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Maintenance Manual
3600 Bar Code Label Printer
P/N 062905-001
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Intermec® Corporation 6001 36th Avenue West P.O. Box 4280 Everett, WA 98203-9280 U.S. technical and service support: 1-800-755-5505 U.S. media supplies ordering information: 1-800-227-9947 Canadian technical and service support: 1-800-688-7043 Canadian media supplies ordering information: 1-800-268-6936 Outside U.S. and Canada: Contact your local Intermec service supplier.
The information contained herein is proprietary and is provided solely for the purpose of allowing customers to operate and/or service Intermec manufactured equipment and is not to be released, reproduced, or used for any other purpose without written permission of Intermec. Information and specifications in this manual are subject to change without notice. © 1995 by Intermec Corporation All Rights Reserved The word Intermec, the Intermec logo, Label Debut, and CrossBar are trademarks of Intermec Corporation. The name Centronics is wholly owned by GENICOM Corporation. IBM is a registered trademark of International Business Machines Corporation. Throughout this manual, trademarked names may be used. Rather than put a trademark ( TM) symbol in every occurrence of a trademarked name, we state that we are using the names only in an editorial fashion, and to the benefit of the trademark owner, with no intention of infringement. The software contained in the 3600 printer and the accompanying materials are copyrighted. Unathorized copying of the software, including software that has been modified, merged, or included with other software, or the written materials is expressly forbidden without the prior written consent of Intermec. All right, title, and interest in all copies of this software are and shall at all time remain the sole and exclusive property of Intermec. Customer may be held legally responsible for any copyright infringement that is caused or encouraged by its failure to abide by these terms.
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Contributors
Technical Writer: Editor: Technical Illustrator: Technical Reviewers: Robert Shaw Craig Thompson George Wilson Cathy Aragon Pixie Austin Daniel Clark John Cramer Allen Crowe Stephen Eckert Pat Helton Laura McCluer Ed Millet Art Millican Matt Roberts Joe Wade
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Contents
Contents
Before You Begin xi Safety Summary xi Warnings and Cautions xii Purpose of This Manual xii Additional Information xv
1
General Information
Overview of the 3600 Printer 1-3 3600 Features 1-4 3600 Printer Specifications 1-4 Dimensions (no options installed) 1-4 Electrical Requirements 1-4 Printing Methods 1-4 Printing Speed 1-5 Printhead Specifications 1-5 Media Specifications 1-5 Ribbon Specifications 1-5 Environment 1-5 Self-Strip Specifications 1-5 Communications 1-6 Fonts and Graphics 1-6 Character Sets 1-6 Memory 1-6 Factory Default Settings 1-7 3600 Printer Options 1-7 Memory Expansion 1-7 Twinax Interface 1-7 Coax Interface 1-8 Parallel Interface 1-8 Network Connectivity 1-8 Kanji/Katakana Character Support 1-8 Batch Takeup 1-8
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Principal Functional Parts 1-9 Basic Printer Setup and Operation 1-11 Front Panel Operation 1-11 Over-Temperature 1-11 Media or System Faults 1-12 Feed/Pause Pushbutton 1-12 Checking the Printer Configuration 1-12 DIP Switch Settings 1-13 Connecting the Printer to a Computer 1-13 Printing 1-14 Using Label Debut 1-14 Using Third-Party Software 1-14 Using the Printer Command Set 1-15
2
Preventive Maintenance
Preventive Maintenance Actions and Intervals 2-3 Inspecting the Printer 2-4 Cleaning the Printer 2-4 Removing the Media Cover 2-5 Cleaning the Printhead 2-6 Cleaning the Rollers and Tear Bar 2-8 Cleaning the Media Guides and Media Path 2-9 Cleaning the Label and Ribbon Sensors 2-11 Cleaning the Printer Covers 2-12
3
Testing and Adjusting
Testing the Printer 3-3 Running Test and Service Mode at the Printer 3-4 Setting DIP Switches 3-4 Printing Test Labels 3-7 Running Test and Service Mode From a Host Computer 3-11 Testing Printer and Host Communications 3-12
