1. Manuals
  2. Brands
  3. Intermec Manuals
  4. Label Maker
  5. EasyCoder 501 E
  6. Service manual

Intermec EasyCoder 501 Service Manual

Hide thumbs Also See for EasyCoder 501:
Table of Contents

Advertisement

Quick Links

Download this manual See also: User Manual, Instruction and Installation Manual
Service Manual
P/N 1-960320-06
Edition 7
October 2001
EasyCoder 501
Bar Code Label Printer

Advertisement

Table of Contents
loading

Related Manuals for Intermec EasyCoder 501

Summary of Contents for Intermec EasyCoder 501

  • Page 1 Service Manual P/N 1-960320-06 Edition 7 October 2001 EasyCoder 501 Bar Code Label Printer...

  • Page 2: Table Of Contents

    Main Parts ....................72 10.6 Print Unit Assy..................73 10.7 Headlift Mechanism ................82 10.8 Ribbon Rewind..................85 10.9 Connection Board................... 86 Intermec EasyCoder 501 Service Manual Edition 7, October 2001 Part No. 1-960320-06 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 3: Introduction

    19. Optional Interface Boards 19.1 Description.................... 156 19.2 Installation..................... 157 20. Serial Interface Board 20.1 Description.................... 158 20.2 Straps ..................... 159 20.3 Connector Confi guration..............160 20.4 Components Diagram ................161 20.5 Circuit Diagrams................... 162 Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 4 25.3 EasyCoder 501 S, Test Mode Diagram..........193 25.4 EasyCoder 501 E, SA, & LL............... 194 25.5 EasyCoder 501 E/501 LL, Test Mode Diagram......... 196 25.6 EasyCoder 501 SA, Test Mode Diagram..........197 26. Trouble Shooting 26.1 Printer “Dead”..................198 - AC power failure ................
  • Page 5 © Copyright Intermec Printer AB, 2001. All rights reserved. Published in Sweden. EasyCoder, EasyLAN, Fingerprint, and LabelShop are registered trademarks of Intermec Technologies Corp. The word Intermec, the Intermec logo, InterDriver, and PrintSet are trademarks of Intermec Tech- nologies Corp.

  • Page 6: Preface

    0.2 Preface This Service Manual is intended to facilitate installation, trouble- shooting and repair of the Intermec EasyCoder 501 series of print- ers in the version delivered at the date of publishing. Thus, all information on the Intermec Fingerprint fi rmware is based on ver- sion 6.14.

  • Page 7: Notices And Approvals

    A prescrites dans le règlement sur brouillage radioélectrique édicté par le Ministère des Communications du Canada. VDE Notice Germany Reparaturen oder sonstige Eingriffe, die sich nicht auf normale Bedienung der Maschine beziehen, dürfen aus- schließlich nur von einem ausgebildeten, zuständigen Fachmann vorgenommen werden. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 8: Intermec Easycoder 501 – Service Manual Ed

    Mölndal 1998-09-01 ..............Hans Lindén President /. Intermec assumes no responsibility regarding the CE Directive if the printer is handled, modifi ed, or installed in other manners than those described in the manuals. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 9: Models And Options

    Chapter 1 1. Models and Options 1.1 Identifi cation The EasyCoder 501 printers come in four different main models, which easily can be identifi ed by their external appearance. EasyCoder 501 S (Standard) has a single Print button on its front panel.
  • Page 10 1 x DB25 + 1 x DB15: Parallel Interface Board Industrial Interface Board Serial Interface Board or RS 485 Interface Board For further inspection of interfaces, the Electronics compartment must be opened, as explained later in this chapter. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 11 Media/Ribbon Low Sensors External Guides (not visible) Thermal Transfer Mechanism 3-inch Adapter Media Roll Retainer Guide Plate Liner/Batch Takeup Unit Ribbon Save Device (not illustrated) Label Slack Absorber (or Guide Shaft) Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 12 1.1 Identifi cation, cont. printer's front, where the cutter replaces the front hatch (see Chap- ter 12). The EasyCoder 501 LinerLess has a spcial cutter. Paper Cutter Unit By opening the front hatch (or the optional cutter unit fi tted in its place), you can check if the printer is fi...
  • Page 13 • Type of interface on "uart1:"? • Optional interface board fi tted? • Type of interface(s) on interface board? Refer to the descriptions of the CPU-board and the various inter- face boards in Chapters 17-23. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 14 You can also check the setup in the Setup Mode or Test Mode, or by means of Intermec Shell. If the printer does not work, you can get some clues from the labels on the EPROM packages.

  • Page 15: Specifi Cations

    Chapter 1 Models and Options 1.2 Specifi cations The table below illustrates the similarities and differences between the four main models of the EasyCoder 501. COMMON STANDARD FEATURES: Smooth Fonts Yes, with Scaleable Fonts Kit Print Directions Display 2 line x 16 characters, LCD Dimensions (W x D x H) excl.

  • Page 16: Measures

    (0.79") Paper slot 30 mm (1.18") 68.8 mm 13 mm 363 mm (14.29") (2.71") (0.51") 481.5 mm (18.96") An optional paper cutter increases the printer’s total length by 28 mm (1.1 inches). Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 17: Front And Keyboard

    At the top part of the front moulding, there is a cavity for the keyboard/display assy. This assembly is affi xed by means of two grub screws which can be loosened using a 2 mm hexagon wrench. Grub Screws Cutter Connector (fi tted as standard) Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 18: Display/Keyboard

    "uart1:", see Chapter 4.2. The display should be adjusted according to the prevailing light conditions when viewed from a normal working position. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 19: Slides

    Error Pri nt Keyboard of EasyCoder 501 S Power Ready Error Pause Setup Feed Pri nt Enter Keyboard of EasyCoder 501 E and 501 LinerLess ˘ ˘ Keyboard of EasyCoder 501 SA Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 20: Keyboard Interface Board; Components Diagram

    Components Diagram LED1 LED2 LED3 Keyboard Interface Board 1-040701-26; Components Diagram Connections: Permanently attached cable to P-2 on CPU Board LCD Display (soldered) Keyboard Provision for separate print key (for special applications) Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 21: Keyboard Interface Board; Circuit Diagram

    74HC04 SHIFT COL6 COL5 COL4 COL3 COL2 PB1 19 COL1 PB0 18 COL0 ROW7 ROW6 CS8255 ROW5 ROW4 ROW3 RESET RESET ROW2 ECLK ROW1 VDISP ROW0 Keyboard Interface Board 1-040701-26; Circuit Diagram Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 22: Hatches And Doors

    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 501 – Service Manual Ed. 7...

