Service Manual
EasyCoder PC4
Bar Code Label
Printer
Intermec Technologies Corporation
Corporate Headquarters
6001 36th Ave. W.
Everett, WA 98203
U.S.A.
www.intermec.com
e information contained herein is proprietary and is provided solely for the purpose of allowing
customers to operate and/or service Intermec manufactured equipment and is not to be released,
reproduced, or used for any other purpose without written permission of Intermec.
Information and specifications in this manual are subject to change without notice.
© 2005 by Intermec Technologies Corporation. All Rights Reserved
EasyCoder, EasyLAN, Fingerprint, and LabelShop are registered trademarks of Intermec Tech
nologies Corp. e word Intermec, the Intermec logo, InterDriver, and PrintSet are trademarks of
Intermec Technologies Corp.
e name Centronics is wholly owned by GENICOM Corporation.
Microsoft is a registered trademark of Microsoft Corporation.
Windows is a trademark of Microsoft Corporation.
roughout this manual, trademarked names may be used. Rather than put a trademark (™) symbol
in every occurrence of a trademarked name, we state that we are using the names only in an editorial
fashion, and to the benefit of the trademark owner, with no intention of infringement.
Intermec EasyCoder PC4—Service Manual iii
Preface
Contents
About is Manual ...............................................................................................................v
Notices and Approvals ..........................................................................................................
vi
1
Models and Options 1
1.1 Models............................................................................................................................ 2
1.2 Options ...........................................................................................................................
3
1.3 EasyCoder PC4 Specifications ........................................................................................
4
1.4 EasyCoder PC4 Measures ...............................................................................................
6
2
Main Parts 9
2.1 Taking the Printer Apart ................................................................................................10
2.2 Reassembling the Printer ...............................................................................................
10
2.3 Exploded View ..............................................................................................................
11
3
Top Cover 13
3.1 Description................................................................................................................... 14
3.2 Tear-Off Plate ................................................................................................................
15
4
Print Frame 17
4.1 Description.......................................................... .........................................................18
4.2 LED and Feed Switch ...................................................................................................
19
4.3 Top Cover Locks ...........................................................................................................
21
4.4 Base Lock Spring Hooks ...............................................................................................
21
4.5 Printhead ......................................................................................................................
22
4.6 Ribbon End Sensor .......................................................................................................
25
4.7 Label Gap Sensor (Emitter) ...........................................................................................
27
4.8 Ribbon Feed Mechanism ..............................................................................................
28
5
Base Frame 33
5.1 Main Parts..................................................................................................................... 34
5.2 Main Board ...................................................................................................................
35
5.3 Platen Roller .................................................................................................................
36
5.4 Peel-Off Mechanism ......................................................................................................
37
5.5 Motor assy ....................................................................................................................
39
5.6 Media Guides ................................................................................................................
40
5.7 Base Locks ....................................................................................................................
41
5.8 Label Gap/Black Mark Sensors ......................................................................................
43
5.9 Media Spindle ...............................................................................................................
45
6
Bottom Cover 47
6.1 Bottom Cover ...............................................................................................................48
iv Intermec EasyCoder PC4—Service Manual
Preface
7
Main Board 49
7.1 Description................................................................................................................... 50
7.2 Accessing the Main Board .............................................................................................
51
7.3 Connections ..................................................................................................................51
7.4 Test Points .....................................................................................................................
52
7.5 Block Diagram ..............................................................................................................
54
7.6 Internal Memory ...........................................................................................................
55
7.7 Schematics ....................................................................................................................56
8
Power Supply 61
8.1 Description.................................................................................................................... 62
9
Memory Cartridge (option) 63
9.1 Description................................................................................................................... 64
9.2 Memory Sizes ................................................................................................................
65
9.3 Schematics ....................................................................................................................66
10
Starting Up 67
10.1 Normal Mode .............................................................................................................68
10.2 Test Mode ...................................................................................................................
69
10.3 Dump Mode ...............................................................................................................
70
11
Firmware Upgrading 71
11.1 Requirements ..............................................................................................................72
11.2 Step-by Step Instructions ............................................................................................
