This manual was created as a reference for maintenance of the Thermal Printer TUP400 Series for personnel who are responsible for periodic inspections or troubleshooting of that equipment. This manual was written for maintenance personnel, and was not intended to be used by the general operator.
General Specifications Printing method Resolution Printable width Printing speeds Printable characters Character matrixes Bar Codes Paper Recommended brands Width Thickness Roll diameters Interface MCBF Head longevity Cutter longevity Power supply Power consumption Operating environment Storage environment Approximately 3.1kg TUP452 Line thermal direct 8 dots/mm (H) 8 dots/mm (V) 50 mm in Line Mode;...
DIP-Switch Settings DIP switches are located on the interface board and they differ according to the type of interface. Setting the DIP Switches 1. Turn the power supply OFF. 2. Remove the screw holding the ROM cover in place. (The screw is located at the base of the paper-roll holder.) 3.
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2. DIP-switch values (1) RS-232C interface This board has a single 8-bit DIP switch. Switch Setting Baud Handshake Data Parity Parity DC1/DC3 Power ON Baud 2400BPS 4800BPS 9600BPS 19200BPS Mode DC1/DC3 Disabled Disabled DC1/DC3 Disabled Addressable *1 The old type is selected. 8 bits No parity Disabled...
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(2) RS-422A interface This board had two DIP switches: one 8-bit switch and one 4-bit switch. DIP switch #1 (8 bits): Identical to the DIP switch on the RS-232C. (Bit 1-7 is disabled.) DIP switch #2 (4 bits): SW2-1 DC1,3 off Address DC1,3 mode on * DIP-SW #2 overrides the DIP-SW #1 DC1/3 setting (bit 1-7).
Print-Density Adjustment Adjust the print density in accordance with the sensitivity of the paper being used. Variable Resistor 1. The variable resistor is located to the left of the interface connector on the back side of the printer. 2. Use a phillips screw driver to rotate the variable resistor to adjust the print density. The variable resistor will rotate approximately 180 .
Sensor Adjustment You must adjust the paper sensor for the paper quality and the black mark print. Remove the screw on the underside of the paper-roll holder and remove the ROM cover. Turn ON the power supply while holding down the push switch on the Near-end Sensor Board. Remove the push-switch within 3 seconds after the "HU"...
HEX Dump Mode/Test Print You can enter the HEX Dump Mode and run Test Prints by turning ON the power supply while pressing the RESUME switch. The HEX Dump mode prints the data sent from the host computer in HEX data format. Turn ON the power supply while pressing the RESUME switch.
Changing the Interface Board You can change the printer’s interface by replacing the interface board. 1. Turn the power supply OFF. 2. Remove the 2 Interface Board Screws. 3. Remove the Interface Board. 4. Insert the new Interface Board by pushing it along the guides. Push until the connector is completely inserted.
THEORY OF OPERATION This chapter describes the operating principles of the circuitry and printer mechanism. 1. Block Diagram ... 16 2. Main Logic Board ... 18 2-1. Data I/O Circuitry ... 18 2-1-2.RS-422A Interface ... 19 2-1-3. Parallel Interface ... 20 2-2.
Block Diagram The following is the block diagram for this printer. Data (Host Computer) Interface Board RS-232C, RS-422A, Parallel (16) (16) Near-end Sensor Board (16) RESUME Switch DC-DC Coverter Power Supply Unit Main Logic Board Gate Array EPROM 128 k x 16 Bit ( Ver. 1 ) 250 k x 16 Bit ( Ver.
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(1) Main Logic Board The interface board relays data from the host computer to the main logic board. The main logic board’s CPU temporarily stores the data into local RAM. It then reads out the data, edits it according to the control program stored in the board’s ROM, and prints the results by issuing the appropriate drive signals to the printer mechanism.
Main Logic Board 2-1. Data I/O Circuitry The main logic board relays data back and forth to the host computer via the interface board. 2-1-1. RS-232C Interface R-CH Data from host to printer passes through the IC1 on the interface board from the RXD terminal and is input to the CPU on the main logic board.