  • Page 23: Front Hatch

    The front hatch can be replaced by an optional paper cutter unit. Alignment is performed in the same way as the right-hand door, see the previous page. The front hatch can be removed by pushing it to the left when it is open. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 24: Left-Hand Cover

    fi rst, then remove the four upper screws. Put the cover plate aside on a soft cloth or similar to avoid scratches. #T10 Screws (4x) #T10 Screws (4x) Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 25: Rear Plate

    Any installed interface board will have to be disconnected before the rear plate can be removed. CPU Board Bracket Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 26: Devices On Rear Plate

    Part 15 Subpart J. Operation of this device in a residential area may cause harmful interference requiring the user to take whatever steps may be necessary to correct the interference. INTERMEC PRINTER AB MADE IN SWEDEN Provision for Optional Interface Board Media Intake "uart1:" Machine Label Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 27: Media Supply

    (1.5 to 1.6 inches). A large crescent-shaped plate keeps the media roll aligned with the print mechanism. In the EasyCoder 501 LinerLess the crescent- shaped plate is replaced by a circular plate fi tted inside the inner- most bobbin module.
  • Page 28 Flange Code Disc Disc Bobbins Felt Pad Shaft Nylon Disc Spring Washer #T20 Torx Screw /. Refer to Appendix 2 for a descrip- tion of how to check the brake torque. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 29 Code Disc Circular Plate Flange Disc Bobbins Felt Pad Shaft Nylon Disc Spring Washer #T20 Torx Screw /. Refer to Appendix 2 for a descrip- tion of how to check the brake torque. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 30 An optional media roll retainer can be fi tted on the bobbins (but not on the adapter) to hold large media rolls. It is not used in connec- tion with EasyCoder 501 LinerLess. Media Roll Retainer Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 31: External Supply

    Chapter 5 Media Supply In addition to the internal media roll, the EasyCoder 501 S, 501 E, 5.2 External Supply and 501 SA printers can also use direct thermal media or receiv- ing face material from an external supply, for example an external roll or a stack of fan-folded tickets.
  • Page 32 Adjust the position of the outer guide to fi t the width of the media. Minium media width is 40 mm (1.575 inches). Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 33 Adjust the inner guide roll so it guides the media exactly 20 mm (.79 inches) from the printer’s center section. Then adjust the outer guide roll according to the width of the media. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 34 EasyCoder 501 E and EasyCoder 501 SA printers are fi tted with a label slack absorber (see Chapter 6), that need to be replaced by a guide shaft.
  • Page 35 Note that if the printer is to be permanently used with an external media supply only, the internal media supply spool, together with the large crescent-shaped guide plate could easily be removed (see Chapter 5.1). Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 36: Label Slack Absorber

    Since the label slack absorber only is required at high speed print- ing (> 100 mm/sec. = 4 inches/sec.), it is has been omitted from the EasyCoder 501 S model, where it is replaced with a simple shaft with two green guide washers (see below).

  • Page 37: Dismantling

    The shaft should be screwed into the fl ange with a tightening torque of 5 Nm. #T20 Torx Screw (2x) Flange #T10 Torx Screw Torsion Spring Spacer #T10 Torx Screw Shaft Grip Edge Guide Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 38: Transfer Ribbon Mechanism

    7. Transfer Ribbon Mechanism 7.1 Description The thermal transfer ribbon mechanism is standard (except on EasyCoder 501 LinerLess which never uses thermal transfer print- ing), but can be omitted on special order. The mechanism consists of three main units: • Ribbon supply unit •...
  • Page 39 Sleeve Circlip Circlip Brake Spring Bearing Plastic Circlip Flange Bearing Shaft Grooves Code Disc Bobbin assy. /. Refer to Appendix 2 for a descrip- tion of how to check the brake torque. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 40: Ribbon Rewind Unit

    The ribbon rewind unit is fi tted to the center section using two #T20 Torx screws inserted from the electronics compartment. One of the screws runs in a crescent-shaped slot to allow adjustment or removal of the belt. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 41 Friction Felt Washers (+7.7 Nmm each) 0–1 Torque Adjustment Shaft Washers (-6.2 Nmm) #T20 Torx Screw /. Refer to Appendix 2 for a descrip- tion of how to check the brake torque. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 42: Ribbon End Sensor

    Obviously, if the printer is fi tted with a thermal transfer mechanism, such a strap must be removed. The ribbon end sensor is connected to P-603 on the CPU board. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 43: Ribbon End

    If that does not help, fi t or remove the jumper on P-604. If the sensor refuses to work, consider the possibility that the mirror plate may be bent before discarding the sensor. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 44: Print Unit

    Chapter 8 8. Print Unit Presently, the EasyCoder 501 printers are manufactured with three 8.1 Different Models types of print units: • The standard direct thermal/thermal transfer print unit. • The LinerLess print unit with plasma coating and a special platen roller to prevent label from sticking to the print unit.
  • Page 45 Chapter 8 Print Unit 8.2 Main Parts, cont. EasyCoder 501 S, E, and SA Headlift Mechanism Stepper Motor Platen Roller Tear Bar Liner Drive Roller Printhead Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 46 Chapter 8 Print Unit 8.2 Main Parts, cont. EasyCoder 501 LinerLess Headlift Mechanism Stepper Motor No Thermal Transfer Mechanism Non-stick Platen Roller Plasma-coated Tear Bar No Liner Drive Roller Printhead Plasma-coated Surface Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 47: Platen Roller

    The platen roller is coated with silicon rubber. It is imperative that the roller is clean, free from uneven wear or dents, and exactly aligned with the printhead (see Chapter 24.3). The EasyCoder 501 LinerLess has a special type of platen roller that prevents labels from stick to the roller.

  • Page 48: Stepper Motor

    All parts of the transfer ribbon mechanism and the liner drive roller are omitted in EasyCoder 501 LinerLess, which also has a differ- ent type of stepper motor bracket, see Chapter 8.2.
  • Page 49 fl ex just a little when you press it with your fi nger. Adjustment of ribbon rewinder belt (not EasyCoder 501 LL) The belt should be adjusted so it neither jump the cogs nor becomes subjected to unnecessary wear.

  • Page 50: Tear Bar

    (peel-off/self-strip operation). In EasyCoder 501 LinerLess, the tear bar is plasma-coated to prevent the linerless media to stick to the bar. When media is to be rewound internally (see Chapter 9), the tear bar must be replaced by an optional takeup guide using the same screws, as illustrated below.

  • Page 51: Label Stop Sensor (Lss)

    • Absence of media lets the light pass uninterrupted. The Intermec Fingerprint fi rmware detects the start of each label, that is, when the condition switches from semi-transparent liner to opaque label. If the light passes without any interruption for more than 61 mm (2.4 inches) of media feed, an out-of-paper condition...
  • Page 52 The Intermec Fingerprint fi rmware detects the rear edges of detec- tion gaps, that is, when the light starts to be interrupted. If no interruption occurs within 61 mm (2.4 inches) of media feed, an out-of-paper condition is assumed.
  • Page 53 Ball Bearing IMPORTANT! Do not loosen this screw! Lower Gable Ball Bearing #T20 Torx Screws Bracket Note. The liner drive roller with its washer and ball bearing is omitted in EasyCoder 501 LinerLess. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 54: Printhead