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Adjusting the Printer 3-13 Adjusting the Print Bias for Print Quality 3-14 Adjusting the Print Intensity 3-15 Adjusting the Printhead Adjustment Lever for Print Quality 3-16 Adjusting the Label Mark Sensor 3-17 Adjusting the Label Gap Sensor 3-19 Adjusting the Label Taken Sensor 3-20 Aligning the Printer 3-21 Aligning the Rollers 3-22 Aligning the Printhead 3-23 Aligning the TTR Supply Hub 3-25
4
Troubleshooting
About Troubleshooting and Repair 4-3 Troubleshooting Tips 4-3 Where to Start 4-3 Repair 4-3 Troubleshooting Checklist 4-4 Error Handling 4-5 Syntax Errors 4-5 Parameter Errors 4-5 Image Overrun Errors 4-5 Invalid Numeric Character Errors 4-6 Insufficient Storage RAM Errors 4-6 Error Codes 4-6 Printer Operation Problems 4-9 Print Quality Problems 4-10 Communications Problems 4-12 Environmental Problems 4-13 Electrostatic Discharge (ESD) 4-13 Electromagnetic and Radio Frequency Interference 4-14 Ground Loops Between Equipment 4-14 Inadequate Earth Ground 4-14 AC Power Problems (Surges, Sags, Spikes, Noise, and Outages) 4-15 Miscellaneous Problems 4-16
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5
Remove and Replace Procedures
Replacing Printer Components 5-3 Replacing the Lithium Battery 5-4 Replacing the Printhead 5-5 Replacing the Bezel PCB 5-6 Replacing the Main PCB 5-8 Replacing the Kanji/Katakana Option PCB 5-9 Replacing the Label Mark Sensor 5-10 Replacing the Label Taken Sensor 5-12 Replacing the Label Gap Sensor 5-13 Replacing the TTR Drive Roller and Gear/Pulley 5-15 Replacing the TTR Takeup Hub, Clutch/Pulley, and Belt 5-18 Replacing the TTR Supply Hub and Adjusting Plate 5-20 Replacing the Platen Roller and Gear 5-22 Replacing the Liner Drive and Takeup Components 5-24 Replacing the Stepper Motor 5-30 Replacing the AC Plug/Input Filter 5-31 Replacing the Power Switch/Circuit Breaker 5-32 Replacing the Transformer 5-33
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PCB Drawings and Schematics
Replacement Parts
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Contents
A
Appendix
Functional Description of the 3600 Mechanics A-3 Functional Description of the 3600 Electronics A-4 Power Supply A-4 +5V A-4 +40V A-4 +24V A-4 Power Fail Detection A-5 Battery A-5 Battery Life Calculations A-5 Reset A-5 Motor Driver A-6 Processor A-7 Chip Selects A-7 TPU A-7 QSM A-8 Interrupt Priority Levels A-8 Crystal A-8 Memory A-9 Static RAM A-9 EPROM A-9 DRAM A-9 Communications Interface A-10 A/D Converter A-10 DIP Switches A-10 ASIC and I/O Option Interface A-10 Address/Data Multiplexor A-10 Chip Select Generation A-11 I/O Option Connector A-11 FIFO A-11 Front Panel Interface A-11 Debug Interface A-11 Functional Description of the 3600 Software A-14 Band Buffering and Font Caching A-14 Image Band Buffering A-14 Image Band Example A-15 Font Caching A-18 Print Energy Compensation A-18 Digital Thermal Compensation A-18 Global Compensation A-18
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Before You Begin
Before You Begin
This section describes the purpose and arrangement of this manual to you. It is intended to bring to your attention, important general safety concerns, specific warnings and cautions, and sources of additional information.
Safety Summary
Your safety is extremely important. Read and follow all of warnings and cautions in this book before handling and operating Intermec equipment. You can be seriously injured, and equipment and data can be damaged if you do not follow the safety warnings and cautions. Do Not Repair or Adjust Alone Do not repair or adjust energized equipment alone under any circumstances. Someone capable of providing first aid must always be present for your safety. First Aid Always obtain first aid or medical attention immediately after an injury. Never neglect an injury, no matter how slight it seems. Resuscitation Begin resuscitation immediately if someone is injured and stops breathing. Any delay could result in death or permanent injury. To work on or near high voltage, you should be familiar with approved industrial first aid methods. Energized Equipment Never work on energized equipment unless you are authorized by a responsible authority. Energized electrical equipment is dangerous. Electrical shock from energized equipment can cause death. If you must perform authorized emergency work on energized equipment, be sure that you comply strictly with approved safety regulations.