2-1-2. RS-422A Interface RD (+) – – RD (–) CS (+) – – CS (–) RS (–) RS (+) SD (–) SD (+) RS-422A Interface Board Data flow from host to printer passes from the RD terminal to the IC1 on the interface board and is input to the CPU. The IC1 converts the RS-422A and TTL voltage levels.
2-1-3. Parallel Interface DATA 1 DATA 2 DARA 3 DATA 4 DATA 5 DARA 6 DATA 7 DATA 8 STROBE BUSY ERROR SELECTED PAPER OUT Parallel Interface Board The host computer sends eight bits of data for DATA 1 - 8 to the CN3 connector when the BUSY signal is LOW (printer is ready).
2-2. Editing and Printing 2-2-1. Editing The CPU reads data sequentially from RAM and edits it in accordance with program instructions stored in EPROM. The edited data undergoes parallel-to-serial conversion in the gate array, and is then output to the thermal head’s drive controller.
CLOCK LATCH STROBE1 STROBE2 STROBE3 STROBE4 STROBE5 COMMON 2-2-3. Head Current Control Heat buildup in the head during operation can cause print quality to degrade. To maintain uniform printing quality, the printer varies the energizing time (time that STROBE remains LOW) in accordance with the head temperature. The thermal head’s surface temperature is calculated based on the resistance value of an attached thermistor.
2-3. Feed-Motor Drive Circuit This printer employs a paper feed motor and a stepping motor. The motor rotates through a certain angle each time it receives a pulse from the drive circuit. This printer employs a 4-phase stepping motor and controls the paper feed motor with a phase 1-2 excitation method.
2-4. Power-On Reset Circuit Immediately following power-on the printer executes a power-on reset, initializing all circuit elements. The power-on reset serves as protection against operational errors. The power-on RESET signal is maintained for approximately 160ms. The reset circuit is illustrated below. RESET RESET IC At power on, voltage-detector circuit IC4 (M51953BL) outputs a LOW signal from its OUT terminal.
2-5. +5V Line Voltage Detector Circuit The voltage-detection IC detects momentary drops or unstable levels in the +5V line voltage. The following illustrates the equivalence circuit of the voltage detector IC (Fig. 2-9 IC4). Fig. 2-11 Equivalence Circuit for Voltage Detecting IC The following operation timing chart shows control is performed by the voltage detector IC output.
Printer Mechanism 3-1. Thermal Head TSP400 series printers employ thermal line printing. The thermal head consists of a horizontal line of 640 heat elements. These elements print one line of dots at a time as the paper passes over the head. The head is fixed in position; only the paper moves.
3-3. Sensor Paper-Out Sensor The paper-out sensor is located at the paper entry slit. The detector consists of a reflective photosensor. The photosensor’s phototransistor remains ON while paper is present. It goes OFF when paper runs out, generating output of a paper-out signal. Black-Mark Sensor This detector senses black marks indicating print start positions.
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Head-Up Detector This detector consists of a leaf switch indicating whether the head is closed (in contact with the platen) or open (separated from the platen). The leaf switch is closed when the head is closed; it opens when the head is opened. Detection Signal Leaf Switch Fig.
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PARTS REPLACEMENT AND RELATED ADJUSTMENTS This chapter describes disassembly and reassembly procedures. Please take note of the following. ALWAYS disconnect the power cord from the AC outlet before beginning a disassembly or reassembly procedure. Except where otherwise stated, the reassembly procedure is the reverse of the disassembly procedure. Coat screw heads with locking sealant after completion of reassembly.
Presenter (TUP482) Cutter Disconnect the power cord from the AC outlet. Remove: Screws 4 pcs. [1] Presenter Holder L and R [2] Presenter [3] Refer to Step 4 to remove the connector which is connected to the main logic board from the Presenter.