    Installation & Operation manual. The basis for all measures and positioning in the Intermec Fin- gerprint programming language is the size of printhead dots. For example, in an 8 dots/mm printhead, each dot has a nominal size of 0.125 mm (4.9 mils).
  • Page 55 3.33 3.28 Dot size (inches): 0.00492 0.00333 0.00328 1 mm: 8 dots 11.81 dots 12 dots 1 inch: 203.2 dots 300 dots 304.8 dots 1/16 inch: 12.7 dots 18.8 dots 19.1 dots Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 56 Chapter 8 Print Unit There are two types of printhead available for the EasyCoder 501 8.7 Printhead, cont. S, 501 E, and 501 SA printers, one with a density of 8 dots/mm (203.2 dpi) and one with 11.81 dots/mm (300 dpi). There is also a special 8 dots/mm printhead for EasyCoder 501 LinerLess.
  • Page 57 • Disconnect the two printhead cables. Pull at the connectors rather than the cables! Locked Position Slot Lock Handle Guide Screw Open Position Replacement Printhead assy. Printhead fi tted in right-hand position. Note the position of the guide screw. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 58 You can switch between printheads with different densities at will (except in EasyCoder 501 LinerLess that only uses an 8 dots/mm printhead). • Turn the locking handle clockwise to locked position.
  • Page 59 Chapter 8 Print Unit EasyCoder 501 S, 501 E, and 501 SA: 8.7 Printhead, cont. 8 dots/mm (203.2 dpi) printhead in left-hand position The 8 dots/mm printhead can be fi tted in two positions. When the printhead is fi tted in the innermost, left-hand position (see illustra- tion), dot No.
  • Page 60 Chapter 8 Print Unit EasyCoder 501 S, 501 E, and 501 SA: 8.7 Printhead, cont. 8 dots/mm (203.2 dpi) printhead in right-hand position The 8 dots/mm printhead can be fi tted in two positions. When the printhead is fi tted in the outer, right-hand position (see illustration), dot No.
  • Page 61 Chapter 8 Print Unit EasyCoder 501 S, 501 E, and 501 SA: 8.7 Printhead, cont. 11.81 dots/mm (300 dpi) printhead The 11.81 dots/mm printhead should only be fi tted in the right- hand position (see illustration). Dot No. 0 is situated 0.8 mm (0.03 inches) inwards of the inner edge of the media.
  • Page 62 10 mm (0.39 in) 104 mm (4.1 in) PRINT PRINT Length WINDOW WINDOW Origin Dot-line on printhead X-start Width FEED Dot 831 DIRECTION Dot 0 max. 114 mm (4.49 in) Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 63 7 mm (0.28 in) 104 mm (4.1 in) PRINT PRINT Length WINDOW WINDOW Origin Dot-line n printhead X-start Width FEED DIRECTION Dot 0 Dot 831 110 mm (4.33 in) max. 114 mm (4.49 in) Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 64: Headlift Mechanism

    Upper Gable Printhead Bracket Handle Illustrations shows the print unit of an EasyCoder 501 S, E, or SA. EasyCoder 501 LinerLess has a different type of print unit (see Chapter 8.2), but the headlift mechanism is identical. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 65 The bracket is fi tted with a locking mechanism for the printhead assy. Do not loosen these screws! (Factory adjusted) Locking Mechanism Shaft Bracket Thermal Printhead Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 66 For information on how to adjust the printhead pressure for various types of media, refer to Chapter 24.3. Turn c.w. to increase pressure Turn c.c.w. to decrease pressure Stop Washer Knob Screw Spring Thrust Journal Sleeve Pawl Pawl Lifting Shaft Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 67: Liner/Batch Takeup Kit

    9.1 Description The liner/batch takeup kit is an optional factory-installed device for EasyCoder 501 S, E, and SA (but not EasyCoder 501 Liner- Less) that makes it possible to auto-dispense self-adhesive labels from the liner (peel-off/self-strip operation), or to wind up printed labels, tickets, or continuous stock internally (batch takeup opera- tion).
  • Page 68 The takeup unit can accommodate the liner from a full roll of labels. Batch Takeup Operation Tear bar replaced by guide plate. Front hatch kept open. The takeup unit can accommodate approx. of a full label roll. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 69: Main Parts

    The stepper motor is connected to P-400 on the CPU board. Stepper Motor Motor Support Plate Belt to Takeup Unit Belt to Liner Drive Roller Tension Roll Takeup Unit Brace Break Shaft Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 70: Takeup Unit

    Slide Bearing Shaft Nylon Washer Friction Washer Compression Spring Washer Carrier #T20 Torx Screw Grub Screw Friction Felt /. Refer to Appendix 2 for a description of how to check the brake torque. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 71: Ribbon Save Device 10.1 Working Principles

    10. Ribbon Save Device The Ribbon Save Device is a factory-installed option for Easy- 10.1 Working Princi- Coder 501 E and EasyCoder 501 SA. It cannot be used with Easy- ples Coder 501 S or EasyCoder 501 LinerLess.The purpose of the...

  • Page 72: Control

    Allow parts to dry before using the printer. The Ribbon Save Device is factory adjusted and no readjustment of the nuts on the printhead bracket should be attempted, except by an authorized service technician. No lubrication is required. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 73: Transfer Ribbons

    See Chapter 10.8. • The connection board controls the DC motor of the headlift mechanism and the stepper motor of the ribbon rewind unit. See Chapter 10.9. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 74: Print Unit Assy

    There is no belt to the ribbon rewind unit since it is driven by a separate stepper motor. Headlift Bridge Guide Plates Pressing Roller assy. Rear Drive Roller LSS Adjustment Screw Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 75 The LSS can be removed without dismantling the lower outer gable. • There are no provisions for retaining the platen roller alignment when the lower outer gable is dismantled. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 76 5 mm (0.2 inches). Spring To Headlift Knob Pressing Roller assy. Printhead Unit Pressure Adjuster Pressure Adjuster Rear Drive Roller Inner Gable Belt (to Platen Roller and Linkage Stepper Motor) Pulley Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 77 1 cm (0.39 inches) from the edge that guides the media. This method is especially useful for black marks (measure the lat- eral position of the black marks with a ruler). Markings (centerpoint) (at 1 cm intervals) Lower Guide Plate Adjustment Screw Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 78 Never loosen the Important! center screw, and never loosen both Do not loosen this screw, the other two screws at the same time, see Caution notice! or the alignment may be lost! Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 79 LSS bracket upward. Then pull the bracket out from the carriage, taking care not to damage the cables. Note! The snap-lock is fragile. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 80 • Put back the guide plates and printhead. • Adjust the lateral position of the LSS. For more information on the LSS, refer to Chapter 8.6. Inner Notch LSS Bracket Outer Notch Snap-Lock Carriage Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 81 Correct distance is 0.3 mm (0.01 inch). Adjust if necessary. Note that the distance will increase when spring pressure is applied to the bracket. Lifting Bridge Screw Printhead Bracket Screw Printhead Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 82 (for example at media load), but not when the printhead is lifted by the headlift motor during ribbon save opera- tion. Excenter Turning Sleeve Tubular Pin E-Ring Spring Tubular Pin Spring Tubular Spacers E-Ring Shaft Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 83: Headlift Mechanism

    The headlift motor is fi tted with an excenter, that engages a lever fi tted on the headlift shaft. The lever is provided with a steel spacer to protect it from wear. Headlift Mechanism and Connection Board Spacer Lever Printhead assy. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 84 The cam is provided with an eccentrically fi tted ball bearing that engages the printhead lift lever (see the previous page). Ball Bearing Sensor Eccentric Ball Bearing Bracket Motor Connection Board Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 85 The distance can be measured with a feeler gauge when the printhead is lowered and should be 0.3 mm (0.01 inch). Insert feeler gauge here! Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 86: Ribbon Rewind

    Adjust- ment of the ribbon rewind unit is usually not required. Stepper Motor Bracket Chassis Bracket Belt #T20 Torx Screws Ribbon Rewind Unit Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 87: Connection Board

    Chapter 10 Ribbon Save Device 10.9 Connection Board Connection Board 1-040702-28; Components Diagram Connections: Permanently attached cable to P-8 on CPU Board Ribbon Rewind Motor Lifting Motor Optical Switch Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 88 TIMING SWE 2 10 CURRENT MC34063 GND 4 CIN 5 PBL3717 AOUT ST6_ENG2 PHASE BOUT ST5_ENG2 EMITTER ST4_ENG2 14 V40 11 VR 3 V40 TIMING 10 CURRENT Connection Board 1-040702-28; Circuit Diagram Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 89: Description

    The Label Taken Sensor (LTS) is an optional device for the Easy- 11.1 Description Coder 501 E, EasyCoder 501 LL, and EasyCoder 501 SA, which enables the printer’s software to detect if the latest printed label, ticket, tag, etc. has been removed before printing another copy.