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Warnings and Cautions
The warnings and cautions in this manual use the following format and address the issues described: Warning A warning alerts you of an operating procedure, practice, condition, or statement that must be strictly observed to avoid death or serious injury to the persons working on the equipment.
WARNING
CAUTION
Caution A caution alerts you to an operating procedure, practice, condition, or statement that must be strictly observed to prevent equipment damage or destruction, or corruption or loss of data.
Purpose of This Manual
The purpose of this maintenance manual is to provide the information you need to clean, adjust, and repair the Intermec 3600 Bar Code Label Printer.
Who Should Read This Manual?
This manual is written for experienced electronic technicians trained by Intermec, who will service and, if necessary, repair the 3600 printer. Detailed operating instructions and specific related information is provided in the 3600 Bar Code Label Printer User's Manual. This document is not intended to support user operations or persons untrained in troubleshooting and repair. You should have a working knowledge of electronics with an advanced understanding of PCs, DOS, data communications, and bar code applications. It is assumed that you are familiar with the installation, programming, and operation of the Intermec 3600 Bar Code Label Printer and all of its options, including a working knowledge of the Label Debut (or Label) software tool.
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Before You Begin
How This Manual Is Organized
You will find the following information in the referenced section: For information about:
A basic description of the 3600
Refer to:
Chapter 1 - An illustrated overview of the 3600 printer; listing printer features, specifications, and options, identifying primary parts, and summarizing some setup and operating information. Chapter 2 - Actions, intervals, and illustrated preventive maintenance procedures. Chapter 3 - Procedures for running printer tests printing test labels, printing out the configuration settings, and for making printer adjustments and alignments. Chapter 4 - Information for identifying, duplicating, isolating, and eliminating conditions or failures in the printer environment or the printer components. Chapter 5 - Instructions for the removal and replacement of key components. Chapter 6 - Engineering drawing and schematic diagram of the main PCB. Chapter 7 - Two lists of the spare parts: one in ascending part number sequence and one alphabetically by description, keyed to exploded illustrations of the printer. Part numbers for tools and documentation are also provided. Appendix - functional descriptions of the 3600 mechanics, electronics, and firmware.
Scheduled cleanings and checks
Making sure the printer is operating correctly and providing quality results
Problem solving
Removing and replacing components
Main PCB drawings and diagrams Spare parts
Theory of operation
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Terms and Conventions
The following terms and conventions occur throughout this manual. A complete glossary of terms is provided in the 3600 Bar Code Label Printer User's Manual.
Terms · "Backing" (or liner) refers to the silicon release portion of the media that carries the label.
· · · "Host" refers to any computer that the printer is connected to. "TTR" refers to the thermal transfer ribbon used when the printer is in thermal transfer rather than direct transfer mode. "Media" is the stock on which the printer prints labels. Media can be made of plain paper, polyester, thermally reactive paper, or other materials with adhesive backing.
Conventions The following conventions are used throughout this manual for operating procedures and descriptions of the printer.
· Downloaded commands appear in the order that you enter them into the printer with the following conventions: Convention
<>
Description
Angle brackets < > enclose mnemonic representations of ASCII control characters. For example, represents the ASCII "End of Text" control character. Braces {} enclose variable data. For example, {n} signifies a variable for which you can designate a constant value. Brackets around a word or letter represent a key on your keypad. For example, [Tab] represents the Tab key and [M] represents the letter M key. When two keys are joined with a dash, press them simultaneously. For example, if you see the command [Ctrl]-[C], press the two keys at the same time. Enter all characters not enclosed in brackets by pressing an individual keypad key. For example, E3;F3; is entered as [E][3][;][F][3][;] with the E and the F in uppercase.
