Intermec EasyCoder 601 XP Service Manual
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Intermec EasyCoder 601 XP Service Manual

Intermec EasyCoder 601 XP Service Manual

Bar code label printer
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Service Manual
P/N 1-960431-01
Edition 2
November 1998
EasyCoder 601 XP
Bar Code Label Printer

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Summary of Contents for Intermec EasyCoder 601 XP

  • Page 1 Service Manual P/N 1-960431-01 Edition 2 November 1998 EasyCoder 601 XP Bar Code Label Printer...

  • Page 2: Table Of Contents

    Paper Feed Principles ..............68 9. Backing Paper Rewind Kit Description ..................70 Main Parts ..................71 Paper Rewind Unit ................ 72 Intermec EasyCoder 601 XP Service Manual Edition 2, November 1998 Part No. 1-960431-01 Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 3 - Label Stop Sensor (LSS) ............138 - Headlift Sensor ................. 138 - Ribbon End Sensor ..............139 - Ribbon Low Sensor ..............139 - Label Taken Sensor (LTS) ............140 Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 4 Information in this manual is subject to change without prior notice and does not represent a commitment on the part of Intermec Printer AB. © Copyright Intermec Printer AB 1998. All rights reserved. Published in Sweden. EasyCoder, Fingerprint, and LabelShop are registered trademarks of Intermec Technologies Corp.

  • Page 5: Preface

    0.2 Preface This Service Manual is intended to facilitate installation, trouble- shooting and repair of the Intermec EasyCoder 601 XP in the version delivered at the date of publishing. Thus, all information on the Intermec Fingerprint firmware is based on version 7.12. The on- going product improvement can be followed in the Printer Techni- cal Bulletins from Intermec.

  • Page 6: Notices And Approvals

    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. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 7: Declaration Of Conformity

    Hans Lindén President /. Intermec assumes no responsibility as regards fulfilling the CE Directive if the printer is handled, modified or installed in other manners than those described in the manuals. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 8: Identification

    Chapter 1 1. Models and Options 1.1 Identification Presently, the EasyCoder 601 XP only comes in one main model; a combined direct thermal/thermal transfer printer with a setup keyboard and a 12 dots/mm printhead. The printer can use 100 – 240 V AC, 50 – 60 Hz mains supply. There is no voltage switch-over.
  • Page 9 Chapter 1 Models and Options 1.1 Identification, The EasyCoder 601 XP can be fitted with a number of built-in cont'd. options: • Paper Cutter (see chapter 11) • Label-Taken Sensor (see chapter 10) • Backing Paper Rewind Unit (see chapter 9) •...
  • Page 10 - Check number of Flash SIMMs. - Check number and size of DRAM SIMMs. • Any optional interface board fitted? - Check type, straps and optional circuits. Refer to chapters 15 – 16 for more information. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 11 Use the VERSION$ function to check version of the Intermec Fingerprint firmware. You can read the setup in the Setup Mode or by means of Intermec Shell, which also allows you to print test label #5 containing the present setup values. To enter Shell if a custom-made autoexec-file prevents access, lift the printhead and press any key on the printer's keyboard (except the <Shift>...

  • Page 12: Specifications

    Std. 1 x 4 Mbytes Real-Time Clock 10+ years life Power Supply Mains Voltage >90 – <264 V AC, 45 – 65 Hz PFC Regulation IEC 61000-3-2 Continuous 175W; Peek ≈ 400W Maximum Power Consumption Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 13 Industrial Interface Board Option External Alphanumeric Keyboard Option Various Windows Printer Drivers Standard Excl. cable MS Windows 95 Printer Driver Standard Excl. cable Flash Memory Cards Option Electronic Keys Future option Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 14: Measures

    An optional paper cutter increases the printer's total length by 28 mm (1.1"). At least 90 mm (3.5") of free space behind the printer is required for the connectors, and for inserting and removing a memory card. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 15: Front

    (4-pin female DIN-type) and a slot, that in other printer models using the same front, gives access to a memory card adapter. Note that the memory card adapter in EasyCoder 601 XP is fitted on the CPU board and is accessible through a slot in the rear plate! Keyboard/Display assy.
  • Page 16 The keyboard is of membrane switch type and is glued to the keyboard plate. There are 54 switches, but only 23 of these are used in EasyCoder 601 XP. One switch is a Shift key, that provides a dual functionality to each of the other keys. A resistor ladder gives...
  • Page 17 “Error”) is usually used to indicate that an error has occurred. Error LED (red) Ready LED (green) Power On LED (green) LCD Display Keyboard Connection Beeper Slave Processor Cable to CPU Board Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 18: Components