  • Page 90: Installation

    • Open the right-hand door and the front hatch, and remove the left-hand cover. • Press the refl ecting sensor assy. into the bracket as illustrated below. Bracket Sensor assy. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 91 LTS assy. #T10 Torx Screw The illustrations show the print unit of an EasyCoder 501 E. The EasyCoder 501 LL has a slightly different type of print unit (see Chapter 8.2) which, however, does not affect the installation of the LTS.

  • Page 92: Adjustments

    Adjust the sensitivity of the label-taken sensor by means of the 11.3 Adjustments potentiometer WR-602 (marked “LTS”) on the CPU board: • Start up Intermec Fingerprint and run the program described in Chapter 11.2. Leave the label in the outfeed slot to create a label-not-taken condition.

  • Page 93: Description

    (see Chapter 11). There are two types of paper cutters, WARNING! a standard cutter for EasyCoder 501 S, E, and SA and a linerless In the standard cutter, the cutting edge cutter for EasyCoder 501 LL. Both cutter units are fi tted on the...
  • Page 94 Chapter 12 Paper Cutter 12.1 Description, cont. Standard Cutter (EasyCoder 501 S, E, & SA) The standard paper cutter is intended to cut through continuous non-adhesive paper strip or through the liner between labels. It must not be used to cut through any kind of adhesive or other...

  • Page 95: Control

    Chapter 12 Paper Cutter 12.2 Control In EasyCoder 501 S, 501 E, and 501 LL, the cutter is activated by CUT or CUT ON statements in the Intermec Fingerprint program, see Intermec Fingerprint v6.14, Reference Manual. In EasyCoder 501 SA, the cutter can be switched on/off by using a menu in the Set Mode, see Intermec Stand-Alone Concept, Oper- ating Instructions.
  • Page 96 /. In food industry and retail applications subject to specifi c regulations, the WD-40 could be replaced with a pure consumable vegetable oil. After dissolving the residue, carefully wipe clean the anvil blade. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 97: Installation

    • Fit the cable from the cutter unit into the DIN connector above the memory card slot on the printer’s front. DIN Connector Press sideways Cutter Unit Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 98 Then tilt up the cutter again and lock it in closed position. Check that the printhead is lowered and switch on the power. Now the printer is ready for operation. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 99 LTS.It is important that the jumper on P-607 is disconnected when fi tting the cutter to an EC 501 LL or when replacing the CPU board in an EC 501 LL. Cutter Unit Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 100 • Switch on power. The cutter will perform an idle cycle in order to occupy its home position. • Use for example the Terminal Setup in Intermec Shell or setup strings to change the startadjust value to -294 and the stopadjust value to +250.
  • Page 101 • Make sure to press the guide plate down as far as the U-shaped indents allow. • Tighten the screws. Linerless Cutter Unit Guide Plate Outfeed Slot #T10 Torx Screws #T10 Torx Key Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 102 fi tted on P-607 on the CPU board. Keep this in mind when install- ing a cutter on an EasyCoder 501 LL or replacing a CPU board. The LTS fi tted inside the cutter on an EasyCoder 501 LL can be used for detecting paper jams. This function does not interfere with the “normal”...

  • Page 103: Replacement

    Before removing the cables, note where each line is connected! Do not dismantle this plate (only removed to improve view) Label Taken Sensor Spring Home-position Microswitch Cover Plate Cutting Mechanism Safety Microswitch Anvil Blade Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 104 (held by two Torx #T20 screws). • Now you have full access to the microswitch. Note the threaded plate under the switch that holds the screws. • Reassemble in reverse order. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 105: Description

    13. Memory Card Adapter The memory card adapter is an optional device available for all 13.1 Description EasyCoder 501 models, either as a factory-installed option, or as a kit for fi eld installation. The memory card adapter allows the printer’s built-in memory to be supplemented by various types of memory cards, see Chapter 13.3.
  • Page 106 Memory Card Adapter Board; Components Diagrams GNDC IC 1 IC 3 IC 4 IC 2 IC 5 Memory Card Adapter Board 1-971706-26; Component Side IC 7 Memory Card Adapter Board 1-971706-26; Soldering Side Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 107 ADS 11 /A22 100nF GAL20V8 IC6B 100nF IC6C 100nF IC6D BVD1 100nF XADS 12 74AC573M BVD2 11 ADS GNDC GNDC 100nF IC6A /A22 CDET2 A22' 74AC86M ADBUS Memory Card Adapter Board 1-971706-26 Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 108 Chapter 13 Memory Card Adapter 13.1 Description, cont. Bus Driver Board; Components Diagrams Bus Driver Board as fi tted on the CPU Board 971712.ØØ P1 MOUNTED ON SOLDERING SIDE Bus Driver Board 1-971712-25; Components Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 109 /AD6 /AD8 /AD5 /AD6 /AD4 /AD4 /AD3 /AD2 /AD2 /AD0 /AD1 74HC245 /AD0 BUSDIR 3EN1 3EN2 /AD15 AD15 AD13 /AD13 AD11 /AD11 /AD9 /AD7 /AD5 /AD3 /AD1 74HC245 Bus Driver Board 1-971712-25 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 110: Installation

    Also fi t the long end of the connection cable to the connector at the rear part of the adapter unit. Cable GAL Circuit Screws Circuit Board Bus Driver Board Bracket Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 111: Memory Card Types

    • Check that a memory card can easily be inserted and pulled out from the adapter. • Close the front hatch and right-hand door, and insert the mains cable. Switch on power. The printer is now ready for use. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 112 SRAM (Static Random Access Memory), each in several sizes in regard of memory capacity, see below. • OTPROM cards can only be read by the Intermec Finger- print fi rmware after being preprogrammed using for example the Toolbox Confi guration program. Once programmed, they cannot reprogrammed.

  • Page 113: Inserting A Memory Card

    • Before removing the memory card, switch off the power. • Open the front hatch and pull the card straight out. Memory Card • Close the front hatch and switch on the power again. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 114: Description

    14. Sensor Kit 14.1 Description As an option, the EasyCoder 501 E and EasyCoder 501 SA can be fi tted with two sensors, that detect the rotation of the media supply spool and the ribbon unwind shaft and update two coun- ters, one for each sensor.

  • Page 115: Installation

    fi tting the ribbon low sensor. • Connect the cable to P-602 on the CPU board, see Chapter 17.4. • Put back the guide plate and the left-hand cover. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 116: Description

    15. Scaleable Fonts Kit 15.1 Description EasyCoder 501 S, E, and LL printers can be fi tted with an optional fi rmware package, that allows the printer to use scaleable outline fonts in Speedo and TrueType formats. The printer must not be fi...

