thermal print media while a ribbon is installed will produce unacceptably poor
print quality.
23
3.2.2 Media
The Printer is designed to make loading media and ribbons a simple task. The following section
describes in detail how to load stock and ribbons.
3.2.2.1 Loading Roll Fed Stock (Fig. 3-2)
¶ Turn the Head Lift Lever clockwise to the UP position.
· Slide the Media Retainer to the outer edge of the Supply Roll Bracket and swing the Media Guide
out and to the DOWN position.
¸ Place media supply roll on the Supply Roll Bracket.
¹ Swing the Media Retainer back to the UP position and slide it in until just touching the supply
roll.
º Route the media between the Guide Plates and Sensor, and over the Platen Roller.
» Turn the Head Lift Lever counter-clockwise to the DOWN position. Flip the Media Guide UP and
slide it in until it just touches the media edge.
¼ Press the FEED button. Note - It may be necessary to feed a few labels before they align
themselves correctly.
RIBBON RIBBON MEDIA
TAKE-UP SUPPLY SUPPLY MEDIA
HUB HUB ROLL RETAINER
DARKER
ON
RIBBON
OFF
HEAD
LIFT
UP
LEVER
DOWN
MEDIA
OUT
PATH
OPTIONS SENSOR MEDIA MEDIA MEDIA MEDIA

PORT (J2) ADJUST SENSOR GUIDE GUIDE SUPPLY
KNOB PLATES MOUNT
Fig. 3-2. Stock and Ribbon Loading Diagram
24
3.2.2.2 Stock Errors
When the stock is correctly loaded, the Media Sensor will detect the leading edge of each label as it
passes through the Printer. If the Printer advances stock more than 12 in. (305 mm.) without detecting
a label edge, an error condition will be triggered - the Printer will stop and the PAPER OUT light
will go ON. If this happens, first, be sure that the stock is routed as shown in Fig. 3-2. If the stock is
routed correct, adjust the Media Sensor by turning the Edge Sensor Adjust Knob (See Fig. 1-6)
clockwise one half-turn at a time until the error condition clears. If the adjustment fails to correct the
problem, refer to Section 4, "Troubleshooting".
If the stock feeds only a short distance and does not seem to stop on a label edge when the FEED
button is pressed, the THERMAL TRANSFER switch may be set to the ON position without a
ribbon installed. For Direct Thermal printing (no ribbon), the Transfer switch must in the OFF
position.
3.2.2.3 Stock Sizes
The Printer accepts a wide range of media sizes. It can be loaded with Roll Fed media of either
Thermal Transfer or Direct Thermal type. The table below lists the range of acceptable sizes
Minimum Maximum
Width .75 in. (19mm) 4.65 in. (118mm)
Maximum Recommended Width 4.25 in. (108mm)
Thickness .0025in (.0535mm) .01 in. (254mm)
Table 3-1 Range of usable stock sizes.
25
3.2.2.4 Ribbon Installation
When using thermal transfer stock, a ribbon must be installed and the Thermal Transfer switch (Fig.
3-1) must be turned ON.
To Load Ribbon (See Fig. 3-2)
¶ Raise the Head Lift Lever clockwise to the UP position.
· Slide the ribbon roll onto the Supply Hub.
¸ Route the ribbon as shown in Fig. 3-2.
¹ Place the ribbon over the hub and slide the Ribbon Clasp onto the hub and ribbon.
º Wrap a few turns of ribbon (counter-clockwise) around the hub.
» Turn the Head Lift Lever counter-clockwise to the DOWN position.
Note: It may be necessary to feed a few labels before the ribbon aligns itself correctly.
To Remove Ribbon
Ribbon may be removed completely from the Printer, if desired. However, the procedure in Sec.
3.2.2.5 is also acceptable, and is generally more convenient.
To completely remove the ribbon:
¶ Raise the Head Lift Lever clockwise to the UP position.
· Remove the Ribbon Clasp, and unwind the end of the ribbon from the Supply Hub.
¸ Carefully pull the free end of the Ribbon back through the media path.
¹ Slide the ribbon roll off of the Supply Hub.
º Turn the Head Lift Lever counter-clockwise to the DOWN position
26
3.2.2.5 Ribbon Removal - Alternate Method
When switching between Thermal Transfer and Direct Thermal media for different printing jobs, it is
not necessary to remove the ribbon completely. The ribbon may be removed from the Media Path,
without removing it from the Printer completely, in the following manner:
¶ Cut or tear the ribbon at a point near the Ribbon Take-up Hub.
· Turn the Head Lift Lever clockwise, to the UP position. It is not necessary to remove the
unused portion of the ribbon. Turn the Ribbon Shaft Supply Hub clockwise to draw the
unused portion of the ribbon back until it is clear of the Printhead.
¸ Turn the Ribbon Shaft Take-up Hub counter-clockwise to roll up the used portion of the
ribbon
¹ Remove the Ribbon Clasp, slide the used ribbon off the Hub and dispose of it.
º Turn the Head Lift Lever counter-clockwise to the DOWN position to lock the Printhead
The unused portion of the ribbon may be left in place until the next Thermal Transfer print job, at
which time it may be re-installed following the ribbon installation procedure
3.2.2.6 Self Test
Once the label stock (and ribbon, in thermal transfer mode) have been loaded, the next step is to
perform a Self Test. See Sec. 4, "Troubleshooting", for instructions on the Self Test.
NOTE - When performing the Self Test, for best results use labels 2.5 in. x 4.25 in. (64 x 108 mm.) or
larger.
27
3.3 Using Printer Options
3.3.1 Memory Modules

The Printer uses external memory modules to expand its own 48K RAM internal memory space. The
internal RAM is called Memory bank A. The external module is called Memory Bank B.
Memory modules are used for storing; (1) graphic images, (2) bitmaps of smooth fonts, (3) label
formats for recall by host computers, and (4) Internal Batch program formats.
Memory modules are inserted into the slot located on the upper left side of the Printer (See Figure 3-3).
Place the module cartridge with the label facing the front of the printer, and slide the cartridge into the
slot until it seats itself.
Fig. 3-3. Memory Module Installation
28
3.3.2 Memory Module Types

There are three types of External Memory Module, ROM, RAM, and FLASH.
3.3.2.1 Font ROM
The Printer has a built-in set of fonts. Additional font styles are available, stored on Font ROM
modules. The modules are programmed at the factory and cannot be used for any other purpose. The
documentation included with each module explains the font style, size range, and the font number for
each size.
3.3.2.2 256K and 512K SRAM Modules
When creating labels, label size is directly related to memory space. Creating larger or longer labels
uses more memory. SRAM modules are a simple way of plugging in more memory, making it possible
to print longer labels. Modules are available in two versions, 256K and 512K. The 256K SRAM
module provides storage space that can be used for fonts, graphic images or label formats. Like the
256K version, the 512K SRAM module sets aside 256K for data storage space. The remaining 256K
is used by the printer to extend its bit-mapped label area from 8.25 in. (210mm) to 20.25 in. (514mm).
When a module is added, the Printer recognizes the module as (external) Memory Bank B and uses it in
addition to its own 48K of built-in memory (Bank A). Data can be stored in the popular HP PCL-4
format (used by the HP LaserJet printer), as well as .PCX, .IMG, and .BMP formats.
RAM modules cannot be selectively erased. In order to remove a part of the data, the entire module
must be erased and the desired data re-loaded. In addition, RAM is "volatile", that is, it requires power
to operate. Turning the printer off, or removing the module, causes immediate loss of the data. (Note -
some popular Bar Code label programs require the use of volatile RAM).
3.3.2.3 256K FLASH Module
FLASH modules provide the same features as RAM modules, with the added benefit of virtually
permanent storage. Unlike the RAM module, FLASH memory does not require power in order to
retain data. In addition, the module contains a WRITE PROTECT switch to prevent data stored on
the cartridge from being overwritten or erased.
29
3.3.3 Cutter Description
This option consists of a Cutter mechanism and a tray. The Cutter mechanism shears off labels from
continuous rolls, under the control of the Printer. The cut labels are collected in the tray. The Printer
may be ordered with the option factory installed, or it may be ordered and installed later by the user.
When ordered separately, the option comes with complete installation instructions.
CAUTION: If attaching or removing the Cutter option, turn the printer OFF for 2 minutes or longer
before proceeding.
3.3.4 Installing the Cutter (Fig. 3-4)
¶ Turn the Printer OFF and unplug the power cord.
· Turn the Head Lift Lever clockwise to the UP position.
¸ Remove the Cover Plate (or Tear-Off Bar, if installed) in the following way:
(a.) Lift the Cover Plate or Tear-Off Bar until it releases, and
(b.) Pull it straight out and away from the printer. Store the Plate or Tear-Off
Bar for future use.
¹ Slide label stock through Cutter (from back to front) until the stock extends a few inches beyond the
mechanism.
º Line up the mounting pins on the back of the Cutter with the installation slots on the Printer (Located
just below the drive roller). Slide the pins straight into the slots and push down until the Cutter snaps
into place. Make sure that the stock is free to flow through the Cutter mechanism.
» Plug the Cutter's power cable into the Options Connection (J2) located on the right side of the
Printer, below the Label Edge Sensor Adjustment Knob (See Fig. 3-4).
30
¼ Turn the Head Lift Lever counter-clockwise to the DOWN position.
½ Locate DIP Switch SW1 (See Figure 2-1 for switch location). Turn the switch in position 8 to the
ON position to enable the options port (J2).
¾ Turn the printer ON. The cutter should complete one cutting cycle when the Printer goes on. Test the
cutter by pressing the FEED button. The Printer should feed and cut one label
Fig. 3-4. Cutter Installation
31
3.4 General Maintenance
3.4.1 Cleaning the Printer - Interior and Exterior

• Interior During normal operation, dust, dirt and debris from label stock can build up inside the Printer.
Clean any debris away regularly using a soft bristle brush or a vacuum cleaner.
• Exterior The exterior surfaces may be cleaned as needed, using a general purpose cleaner and a damp (not
wet) soft cloth or sponge. Do not use abrasive cleansers or solvents.
3.4.2 Cleaning the Printhead