    Chapter 2 Front and Keyboard 2.3 Components 1-971604-01 Console pcb. DISPLAY 1-971704-01 Component Side 1-971604-01 P01 Soldering Side Test Points: +5V C14 Lower soldering GND C14 Upper soldering Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 19: Schematics

    GREEN Ain/PA4 Ain/PA5 PB6/ATIn Ain/PA6 PB7/ATOut Ain/PA7 ST6265 GREEN RESET PC0/Ain PC1/Tin/Ain OSCout PC2/Sin/Ain OSCin 8MHz PC3/Sout/Ain IC3B PC4/SCK/Ain TEST 74HC05 IC3C IC2B Beeper 74HC05 RESET 74HC74 IC2A IC3A 74HC05 74HC74 Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 20: Right-Hand Door

    Shut the door, loosen the screws slightly and align the door with the front moulding. Tighten the screws and check that the door runs freely and is kept shut by the magnetic lock. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 21: Front Hatch

    The front hatch can be replaced by an optional paper cutter unit, see chapter 11. Alignment is performed in the same way as the right-hand door, see previous page. The front hatch can be removed by pushing it to the left when open. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 22: Left-Hand Cover

    Before finally tightening the screws, check that the cover is aligned with the front moulding and the rear plate and that it does not interfere with the right-hand door. #T10 Torx Screws #T10 Torx Screws Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 23: Description

    To avoid ribbon wrinkling and paper misalignment, it is imperative that the printer stands on a plane surface and the centre-line wall is straight. If such problems should occur, especially after transporta- tion, check that the centre-line wall is straight. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 24: Bottom Plate

    Bar Code Wand Connector Main Switch Provision for 1 – 2 Electronic Keys Mains Receptacle RS 232C Serial Interface ("uart1:") Upper External Paper Intake Centronics Parallel Interface Memory Card Slot Lower External Paper Intake Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 25 A large crescent-shaped plate keeps the paper roll aligned with the print mechanism. Maximum diameter of an internal paper roll is 205 mm (8") and maximum width is 168 mm (6.61"). Paper Supply Spool Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 26: Internal Supply

    The brake torque should be 70 ±20 Nmm The code disc fitted at the innermost part of the bobbin package has no use in EasyCoder 601 XP, but is retained for logistic reasons (common assembly with EasyCoder 501/601). Be careful to fit the studs of the innermost bobbin into the holes in the code disk when the package is assembled.
  • Page 27 76 mm (3") cores. Each adapter cont'd. is locked by means of a #T20 Torx screw. Be careful not to let the screw hit the leaf springs or the cams of the bobbins. 3" Adapters Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 28: External Supply

    Chapter 5 Paper Supply 5.2 External Supply In addition to the internal paper roll, the EasyCoder 601 XP printer can also use thermal paper or receiving face material from an external supply, e.g. an external paper roll or a stack of fan-folded tickets.
  • Page 29 Adjust the position of the outer guide to fit the width of the paper. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 30 Note that if the printer is to be permanently used with an external paper supply only, the internal paper supply spool, together with the large crescent-shaped guide plate could easily be removed (see chapter 5.1). Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 31: Description

    The guide is included at delivery of the printer, but is not fitted as standard. Label Slack Absorber Paper Guide (not fitted as standard) Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 32: Dismantling

    The shaft should be screwed into the flange with a tightening torque of 5 Nm. #T20 Torx Screws (2x) #T10 Torx Screw Flange Torsion Spring Shaft Grip (green) Paper Guide (green) Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 33: Description

    • Ribbon unwind unit (see chapter 7.2) • Ribbon rewind unit (see chapter 7.3) • Ribbon-end sensor (see chapter 7.4) Ribbon Rewind Unit Ribbon Unwind Unit Ribbon End Sensor (hidden) Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 34: Ribbon Unwind Unit

    Therefore, the shaft is provided with six grooves which correspond Ribbon Width Position (groove) to the standard widths of Intermec transfer ribbons (see table to the ≤ 60 mm (2.36") 1:st (innermost) left). Choose the groove that comes closest to the ribbon width. By 88 mm (3.5")
  • Page 35 Use a 2 mm hexagon /. Refer to Appendix 2 for a description of wrench to loosen the grub screw. how to check the brake torque. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 36: Ribbon Rewind Unit