  • Page 117: Installation

    /. Refer to Chapter 17, “CPU Board” for more information on the relation between jump- ers on P-100 to P-102 and the type and size of memory pack- ages on IC-100 to IC-105. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 118: Description

    The transformer unit contains wires and components with dangerous voltage 115/230 VAC! Always remove the power cord before touching the transformer unit. On/Off Switch Mounting Plate Voltage Selector AC Power Cord Receptacle Ring Core Transformer Cables not shown Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 119: Dismantling

    • Replace the defective part and reassemble in reverse order. Refer to Chapter 16.4 for wiring diagram. On/Off Switch Voltage Selector Mounting Plate Posidrive Screws AC Power Cord Receptacle Ground Screw Ring Core Transformer Posidrive Screw Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 120: Connection Diagram

    16.4 Wiring Diagram On/Off Switch Black Black Black Yellow Voltage Selector Switch From Transformer Black Orange Brown Black Orange Brown Brown Brown Black AC Power Cord Yellow Receptacle Green/Yellow Black Green/Yellow Black Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 121 Chapter 16 Transformer Unit 16.4 Wiring Diagram, cont. To On/Off Switch and Voltage Selector BLUE BLUE To P-300 on CPU Board Ring Core Transformer Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 122: Access To Cpu Board

    “front” markings are heading in the direction fi tted with table carpet and anti-electro- indicated by the components diagram in Chapter 17.5. static wrist straps grounded to an ESD inlet. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 123: Overview

    The CPU board is equipped with two processors, IC-07 and IC-402, the former of which is a 32CG16 that has an overall con- trol of printer activities, whereas the latter is an HPC 16083M that operates as a slave processor. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 124 CONVERTER 33 V DC/DC DC/DC CONVERTER CONVERTER 24 V 40 V AD-VIN V24-EN VOLTAGE VIN OK WATCH DOG THRESH P-302 D-308 DC/DC CONVERTER Battery & Battery charge AD-CHARGE circuit RESET RESET /RESET Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 125: Circuits And Straps

    Programmable straps (J1 = No transfer unit fi tted) IC-07 CG-16 processor P-10 + 24V enable/disable IC-100 to 101 Intermec Fingerprint EPROMs (or Flash Memory) P-100 to 102 EPROM/FLASH select for IC-100 to 105 IC-102 to 103 Confi guration EPROMs (or Flash Memory) P-200 DTR/RTS select for RS-232 on "uart1:"...
  • Page 126 17.3 Circuits and IC-04 Program GAL 501 The GAL (Generic Array Logic) is a memory-mapped address Straps, cont. decoder that is common for all EasyCoder 501 models. IC-07 Master Processor The 32CG16 processor treats incoming data from I/O ports and...
  • Page 127 fi les and fonts, for EPROMs containing a startup fi le example Intermec Shell, or a customized set of program fi les, setup (for example Intermec Shell), kill fi les, fonts, images, paper setup options, etc.
  • Page 128 "uart1:" is controlled by the slave processor that generates the necessary protocol signals. The slave also sends an interrupt signal to its master when it has stored incoming characters in its internal RAM memory. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 129 There are three types of GAL circuits for IC-700, one for Easy- Coder 501 S, another for EasyCoder 501E and EasyCoder 501 SA, and a third for EasyCoder 501 LinerLess. It is most important the correct type of GAL is fi tted.
  • Page 130 Max. 200 mA. Default: No jumper fi tted CAUTION! The external +5V may cause harm to some devices. Check cable confi gura- tion and specifi cations of the device before making the connection. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 131 The label taken sensor of the linerless cutter requires that no jumper is fi tted on P-607. When replacing the CPU board on an EasyCoder 501 LL with a cutter or when installing a linerless cutter, check that no jumper is fi tted on P-607.

  • Page 132: Connections

    Ribbon End Sensor P-606 Label Taken Sensor P-608 Printhead Lift Sensor P-700 Printhead Logic Some cables are labelled with a reference number that also can be found on the CPU board, for example . Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 133: Components Diagram

    C302 R311 R338 D308 C310 C326 R346 P302 C361 C315 C311 R301 Q306 C317 D311 Q704 Q302 IC304 C314 C304 C325 C300 R303 VAR1 D310 R335 Q305 P301 R328 Q300 D305 R325 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 134: Cg16 Master Processor

    HOLD AD10 NHOLDA AD11 74HC32M HOLDA AD11 32CG16 AD12 AD12 IC08B AD13 AD13 AD14 AD14 NADS AD15 AD15 74AC14M DDIN HOLDA DDIN A16' IC08A A17' A18' +5V +5V 74AC14M IC08D RESET 74AC14M Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 135: A/D And I/O Circuits

    IC22 CGENABLE C32—C33 CGSTART +5V +5V OR–ON 8255AM RESET CS8255A RESET LIFT–HEAD EN–ENG2 EN–ENG1 CUT–OUT BEEPEN IC23 EN-500 EN-DOUBLE V24-EN 8255AM 9 A2 7 CS8255B RESET RESET IC20 CSRTC /RESET STDP RTC-72421 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 136: Interfaces To Printer Devices

    AD4* AD3* AD5* AD2* AD6* AD1* AD7* AD0* CSX0 7 6 5 4 3 IC11 CSX1 OUT1 XINT 74HC541M OUT2 CSBUS & OUT3 OUT4 JUM1 NMIHPC JUM2 +5.3V JUM3 /RESET JUM4 IC14 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 137: Data Shiftout To Printhead

    SHIFT 2C1/G5 IC509C R504 3CT=15 & 3CT=15 SHIFT PCLK 10 R505 DMACLK 5CT=0 5CT=0 CLK/2 R506 CLK/4 R507 74HC163M 74HC163M IC502B IC503C IC509B DMAACK 9 PCLK PCLK & > 74HC32M 74HC00M 74HC74M Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 138: Hpc Slave Processor

    C362 – C410 – 74HC04M C365 C413 AD0 – AD15, A1 – A10 START 74HC074M STRBCLK C502A /RSET NMIHPC BEEP /RTS IC702C IC204F BEEPEN LATCH HPCBUSY & 7406M 74HC08M BEEP R422 R423 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 139: Stepper Motor Drives

    PHASE ST1–ENG1 BOUT ST2–ENG1 EMITTER 14 V40 3 V40 P401 TIMING CURRENT C406 PBL3770 C407 IC405 ST6–ENG1 AOUT PHASE ST4–ENG1 BOUT ST5–ENG1 EMITTER 14 V40 3 V40 TIMING CURRENT C408 PBL3770 C409 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 140: Rom Memory

    WR/A19 A1920 AD0–AD15, 27C080 27C080 27C080 A1–A20 IC101 IC103 IC105 A1920 A1920 A1920 A19/A20 A19/A20 A19/A20 WRH19 WRH19 WRH19 WR/A19 WR/19 WR/A19 27C080 27C080 27C080 C100 – C105, C106 – C109 C110 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 141: Ram Memory

    Chapter 17 CPU Board 17.6:8 RAM Memory IC106 IC107 IC108 IC109 A18/CS 30 A18/CS 30 A18/CS 30 A18/CS 30 CS3B CS3B CS4B CS4B 628512 628512 628512 628512 AD0–AD15, A1–A20 CS3B CS4B A18/CS Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 142: Uart1:" Interface Circuits