{} []
[ ]-[ ]
E3;F3
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Before You Begin
Additional Information
The following documents may be of interest or help to you in servicing the 3600 printer. 3600 Bar Code Label Printer User's Manual (P/N 062732) Label Debut User's Manual (P/N 062982) Data Communications Reference Manual (P/N 044737) The Bar Code Book by Roger C. Palmer
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1
General Information
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General Information
1
This chapter identifies basic features, options, and technical specifications of the 3600 printer. It names principal functional parts and reviews basic printer setup and operation.
Overview of the 3600 Printer
The Intermec 3600 is a microprocessor-based thermal printer that prints standard bar code or 2D symbology, human-readable characters, graphics, lines, and borders on 3-inch (7.62 cm) to 6.6-inch (16.8 cm) wide continuous feed label stock. The 3600 prints directly to thermal label media or can print on regular label media with the use of a thermal transfer ribbon (TTR).
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The 3600 supports applications that need a wider print capability than the Intermec 3400 Bar Code Label Printer can provide.
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3600 Features
The 3600 printer's features are summarized in the following list: · · · · · · · · · · · · · · · Print speed from 2 to 5 ips Programmable, nonvolatile printer configuration Bitmap font capabilities Outline/vector font support User selectable gap feature for fonts 2D symbology support (Code One, PDF 417, and Maxicode) 128k (standard), 512k (optional) storage memory Autoselection of Intermec protocols Printable control characters Image banding and memory management Dot-by-dot digital thermal compensation Self-strip or continuous print (with internal rewind) Media sensitivity numbering system Wide range of label media Label Debut
TM
label design software
3600 Printer Specifications
The specifications and performance parameters for the 3600 printer are itemized in this section.
Dimensions (no options installed)
Height Width Length Weight 11 inches (27.9 cm) 12 inches (30.5 cm) 17 inches (43.2 cm) 45 pounds (20.3 kg)
Electrical Requirements
Frequency
Input Voltage 100, 115, or 230 VAC ± 10% 47 to 63 Hz
Printing Methods
Direct Thermal Thermal Transfer (thermal transfer ribbon (TTR) required)
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Printing Speed
Maximum Minimum 5 ips (50.8 mm per second) 2 ips (127 mm per second)
The print speed can be changed in 1 ips increments only: 2, 3, 4, or 5.
Printhead Specifications
Element size Width Resolution # of Elements X dimensions 0.00492 inch square (0.13 mm) 6.6 inches maximum print (168 mm) 203 dots per inch (8 dots per mm) 1344 per printhead 10 mil to 50 mil or 0.25 mm to 1.27 mm, 5 mil (0.13 mm) in drag mode with specified media
Media Specifications
Roll Length Width Thickness Diameter 6,000 linear inches (152 m) 0.5 inch (13 mm) to 17 inches (432 mm) (stripped media) 3.0 inch (76 mm) to 6.7 inches (170 mm) 0.012 inches (0.3 mm) maximum 8.38 inch maximum diameter (213 mm)
Ribbon Specifications
Roll Widths 6,000 linear inches (152 m) 3.0 inches (76 mm) 4.1 inches (104 mm) 5.4 inches (137 mm) 6.7 inches (170 mm) 2.25 inches maximum (57 mm)
Diameter
Environment
Operating Humidity 50°F to 104°F (10°C to 40°C) 10% to 90% noncondensing
Self-Strip Specifications
The liner takeup hub can spool the backing of an entire 6,000-inch roll of media. Peel Release 10 to 50 grams
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Communications
Asynchronous RS-232C, RS-422, RS-485 interfaces Serial ASCII code Hardware (Ready/Busy) flow control XON/XOFF protocol Intermec Standard Block protocol Polling Mode D protocol Multi-Drop protocol Baud Rates: 1200, 2400, 4800, 9600, 19200
Fonts and Graphics
5x7, 7x9, 7x11, and 10x14 86XX compatible fonts 2 bitmap OCR fonts 3 bitmap fonts measured in point sizes 8, 12, and 20 1 outline font 12 monospaced bitmap fonts Kanji/Katakana bitmap font card (option) Kanji/Katakana bitmap and outline font card (option) UDF size of 4 inches (101.6 mm) maximum UDC size of 4 inches (101.6 mm) maximum
Character Sets
US ASCII UK ASCII German French Swiss Norwegian/Danish Swedish/Finnish Italian Spanish
Memory
Base Optional 512K of DRAM for imaging 128K of SRAM for storage 512K of SRAM for storage
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Factory Default Settings
The following is a list of the factory default settings for the 3600 printer: Configuration
Preamble Character Postamble Character Auto-Transmit 1 Auto-Transmit 2 Auto-Transmit 3 Message Delay Power-Up Mode End-of-Print Skip Distance Top of Form Media Sensitivity Number of Image Bands Maximum Label Length Printer Character Set Label Retract Print Speed Label Stock Type Intercharacter Delay
Default Setting
Disabled Disabled Disabled Disabled Disabled 0 ms Advanced mode 100 dots 20 dots 420 3 1000 dots US ASCII Enabled 3 ips Die-cut 0 ms
3600 Printer Options
The 3600 you are servicing can be equipped with one or more of the following options:
Memory Expansion
Storage memory for formats, pages, graphics, and fonts can be increased to 512K of battery backed static RAM. This option provides an additional 512K of nonvolatile bulk storage to hold more formats, fonts, or bitmap graphics. It also increases the printer's image buffering capabilities.