    215±20 Nmm at 20°C /. Refer to Appendix 2 for a description of how to check the brake torque. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 37 Bobbin Plate Ball Bearing Ball Bearing Spring Washer Circlips Slide Bearing Flange Bobbin Washer Carrier Washers Compression Spring Grub Screw 0–4 Torque Adjustment Friction Felt 0–1 Torque Adjustment Shaft #T20 Torx Screw Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 38: Ribbon End Sensor

    Thermal transfer media No ribbon Error 1027 Out of transfer ribbon Direct thermal media No ribbon Direct thermal media Ribbon The ribbon end sensor is connected to P52 on the CPU board. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 39 If that does not help, fit or remove the jumper on P56. If the sensor refuses to work, consider the possibility that the mirror plate may be bent before discarding the sensor. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 40: Description

    • The headlift mechanism presses the printhead against the ther- mal paper or transfer ribbon, or lifts the printhead to allow paper and ribbon load. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 41 Belt to Ribbon Rewind Unit Stepper Motor Label Stop Sensor (hidden) Headlift Mechanism Ribbon Return Roller Pressing Roller Printhead Tear-Off Edge Rewind Roller Locking Handle (in open position) Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 42 Note that some of the parts illustrated here are not available as separate spare parts, but must be bought as ready- assembled units. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 43: Pressing Roller

    • Adjust the tension of the belts as described in chapter 8.5 and put back the cover. Refer to illustration on next page! Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 44: Stepper Motor

    Belt to Ribbon Rewind Unit #T20 Torx Screw #T20 Torx Screw Belt to Pressing Roller Pulley Ball Bearing Plastic Bearing Spacer Pressing Roller Plastic Bearing Bracket Ball Bearing #T20 Torx Screw Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 45 • Connect the cable of the stepper motor to P420 on the CPU board (marked “STM1”). • Adjust the tension of the belts as described in chapter 8.5 and put back the cover. Refer to illustration on next page! Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 46: Stepper Motor

    #T20 Torx Screw Stepper Motor Bracket Belt Fitted to Centre- (to Pressing Roller) line Wall Fitted on Return #T20 Torx Screws (3x) Roller Shaft Fitted on Pressing Roller Shaft Inner Print Unit Gable Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 47: Belts

    • Adjust the tension of the belts as described in chapter 8.5 and put back the cover. Refer to illustration on next page! Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 48 Belt Stepper Motor #T20 Torx Screw #T20 Torx Screw #T20 Torx Screw Ribbon Rewind Unit #T20 Torx Screw Belt Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 49: Belt Adjustments

    #T20 Torx Screw Stepper Motor Pulley Stepper Motor Belt #T20 Torx Screw Pressing Roller Pulley Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 50 If the idler roller starts to squeak, lubricate the inside of the belt with a small quantity of grease. Idler Roller #T20 Torx Screw Ribbon Rewind Unit Pulley Ribbon Return Roller Pulley #T20 Torx Screw Belt Stepper Motor Stepper Motor Pulley Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 51: Label Stop Sensor

    If a renewed print operation gives the same result, an “out-of-paper” condition is assumed. /. For detection of black marks on the top of the paper, the cables from the two sensors could be switched on the CPU board. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 52 LBLCOND Fingerprint instruction SYSVAR(28). By statement, see Intermec Fingerprint 7.12 Reference Manual. default, the paper feed data are not cleared. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 53: Label Stop Sensor

    If using irregularly shaped labels, align the LSS with the front tips of the labels Upper part of LSS Detection Slot Linear Markings Adjustment Screw Upper part of print unit omitted to improve view. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 54 Do not use any other type of chemicals. Be careful not to scratch the windows. Caution! Isopropyl alcohol [(CH CHOH; CAS 67-63-0] is a highly flammable, moderately toxic and mildly irritating substance. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 55 Note! The snap-lock is fragile. • Remove the two #T8 Torx screws that hold the defective sensor and replace it. LSS Bracket Upper Sensor Lower Sensor Snap-Lock Carriage Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 56 “LSS-TOP”) on the CPU board. • Put back the guide plates, the electronics compartment cover, and the power cord. • Adjust the lateral position of the LSS. Inner Notch Outer Notch Snap-Lock Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 57: Printhead