    R209 +RS422O F218 IC206 74HC32M R211 –RS422O IC204C, E F219 D201 IC19A P206 R216 P201 R217 7406M R215 6N139 74HC04M P207 P205 R208 R207 P208 P209 IC207 GNDC P204 RI– DO– DS8921 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 143: Sensor Interfaces

    IN FILTER C611 OUTPUT TONE IN IC600B C614 TIME CAP. R634 HEAD LIFT COMP TONE OUT – P608 LM567CM C616 R637 P606 LM339M R641 R639 C615 R643 Q603 R645 P607 R646 TRESH HEADLIFT Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 144: Data To Printhead

    AD–TEMP 7406M DATAIN ERROR IC701 R704 – . 25V C700 R720 R702 LM317LZ C702 C703 Q705 Q700 C701 R708 R727 EN-500 Q706 IC703A – R715 R714 AD–RES LM358M IC204D EN-500 Q707 7406M Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 145: Power To Printhead

    Chapter 17 CPU Board 17.6:12 Power to Printhead PPWREN R707 R709 Q702 P301 IC702B R713 R712 Q704 & Q703 Z700 74HC08M C704 HEADLIFT AD–P24 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 146: Power

    R325 IC303 TL7709M B300 D308 C319 OSCOUT C322 COMP C314 C315 – Z300 C311 – CURR C318 U=5V SHUTDOWN C316 LED1 C312 3524 C317 C313 Q303 /RESET R332 RESETB Q304 AD-CHARGE C370 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 147: Test Points

    Reset, active low during power up. High at normal operation. Printhead voltage +24V ±1V during print cycle and cutter operation. +40V Stepper motor voltage +40V ±2V. 24V ±1V, generates P24 and +40V. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 148: Testing The Cpu Board

    - the type of printer cannot be detected. Then the minimum resistance values will be used which may result in a weak printout. - the reference resistance does not stabilize inside allowed limits. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 149: Connector And Cables

    Chapter 18 18. "uart1:" All EasyCoder 501 printers are fi tted with a DB-25pin male inter- 18.1 Connector and face connector on their rear plates (communication port "uart1:"). Cables This connector can be used for an RS-232, an RS-422, or a 20 mA current loop interface depending on how the CPU board is strapped.

  • Page 150: V24)

    Jumper fi tted connects +5V to pin 16. Caution! Max 200 mA. Be careful not to enable the external 5V unin- tentionally, which may cause harm to the terminal, PC, or other device connected to this port! Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 151 Cable confi guration The following ready-made RS-232 connection cables can be cont. ordered from Intermec. Cables procured from other sources should follow the same wiring principles. Caution: Be careful not to connect the external +5V unintention- ally, which may harm your computer or terminal.

  • Page 152: Rs-422

    RS-422 requires an additional circuit and a number of straps to be fi tted on the CPU board: P-203 (external +5V) IC-207 (RS-422 circuit) P203 P-202 (interface select) P202 P208 P206 P209 P207 P204 IC-207 P205 P-204 to P-209 (comm. straps) Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 153 - RS422 OUT P-206 P-207 P-204 P-205 /. Caution! Be careful not to enable the external 5V unintentionally, which may cause harm to the terminal, PC, or other device connected to this port! Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 154: Ma Current Loop

    (that is, supplying the current) or passive. A transmission speed between 300 and 9,600 baud is recommended. P-203 (external +5V) P-202 (interface select) P203 P202 IC-205 IC-205 & IC-206 (optocouplers) IC-206 Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 155 Pin 14 – 20 mA Pin 16 + 5V, 200 mA (if jumper fi tted on P-203) Pin 18 RXD + Pin 25 RXD – . In case of printer being active receiver. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 156 Pin 18 47 ohm Pin 25 RXD- Pin 14 Printer active transmitter/passive receiver Pin 9 TXD+ Pin 11 Transmitter TXD- Pin 12 Pin 10 Receiver RXD+ Pin 18 47 ohm Pin 25 RXD- Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 157: Description

    IN and 4 × OUT ports Please refer to Chapter 1.2 for information on which interface 1 × DB25 + 1 × DB15 boards are available for each of the various models. connectors Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 158: Installation

    • Reassemble the printer in reverse order. • Connect the communication cables. • Connect the power cord and switch on the power. #T10 Torx Screw 230V Rear Plate #T10 Torx Screw Interface Board Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 159: Description

    RS-232 Standard. RS-422 or 20 mA CL Option. Additional circuits required. "uart2:" Fitted on serial interface pcb. RS-232 "uart3:" Fitted on serial interface pcb. RS-232 or 20 mA CL Select by strap. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 160: Straps

    External +5V (max. 200 mA) can be made available on pin 16 by fi tting a strap on P-6. Be careful not to enable this option unintentionally, which may cause harm to the connected terminal, computer, or other device. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 161: Connector Confi Guration

    – – – not used – – – – not used – – – – not used – –RXD – Current loop RXD – */. In case of printer being active receiver. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 162: Components Diagram

    Chapter 20 Serial Interface Board 20.4 Components Diagram 971.703.02 R16 R17 Z1 R1 R2 R10 Z2 R3 R4 D2 R12 +5V EXT D3 D1 Serial Interface Board 1-971703-40 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 163: Circuit Diagrams

    RESET RXDB /TXDB CSX1 /TXDB /TXDB TXDB XINT /DSRB /DSRB /DSRA IC3D /DSRA /CTSB /CTSB 74AC14 /CTSA /CTSA /DTRB /DTRB /DTRA /DTRA /RTSB /RTSB /RTSB /RTSA /RTSA 88C681/40 Serial Interface Board 1-971703-40 Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 164 5 –TXD +TXD +TXD 6N139 –TXD –TXD +20M2 –20M2 +12VA +20M2 +5VEXT –12VA –20M2 +RXD +5VEXT +RXD DTRB IC3A +RXD /RXDCL –RXD DTRB 74AC14 –RXD –RXD 6N139 GNDC GNDC Serial Interface Board 1-971703-40 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 165: Description

    RS-422 or 20 mA CL Option. Additional circuits required. "uart2:" Fitted on RS-422/485 interface pcb. RS-422/RS 485 Type selected by straps and cable confi guration "uart3:" Fitted on RS-422/485 interface pcb. RS-232 Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 166 The RS-422/485 communication enabled. Each printer must be given an address by means of straps port is in most cases referred to on the interface board. See Intermec Fingerprint v6.13, Program- as "uart2:", except in connec- mer’s Guide. tion with the OPEN statement, when it must be referred to as In an RS-485 loop, one of the units must be appointed “master”...