73
12
Troubleshooting 75
12.1 Checklist..................................................................................................................... 76
Intermec EasyCoder PC4—Service Manual v
Preface
About This Manual
is Service Manual is intended to facilitate installation, troubleshooting
and repair of the Intermec EasyCoder PC4 in the version delivered at the
date of publishing. us, all information on the ESim firmware is based on
version 6.xx. e on-going product improvement can be followed in the
Technical Bulletins published at the Intermec Knowledge Center.
is Service Manual is supplemented by the following publications, which
the service technician also should keep easily available in their latest ver
-
sions:
• Intermec EasyCoder PC4, Quick Start Guide (multilingual)
• Intermec EasyCoder PC4, User’s Guide
• Intermec EasyCoder PC4, Spare Parts Catalog
• ESim v6.xx, Programmer’s Reference Manual
Please note that the operations described in this manual only should be car
ried out by skilled and authorized personnel with proper training and full
understanding of written English. Moving parts may cause harm, if incor
-
rectly manipulated.
It is assumed that the reader possesses adequate skills in mechanics and
electronics and is familiar with the ESim protocol and its related standard
application programs. It is also assumed that the reader has access to the
standard tools of an electronics workshop.
vi Intermec EasyCoder PC4—Service Manual
Preface
FCC Notice (United States of America)
WARNING
is equipment generates, uses, and can radiate radio frequency energy
and if not installed and used in accordance with the instructions manual,
may interfere with radio communications. It has been tested and found to
comply with the limits for a Class A computing device pursuant to Sub
part J of Part 15 of FCC Rules, which are designed to provide reasonable
protection against such interference when operated in a commercial envi
ronment. Operation of this equipment in a residential area is likely to cause
interference in which case the user, at his own expense, will be required to
take the appropriate measures needed to correct the problem.
DOC Notice (Canada)
Canadian Dept. of Communication
REGULATIONS COMPLIANCE
(DOC-A)
is digital apparatus does not exceed the class A limits for radio noise
emissions from a digital apparatus as set out in the radio interference regu
-
lations of the Canadian Department of Communication.
Ministère des Communications du Canada
CONFORMITE DE REGLEMENTS
(DOC-A)
Le présent appareil numérique n’émet pas de bruits radio-électriques dépassant les limites applicables aux appareils numériques de classe A prescrites
dans le règlement sur brouillage radioélectrique édicté par le Ministère des
Communications du Canada.
EU Standard EN 55022 (The European Union)
WARNING
is is a Class A ITE product. In a domestic environment this product
may cause radio interference in which case the user may be required to take
adequate measures.
Notices and Approvals
Intermec EasyCoder PC4—Service Manual 1
1
Models and Options
is chapter provides information on the various models of the EasyCoder
PC4 and contains specifications and physical measures.
2 Intermec EasyCoder PC4—Service Manual
Chapter 1—Models and Options
1.1 Models
ere are two main models of the EasyCoder PC4; one dedicated direct
thermal (DT) model and one dual-capable direct thermal/thermal transfer
(TTR) model. Both models are based on a common double clam-shell
mechanical platform and have the same type of electronics, so except from
the fact that the direct thermal model has no transfer ribbon mechanism,
there are very few differences.
Both models are available with two different printheads; one with a density
of 203.2 dots per inch (8 dots per mm) and a maximum print width of 4.1
inches (104 mm), and another with a density of 300 dots per inch (11.81
dots per mm) and a maximum print width of 4.02 inches (102.2 mm).
Since there is no need to open the top cover in the DT model, the top
cover locks are cut off in flush with the bottom of the print frame.
e machine label, which provides information on model, part number,
serial number, etc. is attached to the bottom of the base frame.
e EasyCoder PC4 has a separate power supply unit that delivers 24
VDC to the printer's main board, where it is transformed to the various
voltages required by the printhead, motor, and logics (see Chapter 8.1).