    Information on how to switch between direct thermal and thermal transfer printing is provided in the Installation & Operation manual. The basis for all measures and positioning in the Intermec Finger- print programming language is the size of printhead dots. In an 12 dots/mm printhead, each dot has a nominal size of 0.083 mm (3.28...
  • Page 58 1.0 mm (0.04") 2.7 mm (0.11") 165.3 mm (6.49") PRINT PRINT Length WINDOW WINDOW Origin Dot-line on printhead X-start Width PAPER FEED Dot 1983 DIRECTION Dot 0 max. 168 mm (6.61") Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 59 • The innermost cable (20-p blue flat cable) is used for data to the printhead and is connected to P41 (marked “TPH”) on the CPU board. Blue Connector (to CPU Board) “Finger” Bracket Printhead “Finger” White Connector (to Power Supply) Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 60 Note the snap-lock on the white connector and pull at the connectors rather that at the cables! • Connect the cables to the replacement printhead assy, blue connector to the left – white connector to the right. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 61 • Use original Intermec transfer ribbons only. These are optimized specifically for your printer. Inferior back coating on a non- approved transfer ribbon may cause residue which can com- pletely destroy the printhead.

  • Page 62: Headlift Sensor

    • Tighten the screw and check that the arm runs freely inside the fork-shaped sensor. • Put back the cover and power cord and turn on the printer. Headlift Shaft #T10 Torx Screw Sensor Arm “Printhead Open“ position Sensor “Printhead Closed” position Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 63 • Reassemble in reverse order. The senor's cable should be connected to P50 (marked “HEADL”) on the CPU board. • Check that the sensor works properly using a PRSTAT AND 1 statement, see Intermec Fingerprint 7.12 Reference Manual. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 64: Headlift Mechanism

    Return Spring Sensor Arm Headlift Shaft Pressure Adjuster Linkage Headlift Sensor Headlift Arm Eccenter Printhead Pressure Grub Screw Printhead Lift Knob (factory-adjustment) Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 65 1 kp to a total of 4 – 5 kp (39.2 – 49.0 N). • Fine-adjust by means of test labels and the trial-and-error method (possibly after having loaded the transfer ribbon again). Adjustment Knob (green) Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 66 • After having centred the arm, lock it by tightening the knob. • Reload the ribbon, if any. Knob Centre of Paper Web Tip of Headlift Arm Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 67: Ribbon Return Roller

    The key will engage cogs in the plate that holds the outer end of the return roller inside the gable. Ribbon Return Roller Locking Screw #T20 Torx Screwdriver Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 68 • You will need to print several labels before a new adjustment has any noticeable effect. • When you are satisfied that the problem is cleared, tighten the locking screw and test again by printing several more labels. Readjust if necessary. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 69: Paper Feed Principles

    Tear off (print at top of label): 15.7 mm Start Adjust: -175 Stop Adjust: 0 Dot Line on Printhead Tear Off Edge Label Stop Sensor Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 70 If the black mark is placed further down the web, this must be compensated for by a negative Stop Adjust setting. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 71: Description

    • A rewind unit that takes up the spent backing paper to be manually removed in connection with next paper load. Peel-Off Operation The rewind unit can accommodate the backing paper from a full roll of labels. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 72: Main Parts

    The stepper motor is connected to P421 on the CPU board, see chapter 15.3. Stepper Motor Motor Support Plate Belt to Rewind Unit Belt to Rewind Roller Tension Roller Brace Backing Paper Rewind Unit Break Shaft Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 73: Paper Rewind Unit

    Nylon Washer Friction Washer Compression Spring Carrier Washer #T20 Torx Screw Grub Screw Friction Felt /. Refer to Appendix 2 for a de- scription of how to check the brake torque. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 74: Label-Taken Sensor Description

    Vertical detection range is adjustable from 5 mm (0.2") above the edge of the tear-off/dispenser edge to max. 50 mm (2") below the edge (with strap fitted on P55). Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 75: Installation

    The LTS must either be enabled by means of an LTS& ON statement, or the status of the LTS has to be polled in the Intermec Fingerprint program by means of the PRSTAT function, as other- wise the printer will not react on the LTS signal.
  • Page 76 • Insert the power cord and turn on the power. CAUTION! The electronics compartment contains high voltage wires and components. Use a non-conductive screwdriver to avoid the risk of causing a short-circuit! Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 77: Adjustments

    Adjust the sensitivity of the label-taken sensor by means of the potentiometer WR51 (marked “LTS”) on the CPU board: • Start up Intermec Fingerprint and run the program described in chapter 10.2. Leave the label in the outfeed slot to create a label- not-taken condition.