Occasionally foreign particles may collect on the Printhead. This can cause characters or bar codes to appear
light or faded, or, labels may show spots, spaces, or a continuous light streak in the same physical position on
each printed line.
NOTE: This condition will be encountered more often if poor quality paper has been used. To minimize the
chance of this happening, always use good quality stock. Your local printer supplier can provide a
list of approved stock types.
3.4.2.1 Recommended cleaning intervals:
The Printhead must be cleaned as needed. If spots, streaks, or drop-outs appear on printed labels, the first
step in improving print quality should be to clean the Printhead.
In Thermal Transfer printing, the ribbon will help to keep the Printhead clean, so, remember that if Direct
Thermal is the main printing mode in use, the Printhead will require cleaning more often.
Two cleaning methods are outlined below. The quick cleaning method is convenient, since it does not require
that the Printhead be removed. However, this method may not remove heavy buildups of debris. In these cases,
the Thorough Cleaning method should be used.
32
3.4.2.2 Quick Cleaning
¶ Turn power OFF and unplug the Printer.
· Raise the Printer cover and turn the Head Lift Lever to the UP position.
¸ Moisten a cotton swab with isopropyl alcohol solution. Do not saturate.
¹ Insert the swab into the Printhead area as shown in Fig. 3-5. Gently rub the underside of the
Printhead with the moistened swab.
Fig. 3-5. Quick Printhead Cleaning
33
3.4.2.3 Thorough Cleaning
¶ Remove the Printhead from the printer. (See Section 6.3.1, Printhead Replacement and
Adjustment, steps 1-7.)
· Lay the Printhead on a flat surface with the aluminum heat-sink side facing down.
¸ Dampen (do not soak) a soft clean cloth with Isopropyl (Rubbing) alcohol solution, and rub the
Printhead gently until the dirt is removed from the surface of the Printhead.
CAUTION - The edges of the Printhead are sharp. Avoid touching them. Also, do not touch the print
surface of the Printhead with any sharp object.
¹ Allow the Printhead to dry for 2-3 minutes.
º Reinstall the Printhead into the printer. (See Sec. 6.3.2, Printhead Replacement and Adjustment,
steps 8-10.)
Fig. 3-6. Thorough Printhead cleaning.
34
3.5 Cleaning the Drive Roller
Print quality may also be adversely affected if the drive roller becomes contaminated with grit, label adhesive
or ink.
To clean the roller:
¶ Remove the tear-off plate (Sec. 6.2.1).
· Turn the Head Lift Lever to raise the Printhead to the UP position.
¸ Dampen a soft, clean cloth with Isopropyl (Rubbing) alcohol and wipe off any accumulated debris
from the Drive Roller.
NOTE - For very bad soiling, acetone may be used to remove severe contamination build-ups.
3.6 Lubrication
All bearings in the Printer are either permanently lubricated or made of materials that do not require
lubrication. The Slip Clutches are pre-lubricated, and therefore, under normal circumstances they need no
lubrication. However, if the Ribbon Supply Slip Clutch begins to squeak or hum, it may be lubricated as
follows:
3.6.1 Ribbon Supply Clutch Lubrication
To lubricate:
¶ Remove the Printer cover to expose the electronics compartment. (Sec. 6.1)
· Using needle-nosed pliers, or a similar tool, unhook one end of the Clutch Spring from the Shaft Support
Bracket (Fig. 3-7).
¸ Apply small amount of IBM #23 grease into groove on the Slip Clutch pulley.
¹ Re-attach the Clutch Spring.
º Replace the Printer Cover.
35
Fig. 3-7 Lubrication Point for Slip Clutch
36
4. Troubleshooting
• Self Test
• Configuration and Test Labels
• Increasing Processing Speed
• Troubleshooting Procedures
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
38
4.0 Overview
This chapter discusses a number of topics related to troubleshooting the Printer. It covers the
generation and use of the pre-programmed Configuration and Test Labels, the Printer's Power On Self
Test, Error Messages and their causes, and some techniques for isolating and correcting faults.
When faults are isolated to the Main Logic or Operator’s Panel P.C. boards, it is recommended that the
entire P.C. board be replaced. Only insertion and removal instructions for socketed components, (i.e;
RAM, EPROM, etc.) and jumper settings are provided in this manual. It is not generally feasible to
provide component level service in the field.
4.1 About the Self Test
To begin the Self-Test:
¶ If the Printer is ON, turn the power OFF.
· Press the FEED button, and, while holding the button down, turn the power ON.
The printer will power up in the Self Test mode. It will feed one blank label and then print two Test
Labels. The first label is the Configuration Test Label, which contains a listing of the Printer's
current set-up and status. The second label is the Dot Pattern Test Label, which is an array of printed
dots that is very useful when testing for possible Printhead faults.
4.1.1 Character Dump Mode
When the self test is complete, the printer shifts to the Character Dump mode. In its normal mode,
some of the data sent to the Printer would represent the characters to be printed, while other data would
be format commands and other control codes. In Character Dump mode, the Printer will print the
numerical data sent from the host as though they were all ASCII characters. This mode is useful
when testing serial transmissions from the host device to the printer.
39
4.1.2 Testing with Continuous Media

Continuous media presents a special problem when performing the Self -Test. Each time the Printer is
turned on, all set-up options revert to the default settings. One of the settings that is changed is the
Label Edge Sensor. If the label stock in use is of the Continuous type, the Label Edge Sensor will not
detect any label edges, which will trigger an error condition.
To avoid this problem, a special software command was written which starts the Self-Test without
allowing the Printer to re-set the defaults. The command STX Z will print the Self Test information
and STX P will change to Character Dump Mode.
A sample program which will send these software commands is listed in the Appendix. Complete
information on sending software commands may be found in the Programmer's Manual for Allegro,
Prodigy, and Prodigy Plus (Part No. 88-2054-01).
4.1.3 Loopback Plug Tests
The operation of the Serial Ports (RS-232c or RS-422) can be checked by plugging a Loopback Test
Plug into the Serial Port and performing the TXD/RXD and CTS/RTS loop check tests. The Loop
Checks will automatically be performed as a part of the Self-Test, so long as the Test Plug has been
plugged in before the tests are started.
If a Test Plug is not available, one can be made by following the connection pattern shown in Appendix
Sec. A-1.
If the Loopback Tests were successful, the test results will be printed on lines 7 and 8 of the Test
Label.
If the tests are not successful, lines 7 and 8 of the Test Label will be blank.
If the Printer passes one test and fails the other, the result of the successful test will be printed in the
appropriate line.
40
4.1.4 Test Label
Figure 4-1, below, is an example of the Self Test Label. The remainder of this section describes the
items on the label in detail.
TUE JANUARY 25, 1994 Ø9:29 Ø25

VER: CAØ1 - Ø1.Ø1 12/25/93
SYSTEM ROM CHECKSUM: A882 IS GOOD

SYSTEM RAM CHECKS GOOD
SERIAL PORT BAUD IS 9600
SERIAL LOOP BACK CHECK IS GOOD
CTS & DTR LOOP BACK CHECK IS GOOD
TRANSFER SWITCH IS OFF

SETUP SWITCH 1 2 3 4 5 6 7 8
OFF OFF OFF OFF OFF OFF OFF OFF
ANALOG INPUT VALUES:

PAPER :229 EDGE: 173 VOLT : 195
TEMP :062 POT :133
ROM MODULE CHECKSUM: OCA3 IS GOOD
Fig. 4-1. Configuration Self-Test Label
4.1.5 Configuration Test Label Information.
Entries from the label itself are listed in bold print.
Line# Sample Contents and Explanation
1. MON AUGUST 31, 1992 11:33 244

Date and time information from the TOD chip on the Printer's Main Logic Board. The last three
digits are the Julian date, which is the total number of days that have elapsed since January 1 of
the current year.
2. VER: CA – 01.01 08/31/92

The version and release date of the firmware installed in the Printer. As the Printer's firmware
evolves, new versions are published and installed in new Printers. The firmware version number is
useful if factory technical support is needed.
41
3. Blank Line - not used.
4. SYSTEM ROM CHECKSUM: A882 IS GOOD

Checksum is a method used to test the validity of data stored in the printer's ROM memory. The
test result should be GOOD. If the data in the ROM has been damaged, the checksum will say
BAD, indicating that the system EPROM has been corrupted and should be replaced.
5. SYSTEM RAM CHECKS GOOD

RAM memory is tested in a way similar to the ROM checksum. The test result must say GOOD. A
defect with the printer’s internal RAM will cause the test result to say BAD, indicating a problem
on the Main Logic Board, usually with the installed RAM.
6. SERIAL PORT BAUD RATE IS 9600

The baud rate (Serial data transmission rate) is selectable, using the DIP switches located on the
back of the printer. The default rate is 9600 baud. The actual current setting is printed on the Test
Label.
7. SERIAL LOOP BACK CHECK IS GOOD

This is the result of the test of the Printer's TX and RX communication line. This is the only line
needed for the XON/XOFF communications protocol.
8. CTS & DTR LOOP BACK CHECK IS GOOD

This is the result of the test of the Printer's hardware handshaking signals. These lines must operate
properly for hardware handshaking to work.
NOTE - Lines 7 and 8 will be printed only if the Test Plug is installed and the Serial
communications are operating correctly. If the test plug is installed and this line still
does not appear on the test label, a hardware problem with the printer’s
communications system should be suspected.
42
9. Blank Line - not used
10. TRANSFER SWITCH IS OFF

Lists the current position of the Thermal Transfer switch, either ON or OFF. With the switch set to
ON, the Printer is set for Thermal Transfer media, the Ribbon Sensor is enabled, and the Printhead
temperature is reset to a lower value.
11. DIP SWITCH 1 2 3 4 5 6 7 8
12. OFF OFF OFF OFF OFF OFF OFF OFF
Lines 11 and 12 of the Test Label indicate the positions of the switches of DIP switch SW1. These
switches should be correctly set during the Printer's initial configuration. The meanings of the switch
settings are discussed in Sec. 2.1.
14. ANALOG INPUT VALUES:
15. PAPER: 229 EDGE: 173 VOLT: 195
16. TEMP: 062 POT : 133
LINES 14 - 16 of the Test Label are values which correspond to the voltages that were detected in the
Analog to Digital converter circuits on the Printer's Main Logic Board. The voltages will normally vary
slightly from printer to printer and from label to label. The information is usually most useful during
in-shop technical support, but may also be useful when troubleshooting in the field.
Values may range from 0 to 255, where 000 = 0.0 V, 1.00 = 19.6 mV, and 255 = 5.0 V.
PAPER: 229
EDGE: 173
The PAPER and EDGE values are voltages measured in the Media Edge and Reflective Sensors.
Potentiometer RP2 controls this value. The PAPER value represents the voltage detected when paper is
present in the sensor. The EDGE value represents the voltage detected when only media backing is
present at the sensor. The PAPER value should always be larger than the EDGE, usually about 120%
greater.
43
TEMP: 062
The TEMP value is the voltage detected at the Printhead Thermistor. During power up or idle at
room temperature, this value should be between 060 and 065. Normal printing will produce readings
ranging from 070 to 120. Consistent readings above 130 indicate voltages that could decrease the life
of the Printhead.
POT: 133
POT is the voltage setting of the Darkness Potentiometer on the front panel board. It will vary from
000 (darkest) to 255 (lightest). Generally, this value should be set to a midrange of 128.
VOLT: 195
VOLT is a voltage reading is meant expressly for engineering and production use at the factory. It
should be somewhere near 190.
18. ROM MODULE CHECKSUM: OCA3 IS GOOD
This is a test of the data in the Font Cartridge. The test will be performed if a font module is installed
in slot B. Each module has a different checksum value. Table 2-1 lists the proper checksums for each
type of module.
Checksum Module
0CA3 CG Triumvirate Italic
41E5 CG Triumvirate Bold
8B5A CG Times
F146 CG Times Bold
62E9 Plantin
F0E9 Futura Extra Bold Condensed
Table 4-1. Module Checksums
44
4.1.6 Self-Test Dot Pattern Label
The second label printed is the Dot Pattern Label. This is an element and electronic matrix test which
checks all of the Printhead’s electronic circuitry. If there is a hardware problem, such as a burned out
Printhead element, the defect will show up on the test label (shown below). This label will print the
entire width of the Printhead. If there are areas of missing print, including streaks or spots, refer to Sec.
4.4.3, Troubleshooting, "Problem Isolation Checklist - Print Quality".
Fig. 4-2.
Dot Test Label
4.1.7 Using the Character Dump Mode
Once the Dot Pattern Test Label has been printed, the Printer will set itself to Character Dump Mode.
This means that all data sent from the host device will be printed as a continuous string of data. Any
numeric value that equals an ASCII character will be printed as that character (Any ASCII values less
than 20 are interpreted as control characters).
The Printer will begin to print the data in its buffer as soon as a full line of information has been
received from the host, or whenever the data stream from the host has been paused for more than 0.25
second.
45
4.1.8 Using a Character Dump Label
Character Dump mode is used mainly to detect problems in the data flow from the host to the Printer.
The simplest way to check the data flow is to repeatedly send label data (such as the example shown in
Fig. 4-3) to the Printer. The test will uncover such errors as data corrupted by a defective cable, Serial
Port malfunctions, or overflow of the Printer's buffer (which is characterized by large gaps in the
printed text). A sample Test Label program is included in Appendix Section A2.1.
MONITORED MODE ENABLED CONTROL CHARACTERS