Thermal transfer
mechanism
(omitted in DT model)
Printhead
Top cover locks
(differ in DT and
TTR models)
Print frame
Top cover
Base Frame
Bottom Cover
Intermec EasyCoder PC4—Service Manual 3
Chapter 1—Models and Options
e power supply unit (PSU) accepts 100 to 240 VAC/50 to 60 Hz. e
power supply has a standard 2-pin input voltage socket, so various types of
power cords can be used according to local voltages and standards.
e power supply has a fixed 1.5 m (4.9 ft) long cable that is connected to
the printer’s rear plate.
1.2 Options
e available options for the EasyCoder PC4 are memory cartridges, USB,
serial and parallel interface cables, a keyboard/display unit, a paper cutter,
a battery unit and an assortment of power cords. Refer to the EasyCoder
PC4, Spare Parts Catalog
or Spare Parts List for updated information.
4 Intermec EasyCoder PC4—Service Manual
Chapter 1—Models and Options
1.3 EasyCoder PC4 Specifications
Printing
Print Technique ermal Transfer and/or Direct ermal
Printhead Resolution
203.2 dpi (8 dots/mm) or
300 dpi (11.81 dots/mm)
Print Speed (selectable) 30, 40, 50, 75 or 100 mm/sec.
(1.2,1.6, 2, 3 or 4 in/sec.)
Print Width (max) at 203.2 dpi 104 mm (4.1 inches) = 832 dots
Print Width (max) at 300 dpi
102.2 mm (4.02 inches) = 1208 dots
Print Length (min/max) at 203.2 dpi 6.35/472.5 mm (0.25/18.6 inches) Standard (no cartridge)
Print Length (min/max) at 300 dpi 6.35/220.0 mm (0.25/8.66 inches) Standard (no cartridge)
Media Width (min/max) 25.4 to 118 mm (1.00 to 4.65 inches)
Media ickness (min) 0.06 mm (0.003 inches)
Media ickness, rolls (max) 0.15 mm (0.006 inches)
Media ickness, fan-folds (max) 0.17 mm (0.006 inches)
Media Roll Diameter (max) 127 mm (5.0 inches)
Media Roll Core Diameter 25.4 or 38.1 mm (1.0 or 1.5 inches)
Ribbon Width (min/max) 33 to 110 mm (1.33 to 4.33 inches)
Ribbon Roll Diameter, Outer (max) 41 mm (1.6 inches)
Ribbor Roll Core Diameter, Inner 13 mm (0.5 inches)
Print Directions 4
Modes of operation
Tear Off (Straight-through) Yes
Peel Off (Self-strip) Yes
Firmware
Operating System Intermec ESim v6.xx
Fonts 5 resident
Font Magnification Horizontal max 8 times, vertical max 9 times
Built-in Bar Code Symbologies
33
Physical Measures
Dimensions (W × L × H) 230 × 257 × 167 mm
(9.06 × 10.11 × 6.58 inches)
Weight (excluding PSU and media) Approx. 2.3 kg (5 pounds) Depending on model
Ambient Operating Temperature +5°C to +40°C (+41°F to +104°F)
Ambient Storage Temperature
-20°C to +50°C (-4°F to +122°F)
Humidity
10 to 90% non-condensing
Electronics
Microprocessor 16-bit 20 MHz (16M of address space)
On-board Flash memory 1024K (774K firmware, 250K available to user)
On-board RAM memory 2048K (576K firmware, 1050K print buffer)
Power Supply Unit Separate unit
Input Voltage 100 to 240 VAC, 50 to 60Hz, 1.9A
Output Voltage 24 VDC, 3.0A
Input Voltage (mobile applications) 23.5 VDC ± 0.5V, 6A peak No PSU connected
Intermec EasyCoder PC4—Service Manual 5
Chapter 1—Models and Options
Sensors
Label Gap/Black Mark/Out of Paper Yes
Label Taken Yes Not with cutter
Print Frame Open/Closed Yes
Ribbon End Yes TTR model only
Head up (DOOR L & R) Yes
Controls
Control Lamps
1 Tri-colored LED
Feed Button 1
Data Interfaces
Serial
1 × RS-232 + 1 × USB(v1.1)
Parallel
1 × Centronics
Accessories and Options
Parallel Interface Cable Standard
RS-232 Cable Option
Memory Cartridge Option 1MB flash
Keyboard/Display Unit Option
Paper Cutter Option
V-spring for stiff/thick media Option
>150µm/5.9 mils
Mobile Battery Unit Option
Battery Pack Option
Battery Charger Option
USB cable Option
6 Intermec EasyCoder PC4—Service Manual
Chapter 1—Models and Options