  • Page 78: Paper Cutter

    11. Paper Cutter 11.1 Description The EasyCoder 601 XP can easily be fitted with an optional Paper Cutter unless the printer is not already fitted with an label-taken sensor (see chapter 10). The cutter unit is fitted on the same hinges as the front door, which it replaces, and is connected by a single cable to the DIN-connector on the printer’s front.

  • Page 79: Controlling The

    Turn off the power or disconnect the cutter before cleaning. Keep fingers away from cutting parts! Do not force the spring-loaded anvil blade open more than 5–10 mm (.2–.4"), or the spring may be damaged. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 80: Installation

    • Fit the cable from the cutter unit into the DIN connector on the printer's front. DIN Connector Press Sideways Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 81: Spring Replacement

    • Remove the right-hand gable of the cutter mechanism (two #T20 Torx screws + three Posidrive screws). • Replace the spring and assemble in reverse order, making sure to put back all the washers. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 82: Ribbon Low Sensor

    12. Ribbon Low Sensor 12.1 Description As an option, the EasyCoder 601 XP can be fitted with a sensor, that detect the rotation of the ribbon unwind spool and updates a counter. By means of custom-made application program, the counter can be...

  • Page 83: Installation

    PRINT SYSVAR(13) instruction in Intermec Fingerprint while manually rotating the ribbon unwind spool. Ribbon Low Sensor #T10 Torx Screw NOTE! The Ribbon Unwind Unit does not need to be dismounted! Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 84: Electronics Compartment 13.1 Introduction

    When fitting back the cover plate, press it forcefully inwards against the conductive leaf springs before tightening the screws. Check that the cover is properly aligned with the front and does not interfere with the right-hand door. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 85: Main Parts

    Centronics interface board removed to improve the view of the CPU board. Power Supply Ribbon Unwind Unit Ribbon Rewind Unit (hidden) CPU Board Paper Rewind Motor Print Unit Stepper Motor Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 86: Power Supply 14.1 Description

    Converter Converter Pulse Width Pulse Width Rectifier 24V Modulator Modulator Forward (w. Power Factor Contr.) Buck Converter (24V ⇒ 5.3V) Temperature Control & Power Fail Interrupt Control Vout (24V & 42V) Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 87 PSU with four plastic screws and connected to X4. If a fuse is blown, do not try to repair the PSU, but replace the entire unit! Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 88: Components

    Chapter 14 Power Supply 14.2 Components 1-971601-26 Power Supply Unit; Front Side 1-971601-27 Power Supply Unit; Front Side 1-971601-27 only Power to CPU Board Low Voltage High Voltage 24 V Trim Potentiometer Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 89 Chapter 14 Power Supply 14.2 Components, 1-971601-26 Power Supply Unit; Back Side 1-971601-27 Power Supply Unit; Back Side cont'd. 1-971601-26 only Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 90: Schematics

    Chapter 14 Power Supply 14.3 Schematics 1-971601-26 Power Supply Unit; Main Schematics 1-971601-27 Power Supply Unit; Main Schematics C56 and C68 removed on 1-971601-27 Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 91 Chapter 14 Power Supply 14.3 Schematics, cont'd. 1-971601-26 Power Supply Unit; Buck Converter 1-971601-27 Power Supply Unit; Buck Converter 1-971601-27 only Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 92: Cpu Board

    I/O DATA Support Reset Chip & Stepper Watchdog Sensors Logic Driver I2C-BUS Expansion Electronic Slave Processor Key/RTC A/D Converter Flash Bar Code Electronic Electronic Optional DRAM Console Centronics Memory Wand Board Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 93: Circuits And Straps

    256 kbyte Kernel programs are included in the kernel: 192 kbyte Kernel ERRHAND.PRG 16 kbyte TMP area Paper feed info, odometer value FILELIST.PRG 16 kbyte Parameters MKAUTO.PRG 32 kbyte Boot Startup Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 94 (device "c:") and a 16 kbyte TMP sector for the parameters sector. The Boot sector is necessary for Intermec Fingerprint to start. There is a boot sector in all flash SIMMs at delivery, but the firmware will only accept a boot sector of the SIMM fitted in P22 (marked “ROM2 Boot-Bank”).
  • Page 95 10 years. When the printer is on, the circuit is power supplied via the CPU board and will not consume any power from the battery. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 96 This potentiometer decides the sensitivity of the receiver in the ribbon end sensor (also see chapter 7.4). Debug Strap (P13) This strap is used for debugging and program development and must always be fitted with a jumper during normal operation. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 97: Connectors