PRECEDED BY A ^ .
^Bs^M^BO0000^M^BM3000^MBL^M:0001^MC0000^MH
10^MD11^MR0000^M^01^M1Y1100000050000MAN3^M
191100700850097PACKING^M191100700450097LIS
T^M191100700050097ENCLOSED^MQ0005^ME^M
Fig. 4-3. ASCII Character Dump Label
NOTE - When the self test is complete, to reset the printer, turn the power OFF, wait approximately two
seconds, and turn power back ON. This is the only method that will return the printer to normal
operation.
46
4.2 Improving Printer Performance
4.2.1 Decreasing Processing Time and Increasing Throughput:

An important question with any machine is, how quickly and efficiently can it perform it's task? Before
looking at ways to decrease the Printer's processing time and increase the speed of its throughput, it
may help to understand what happens during the Printer's processing phase.
The label formatting process requires time to read the label field data and to move it into the Printer's
bit-mapped buffers. Before the Printer can begin to print the label it must process and map 203 Kbytes
of data. This can take from virtually no time at all to several seconds, depending on the complexity of
the label format and the size of the area that will be printed on.
When the processing and mapping process is complete, the printer will begin to print as many labels as
were requested by the software's Quantity command. Generally there is no delay between the printing
of each label. However, the following situations will tend to add time between each label.
• Printing different data on each label. A batch of different labels are being sent to the printer in
a continuous string of data. The Printer must process and map between each label.
• Placing an incrementing field in the label format. An Incrementing field is one in which the
value of the field changes by a set amount between each label. These fields are embedded in the
label format and will continue to change the label format until the end of the batch has been
reached.
• Including a time and date field in the label format. If the time and date are to be printed on the
label, the field must be updated for every label printed in the batch.
• Using external module fonts. Time is added because the Printer must refer to the external
module in addition to the normal processing time.
• Printing in rotations other than 1. Rotation adds a step to the normal processing cycle.
• Using the Cutter option. The printer must stop and wait for the cutter to execute the cutting
cycle.
47
4.2.2 Preventing Data Loss:
Data loss and other communication problems can have many sources. This section presents some ideas
on ways to isolate these problems and determine their cause.
The Printer is a Serial ASCII device, that is, the host system must be able to interface to other
equipment in ASCII format, using a serial communication I/O port. The Printer uses both hardware
and software handshaking and sends both forms of handshaking simultaneously whenever the printer's
input buffer is full. Handshaking is the practice of using a standard set of control signals, either
software codes or signals sent by wire, to reduce the occurrence of lost data. Loss of data will cause
printing errors.
The Printer's hardware handshaking is the logic state on pin 20 of connector J4, the RS-232/422
communications port located at the back of the printer (See Figure 1-4 for location). This signal will be
High when the printer is ready to receive data. The signal will be Low when the Printer's input buffer
is full. In this state, the printer is busy and can no longer receive data.
The Printer uses the software handshaking standard called XON/XOFF. In this system, when the
Printer's input buffer is full, an XOFF (CHR$19) character is sent, which tells the host system that
the printer is full and cannot receive any more data. When the input buffer has memory space
available, the printer will send an XON (CHR$17) character. This tells the host device that the printer
is ready to receive more data.
If the printer seems to have communication problems, check the following first:
¶ Verify that the correct interface cable is installed between the host device and the Printer.
The wrong kind of cable will make it impossible for the Printer to communicate correctly.
· Verify that the DIP Switch positions (Switch S1, located on the back of the printer) are set
correctly for the current application.
Printing the Configuration Test Labels, using the Character Dump Mode, and performing the
Loopback Tests will help identify the type of printer set-up errors that can generate
problems.
48
4.3 Printer Cabling and Interfacing
When the printer receives data from any host system, it will not function properly with an incorrectly
wired cable. Proper wiring diagrams can be found in the Appendix. Table 4-2, below, lists the signal
lines that must be correctly wired for the printer to operate properly.
Signal Pin
TX 2
RX 3
BU 20
SY
Gro 7
und
Jum 4 to
per 5
Shie 1
ld
Table 4-2. I/O Port Wiring
Each time the Printer is powered up, it will reset itself to default (pre-determined) interfacing
parameters. The default values are in listed in Table 4-3.
Parameter Default Value

Baud 9600
Rate
Data Bits 8
Parity NONE
Stop Bits 1
Table 4-3. Printer Default Communication Parameters
Changing the positions on DIP Switch SW1 (on the back of the Printer) sets the unit for applications
needing settings other than the defaults. Table 2-2 lists all of the switch positions and their meanings.
49
4.4 Troubleshooting
Should the Printer malfunction and require service, the following procedures should be used to isolate
and correct the malfunction.
4.4.1 Initial Steps
WARNING - ALWAYS UNPLUG the unit before attempting to replace any parts. ALWAYS be
sure that the Printer has been placed on a level, stable surface.
Before attempting any service:
¶ Be sure the Printer's power cord has been plugged into a known good outlet of the correct
voltage.
· Be sure the unit has been installed in an area which is within acceptable environmental
conditions Sec. 1.3).
¸ Perform a visual inspection of the Printer. Excessive accumulation of dirt or dust should
be removed (Sec. 3.4.1).
¹ Confirm that the Printer has been correctly loaded with media of an acceptable type (Sec.
3.2).
4.4.2 Using the Troubleshooting Charts
After performing the initial checks and confirming that conditions are correct, follow the Problem
Isolation Checklist (Sec. 4.4.3). The Checklist is designed to direct the Technician to the appropriate
repair routine.
Always begin with Step 1, follow the instruction listed under Check Item, and answer the question,
either Yes or No, listed under Result. The Corrective Action will direct the Technician either to
another step or to one of the Troubleshooting Procedures.
When using the Troubleshooting Procedures, again, always begin with Step 1 and proceed in the
same way as with the Problem Isolation Checklist. The Corrective Action will direct the Technician
either to another step or to a suggested repair.
50
4.4.3 Problem Isolation Checklist
Step Check Item Result Corrective Action

1. Turn power on. YE Go to Step 2.
S
Does the POWER light come on? NO Go to Procedure 1.

2. Turn power off. Hold down the FEED button
and, while holding, turn power back on. YE Go to Step 3.
S
Does the Printer print Test Labels? NO Go to Procedure 2.

3. Hold down the FEED button and, while Unit tests OK. If the
holding, press and release the ON problem was reported by
LINE/PAUSE button. an operator, have them
The Printer will print a Test Label. demonstrate the
malfunction. The
problem may appear
intermittently, or may be
YE the result of operator
S error.
Is the Test Label print quality good? NO Go to Procedure 3.
51
4.4.3.1 Procedure 1. - Printer Does Not Power Up.

Check Power Cord and outlet.
Be sure the Printer is correctly plugged into a
good outlet of the appropriate voltage. YES Go to Step 2.
Plug the Printer into a
good outlet with correct
1. Is the Printer plugged in correctly? NO voltage, and re-test.
Check the Printer fuse.
(One fuse on the 115 V model - two fuses on the
230 V). YES Go to Step 3.
Replace the defective fuse
2. Is the fuse good? NO and re-test.
Remove any memory cartridges from the Replace the memory
Printer. Turn power ON. YES cartridge. Re-test.
3. Does the POWER light go on? NO Go to Step 4.

Remove the Printer's outer Cover (Sec. 6.1.1).
Remove the Front Panel Cover (Sec. ). Check
the ribbon cable from the Front Panel to J2 on
the Main Logic Board. Be sure the cable is
correctly plugged in (to both the Front Panel
and Main Logic PCB's) and is not chaffed or
damaged. YES Go to Step 5.
Plug the cable in
correctly. Replace any
4. Is the cable correct? NO damaged cable. Re-test.
Replace the Front Panel P.C. Board and re-test.
YES Unit OK.
5. Does the Printer power up? NO Go to Step 6.

Check TP2 on the Main Logic Board for the
presence of +5 Volts DC. YES Go to Step 8.
6. Is the voltage present? NO Go to Step 7.

Turn Power OFF. Disconnect the Power
connector from the Main Logic Board at J3.
Check connector J3, pins 3 and 4, for the Replace the Main Logic
presence of +5 Volts DC. YES Board and re-test.
7. Is the voltage present? NO Replace Power Supply.
52

Turn Power OFF. Disconnect the Motor Power
connector from J9 on the Main Logic Board.
Turn power back ON.
YES Replace the Stepper
Motor
8. Does the Printer power up? NO Go to Step 9.
Turn Power OFF. Connect the Motor Power
connector to J9. Disconnect the Printhead
connector from J7. Turn power back ON.
YES Replace the Printhead.
9. Does the Printer power up? NO Replace Power Supply.
53
4.4.3.2 Procedure 2 - Printer Powers Up, But Will Not Print Test Labels.

YES Go to Step 2.
On the attempt to print a Configuration Label,
1. did the label stock show any motion? NO Go to Step 8.
YES Go to Step 3.
2. Was anything at all printed on the label? NO Go to Step 4.
Unit tests OK. If the
problem was reported by
an operator, have them
demonstrate the problem -
it may be intermittent, or
YES the result of Operator
error.
3. Is the print quality good? NO Go to Procedure 3
If Thermal Transfer media is loaded, confirm
that the correct ribbon is installed, and the
Printer set for Transfer mode. YES Go to Step 5.
Correct the setting or
4. install the proper ribbon.
Are the Ribbon and Printer setting correct? NO Re-test.
Remove any installed memory cartridge. Turn
power off. Hold down the FEED button and,
while holding, turn power back on. Replace the memory
YES cartridge.
5. Does the unit print Test Labels? NO Go to Step 6.
Rotate the Head Lift Lever to raise the
Printhead. Check to see that the Printhead cable
is properly plugged in. YES Go to Step 7
Plug in the connectors
6. Is the connector plugged in correctly? NO correctly. Re-test.
Remove the Printer's cover. Locate connector
J7 on the Main Logic Board. Check that the
cable to J7 is plugged in and undamaged.
Replace the Printhead and
YES re-test.
Plug in or replace the
7. Is the cable to the J7 connector correct? NO cable.
Press the FEED button and listen for the sound
of the motor.
YES Go to Step 7.
8. Does the motor attempt to operate? NO Go to Step 10.
54

The Head Lift Lever should already be in the
DOWN position. Without lifting the lever, try
to pull the media back into the Printer.
YES Go to Step 10.

Does the Drive Roller firmly hold the media in
9. place? NO Replace the Drive Roller
Turn the Printer OFF. Try to turn the Drive Remove and clean or
Roller by hand. replace the Drive Roller.
YES Re-test
10 Is the Drive Roller jammed? NO Go to Step 11.

.
Remove the Printer's cover. Replace damaged or
Locate the Timing Belt. YES broken belt.
11 Is the belt damaged, broken or slipping? NO Go to Step 12.

.
Remove the Printer's cover.
Check Test Point TP3 on the Main Logic
Board. (Sec. 5.9.3) Replace the Stepper Motor.
YES Re-test
12 Is +24 Volts DC present? NO Go to Step 11.
.
Disconnect power from the Main Logic Board
by unplugging connector J3.
Check for +24 Volts DC on J3 between Pins 1
and 2. Replace the Main Logic
YES Board.
13 Is +24 Volts DC present? NO Replace the Power Supply.
.
55
4.4.3.3 Procedure 3. - Poor Print Quality

Press the ON LINE/PAUSE and the
FEED buttons together and, while holding
the FEED button, release ON
LINE/PAUSE. The Printer should print
Test Labels.
YES Go to Step 2.
1 Is anything printed on the Test Label ? NO Go to Step 7.
.
YES Clean the Printhead (Sec 3.4.2).