259 mm (10.20 in)
166 mm (6.54 in)
314 mm (12.36 in)
333 mm (13.11 in)
1.4 EasyCoder PC4 Measures
Side View
Intermec EasyCoder PC4—Service Manual 7
Chapter 1—Models and Options
50 mm (1.97 in) 133 mm (5.24 in)
77 mm (3.03 in)
Front View
Rear View
8 Intermec EasyCoder PC4—Service Manual
Chapter 1—Models and Options
230 mm (9.06 in)
188 mm (7.40 in
)
39 mm (1.54 in)
17 mm (0.67 in)
9 mm (0.35 in)
168 mm (6.61 in)
209 mm (8.83 in)
150 mm (5.91 in)
4.6 mm (0.18 in
)
184 mm (7.24 in)
154 mm (6.06 in
)
Top View
Bottom View
Intermec EasyCoder PC4—Service Manual 9
2
Main Parts
is chapter shows the printer’s main parts and explains how the printer is
taken apart and reassembled. Each of the main parts is described in more
detail in the chapters that follow.
10 Intermec EasyCoder PC4—Service Manual
Chapter 2—Main Parts
2.1 Taking the Printer Apart
e EasyCoder PC4 is a so called double clam-shell design, where the print
frame and the top cover are hinged to a base frame.
e bottom part of the base frame is enclosed by the bottom cover, which
is held by four Phillips screws. Once the bottom cover has been removed,
the two pairs of bolts and E-rings that hold the base frame, the print frame,
and the top cover become accessible. You will also need to disconnect a
number of cables from the main board.
In most cases, you do not need to dismantle the base frame, print frame,
and top cover.
In the illustration in Chapter 2.3, all cables have been omitted. Detailed
descriptions of the main parts and their sub-assemblies can be found in
Chapters 3 to 7.
All screws are Phillips-type of various sizes.
2.2 Reassembling the Printer
Reassemble the printer in reverse order. Refer to Chapter 7.3 for a connection diagram, which helps you put all the cables back correctly. When put
ting the printer back into the bottom cover, tilt it a little so the rear plate is
inserted first, then carefully manipulate the front part in place. Secure the
assembly with the four Phillips screws.
Intermec EasyCoder PC4—Service Manual 11
Chapter 2—Main Parts
2.3 Exploded View
Top Cover
Print Frame
Base Frame
Bottom Cover
Bolts
E-ring
E-ring
12 Intermec EasyCoder PC4—Service Manual
Chapter 2—Main Parts
Intermec EasyCoder PC4—Service Manual 13
3
Top Cover
is chapter describes the parts of the top cover and explains how to
replace the tear-off plate.
14 Intermec EasyCoder PC4—Service Manual
Chapter 3—Top Cover
3.1 Description
e top cover encloses the print frame. It is attached to the base frame
using the same pair of bolts and E-rings as the print frame. e top cover
and the print frame opens together when the base locks on either side of
the printer are pressed. en the top cover can be released from the print
frame by pressing the two green locks at either side of the print frame, as
shown below. Note that in case of a PC4 DT printer, the locks are cut off
and you will need to insert a flat screwdriver or similar to release the locks.
Base locks
Top cover locks
Intermec EasyCoder PC4—Service Manual 15
Chapter 3—Top Cover
e top cover is made up of the following parts:
• Top cover plastic moulding
• Clear plastic window (permanently glued to the moulding)
• Two media load instruction labels
• Tear-off plate (snap-locked to the moulding)
• Name plate (glued to the moulding)
3.2 Tear-Off Plate
e only part that can be replaced easily is the tear-off plate. It is provided
with two snap-lock tabs that engage bars at the inside of the top cover. Two
L-shaped rails hold the plate. If you need to remove the tear-off plate with
-
out discarding it, be careful not to break the tabs, which are quite delicate.