    P50 Headlift sensor P58 Cable to cutter interface on printer's front P37 Console pcb P31 Centronics interface board (see chapter 16.3) P41 Thermal printhead data P420 Stepper motor 1 (print unit) Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 98: Special Devices

    JEIDA-4 PC Memory cards There are two types: • DOS-formatted memory cards Such cards can be both read from and written to. In Intermec Fingerprint they are referred to as device "card1:". • Non DOS-formatted memory cards Such cards are read-only and are referred to as device "rom:" in Intermec Fingerprint.
  • Page 99 • Storage, which is used to store short files of data. Electronic keys for various purposes can be ordered from Intermec. Electronic Key Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 100 For more demanding applications or for reading bar codes other, choose a regular bar code scanner from Intermec's wide product range and connect it to the serial port. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 101: Test Points

    Logic power, 5V ± 5% V 5.0 RESET High level = active printer Feed voltage for P24, 24V ±5% Printhead and cutter voltage, approx. 24V when active Feed voltage for stepper motors, 42V ±10% Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 102: Startup

    Chapter 15 CPU Board 15.6 Startup The prerequisite for Intermec Fingerprint to start is that a flash memory SIMM with a boot sector is fitted in P22 (marked “ROM2 Boot-Bank”). A DRAM SIMM must also be installed in P20 (marked “ROM0”).
  • Page 103 (9600 baud, 8 bits, parity none, 1 stop bit) on the standard serial port "uart1:". For each of the steps listed above, either “OK” or “Fail” is returned on "uart1:". In addition, some other useful information is also returned. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 104: Components

    Chapter 15 CPU Board 15.7 Components 1-971600-26 CPU Board Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 105: Schematics

    Chapter 15 CPU Board 15.8 Schematics 1-971600-26 CPU Board; Top Level Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 106 Chapter 15 CPU Board 15.8 Schematics, 1-971699-01 CPU Board; Core cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 107 Chapter 15 CPU Board 15.8 Schematics, 1-971699-10 CPU Board; Memory cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 108 Chapter 15 CPU Board 15.8 Schematics, 1-971699-21 CPU Board; Peripherals cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 109 Chapter 15 CPU Board 15.8 Schematics, 1-971699-30 CPU Board; Sensors cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 110 Chapter 15 CPU Board 15.8 Schematics, 1-971699-40 CPU Board; Thermal Printhead Interface cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 111 Chapter 15 CPU Board 15.8 Schematics, 1-971699-50 CPU Board; Stepper Motor Drivers cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 112: Interfaces 16.1 Introduction

    OUT port, use an Intermec Fingerprint SETSTDIO state- ment (see Intermec Fingerprint 7.12 Reference Manual). Note that many application programs, e.g. Intermec Shell, contains instruc- tions that select the correct std I/O for the application in question. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 113: Serial Communication Port "Uart1

    Chapter 16 Interfaces 16.2 Serial Communi- The EasyCoder 601 XP is as standard always fitted with one RS 232C communication port. In Intermec Fingerprint, this port is cation Port "uart1:" designated "uart1:" (Universal Asynchronous Receiver and Trans- mitter). The circuitry is fitted on the CPU board (see chapter 15) and has a fixed set of signals in a DB25 male connector which protrudes through a slot in the printer's rear plate.

  • Page 114: Parallel Interface "Centronics

    Chapter 16 Interfaces 16.3 Parallel The EasyCoder 601 XP is, as standard, fitted with a separate Centronics communication board with a one-way parallel port. In Communication Port Intermec Fingerprint, this port is designated "centronics:". "centronics:" The Centronics pcb only supports the compatible mode, i.e. one- way communication only.
  • Page 115 IOD4 STROBE IOD5 IOD6 IC3B IC3A IC2A IOD7 SYSCLK RESET ‹ BUSY PERR SELECT 74AC244 INIT ERROR IC2B ERROR ‹ 74AC244 INIT CGND IC3C 74HCT04 IC3D 74HCT04 IC3E 74HCT04 IC3F 74HCT04 Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 116: Industrial Interface Board