  • Page 167: Straps

    Connects +5V to pin 16 on "uart3:". Max 200 mA. Caution! Be careful not to enable the external +5V unin- tentionally, which may cause harm to the terminal, com- puter, or other device connected to this port! Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 168 P-8 and P-9 strapped on master unit. No straps No straps P-10 strapped on last unit. P-10 strapped on first unit. Connection P-2 pin 7 to Chassis GND (for example P-2 pin 1) on one unit only. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 169: Connector Confi Guration

    + 5V 200 mA, if strap on P6 -RS422 IN RS-422 only – – – +RS422 OUT RS-422/485 – – DTRB DTR permanently high -RS422 OUT RS-422/485 – – – – – – – – – Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 170: Components Diagram

    Chapter 21 RS-422/485 Interface Board 21.4 Components Diagram C15 + C12 + + C13 C14 + MASTER P10 P11 R15 R16 IC10 RS-422/485 Interface Board 1-971708-40 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 171: Circuit Diagram

    JUM4 GNDC /CTSB CTSB /CTSB /DSRB DSRB JUM5 +5VEXT +5.3V MC145407 /JUMEN GNDC JUM1 DTRB JUM2 /DTRB XINT JUM3 IC3D GNDC JUM4 /RTSB JUM5 /RTSA 74AC14M /JUMEN 88C681/40 RS-422/485 Interface Board 1-971708-40 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 172: Description

    Fitted on Parallel interface pcb. Centronics parallel interface The setup is in no way affected by the Parallel Interface Board, since the Centronics interface does neither require any communi- cation setup nor uses any buffers. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 173: Straps

    Jumper fi tted on S-3 = BUSY signal on rising edge of /STROBE signal (that is, as on previous versions of this board). /. A jumper must be fi tted on either S-2 or S-3! Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 174: Connector Confi Guration

    Note: The PE signal (Paper End) on pin 12 requires an error-trapping routine to be included in the Intermec Fingerprint software, acti- vating the BUSY and READY statements. Here is an example on how such a routine may be written:...

  • Page 175: Components Diagram

    Chapter 22 Parallel Interface Board 22.4 Components Diagram Parallel Interface Board 1-971704-41 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 176: Circuit Diagram

    & XINT CSX0 74HC367B POLL NMIHPC 74HC138 +5.3V RDDATA IC7B /RESET POLL 74HC367A POLL 74HC423 /SLCTIN /INPRM & +12V CSX0 TESTID DREADY & -12V IC7A GNDI ADBUS IC6B Parallel Interface Board 1-971704-41 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 177: Description

    The input and output signals can be read by means of the Intermec Fingerprint function PORTIN and output signals can be controlled by PORTOUT ON/OFF state- ments.

  • Page 178: Straps

    Closed PORTOUT (<nexp>) OFF 2–3 (upper position) Open /. Be careful not to enable the external +5V unintentionally, since it may cause harm to the con- nected terminal, computer, or other device. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 179: Connector Confi Guration

    DTR permanently high PORTIN (<nexp>) functions. – not used Also see Intermec Fingerprint v6.14, Reference Manual. – not used – not used – not used */. If strap fi tted on P-1 Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 180 1 A Switching power max. 100VA AC Switching voltage max. 100V AC Max. DC Load Breaking Capacity 30 40 50 a: resistive load DC Voltage (VDC) b: inductive load L/R=20 ms Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 181: Components Diagram

    Chapter 23 Industrial Interface Board 23.4 Components Diagram C6 + C4 + + C3 C5 + R8 R12 R14 REL4 REL3 R9 R10 REL2 REL1 Industrial Interface Board 1-971709-40 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 182: Circuit Diagrams

    CEXT – OUT4 /TXDB 11 TXDB OUT3 /RTSB 13 RTSB /DTRB 15 DTRB /DTRB /DTRB OUT2 /RXDB 12 RXDB OUT1 /CTSB CTSB /RTSB /RTSB /DSRB DSRB MC145407 88C681/40 Industrial Interface Board 1-971709-40 Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 183 IC4B REL3 OUT3 74HC04 ULN2003 IC6A IC4A REL4 OUT4 74HC04 ULN2003 IC3E IC5D 74AC14 TTL193B IC3B IC5C 74AC14 TTL193B IC3F IC5B 74AC14 TTL193B IC3D IC5A GNDC 74AC14 TTL193B Industrial Interface Board 1-971709-40 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 184: Test Labels

    • Setup Mode (EasyCoder 501 E & 501 SA only). See Installation & Operation manuals and diagram in Appendix • Intermec Shell (EasyCoder 501 S, 501 E, and 501 LL only). See Installation & Operation manuals and diagrams in Appen- dix 1.
  • Page 185 EAN 13 bar code printed in picket fence attitude, that is, with the bars running along the media feed direction The readability could be checked visually or with a bar code scanner. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 186 (for example because of three sets of serial communication parameters and buffers), additional labels will be produced until all setup values have been printed. After examining the test labels, take appropriate action according to the lists in Chapter 24.2. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 187: Possible Printout Troubles

    Check arm is closed Chapter 12.3 Check switch Chapter 12.5 Wrong Fingerprint version (< v6.1) Check version Fingerprint manuals Printer does not feed LTS erroneously detects label not taken Adjust LTS Chapters 11 & 12 Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 188: Mechanical Adjustments

    At each quarter of a turn, the resistance increases and a clicking sound can be heard. Adjustments Knobs c.w. = more pressure c.c.w. = less pressure Illustration shows the print unit of an EasyCoder 501 E/SA. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 189 If the desired result cannot be obtained, increase or decrease the pressure by turning both knobs a quarter of a turn in the same direction, then fi ne-adjust the outer knob. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 190 #T20 Torx Screw- driver Locking Screw Illustration shows the print unit of an EasyCoder 501 E/SA. • By turning the Torx screwdriver, you can move the outer end of the ribbon assist roller back and forth: - Turn it clockwise to move the end of the roller forward.
  • Page 191 • You will need to print several labels before a new adjustment has any noticeable effect. • When you are satisfi ed that the problem is cleared, tighten the locking screw and test again by printing several more labels. Readjust if necessary. Intermec EasyCoder 501 – Service Manual Ed. 7...
  • Page 192 The printhead bracket is factory-adjusted in relation to the headlift shaft by means of oversized holes for the three screws that hold the two parts together (see Chapter 8.8). Adjustment requires a special fi xture and should not be otherwise attempted. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 193: Description

    • A full test mode for EasyCoder 501 E, EasyCoder 501 SA, and EasyCoder 501 LL. You can enter the full test mode on an EasyCoder 501 S if a special Service GAL circuit is fi tted on IC-700 on the CPU board and a Service Keyboard is connected to P-2, replacing the existing key- board.

  • Page 194: Easycoder 501 S, Test Mode Diagram

    <PRINT> = PRINT Lift head = EXIT To exit, lift head Print and press Print 618 ohms / 8 dots Print Print CODE39 CODE39 1 23 45 67 890 12 8 Print Print Print Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 195: Easycoder 501 E, Sa, & Ll

    Chapter 25 Test Mode 25.4 EasyCoder 501 E, The full Test Mode works in EasyCoder 501 E, 501 SA, and 501 SA, & LL However, when entering the Test Mode in an EasyCoder 501 SA printer, the Stand-Alone autoexec-fi le that defi nes the alphanu- This chapter also applies to an EasyCoder meric keyboard is bypassed.
  • Page 196 The printer can be started up again with no changes made to its original setup values or RAM memory. 2. By pressing the <Setup> key (EasyCoder 501 E/LL) or the <U> key (EasyCoder 501 SA). The printer will enter the Intermec Fingerprint's immediate mode with its communication reset to default (see above).

  • Page 197: Easycoder 501 E/501 Ll Test Mode Diagram

    Chapter 25 Test Mode 25.5 EasyCoder 501 E/501 LL Test Mode Diagram TESTMODE: TESTMODE: TESTMODE: TESTPRINT LSS ADJUST HEAD RESIST Enter Enter Enter Enter <PRINT> = PRINT LABEL <> HEAD RESIST: <C> = EXIT PASSWD:1138 Print Enter Enter HEAD RESIST:...