Does the Test Label show random spots,
2 streaks or gaps? NO Go to Step 3.
.
YES Go to Step 4.
3 Is the print blurred or smeared? NO Go to Step 5.
.
Perform the Tag Stock
YES Adjustment (Sec. 5.5).
Direct Thermal - Use stock with
a lower Reaction Temperature
(Sec 5.2).
Is the media thicker than standard Thermal Transfer - install a new

4 (4 mil)? NO ribbon of the correct type.
.
Perform the Direct Thermal
YES Stock Adjustment (Sec. 5.6)
Did the loss in print quality occur after
changing from Thermal Transfer to Direct
5 Thermal Media? NO Go to Step 6.
.
Printhead is in a skewed position
- use the Printhead Adjustment
screws to straighten the
YES Printhead (Sec.5.6)
Does the print gradually fade across the
6 width of the label? NO Go to Step 7.
.
56
Does the print suddenly stop across the

7. width of the label? NO Go to Step 8.
Open the Printer's door. Rotate the Head
Lift Lever to raise the Printhead. Check
the cable which plugs into the Printhead.
(See Sec. 6.4)
YES Go to Step 9.
Plug the cable in correctly and
8. Is the cable correctly plugged in? NO re-test.
Remove the Printer's cover.
Locate connector J7 on the Main Logic
Board. Replace the Printhead. (Sec.
YES 6.2).
Plug in the cable correctly and
9. Is the cable correctly plugged in? NO re-test.
57
58
5. Adjustments
• Printhead Alignment
• Non-Standard Stock
• Sensors
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
60
5.1 Introduction
This chapter discusses the adjustments that might sometimes be necessary to keep the Printer at
maximum performance. Most often, adjustments are needed when the label stock being used varies
significantly from the standard size of 4 in. width and 4 mil thickness. There are also adjustments that
should be made when major components, such as the Printhead, have been replaced.
5.2 Controlling Print Quality

In order to offer the greatest flexibility, the Printer operates in both Direct Thermal and Thermal
Transfer modes. However, due to the differences in these two technologies, some "fine tuning" may be
required to maintain the highest print quality. These adjustments are discussed below.
The two most important factors that determine print quality are the amount of heat applied to the
Printhead, and the position of the Printhead relative to the label media.
Applied Heat
The heat that must be generated by the Printhead depends on the Reaction Temperature of the Print
Media or Thermal Transfer Ribbon. The reaction temperature is the amount of heat needed to turn the
media black, or to transfer an image from the ribbon. Many low cost types of direct thermal stock have
very high reaction temperatures - it takes a great deal of heat to make clear images on this type of
paper. On the other hand, Thermal Transfer Ribbons have a relatively low Reaction Temperature. The
Printer has limits placed in the range of possible heat adjustments, in order to prevent settings that
could damage the Printhead. The applied heat may be controlled either by adjusting the Darkness
potentiometer, or by increasing the burn time through software. (For more information on adjusting
burn time with software, see the Programmer's Manual for Allegro, Prodigy and Prodigy Plus,
"Label Format Commands".)
Printhead Position
The Printer has been factory set to produce good print quality with most media. However, when using
stock other than the recommended 4 mil thickness, the Printhead position, ribbon, and media
tracking may all require slight adjustments in order to maintain highest quality.
61
5.3 When Adjustments are Needed

Adjustments must be considered when dealing with any of the following situations:
• Narrow Stock
When using stock narrower than the standard 4 in. width, an adjustment may be needed to prevent the
Printhead from rubbing on the Drive Roller.
• Tag Stock and Stiff Media

When stock that is thicker than 4 mil is in use, the Printhead can be moved forward,
providing a slightly larger gap and allowing the thicker media to move freely along the media
path.
• Direct Thermal Stock

Direct Thermal media generally requires greater heat than Thermal Transfer media in order to produce a
comparable image. The print "burn point" can be moved closer to the Drive Roller, where the heat is
greater.
• Printhead Mounting Assembly

The Printhead mounting system is designed so that there is normally no need to align a newly installed
Printhead. However, if the Head Mount Assembly has been removed (for example, when replacing the
Drive Roller), this adjustment should be performed.
• Electrical Adjustments
It is normal for the Printer's Edge Sensors to occasionally need small electrical adjustment to keep the
sensor's sensitivity in the correct range. It may also sometimes be necessary to confirm the Power
Supply voltage levels or ground.
NOTE - Unless otherwise stated, all adjustments should be performed with label stock that is at least 4 in.
(102mm) wide. If the media that will normally be used is of a different size, make the standard
adjustments first (using 4 in. media), and then fine tune the adjustments using the stock size that
will be actually used.
62
5.4 Adjusting for Narrow Stock

This adjustment should be performed when the stock to be used is narrower than 3.5 in. (89 mm). The
parts involved in the adjustments are shown in Fig. 5-1 and 5-2.
Fig. 5-1. Printhead Mount Assembly
The Head Support Plate, shown in the figure above, is designed to support the outer end of the
Printhead when narrow stock is in use. Engaging the Support Plate ensures that the Printhead does not
contact the Drive Roller, which would potentially damage the Printhead and prematurely wear out the
Drive Roller.
63
To Adjust for Narrow Stock:
¶ Loosen the two screws that attach the Head Support Plate and Ribbon Shield to
the Printhead Mount frame. Leave the left side screw slightly snugged.
· Load a supply of 4 in. wide label stock. (See Sec. 3.2.2.1 for stock loading
instructions). Turn the Head Lift Lever to the DOWN position to engage the Printhead.
¸ Push down the right side of the Head Support Plate until the Plate just contacts the Bearing Block
Mounting Bracket
¹ Turn the Head Support Adjustment Screw until it just contacts the Bearing Block Mounting
Bracket.
º Tighten the two screws to secure the Head Support Plate and Ribbon Shield.
NOTE - The same screws secure both the Head Support Plate and Ribbon Shield, so that moving one
could cause the other to move. Be aware, and avoid this if possible.
64
5.5 Adjusting for Stiff or Tag Stock

The horizontal position of the Printhead is set by turning the right and left Head Adjustment Screws,
which move the corresponding side of the Printhead in or out. When using stock that is much thicker
than 4 mil, adjusting the Printhead away from the Roller may improve print quality. Note - This is a
sensitive adjustment - A small turn can make a large difference in the print quality. Adjust these screws
no more than 1/4 turn at a time until the print is satisfactory.
CAUTION: Do not turn the head adjusting screws more than 2 complete turns in either direction.
Damage to the head mount assembly will result if the adjustment screws are turned too far.
5.6 Adjusting for Direct Thermal Stock

When the Printhead is set-up for use with thermal transfer stock, the Printhead burn point is set at a
position on the roller where the ribbon separates from the label while the wax ink is still hot enough to
be in a liquid state.
When direct thermal stock is used, the Printhead burn point should be moved slightly back, to a point
where there is greater contact with the roller, causing heat to transfer to the media more efficiently.
For best results when using direct thermal label stock, turn both of the two Head Adjust screws 1/4
turn clockwise. Figure 5-2 is a partial cut-away view from the right side of the Printer, showing the
Adjustment Screw Location. This adjustment will move the Printhead 0.006 in. (0.15mm) back on the
roller. Remember to adjust back to the original position when returning to Thermal Transfer media.
65
5.7 Adjusting for Printhead Alignment

The Printhead is precisely positioned on mount plate locating pins that are set at the factory. The
locating pins should ensure correct alignment of all future replacement heads - it should not normally
be necessary to re-align each new Printhead. However, if the Printhead mount assembly has been
removed or disassembled, and there has been a consequent loss of print quality, the following
alignment procedure may be required. Performing all steps, in the order given, should eliminate any
problems with print quality.
Figures 5-1 and 5-2 illustrate the portions of the Printhead mounting assembly that are involved in the
adjustment procedures.
There are four adjustments required to align the Printhead. They are:
¶ Stock Tracking Adjustment
· Ribbon Feed and Tracking Adjustment
¸ Printhead Fine Adjustment
¹ Printhead Pressure and Support Adjustment
Fig. 5-2. Printhead, right side view - Adjustment details.
66
5.7.1 Stock Tracking Adjustment
For proper performance, it is critical that the stock move evenly through the media path. Any skewing
will affect the print quality, and in some cases can cause jamming. The Stock Tracking Adjustment
must be done with the printer power ON and a full roll of 4" (102mm) stock installed.
¶ Load the stock in the normal way, but keep the Media Retainer in the DOWN position.
· Use the FEED button to feed a few labels. At first the edge of the stock may move in and out as
the media advances. After a few labels the stock should begin to track at a stable position.
¸ At this point, slightly bend the Media Guide Plate up or down to adjust the tracking position to
within approximately 0.3 in. (8 mm.) of the center plate. Bending the Plate down will move the
tracking position closer to the Center Plate, while bending up will move the tracking position
farther from the Center Plate.
(NOTE - It is suggested that a small object, such as a pen or pencil, should be placed between the
Guide Plates. This will prevent bending the Plates so close together that the media will no longer
feed smoothly.)
¹ Rotate the Media Edge Guide to the UP position, and stop feeding labels.
67
5.7.2 Ribbon Feed and Tracking Adjustment
This adjustment must be performed with the printer power ON, a full roll of 4" (102mm) stock, and a
ribbon installed. (See Chapter 3, Fig 3-2 for Ribbon Loading instructions). Complete the steps for
installing the ribbon, except, do not secure the ribbon to the Ribbon Take-Up Hub.
¶ Press the FEED button several times and check to see if any wrinkling or bagging of the ribbon
occurs as it moves from the supply hub and goes under the Printhead assembly. If rippling or
bagging does occur, go to step 2. If no wrinkling is observed, go on to the Printhead Fine
Adjustment procedure, Section 5.7.3.
· The next step is to adjust the tension and position of the Ribbon Supply Hub. Maintaining an
even tension will help eliminate ribbon wrinkling. On the Shaft Support Bracket, slightly loosen
(but do not remove) the four screws securing the bracket to the Center Plate (Fig. 5-3).
¸ Apply moderate pressure up or down on the Ribbon Supply Hub or the Shaft Support Bracket
while pressing FEED to advance labels. The object is to reposition the Supply Hub so that
ribbon tension is even across entire width of the media path. An even tension should eliminate
any ribbon wrinkling.
Fig. 5-3 Adjusting Ribbon Tension.
68
¹ Once the bracket is positioned properly, re-tighten the four screws that attach the bracket to the
Center Plate. Feed three or four more labels to re-check the ribbon. Make certain that the ribbon
does not ripple or bag.
º Feed ribbon and labels together from the front of the printer. Check the ribbon to be sure that the
ribbon and label edges stay aligned. If the ribbon overlaps one edge of the paper stock, the ribbon
and paper are not following the same path. Should this happen, the Ribbon Shield position may
need to be adjusted. If the ribbon shows no overlap, proceed to the Printhead Fine Adjustment
procedure, Section 5.7.3.
» To adjust the Ribbon Shield, gently push the ribbon out of the way and loosen (but do not
remove) the screw securing the left side of the Head Support Plate and Ribbon Shield (Fig. 5-4).
¼ Press the FEED button to advance labels, while moving the left side of the Ribbon Shield up or
down until the edges of labels and ribbon track together.
Fig. 5-4 Printhead Support Plate and Ribbon Shield - detail.
69
5.7.3 Printhead Fine Adjustment
¶ Print a few labels with Bar Codes rotated at either 90° or 270°, and inspect the print quality.
Imperfections in the print will be more evident in the rotated Bar Code images. If the print
quality is less than satisfactory, go to step 2.
Rotated Bar Codes are available on the Ribbon Test Label. To produce this label:
• Simultaneously press the PAUSE and FEED buttons. The Printer will generate a label
with a Bar Code in normal rotation.
• Press the STOP/CANCEL button.
• Press the PAUSE button. The Printer will generate a label with Bar Codes in 90°
rotation.
· With a 1/16" (1.59mm) hex key, turn the left and right Head Adjustment Screws (Fig. 5-2)
either clockwise or counter-clockwise 1/4 to 1/2 turn at a time, until the desired print quality is
achieved.
Never turn these screws more than 1/2 turn at a time or more than 2 full turns in total.
¸ Adjusting the head position often moves the Bearing Block out of contact with the Head Support
Plate. Loosen the two screws that secure the Bearing Block Mounting Bracket. Push the Bearing
Block back until it just contacts the Head Support Plate.
¹ Tighten the two mounting screws to secure the Bearing Block and Mounting Plate.
º Sometimes performing the Printhead Fine Adjustment can slightly change the stock and ribbon
tracking settings. Feed a few labels and look for any return of ribbon wrinkling. If there is any
sign of ribbon tracking problems, return to Section 5.7.2 Ribbon Feed and Tracking
Adjustment, and repeat the adjustment.
70
5.7.4 Printhead Pressure and Support Adjustment
The function of the Head Support Plate is to support the outer end of the Printhead when narrower
media is being used. Without this support, the Printhead would press on the drive roller, causing poor
print quality, premature wear and possible Printhead damage. The head support plate is needed only
when the media width is less than 3.5".
Pressure for the Printhead is provided by two springs in the head mount assembly. These springs apply
a constant force on the Printhead. If media that is less than 3.5 in. (89 mm.) wide is to be used, the
Printhead Support Plate should be adjusted. Figure 5-4 shows the assembled Printhead Mount. Figure
5-1 illustrates the relevant parts of the Printhead Mount in an exploded view.
To adjust:
¶ Loosen the two screws securing the Head Support Plate to the Printhead Mount. Leave the screw on
the left side slightly snug (Fig. 5-4)
· Load a supply of the media to be used. Turn the Head Lift Lever to the DOWN position to engage
the Printhead.
¸ Turning the Head Support Adjustment Screw will raise and lower the right side of the Printhead.
Turn the Adjustment Screw clockwise until the print on the right side of the label begins to degrade.
¹ Turn the Adjustment Screw back 1/4 turn counter-clockwise to set the correct adjustment.
º Finally, tighten the two mounting screws to secure the Head Support Plate.
71
5.8 Sensor Adjustments
The Printer contains a pair of sensors in the media path which merit discussion. Both the Label Edge
Sensor and the Reflective Edge Sensor are designed to operate without adjustment. However, if
components in either sensor's circuit have been replaced, the sensor may need a set-up adjustment.
Procedures for adjusting both sensors are given below.
5.8.1 Label Edge Sensor Adjustment
¶ Remove the Printer's outer cover to expose the Main Logic Board (Sec. 6.1).
· Remove a few labels from their backing, and locate the Media Sensor (Fig. 5-5).
¸ Place the label backing material between the "fingers" of the sensor.
¹ Connect a Multi-meter to the Main Logic Board - the black lead connects to the
heat sink, and red lead to Test Point TP1
º Adjust potentiometer RP2 until the meter shows a reading of between 0.15 and 0.35 volts DC.
» Press the FEED button. The Printer may feed a few labels while it aligns itself.
Afterwards, it will feed one label each time the Feed button is pressed. When a
label is in place in the sensor, the voltage at TP1 should be greater than 2.0 volts DC.
¼ Replace the Printer's cover.
Fig. 5-5 Insert the Label Backing between the Sensor "fingers".
72
Fig. 5-6 Main Logic Board - Sensor Adjustment Points
73
5.8.2 Reflective Edge Sensor Adjustment
The Reflective Edge Sensor detects the motion and position of label stock by sensing the presence of a
"carbon black" line on the back side of the label. Since the sensor operates by detecting interruptions in
a beam of infra-red light, this line must be a non-reflecting flat black that will absorb the infra-red
beam.
This adjustment should be performed with power on, 4 in. width label stock loaded, and the Printer
connected to a host terminal. The labels used in the procedure must be reflective type, with a black
line on the back.
¶ Remove the Printer's cover to expose the Main Logic Board (Sec. 6.1).
· Remove a few labels from their backing, and locate the sensor.
¸ Place some of the label backing material between the "fingers" of the sensor so that
black line on the label back is not within the sensor.
¹ Connect a Multimeter to the Main Logic Board. Connect the black lead
(Common) to the heat sink, and red lead (Positive) to Test Point TP1 (Fig. 5-6).
º Set the Printer to Reflective Sensor mode. (Note - Changing the sensing mode requires that the
Printer be connected to a host unit. Sending the command string "<CTL> B r" from the host unit
switches the Printer to Reflective sensing mode. (A sample program to send this command string
may be found in Appendix Sec. A2.0). See the Programmer's Manual for Allegro, Prodigy, and
Prodigy Plus (Part No. 88-2054-01) for further information on using command strings.
» Adjust potentiometer RP1 until the meter reads 0.75 Volts DC.
¼ Press the FEED button. The Printer may feed a few labels while it self-aligns. It will then feed
one label each time the button is pressed. When the reflective black mark is in place within the
sensor, the voltage at TP1 should be greater than 2.0 volts DC.
½ Replace the Printer's cover.
74
5.9 Electrical Checks