    Description The Industrial Interface Board is an optional device for EasyCoder Board 501 XP and EasyCoder 601 XP, that provides the printer with two extra interfaces. Industrial Interface This interface contains 8 digital IN and digital 8 OUT ports with opto-couplers, plus 4 OUT ports with relays.
  • Page 117 • Using the remaining two screws, attach the narrow cover plate included in the delivery so it covers the right side of the slot. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 118 Now you have two new interface connectors on the printer's rear plate in addition to the standard serial interface "uart1:" and the standard parallel interface "centronics:". Industrial Interface Serial Interface "uart2:" Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 119 Fit RS 232 circuit on IC2 No circuits on IC3, IC4 or IC18 IC18 Strap on S4 deactivated (fitted on one pin only) Strap on S4 deactivated (fitted on one pin only) Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 120 1-971606-01.P01 IC17 IC10 IC14 IC13 REL1 REL2 REL3 REL4 IC12 IC11 No circuit on IC2 Fit RS 422 circuit on IC3 IC18 Fit strap on S4 Fit strap on S2 only Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 121 -RS422DO/-RS485 -RS 422 Transmit/-RS 485 RS 232 Ring Indicator Shield Optional shield for RS 422 and RS 485 24–25 Not connected /. The external 5V is automatically turned off at overload. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 122 The Industrial Interface has no straps or circuits to be fitted or removed. All signals are available on a female DB44 connector and the various ports are controlled by the Intermec Fingerprint instruc- tions PORTIN and PORTOUT ON/OFF (see Intermec Fingerprint 7.12 Reference Manual).
  • Page 123 Collector Opto Out Channel 7 Out7e Emitter Opto Out Channel 7 Out8c Collector Opto Out Channel 8 Out8e Emitter Opto Out Channel 8 IC13A OUT1c OUT1e TIL193B Simplified schematics of a digital OUT port. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 124 Relay 3 Common REL4nc Relay 4 Normally Closed REL4no Relay 4 Normally Open REL4com Relay 4 Common REL1A REL1nc IC12D REL1B REL1no REL1com ULN2003A Simplified schematics of a relay OUT port. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 125 Chapter 16 Interfaces 16.4 Industrial Interface 1-971-606-25 Industrial Interface pcb.: Components Board, cont'd. 1-971606-01.P01 IC15 IC16 IC14 IC13 IC10 REL1 REL2 REL3 REL4 IC12 IC11 IC18 Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 126 Chapter 16 Interfaces 16.4 Industrial Interface 1-971-606-25 Industrial Interface pcb.: Schematics 1 Board, cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...
  • Page 127 Chapter 16 Interfaces 16.4 Industrial Interface 1-971-606-25 Industrial Interface pcb.: Schematics 2 Board, cont'd. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 128: Trouble Shooting 17.1 Diagnosing The Printer

    The procedure of starting up Intermec Shell, regardless what autoexec.bat files the printer's memory contains, will be called the Test Mode. In fact, it is just a convenient way of accessing Intermec Shell and – via Intermec Shell – also the Setup Mode.
  • Page 129 - Paper feed does not work properly • Transfer ribbon troubles 17.13 - Transfer ribbon gets wrinkled - Transfer ribbon breaks • Rewind troubles 17.14 • Cutter troubles 17.15 • Memory card troubles 17.16 Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 130: No Reaction At Power Up

    If the error persists, examine the power supply as described in chapter 17.5. • Faulty power supply unit. - Refer to chapter 17.5. • Faulty console unit. - Refer to chapter 17.6. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 131: Printer Stops Working After Startup

    • Error in the supply of mains power to the printer. - Refer to chapter 17.2. • Faulty console, power LED or cabling between CPU board and console. - Refer to chapter 17.6. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 132: Cpu Board Failures

    - Execution of the initial boot sequence can be checked as described in chapter 15.6. If the execution stops prematurely, note when it happens and contact our Technical Product Support dept. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 133: Power Supply Unit Failures

    P/N 1-971601-27 or later). - Check the voltage P24 ( ≈ 24V when active). Has to be enabled. - Check the voltage V40 (42V ± 10%). Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 134: Console Errors

    - If there is no display function in the Test Mode, the display is out of order and the console unit needs to be replaced. Else, check out the custom-made program. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 135: Error Messages

    - The printer stops functioning - The Error LED is usually lit. • Consult the Intermec Fingerprint 7.12 Reference Manual for the meaning of the different error codes and use that information to correct the error.