Top cover moulding
Clear window
Tear-off plate
Name plate
16 Intermec EasyCoder PC4—Service Manual
Chapter 3—Top Cover
Intermec EasyCoder PC4—Service Manual 17
4
Print Frame
is chapter describes the print frame which contains the thermal printhead, the transfer ribbon supply, the LED control lamp, the Feed key, and
the emitter of the label gap sensor. It also provides instructions for how to
replace the various parts.
18 Intermec EasyCoder PC4—Service Manual
Chapter 4—Print Frame
4.1 Description
e print frame comes in two versions; one for the DT model and another
for the TTR model. Both are based on the same plastic moulding. ey
both have either a 203.2 dpi (8 dots/mm) printhead or a 300 dpi (11.81
dots/mm) printhead.
Direct Thermal (DT) Model
Thermal Transfer (TTR) Model
Print frame moulding
LED control lamp
Feed switch
(No ribbon load label)
(No transfer
ribbon mechanism)
(No ribbon end sensor)
Short top cover locks
Print frame moulding
LED control lamp
Feed switch
Ribbon load label
Transfer
ribbon mechanism
Ribbon end sensor
Long top cover locks
Printhead
Printhead
Label gap sensor
(Emitter)
Label gap sensor
(Emitter)
Intermec EasyCoder PC4—Service Manual 19
Chapter 4 —Print Fram
4.2 LED and Feed Switch
Description
e LED control lamp and Feed switch are fitted on the same Feed Switch
PCB inside a housing on the left side of the print frame. e board is con
nected to JP9 on the main board via a four cables that run inside the left
side hinge of the print frame. e control lamp shines through a transpar
ent window and the Feed switch is activated via a dome, both in the name
plate on the top cover.
Replacement
e Feed Switch PCB can be accessed for replacement by removing the
cable cover, which is held in place by a Phillips screw and a snap lock. e
Feed Switch PCB is inserted between two rails in the moulding and is cov
-
ered by an isolation sheet.
Green (solid) Media loaded
Ribbon loaded (TTR only)
Green (flashing) Receiving data
(T
est Mode only)
Red (solid) Out of media
Out of ribbon (TTR only)
Printer reset
Red (short flashes) Upgrading firmware
Ov
ertemperature
Red (long flashes) Media jam in cutter
Ov
erheated printhead or
stepper moto
r
Orange
Error condition detecte
d
Dark
Po
wer off
Color Meaning
Feed switch PCB
Cable cover
Screw
Snap lock
Print frame
Isolation sheet
20 Intermec EasyCoder PC4—Service Manual
Chapter 4—Print Frame
Schematics
JP1
1
2
3
4
LED1
RED
SW1
LED1
YELLO
W
R1
R2
Intermec EasyCoder PC4—Service Manual 21
Chapter 4 —Print Fram
4.3 Top Cover Locks
Description
e top cover locks are shorter in the DT model than in the TTR model,
because there is normally no need to separate top cover and the print
frame, when there is no need for ribbon reload.
Note: Parts are marked with “L” or “R” indicating left or right side (frontal
view).
DT Model TTR Model
Replacement
e locks are attached to the print frame moulding with Phillips screws. To
access the left side lock, you will need to remove the cable cover as shown
in the instructions for replacing the Feed Switch PCB earlier in this chap
-
ter.
4.4 Base Lock Spring Hooks
Description
Two spring hooks that are engaged by the base lock (see Chapter 5.7) are
fitted to the print frame moulding using Phillips screws. e spring hooks
are identical for the DT and TTR models.
Replacement
e left-side spring hook is fitted inside the same housing as the Feed
switch PCB. To access it, you will need to remove the cable cover as shown
in the instructions for replacing the Feed Switch PCB earlier in this chap
-
ter.
e right-side spring hook is easily accessible in the DT model whereas in
the TTR model, you will need to dismantle the ribbon takeup mechanism
(see Chapter 4.8).
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