  • Page 198: Easycoder 501 Sa Test Mode Diagram

    ERROR STAT ERROR STAT ERROR STAT ALL SYSTEMS: GO! ALL SYSTEMS: GO! LABEL NOT TAKEN ERROR STAT LAST LABEL ERROR STAT HIGH TPH VOLTAGE ERROR STAT ALL SYSTEMS: GO! Any key Print Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 199: Printer "Dead

    40-50V, the associated power transistor is probably short- circuited. • Continue with the stepper motor voltage +40V. If the voltage is too low (24V), the step-up switch is broken. Remove strap on P-10. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 200: Transformer And Cabling Failure

    • If the transformer repeatedly heats up, it has probably got an internal short-circuit. If so, replace it, as otherwise there will be a safety hazard, when mains are no longer isolated from the secondary side of the transformer. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 201: Cpu Board Failure

    IC-104 and IC-105, check that straps are fi tted correctly on P-100, P-101, and P-102, see Chapter 17.3. • Check that Intermec Fingerprint EPROMs IC-100 and IC-101 “Front” Mark are marked with IC-1 and IC-2 respectively and that both have the same part number, see Chapter 17.3.

  • Page 202: Printhead/Cpu Board Mismatch

    (Part No. 1-040700-28) causes an electrical mismatch that will prevent the printer from starting up. Such CPU boards were installed in EasyCoder 501 printers manufactured before Sep- tember 30, 1996. CPU boards with Part No. 1-040700-29 or later in combina- tion with 8 dots/mm printheads with Part No.

  • Page 203: Single Function Failure

    KEY BEEP statement in the running program. • If the printer does not react on some or several key depressions in the setup mode, the keyboard is probably out of order and needs to be replaced. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 204: Error Messages Transmitted Or Displayed

    OUT channel (serial communica- tion only). By default, "uart1:" is standard IN/OUT channel. • In the immediate mode of Intermec Fingerprint, the fi rmware can detect and display three error conditions, provided the printhead is lowered and a media feed is executed: - Error 1005 (“Out of paper”)

  • Page 205: No Memory Backup Storage

    • There are several ways to fi nd out what parameters a certain printer interface is set up for: - If the printer is fi tted with an Intermec Shell startup program, P201 C203 there are various ways for printing or reading the setup, see the Installation &...

  • Page 206: No Communication (Standard Serial Interface)

    IC-207 and that the communication straps P-204 – P-207 are fi tted correctly, see Chapter 18.3. • Using an oscilloscope, verify that all signals during receiving and transmitting data have the appearance described in this manual. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 207: Label (Ticket) Gap Or Black Mark Not Detected

    1022 “Head lifted” will be indicated at any attempt of printing a label. • Check the sensor for dust or foreign objects. • Check that the sensor’s cable is connected to P-608 on the CPU board. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 208: Ribbon-End Sensor Out Of Order

    • Adjust the sensitivity of the receiver by means of potentiometer WR-601 on the CPU board. • Fit or remove strap on P-604 to change the intensity of the light emitter. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 209: Printing Troubles

    • Check that the printhead is completely lowered and pressing against the media with a suffi cient force, see Chapter 24.3. • Check that the headlift sensor is in order, see “Printhead lift sensor out of order” in Chapter 26.2. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 210: Overall Weak Printout

    Replace the print- head. • Circuit IC-700 generates all signals to the thermal printhead. Therefore, unexpected printouts or strange patterns could appear if IC-700 has been damaged. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 211: All Or Most Dots Printed

    If they are found OK, the control and drive circuits IC-403 and IC-405, or the CPU board, are probably damaged and the whole board needs to be replaced. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 212: Transfer Ribbon Troubles

    • Check that the ribbon is fi tted above the label stop sensor. • Check that the printer is set up for the type of thermal transfer ribbon in use. • Check printhead voltage on Testpoint P24, see Chapter 17.7. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 213: Liner/Batch Takeup Troubles

    If they are found OK, the control and drive circuits IC-400 and IC-401, or the CPU board, are probably damaged and whole board needs to be replaced. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 214: Ribbon Save Device Troubles

    If they are found OK, the control and drive circuits IC-2 and IC-3, or the Connection Board, are probably damaged. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 215: Jammed Receiving Face Materials

    (RIBBON SAVE OFF). • Check that the nuts are properly adjusted in relation to the lift- ing bridge, see Chapter 10.7. • Also refer to the checklist in Chapter 24.2. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 216: Lts Troubles

    fi tted. However, in this case time and date must be ”manually” reset after each startup, else errors will occur. Also see Intermec Fingerprint v6.13, Reference Manual. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 217: Standard Cutter Troubles

    • The return spring in the cutter mechanism could eventually get slack and need to be replaced. • If no cause of malfunction could be found, the cutter is prob- ably defective. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 218: Linerless Cutter Troubles

    • Verify that the printer is set for the right media type. • Verify that the LSS works correctly correctly, see Chapter 26.2. • Verify that the LTS is managed by the appropriate Fingerprint instructions. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 219: Memory Card Adapter Troubles

    • Inspect the memory card for mechanical damages. Examine the memory card adapter pcb for breakages or bad soldering. • Check that the GAL package on the memory card adapter is a 20V8 and that it is mounted correctly. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 220: Sensor Kit Troubles

    • In case of RS-485 on "uart2:" carefully examine the program and the printer’s setup. Refer to Intermec Fingerprint v6.13, Programmer’s Guide. • Check the polarity of the wires in the RS-422 or RS-485 cable.

  • Page 221: Parallel Interface Board Troubles

    • Verify, by means of an oscilloscope, that all signals during receiving and transmitting data have the appearance described in Chapter 23. Verify also that oscillator Y-1 on the Industrial Interface Board is running. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 222: Intermec Shell 4.01 Standard

    CLEAR RAM MEMORY Y=H DOWN/ N=H UP CLEARED by transmitting T T T HU/PP to printer, when menus marked with grey SHELL Exit Shell and enter last selected application! HD/PP are displayed! REBOOT HU/PP Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 223: Intermec Shell 4.01 Enhanced

    Y=ENTER/ N=F5 CLEARED by transmitting T T T or t t t to printer, when menus marked with a SHELL Exit Shell and enter last selected application! shade of grey are displayed! REBOOT Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 224: Easycoder 501 S Setup Overview

    TESTFEED HD/PP CONTRAST HD/PP HD/PP HD/PP Menus in this example show default UART1,NEW LINE UART1,BAUDRATE PERFORMANCE setup for an EasyCoder 501 S with a 9600 CR/LF NORMAL HD/PP HD/PP HD/PP printhead density of 8 dots/mm. UART1,PARITY START ADJ IMAGE BUFF SIZE...

  • Page 225: Easycoder 501 E, Sa, & Ll: Setup Mode Overview, Part 1

    • Press Enter to enter the Service part (see next page). SETUP: • Press F5/–> to go back to the “Setup; Contrast” menu. SERVICE • Press Setup/Save to exit the Setup Mode. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 226: Easycoder 501 E, Sa, & Ll: Setup Mode Overview, Part 2

    E nt er • Press F4/<– to return to the “Detection” menu in part 1. • Press F5/–> key to return to “Media Size” menu. • Press Setup/Save key to exit the Setup Mode. Intermec EasyCoder 501 – Service Manual Ed. 7...

  • Page 227: 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 501 – Service Manual Ed. 7...

Table of Contents