Three electrical tests may occasionally be needed, since incorrect voltage levels or bad grounds can
generate many problems in the Printer. These are tests of the ground, the 5 Volt and the 24 Volt supply
voltages, which are discussed below. If the ground or the voltage levels are not within the required
tolerances, refer to Section 4, Troubleshooting, and follow the procedures listed.
5.9.1 Ground Test
¶ Connect a Voltmeter to the Printer in the following way: Connect the Common lead (black) to
the heat sink located at the base of the Main Logic Board. Set the meter to measure the range
around 10mV. Connect the Positive lead (red) to the left side lead of capacitor C45, located
near the top of the Main Logic Board.
· The voltage measured should be less than 10mV. If the voltage reading is above 10mV, or if
it shows large fluctuations, re-connect the Common lead to the heat sink and then re-measure.
If the voltage is still wrong, check the components connected to the heat sink - one of them
may be defective.
Fig. 5-7 Main Logic Board - Test points.
75
5.9.2 5 Volt Supply Test
the heat sink located at the base of the Main Logic Board (Fig. 5-7).
· Connect the Positive lead (red) to test point TP2 on the Main Logic Board.
¸ Acceptable voltage will be between 4.75 and 5.25 Volts DC.
5.9.3 24 Volt Supply Test
the heat sink at the base of the Main Logic Board.
· Connect the Positive (red) lead to test point TP3 on the Main Logic Board (Fig. 5-7).
¸ Acceptable voltage will be between 21.5 and 26.5 Volts DC.
CAUTION - Shorting the voltage probes with this relatively large voltage could cause damage to the meter
or the Printer.
76
6. Removal and Replacement
• Printhead
• Circuit Boards
• Sensors
• Electro-mechanical Parts
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
P/N: 510391 78
6.0 Introduction
Even with the best design, manufacture and owner maintenance, occasionally parts will need replacement.
This section provides detailed removal and replacement procedures for the parts that most often need service.
The manual also contains complete assembly drawings and part numbers, so that any missing or defective part
may be replaced.
WARNING - Unless otherwise indicated, before proceeding with any removal or

replacement procedure, turn power OFF and UNPLUG the
Printer. Failure to do so could result in serious injury or damage to
equipment.
P/N: 510391 79
6.1 Cover Removal and Replacement

When servicing the Printer, the first step is almost always removal of the outer cover.
Use the following procedure:
Removal
¶ Turn the Power Switch OFF, and unplug the Printer's power cord.
· Remove the two screws on the upper, inside cover which attach the cover to the center plate.
¸ Gently pull outwards and up at a point in the center of the cover below the memory module slot. Slowly
move the cover straight up to remove it.
CAUTION - The cover must NOT be removed from the top first. Doing so can damage the cover.
Fig. 6-1 Cover screw location
P/N: 510391 80
Replacement
¶ To replace, gently slide the cover straight down onto the Printer, and see that the groove at the rear of the
cover slides into place around the back panel.
· When it is almost in place, gently pull outward on opposite sides of the bottom of the cover. This will
widen it and allow it to pass over the catch that holds the cover in place.
¸ With the cover fully in place, replace and tighten the two screws on the upper inside part of the cover.
Fig. 6-2 Cover catch location.
P/N: 510391 81
6.2 Tear Bar
Removal
¶ Place thumbs or fingers firmly against the tear bar plate.
· Press in on the plate while sliding it upwards, until it disengages.
¸ Pull the plate straight out to remove.
Fig. 6-3 Tear Bar removal.
Replacement
Reverse the above steps to re-install.
P/N: 510391 82
6.3 Printhead Replacement and Adjustment
Removal
¶ Turn the Power Switch OFF, and unplug the Printer's power cord.
· Unload the label stock and remove the ribbon (if installed). See Sec. 3.2.4.
¸ Turn the Head Lift Lever counter-clockwise to the Down position.
¹ While looking into Printhead area from the side, place a small flat-head screwdriver into the notch in the
side of the Printhead plug, and gently move the screw driver back and forth to loosen the plug.
º Using needle-nosed pliers, carefully disconnect the Printhead cable from the Printhead. Be especially
careful not to damage the ribbon cable.
Fig. 6-4 Unplugging the Printhead Cable.
P/N: 510391 83
» The Printhead mounting screw is located inside a small circular opening on the top of the Printhead
assembly. Loosen the mounting screw. (Note - This is a captive screw that stays with the mounting
assembly - Do not attempt to remove it completely; loosen the screw only until it disengages from the
Printhead.)
CAUTION - To prevent damage to the Printer from static electrical discharge, the technician should always
ground himself by touching the Printer chassis before handling the Printhead.
Fig. 6-5 Printhead Mounting Screw location.
¼ To release the Printhead, turn the Head Lift Lever fully clockwise, and slide the Printhead out from the
side of the assembly, being careful not to scratch the printing surface of the Printhead.
P/N: 510391 84
Replacement
½ Carefully slide a replacement Printhead into the assembly, making sure that the dowel pins on the
Printhead bracket fit into the hole on the left side of the Printhead and the slot on the right side of the
Printhead. Make sure the Printhead is flush with the head mount bracket.
Fig. 6-6 Printhead positioning holes.
¾ Secure the Printhead to the mechanism by tightening the Printhead mounting screw. Be careful not to
over-tighten the screw.
¿ Insert the Printhead cable and press it in until it snaps into place.
Adjustment
Use the Self Test function to generate test print labels. Adjust the Darkness Pot, (See Fig. 3-1 for
location) until the new Printhead achieves the same print contrast as the original.
NOTE - The Locating pins on the mount assembly act to automatically position the Printhead. Normally there
will be no need to make any alignment adjustments after installing a new Printhead. However, should
a replacement perform poorly, there are some adjustments that may help improve performance.
These are discussed in Sec. 5.3, Adjustments.
P/N: 510391 85
6.4 Printhead Spring

Removal
¶ Remove the Printer's outer cover to expose the electronics compartment. (Sec. 6.1) Remove the tear bar
unit from the front of the printer. (See Sec. 6.3)
· Using retainer ring pliers, remove the C-clip Retaining Ring which secures the electronics side of the
Cam Shaft Assembly.
¸ Loosen the Allen Set Screw with a 1/16" Allen wrench and remove the head lift lever.
¹ Remove the three screws holding the actuator mount plate, and remove the Mount Plate.
Fig. 6-7 Printhead Spring replacement - Removing the Actuator Mount Plate.
P/N: 510391 86
º With the Mount Plate removed, the Cam Shaft Assembly and the two Ribbon idler rollers are freed and
should now be removed.
Fig 6-8 Printhead Spring removal - Cam Shaft and Idler rollers.
P/N: 510391 87
» Remove the two Head Adjust Screws (Fig. 5-2).
¼ Remove the two screws which secure the Cam Lift Bracket, and remove the bracket.
½ Remove the two Printhead Springs.
Fig. 6-9. Printhead Spring removal.
Replacement
Insert the replacement springs, making certain that they fit into the retaining pockets. Then reverse the above
procedure to re-assemble.
P/N: 510391 88
6.5 Front Panel Board Assembly