  • Page 136: No Communication (General)

    Installation & Operation manual). • Electrical disturbances from external units (printers produced before week 743 only). - Connect a grounding wire on the power supply unit as described in Printer Technical Bulletin No. 42/1997. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 137: No Serial Communication

    Intermec Direct Protocol, verbosity is by default disabled. Check the program for instructions that may affect the ver- bosity. - Verify that the correct communication port is selected as standard IN/OUT channel. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 138: No Parallel Communication

    Do not attempt to repair a damaged interface board. • Wrong std IN channel selected in custom-made program. - Verify that the Centronics communication port is selected as standard IN channel. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 139: Sensor Malfunctions

    • Bad connection. - Check that the sensor's cable is connected to P50 on the CPU board. Inspect cable for damage. • Faulty sensor. - Replace as described in chapter 8.8. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 140: Ribbon End Sensor

    • Bad connection. - Check that the ribbon low sensor is connected to P57 on the CPU board and that the cable is undamaged. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 141: Label Taken Sensor (Lts)

    - The sensitivity of the sensor's receiver and the light intensity of the sensor's emitter are adjustable, see chapter 10.3. • Defective sensor. - If still no reaction, the sensor is probably defective and should be replaced. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 142: Troubleshooting, Cont'd. 17.12 Printing Troubles

    - Check that the printhead is completely lowered and pressing against the paper web with a sufficient force, see chapter 8.9. • Headlift sensor out of order. - Check the headlift sensor as described in chapter 17.11. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 143: Overall Weak Printout

    - Verify that the receiving face material and transfer ribbon in use match the paper type options selected in the Setup Mode. • Wrong printhead voltage. - Measure voltages V24 and P24, see chapter 17.5. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 144: Weak Or Missing Printout Of Some Dots

    - The printhead is most certainly damaged too and will also need to be replaced. Description: Only first part of label printed. Possible Causes and Suggested Remedies: • Bad headlift sensor adjustment. - Adjust as described in chapter 8.8. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 145: Paper Feed Does Not Work Properly

    • Power supply malfunction. - Check the voltage on test point V40 on the CPU board, see chapter 15.5. If V40 is not +42V ± 10%, the power supply unit is probably faulty. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 146: Transfer Ribbon Troubles

    (i.e. c.w. instead of c.c.w.), the brake springs may break. This typically occurs if the operator uses transfer ribbons with the ink on the wrong side. Replace the damaged unit. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 147: Rewind Troubles

    • Bad internal rewind of printed labels. - Check that the rewind guide is fitted correctly, see chapter 9.1. - Check that the paper is threaded correctly as shown in chapter 9.1. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 148: Cutter Troubles

    - The return spring in the cutter mechanism could eventually get slack and need to be replaced. • No cause of malfunction could be found. - The cutter motor is probably defective. Replace the entire cutter or just its mechanism. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 149: Memory Card Troubles

    "rom:" (non DOS-formatted cards), or FILES "card1:" (DOS- formatted cards). • Hardware error. - Inspect the memory card for mechanical damage. - Examine the memory card adapter on the CPU board for breakage or bad soldering. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 150: Appendix 1 Intermec Shell 4.2 Overview

    When the Shell countdown begins, release the key and press <Enter> to start Shell. Do not forget to lower the printhead if you want to print e.g. test labels. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 151: Easycoder 601 Xp: Setup Mode Overview, Part 1

    (read-only): CONNECTED HW RS232 • RS 232 • 422 NON ISOLATED • 422 ISOLATED STARTADJ: SETUP: DETECTION: FEEDADJ: FEEDADJ STARTADJ [0]: FEEDADJ FEEDADJ: STOPADJ: STOPADJ [0]: Continued on next page! Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 152: Easycoder 601 Xp: Setup Mode Overview, Part 2

    TESTPRINT <F5> = NEXT #1 If no label is printed, press <F3> for error message. PRINT DEFS: PRINT SPEED: PRINT SPEED [150]: • Press Setup key to exit the Setup Mode. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 153: Measuring The Break Torque

    • Fit the end of the ribbon to the dynamometer and pull. • Read the dynamometer. • Calculate the torque using the formula: Torque (Nmm) = Radius (mm) ¥ Force (N) Dynamometer Force Formula: Torque = Force x Radius Intermec EasyCoder 601 XP – Service Manual Ed. 2...

  • Page 154: Appendix 3 Lss-Sensor.prg

    This values are important when you need to discuss an LSS-related problem with the central support department. Using LSS- Enter the immediate mode of Intermec Fingerprint, e.g. by selecting the Fingerprint option in Intermec Shell . Use an ordinary terminal SENSOR.PRG...
  • Page 155 Shell and select another application. The operator must also allow the printer to auto-adjust the paper feed by sending a TESTFEED instruction or by simultaneously press the <Shift> and <Feed> keys. Intermec EasyCoder 601 XP – Service Manual Ed. 2...

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