Printer Mechanism Main Logic Board Remove the power supply connector. Remove: Screws 4 pcs. [1] Connector [2] Cut the wire band in four places. Printer Mechanism [3] Refer to Step 4 to remove the connector which is connected to the main logic board from the printer mechanims.
Print Head Unit [ 2 ] [ 1 ] [ 3 ] Feed Motor Assembly [ 1 ] Pull the pressure stay [1] forward to open the head frame unit [2]. Slide the head clamp [3] in the direction indicated by [ 4 ] the arrow.
Sensor Unit Old Type [ 4 ] New Type [ 4 ] Remove: Printer mechanism (See 3. above.) Two wire band screws holding the lead wire [1]. Screws 2 pcs. [1] Transmit sensor [2] [ 3 ] Screw 1 pc. [3] Head-up sensor [4] [ 1 ] Note: There are two types of transmit sensors.
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Maintenance Proper maintenance is necessary to maintain printer performance and forestall potential problems. Please carry out maintenance as described below. 1-1. Cleaning Surface dirt Clear away dirt with a soft cloth. If necessary, apply a small quantity of alcohol to the cloth to improve cleaning power.
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Lubrication Proper lubrication is essential for maintaining the printer’s performance level and preventing breakdowns or other problems. 2-1. Lubricants Choice of lubrication can significantly affect the printer’s performance, longevity, and low-temperature characteristics. We recommend the following lubricant for the TSP400 series. Type Name Grease...
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HOW TO USE PARTS LIST DRWG. NO. This column shows the drawing number of the illustration. REVISED EDITION MARK This column shows a revision number. Part that have been added in the revised edition are indicated with "#" Part that have been abolished in the revised edition are indicated with "*" #1:First edition Second edition PARTS NO.
3-2. Parts List DRWG.NO. REV. PARTS NO. 37517000 37514010 33120210 33101410 32012010 30520510 04020017 02206002 37513010 04300781 37512010 33140020 37510010 33215010 32025010 30045040 30045011 04033001 04020010 00930609 00820304 <Note 1> If DRWG. NO. 10 is removed, it should be replaced with new ones. PARTS NAME DETECTOR BOARD UNIT SLIP GEAR UNIT...
4-3. Parallel Interface Type PARALLEL I/F BOARD STROBE DATA 1 DATA 2 DATA 3 DIN1 DATA 4 DIN3 DATA 5 DIN5 DATA 6 DIN7 DATA 7 DATA 8 Vcc(+5V) ERROR BUSY SLCT BUSY SLCT F-GND Vcc(+5V) RETURN-GND PEXT1 RETURN-GND VEXT RETURN-GND RETURN-GND RETURN-GND...
Main Logic Board (Ver.1) 5-1. Circuit Diagram <Note 1> The unit of resistor and resistor array is " ", and no indication of wattage means 1/6W, 1/8 respectively. <Note 2> The unit of capacitor and capacitor array is "F", and no indication of Voltage means 50V. <Note 3>...
15. Presenter Sensor Board 15-1. Circuit Diagram 51004-0500 PR-sig S-GND 15-2. Parts List DRWG.NO. REV. PARTS NO. 05532234 06051235 06055614 06053324 07227853 08300082 C1740 SENSOR BOARD PRESENTER DC MOTOR PARTS NAME CAPACITOR 0.022UF 25V RD RESISTOR 12 K-OHM 1/6W RD RESISTOR 560 OHM 1/6W RD RESISTOR 3.3 K-OHM 1/6W TRANSISTOR 2SC1740SE PHOTO-INTERRUPTER PS6002A-KS...
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HEAD OFFICE STAR MICRONICS CO., LTD. JAPAN 536 Nanatsushinya, Shimizu, Shizuoka, 424-0066, JAPAN Tel: 0543-47-0113 Telefax: 0543-48-5013 Please access the following URL http://www.star-micronics.co.jp/service/t_mans_e.htm for the lastest revision of the manual. Distributed by OVERSEAS SUBSIDIARY COMPANIES STAR MICRONICS AMERICA, CO. 70-D Ethel Road West.