Removal
¶ Remove outer cover to access the electronics compartment.(Sec. 6.1)
· Remove the 3 screws holding the Front Cover assembly. Two screws are located on the left and one on
the right side of the cover.
Fig. 6-10 Front Cover screw locations
¸ Carefully pull out the front plate assembly and disconnect the attached ribbon cable from the Front
Panel P.C. board.
Fig. 6-11. Front Panel Ribbon Cable.
P/N: 510391 89
¹ Remove the four screws securing the Front Panel P.C. board.
Fig. 6-12. Front Panel P.C. board screw location.
º Remove the Front Panel P.C. board. The Push-buttons will remain secured in the front panel board
assembly. They may be removed by bending back the securing catches until the buttons are released.
Replacement
Reverse the above procedures for reassembly.
P/N: 510391 90
6.6 Front Panel Mounting Bracket
Removal
¶ Remove the Printer Cover (Sec. 6.1)
· Remove the retaining ring and the two washers from the electronics bay end of the Sensor Shaft.
Pull the opposite side of the shaft outwards until the shaft end disengages from the Front Panel
Mounting Bracket.
Fig 6-13. Sensor Assembly and Shaft.
P/N: 510391 91
· Remove the six screws holding the Front Panel Mounting Bracket in place, and remove the Bracket.
Fig. 6-14. Front Panel Mounting Bracket screw locations.
Replacement
Reverse the above procedures for reassembly.
P/N: 510391 92
6.7 Drive Roller Removal and Replacement

Removal
¶ Remove outer cover to access the electronics compartment (Sec. 6.1).
· Remove the Front Panel assembly and front panel Mounting Bracket (Sec. 6.5 and 6.6).
¸ Unscrew the sensor shaft counter-clockwise and remove it.
¹ Remove the two screws holding the Stepper Motor, and remove the Stepper Motor. It is not necessary to
disconnect the cable to the main board - simply place the motor to the side, out of the way.
Fig. 6-15. Removing the Stepper Motor
P/N: 510391 93
º Remove the two screws holding the Motor Mount Bracket and remove the Bracket.
» Remove the Gear Retainer Clip and the 5 mm E-Ring, and then remove the Roller Drive gear and the
Compound Idler Gear from the Hub Shafts.
Fig. 6-16 Removing the Drive Gears.
P/N: 510391 94
¼ Pull the Clutch Pulley off the shaft. The assembly fits snugly, so it may be necessary to turn the
pulley back and forth to remove it.
½ Remove the Timing belt.
¾ Remove the drive roller retaining ring (5 mm E-ring)). The drive side of the roller is now prepared for
removal.
Fig. 6-17 Removing the Timing Belt and Pulley
¾ Turn the Printhead lever fully clockwise until the Printhead is in the UP position.
¿ Pull out the old drive roller and insert the new one.
Replacement
Reverse the previous steps for replacement.
P/N: 510391 95
6.8 Label Edge Sensor Assembly

Removal
¶ Remove outer cover to access the electronics compartment (Sec. 6.1)
· Remove the retaining ring and the two washers from the electronics bay end of the Sensor Shaft. Pull
the opposite side of the shaft outwards until the shaft end disengages from the Front Panel Mounting
Bracket.
¸ Unscrew the sensor shaft (counter-clockwise), and remove the shaft and spacer.
¹ Unplug the six wire cable connected at Socket J4 on the Front Panel P.C. board. The sensor assembly is
now free to be removed from the printer.
Fig. 6-18. Label Edge Sensor removal
Replacement
Reverse the above procedure for reassembly.
P/N: 510391 96
6.9 Ribbon Sensor Assembly

Removal
· Disconnect the ribbon sensor cable from the Main Logic Board at Socket J6.
¸ Unhook and remove the Spring from the Slip Clutch Pulley Assembly (Fig. 6-24). Loosen
the Allen Set Screw.
¹ Remove the one screw securing the Ribbon Sensor Board assembly. Remove the Sensor
Board.
P/N: 510391 97
Fig. 6-19. Ribbon Sensor Assembly removal.
Replacement
P/N: 510391 98
6.10 Main Circuit Board Assembly

Removal
· Disconnect all of the cables connected to the Main Logic Board.
¸ Remove the five screws that secure the Main Logic Board in place (Fig. 6-20)
¹ Remove the two screws that attach the heat sink to the bottom of the printer baseplate.
º Carefully slide the Main Logic Board towards the front of the printer, until the Serial Connector
(J4) is disengaged from the back plate.
» The main board can now be removed. Be careful to keep the main board free from any wires
while removing it.
Fig. 6-20. Main Logic Board - screw locations.
Replacement:
Note: Always apply a liberal amount of Thermal Heatsink Compound to the heatsink that mates with the
centerplate, (p/n 13-0136-01).
P/N: 510391 99
6.11 Back Panel Assembly

Removal
· Remove the screw securing the Electrical Safety Shield.
¸ Remove the three screws that hold the Back Panel in place. Remove the Back Panel.
¹ Remove the Electrical Safety Shield.
º Remove the two transformer wires and the ground strap screw.
Fig. 6-21. Removing the Back Panel and Shield
Replacement
P/N: 510391 100

6.12 Transformer
Removal
¶ Remove outer cover to access the electronics compartment Sec. 6.1).
· Remove back panel assembly (Sec. 6.11).
¸ Remove the Power Cable connected to the main board at J3.
¹ Remove the four screws holding the transformer in place.
º Remove the Transformer.
Fig. 6-22. Removing the Transformer and Ground Strap.
Replacement
P/N: 510391 101

6.13 Options Board Assembly

Removal
· Remove the retaining ring and the two washers from the electronics bay end of the Sensor Shaft. Pull
the opposite side of the shaft outwards until the shaft end disengages from the Front Panel Mounting
Bracket. (Sec. 6.6.1)
¸ Unscrew the Sensor Shaft (counter-clockwise) and remove it.
¹. Disconnect the Options Cable from the Main Logic board at connector J1.
º Remove the three screws from the Roller Mount Plate Assembly(Fig. 6-18) and pull the assembly away
from the drive roller.
» Loosen the two screws that secure the Options Board and remove the board form the Mount
Plate. (Fig. 6-23)
Fig. 6-23. Options board - detail.
Replacement
Reverse the above steps to reassembly.
P/N: 510391 102

6.14 Ribbon Hubs

Removal
¶ Remove the Printer's cover. (Sec. 6.1)
· Using needle-nosed pliers, or a similar tool, unhook one end of the Spring from the Shaft
Support Bracket. Remove the Spring.
¸ Using a 1/16th in. Allen key, loosen the two Allen Set Screws.
¹ Remove the Slip Clutch Pulley and the 5/16th in. Collar.
Fig. 6-24. Ribbon Hub removal - Spring and set screws
P/N: 510391 103

º Loosen and remove the four screws securing the Shaft Support Bracket to the Center Plate.
» Remove the Shaft Support Bracket.
Fig. 6-25. Ribbon Hub removal - Bracket screws
P/N: 510391 104

¼ Using a 1/16th in. Allen Key, loosen the Allen Set Screw securing the Ribbon Drive Assembly to
the shaft of the Ribbon Take-Up Hub.
½ Slide the Ribbon Drive Assembly off the Hub shaft. Move the Timing Belt aside, out of the way.
¾ At this point, the two Ribbon Hub Assemblies can be removed.
Fig 6-26. Ribbon Hub removal.
Replacement
Reverse the previous steps to re-install.
P/N: 510391 105

7. Circuit Description
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Circuit Description
P/N: 510391 107

7.0 Circuit Description
7.1 General Overview

The Printer uses a single board design, in which functions to control the receipt of data and generation of dot
patterns for the printing process, as well as the Printer's internal housekeeping and control, all reside on one
Main Board. The Printer uses extensive software processing, rather than relying on hardware, to convert
ASCII string commands into the dot patterns that will be printed.
Because of this, typical troubleshooting techniques for hardware-based systems do not apply well to this
product. For some components, such as keypad I/O, RS-232/422 I/O, motor function, and switch input,
replacing socketed components could be economical. However, in most other cases it is more efficient and
economical to replace the complete Main Board.
Several other smaller boards and devices attach to the Main Board. These boards, such as the Front Panel,
Options Interfacing and Sensor LED boards, primarily contain discrete component circuitry. A wiring
diagram is included with the Schematic Drawings at the back of this manual. It shows the Main Board and its
relationship to all of the connecting devices.
This section explains the function and operation of these boards. The information will provide assistance when
it is necessary to connect other devices to the Printer, or to repair a unit that has been damaged.
7.2 Input Power Circuitry

Input power is connected through connector CJ1, located at the rear of the printer. The CJ1 circuit uses a
CORCOM filter to filter out common line noise. However, it will not protect the printer from all types of EMI
or RFI noise. Its main purpose is to keep the Printer from passing noise back down the line to other devices.
Power is applied through the Power-On switch. This is a SPST (Single Pole Single Throw) switch for the
115V model, and DPST (Double Pole Single Throw) for the 230V model.
The printer has one Line Transformer which is fuse linked both internally and externally. The external fuse for
the 115V model is a 1.0 Amp slow blow fuse. The 230V model requires two .5 Amp slow blow fuses. The
Transformer has a single primary, so, the wiring can not be changed in the field - the printer must be
ordered with the desired voltage configuration factory installed.
P/N: 510391 108

7.3 Main Logic Board

The Main Logic Board contains the power supplies, CPU, memory, Serial I/O, front panel and motor I/O
logic, as well as the logic that supplies data to the Printhead. The following is an explanation of the function of
the most important components on the Main Logic Board. Details of the board may be found in the Schematic
Diagram section at the end of this manual.
Quick board repairs may sometimes be made simply by swapping out socketed components. However, it is not
recommended that the board be repaired to any further degree. When problems are detected with the Main
Logic Board, the best approach is to replace the entire board!
U4 & U8 RS-232C and RS-422 line drivers. If these chips are damaged by high voltage spikes or
misuse, they may be replaced. The outputs of these two components connect to other
circuitry in such a way that they are enabled by connecting wires to the pins on connector
J4.
U3 & U9 System RAM. It is also checked when the Self-Test is run. A RAM error statement on the
Configuration Label can usually be corrected by replacing the indicated chip.
U10 74HC245 IC. Buffers the settings of the DIP switch (SW1, on the back of the Printer)
from the Main Board's data bus. If the Configuration Label, printed by the self-test,
indicates that the switch values do not change after the DIP switch has been physically
changed, this componant may be defective. The DIP switch bank may also be changed, if
necessary.
U13 System ROM. It is checked during power up and any other time the Self-Test is run. A
ROM error statement on the Configuration Label can usually be corrected by replacing
the indicated chip.
U22-U24, U27 Refresh and Bank Select. These components control the refresh cycles and bank select
of the dynamic RAM.
P/N: 510391 109

U2 & U6 Act as Buffers between the Main Board and the Front Panel Board and Sensors.
This I/O device can sometimes be damaged by unusually strong static electrical
discharges. Since this component acts to buffer TTL level data, if there is no LED
or push-button response from the front panel, replacing the chip may correct the
problem.
U14, U21, U25, U27 Printhead Control Circuit. These components are the IC's that most directly
affect the burning of dots by the Printhead. These components are seldom
damaged, but if replacing them is considered, replace the complete set of four.
U5, U14, U16, Memory Module Control Circuit. These are the IC's which control
U17, U24, U27 the operation of all the memory modules. U16 supplies the voltage used to
program Flash modules. U17 buffers the addressing of the Memory Modules. The
other IC's primarily control the selection of modules, or the function being
performed.
7.4 Front Panel Board

The Front Panel Board controls the front panel switches, transfer switch, LED's and the Darkness
pot. This board connects to the Main Board through a single ribbon cable.
7.5 Label Sensor Assembly

This board is mounted to the Sensor Shaft, just below the Printhead. The assembly includes two small
brackets which guide the media through the sensor. The Sensor itself consists of paired LED's and
optical receivers. Inputs from these components pass directly to the Main Board through the J5
connector. The Main Board both samples and buffers these inputs as part of the printing control
process.
The Label Sensor can operate in either an Edge or a Reflective sensing mode. The Main Board
controls which type of sensing operation is used.
P/N: 510391 110

7.6 Ribbon Sensor Assembly

The Printer uses a "movement present" type sensor, in contrast to the more common "see-through"
type. This sensor scheme detects the rotation of a reflective label attached to the inside of the Ribbon
Supply Hub. When the sensor fails to detect Hub motion, the Printer triggers a RIBBON OUT
condition. The RIBBON/TRANSFER switch, located on the front of the printer, disables the Ribbon
Sensor completely when Direct Thermal label stock is in use.
7.7 Printhead
The Printhead connects to the Main Board through connector J7. Most Printhead functions require +24
Volts DC. The Printhead itself is a thin-film type head, with both latch and forward type logic, to help
decrease the delay time between the printing of each row of dots.
7.8 Stepper Motor

The Stepper Motor is a 6 Volt DC motor capable of generating about double the torque required to pull
six inch rolls of media and a matching ribbon through the printer. If Stepper Motor related problems
occur, the first item to check for is a stock jam in the Printer.
The Stepper Motor is connected to the Main Board through connector J9. Component U20 (which is
not easily replaced) contains the drive transistors for the stepper motor. In most cases, replacing the
entire Main Board and/or Stepper Motor is the most efficient way to service the unit.
7.9 Memory Module

The Printer contains two memory banks. Bank A refers to the Printer's built-in RAM. Bank B refers to
the external Memory Module. There are four different Memory Modules that can be used by the
Printer; Font, 256K Flash, 256K RAM, and 512K RAM. The memory modules may be tested by
running the Printer using "PC-Batch" labeling software or an equivalent program, using the Memory
Module Maintenance (ALT-S) screen or it's equivalent. It may also be tested by running the Printer's
built in Self-Test, and checking the Configuration Label RAM Test results.
P/N: 510391 111

7.9.1 256K Flash EPROM Module

This type of module is based on the 256K Flash EPROM, which is similar to the standard EPROM
except that it can be erased electronically. Flash EPROMs have the advantages of RAM data storage,
with the added feature of not requiring power to retain data. The only significant disadvantage with
the Flash module is that it is somewhat slower than RAM when reading or writing data.
Flash modules may be used to store any combination of graphic images, charters fonts, or label
formats. This type of module features a write protect switch, to prevent important data from being
accidentally overwritten. The module can be programmed when the write protection is off (the write
protect switch on the module is moved towards the center of the module). The Flash module is rated to
be re-programmed 10,000 times without failure.
7.9.2 256K and 512K RAM Module
The 256K and 512K RAM Modules may be used for the same type of data storage as the Flash
Module. However, since RAM memory is volatile, when the Printer is turned OFF, all data will be
immediately lost. Both 256K and 512K RAM Modules provide an additional 256K of memory for
storing soft fonts, graphics, and label format data. The additional 256K of storage space in the 512K
RAM module can be used to increase the label format buffer from its normal limit of 8.25 inches to as
much as 20 inches.
7.9.3 Font Modules
The Font Modules contain pre-programmed data which is permanently stored. Font Modules cannot
be written to or erased. It is, however, sometimes possible for Font Module data to be corrupted.
To test a Font Module for corrupt data;
¶ Load the Font Module into the Printer's Module slot;
· Turn the printer OFF.
¸ Press and hold the front panel FEED button, and, while holding, turn the printer ON. The Printer
should print a Test Label which will contain the Font Module checksum and will state whether the
module is GOOD or BAD.
P/N: 510391 112

P/N: 510391 113

Spare Parts List
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Spare Parts List
Drawing 1 - First Stage Disassembly, Right Side View
P/N: 510391 115

Drawing 1 - First Stage Disassembly, Right Side View

Item Description Q Part #
# t
y
.
1. Label, Allegro 1 764239
2. Label - "Loading Instructions" 1 764240
3. Cable Assembly - Printhead 1 764127
4. Screw - M4.7 x 6 Ext. Sem. 2 130940
5. Screw - M3.5 x 10 Ext. Sem. 5 130939
6. Assembly - Main Logic Board 1 140131
7. Wire Ribbon, 10 Pin 1 090028
8. Screw - M3.5 x 6 Ext. Sem. 5 130938
9. Assembly - Mechanism 115 V. 1 764107
or Assembly - Mechanism 230 V. 1 764120
10. Label, Serial Number 1 14-2238-01
11. Assembly - Main Cover 1 764101
12. Power Cord 1 130063
13. Assembly - Front Panel Cover 1 764104
14. Assembly - Tear Bar 1 764106
15. Printhead 1 220039
16. Label - "Important..." 1 895504
17. Ribbon Clasp 1 764247
P/N: 510391 116

Drawing 2 - Cover Assembly
P/N: 510391 117

Drawing 2 - Cover Assembly
Ite Description Q Part

m# t #
y
1. Spring, Torsion 1 150085
2. Bracket, Module Front 1 764229
3. Bracket, Module Rear 1 764230
4. Assembly, Cover 1 764102
5. Cover, Module Door 1 764404
6. Screw, Self Tapping 4 130968
P/N: 510391 118

Drawing 3 - Cover Detail
P/N: 510391 119

Drawing 3 - Cover Detail

Item Description Q Part #
# t
y
1. Cover, Left 1 764400
2. Cover, Right 1 764401
3. Pin, Hinge 2 12-2370-01
4. Window 1 764407
P/N: 510391 120

Drawing 4 - Front Panel Assembly
P/N: 510391 121

Drawing 4 - Front Panel Assembly

Item Description Qt Part #
# y.
1. Cover, Front Panel 1 764402
2. Buttons, Front Panel 2 764403
3. Assembly, Front Panel Circuit Board 1 140132
4. Screw, Self-Tapping 5 130968
5. Button, Middle 1 764406
6. Bracket, Front Panel 1 764233
P/N: 510391 122

Drawing 5 - Tear Bar Assembly
P/N: 510391 123

Drawing 5 - Tear Bar Assembly

# y.
1. Cover, Tear Bar 1 764405
2. Washer, Accessory Mount 2 764232
3. Screw, Self Tapping 2 130963
4. Plate, Tear Bar 1 764208
P/N: 510391 124

Drawing 6 - Second Stage Disassembly, Right Side View
P/N: 510391 125

Drawing 6 - Second Stage Disassembly, Right Side View

Ite Description Q Part #
m# t
y
.
1. Screw, 4-40 x 1 in. Flat Hd Socket 2 130812
2. Washer, Spring 1 130907
4. Screw, M3.5 x 6 Ext. Sem. 5 130938
6. Screw,M5x.8x12 Ext. Sem 4 130943
7. Retaining Ring, .25 Ext. C 1 140048
8. Retaining Ring, .156 1 140065
12. Bearing, Flanged Nyliner .25 1 150504
13. Bearing, Flanged Nyliner 3/16 1 150505
16. Plate, Upper Label Guide 1 764210
17. Plate, Lower Label Guide 1 764211
18. Plate, Label Backing 1 764212
20. Plate, Actuator Mount 1 764218
23. Washer, Belt Tensioner 2 764255
25. Ass'y - Lever, Head Lift 1 15-2339-01
28. Spacer, Pivot Shaft 1 899210
30. Plate, Stiffener 1 899244
33. Assembly, Chassis, 115 V 1 764108
or Assembly, Chassis, 230 V 1 764121
34. Assembly, Media Sensor Mech. 1 764112
41. Assembly, Label Retainer 1 899073
42. Assembly, Cam Shaft 1 899092
43. Assembly, Printhead Mount 1 899603
45. Plate, Radius 1 764242
46. Spacer, Sensor Shaft 1 899325
47. Screw, M4 x 10 Ext. Sem. 6 130942
50. Roller, Ribbon Idler 2 899124
52. Assembly, Supply Hub 1 764113
53. Assembly, Take-up Hub 1 764118
P/N: 510391 126

Drawing 7 - First Stage Disassembly, Left Side View
P/N: 510391 127

Drawing 7 - First Stage Disassembly, Left Side View

m# ty
.
4. Screw, M3.5 x 6 Ext. Sem. 5 130938
5. Screw, 4x.7x6 Ext. Sem. 1 130940
0
9. E-Ring, 5mm. 2 140077
11. Spring, Belt Tensioner 1 150086
14. Belt, Timing, 2.03mm P, 140 Teeth. 1 220016
15. Front Plate 1 764204
19. Ass'y - Bracket , Shaft Support 1 15-2337-01
21. Gear, Compound Idler 1 674252
22. Gear, Roller Drive 1 764253
24. Clip, Retainer 1 897144
26. Spacer, Ribbon Axle 1 899157
27. Ass'y - Pulley, Slip Clutch 1 15-2338-01
29. Collar, Set Screw 5/16th in. 1 899231
32. Washer, Retainer 1 899357
33. Assembly, Chassis, 115 V 1 764108
or Assembly, Chassis, 230 V 1 764121
35. Assembly, Belt Tensioner 1 764114
36. Assembly, Ribbon Drive 1 764115
37. Assembly, Sensor Shaft 1 764116
38. Screw, M3x.5x10. Ext. Sem. 1 130939
40. Assembly, Motor Pinion 1 764125
44. Pulley Clutch Ass'y 1 764251
48. Bracket, Motor Mount 1 764209
49. Spring, Slip Clutch 1 899350
P/N: 510391 128

Drawing 8 -Second Stage Disassembly, Left Side View
P/N: 510391 129

Drawing 8 - Second Stage Disassembly, Left Side View

# y.
1. Screw M3x.5x 6 Ext. Sem. 6 130938
2. Screw M4x.7x 10 Ext. Sem. 17 130942
3. Screw M5x.8x 12 Ext. Sem. 3 130943
4. Foot, Rubber Bumper 4 140073
6. Assembly, Transformer, 115 V. 1 764109
or Assembly, Transformer, 230 V. 1 764122
7. Plate, Base 1 764201
8. Ass'y - Center Plate 1 24-2241-01
9. Shield, Electrical Safety 1 764214
10. Bracket, Base Plate Stiffener 2 764235
11. Bracket, Actuator 1 764237
12. Screw, 3mm dia. 0.5mm pitch x 5mm 1 10-2317-01
13. Spring, Sensor 1 899328
14. Spring, Head Adjuster 1 899339
16. Assembly, Back Plate, 115 V. 1 764110
or Assembly, Back Plate, 230 V. 1 764123
17. Assembly, Accessory Mounting Bracket 1 764111
18. Block, Bearing 1 899353
19. Plate, Bearing Block 1 764217
20. Assembly, Roller Mount Plate 1 764124
21. Roller, Label Drive 1 764215
22. Screw M4x.7x 6 Ext. Sem. 9 130940
23. Washer, Retainer 2 899357
24. Guide - Label 1 12-2365-01
P/N: 510391 130

Drawing 9 - Electrical Back Plate Assemblies, 115 & 230 Volt
P/N: 510391 131

Drawing 9 - Electrical Back Plate Assemblies, 115 & 230 Volt

m# t
y.
1. Switch 1 120010
2. Fuse, 1A, 250V., Slo-Blo 1 130054
3. Fuse Holder 1 130103
4. Nut, MB, EXT KEP 2 130944
5. Cable Assembly, Fuse Holder 1 764129
6. Back Plate, 115 V. 1 764203
7. Cable Assembly, Switch 1 899064
8. Screw M3 x 10 Ext. Sem. 2 130939
9. Ass'y - Filter 115V. 1 130067
10. Switch, On/Off 1 120011
11. Fuse, 0.5A., 250V. Slo-blo 2 130052
12. Ass'y - AC Inlet Filter 1 24-2336-
01
13. Fuse Holder, LF 345633 2 130104
14. Fuse Holder, LF 345633 2 130104
15. Nut, M3 EXT KEP 2 130944
16. Cable Assembly, Fuse Holder 2 764129
17. Screw, M3 x 10 EXT SEM 2 130939
18. Plate, Back, 230 V. 1 764206
P/N: 510391 132

Drawing 10 - Accessory Mount Bracket Assembly
P/N: 510391 133

Drawing 10 - Accessory Mount Bracket Assembly

m# t
y
.
1. Screw 4-40 x .25 PH SEMS 1 130809
2. Screw, M3 x 6 EXT SEM 4 130938
3. Bracket, Accessory Mount 1 764205
4. Spring, Accessory Mount 1 764236
5. Plate, Spring Mount 1 764238
6. Guide, Label Adjust 1 899290
7. Plate, Bearing 1 899294
8. Spring, Compression .24 in. x .50 in. 1 899358
9. Plate, Guide 1 764221
P/N: 510391 134

Drawing 11 - Sensor Assemblies
P/N: 510391 135

Drawing 11 - Sensor Assemblies

m# t
y.
1. Nut, HEX, Mini 4-40 1 10-2380-01
2. Board Assembly, Media Sensor 1 51-2108-01
3. Bracket, Top Sensor 1 764226
4. Bracket, Bottom Sensor 1 764225
5. Stud 1 10-2381-01
6. Washer, Fiber 2 10-2383-01
7. Bracket, Sensor Guide 1 899298
8. Screw, M3 x 6 EXT KEP 1 130938
9. Board Assembly, Ribbon Sensor 1 140135
10. Shield, Ribbon Sensor 1 764213
11. Bracket, Ribbon Sensor 1 764234
12. Nut, M3 EXT KEP 1 130944
P/N: 510391 136

Drawing 12 - Hub Assemblies
P/N: 510391 137

Drawing 12 - Hub Assemblies

m# t
y.
1. Hub, Ribbon Supply 1 12-2372-01
2. Clamp, Spring 1 899144
3. Screw, 4-40 x 3/16th PH Phil. 1 130806
4. Screw, 10-32 .25 S Set 1 130897
5. Rim, Ribbon Guide 1 899136
6. Shaft, Ribbon Hub 1 764244
7. Hub, Ribbon Take-up 1 12-2372-01
8. Clamp, Spring 1 899144
9. Screw, 4-40 x 3/16th PH Phil. 1 130806
10. Screw, 10-32, .25 S SET 1 130897
11. Shaft, Ribbon Hub 1 764244
P/N: 510391 138

Drawing 13 - Accessory Connector Bracket Assembly
P/N: 510391 139

Drawing 13 - Accessory Connector Bracket Assembly

Item # Description Qty. Part #
1. Screw, M3 x 6 EXT SEM 4 130938
2. Plate, Roller Mount 1 764207
3. Bearing, Flanged Plastic, 25 1 899228
4. Bracket, Accessory Connector 1 764241
5. Board Assembly, Accessory 1 140137
P/N: 510391 140

Drawing 14 - Ribbon Drive, Sensor Shaft and Belt Tension Assemblies
P/N: 510391 141

Drawing 14 - Ribbon Drive, Sensor Shaft and Belt Tension Assemblies

Item # Description Qty. Part #
1 Retaining Ring 1 140078
2 Washer, Spring Retainer 1 764271
3 Spring, Compression 1 150087
4 Washer, Friction Disc 1 764272
5 Pulley, Timing Belt (42GRV) 1 764273
6 Screw, M 4 x 4 Socket Set 1 130945
7 Collar, Ribbon Take-up 1 764270
8 Shaft, Sensor 1 764228
9 Roll Pin 1/16th x 3/8th 1 130854
10 Knob, Sensor Adjust 1 899297
11 Mount, Belt Tensioner 1 764258
12 Axle, Belt Tensioner 1 764257
13. Pulley, Tension 1 899190
14 Ring, Retaining. E .25" 1 140062
P/N: 510391 142

P/N: 510391 143

Appendix
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Appendix
P/N: 510391 A-2

Appendix
A1.1 Test Plug Pin Connections
Fig. A-1. Test Plug pin configuration
A1.2 Cable Pin Connections

Figures A-2 to A- 6 show the pin connections for the various cables used with the
Printer. The correct cable to be used depends on the needs of the host device.
The Printer will not operate properly with an incorrect cable.
Fig. A-2. Null Modem Cable (MXM)
NOTE - This cable is typically used to connect to DCE equipment using XON/XOFF flow control. Part
Number: 556000.
P/N: 510391 A-3

Fig. A-3. Straight Cable (MM)
NOTE: This cable is typically used to connect to other DCE equipment using XON/XOFF flow
control.
Fig. A-4. Personal Computer (Serial DB25P) to Printer.
NOTE - This cable is used to connect to a P.C. with DB25P serial ports. Flow control is either
XON/XOFF or CTS/DTR. Cable Part Number: 556002.
P/N: 510391 A-4

Fig. A-5. Personal Computer Serial (DB9P) to Printer
NOTE - This cable is used to connect to a P.C. with DB9P communication ports. Flow control is either
XON/XOFF or CTS/DTR. Cable Part Number: 556001.
Fig. A-6. RS-422 to Printer
P/N: 510391 A-5

A1.3 Serial to Parallel Adapter
A1.3.1 Adapter Description

The Parallel to Serial Interface Adapter is designed specifically for use with the Printer. It is a one-way
communications, self-powered device, and therefore, no external power source is required. Although
the adapter resembles a standard interface cable, it actually has sophisticated microprocessor circuitry
built into the head assembly. This circuit converts standard parallel data to the RS-232 serial
communication standard. This adapter is used when connecting with a PC that has only a parallel port
available.
A1.3.2 Installing the Parallel to Serial Adapter
¶ Turn the Printer OFF.
· Connect the cable according to the label on each plug - the side labeled PC must plug into the PC's
parallel printer port, and the side labeled PRINTER must plug the Printer's RS-232 serial port.
¸ The Printer must be set to default communication settings. These are: 9600 baud,
8 data bits, 1 stop bit, no parity. (The default settings are selected by setting DIP Switch SW1,
positions 1, 2, 3, and 4 to OFF).
¹ Turn the Printer ON.
CAUTION - Always TURN POWER OFF BEFORE connecting the Parallel to Serial
Interface Adapter.
P/N: 510391 A-6

Fig. A-7. Centronics Parallel Interface Converter
Fig. A-8. Serial to Parallel .
NOTE - This cable is used to connect to a P.C. with a DB25M Parallel port. Flow control is
CTS/DTR only. Cable Part Number: 899516.
P/N: 510391 A-7

A2.0 Sample Programs
The following sample programs are intended to aid the technician in testing and performing
adjustments. They provide a useful test label and some software switching functions.
These programs are created in the DOS environment, using the EDIT command. Additional
information on DOS and EDIT can be found using the DOS HELP function, or the DOS manual.
• All of the sample programs require the use of the ^B character. Creating the ^B character in DOS is
done in the following way:
¶ At the DOS prompt, simultaneously press the CTRL key and the "P" key.
· Simultaneously press the CTRL key and the "B" key.
• When entering command sequences (e.g.; ^BZ) there should be no space between the ^B character and
any following characters (^BZ, not ^B Z).
• If the host unit's COM port has not been set, it may be necessary to run the DOS MODE command. To
do so:
¶ At the DOS prompt, type MODE COM1:9600,N,8,1
· Press ENTER.
P/N: 510391 A-8

A2.1 Sample Test Label
The following program will produce a useful Test Label that includes Human Readable data in
different sizes and orientations, as well as a Bar Code sample.
To create the file;
¶ At the DOS prompt, type
EDIT TEST.TST
· Press ENTER. The DOS EDIT program will start.
¸ Type the following:
^BO0100
^Bf120
^BM1300
^BL
PE
SE
D11
H14
131100001000050TODAY IS DAY 1
132100001500000TODAY IS DAY 2
131300002000050TODAY IS DAY 3
241100002500250TODAY IS DAY 4
1A6204000500100ABC 555
151100000000000..$......
E
¹ From the EDIT menu at the top of the screen, select SAVE and EXIT.
To print the file:
º At the DOS prompt, type
COPY TEST.TST COM1:
» Press ENTER. The Printer should now print this Test Label.
P/N: 510391 A-9

A2.2 Beginning the Self Test Without a Printer Reset
As noted in the text, testing the Printer with Continuous media installed presents a special problem,
since the Test sequence begins with a reset, which changes the Printer to its default settings. After a
reset, the Label Edge Sensor will be active, but will fail to detect label edges on the Continuous media.
The following program will avoid this problem by beginning the Self Test or the Character Dump mode
without allowing the Printer to reset.
To create the file:
EDIT TEST.LAB
· Press ENTER. DOS's EDIT program will start.
¸ Type
^Bc0100
^BZ (for Self Test) or ^BP (for Character Dump Mode)
¹ From the EDIT menu at the top of the screen, choose SAVE and EXIT.
To send the file:
COPY TEST.LAB COM1:
» Press ENTER. The Printer should now begin the chosen function.
P/N: 510391 A-10

A2.3 Setting the Printer to Reflective Mode
The Printer can only be set to Reflective Sensing Mode through the use of a software command. The
following program will switch the Printer from Transmissive to Reflective Mode.
To create the file:
EDIT TEST.REF
· Press Enter. DOS's EDIT program will start.
¸ Type
^Br
¹ From the EDIT menu at the top of the screen, choose SAVE and EXIT.
To send the file:
COPY TEST. REF COM1:
» Press ENTER. The Reflective Sensor should now be active.
P/N: 510391 A-11

P/N: 510391 A-12

Schematic Diagrams

510391C

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510391C

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Allegro

© Copyright 1999 by Datamax Corporation

All rights reserved. Printed in the United States of America.

Part Number: 510391

UL: UL1950 Information Technology Equipment

1.Nur für Gebrauch innerhalb eines Gebäudes geeignet.

1.This unit is intended for indoor use only.

FCC: This device complies with Part 15 of FCC rules.

• Read and follow all warning instruction labels on the printer.

• Place the printer on a flat, firm, solid surface.

• Do not place the printer on or near a heat source.

♦ Introduction and Overview

♦ Setting up the Printer

♦ Creating Labels Using Internal Batch Software

Figure 1-1 Allegro Printer

Lights and Switches

Lights: Power, Paper/Ribbon, Pause

Word Length: Selectable 7-bit or 8-bit data format

Handshaking: Xon/Xoff (in receive mode only) and CTS/DTR

Grounding: Unit must be connected to a properly-grounded receptacle

Humidity: 10% to 95% non-condensing

Ventilation: Free air movement

Dust: Non-conducting, non-corrosive

Weight: 23 lbs. (10.4 kg)

Cutter with Tray: Maximum thickness of 0.010" (.254mm)

Font Memory Cartridges: Pre-loaded from the manufacturer

256K Flash EEPROM

Parallel Adapter: Converts Centronics Parallel type data to RS-232C

PC-Batch Software: Stand-alone label creation software package for IBM-PC or

1.3 Location of Parts on the Printer

Figure 1-2 Front and Left Side View.

Figure 1-3 Front and Right Side View

Figure 1-4 Back view, 115 VAC model.

Figure 1-5 Back view, 230 VAC model.

Figure 1-6 Cover removed - Media Transport and Print Mechanism.

2.1 Printer Set-up

1. Check the operating environment and power

• Ensure that the printer is placed on a firm, flat surface.

• Ensure that power is supplied from a properly-grounded outlet.

2. Determine the set-up requirements

• Determine the communications set-up (Serial or Parallel).

• If Serial communication is chosen, complete the following steps:

1. Select the protocol (either RS-232c or RS-422);

Part Number Description

Table 2-1 Cable Types

3. Install the Options

Fig. 2-1. Printer rear view - Connector and Switch locations

4. Set the Switches

Table 2-2 DIP Switch settings

Step 5 Plug in the Printer

Step 6 Load Media and Ribbon

Step 7 Perform a Self Test

2.2 Installing Options

2.2.1 The Cutter Option

2.2.2 Memory Modules

Name Part Number

Table 2-3 Font Modules

NOTE - Install all modules label forward, as shown in Figure 1-2.

2.2.2.1 RAM Modules

2.2.2.2 FLASH Modules

2.2.2.3 FONT Modules

2.2.2.4 Main Logic Board Connectors and Test Points

Items indicated in Fig. 2-2.