Twinax Interface
Allows connection of the 3600 printer to IBM Twinax systems. The printer emulates an IBM 5256 Model 1 printer and can operate with an IBM System 34/36/38 or AS/400 host computer.
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Coax Interface
Allows connection of the 3600 printer to IBM coax systems. The 3600 emulates an IBM 3287 printer by connecting the printer to IBM 3270 Type A coax cable computer systems operating in the VTAM (CICS/IMS/TSO) or 8100 (DPPX) environments. Connection can be made to an IBM 3174/76/99 system controller/multiplexer.
Parallel Interface
This option lets the user connect the 3600 to a PC through any CentronicsTM parallel interface in addition to the standard serial interface.
Network Connectivity
Using the Parallel Interface option and an Ethernet or other network adapter, the 3600 can be connected to a network.
Kanji/Katakana Character Support
The 3600 has two Kanji/Katakana options: bitmap fonts only, or outline and bitmap fonts. Users shipping finished materials or work in process materials to Japan can meet Japanese label requirements for Kanji/Katakana (JIS Interleaved 2 of 5).
Batch Takeup
A larger diameter liner takeup hub permits printed labels to be spooled for later use without causing as much label curl as the smaller diameter hub. The maximum takeup outside diameter is 5 inches.
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Principal Functional Parts
The following illustrations identify the common name and location of the major functional elements of the 3600 printer.
Media window
Front Panel
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Media cover
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Media access door
Darkness adjust control DIP switches Optional I/O board port Serial communications port
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AC power cord receptacle Fanfold media access slot
Power on/off switch
3600M.002
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Media post TTR supply hub TTR takeup hub
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Tear bar Platen roller Upper media guide Lower media Edge guide guide Thermal printhead
Self-strip/ liner roller
TTR/ribbon Media roll
Media roll retainer
Media post
Lower media guide Media access door Self-strip/ liner roller Printhead lift lever
Liner takeup hub Tear bar
3600M.003
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Basic Printer Setup and Operation
Detailed operating instructions for the 3600 printer are contained in the user's manual. This section summarizes the following basic setup and operating information for you as a quick reference:
· · · ·
Front panel operations Checking printer configuration Connecting the printer to a computer Printing
Front Panel Operation
The three light emitting diodes (LEDs) on the printer's front panel (Power, Alert, and Empty/Pause) indicate the conditions identified in the following illustration:
LED State
Indication
Green LED Orange LED Yellow LED
Power Alert Empty/Pause
Off On steady Off On flashing On steady Off On flashing On steady
Power off Power on Printing or idle Over-temperature System fault Printing or idle Paused Media fault
Feed/Pause
3600M.004
Over-Temperature
If the printhead reaches an over-temperature condition, the Alert LED on the printer flashes and the printer halts printing. Usually, you will not need to intervene. If you allow the printer enough time to cool down, it normally resumes operation on its own.
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Media or System Faults
If you are servicing a printer indicating a media or system fault, refer to Chapter 4, "Troubleshooting," for information about the problem.
Feed/Pause Pushbutton
Operating the Feed/Pause button produces the following actions, depending on what condition the printer is in: Printer Condition
If the printer is idle:
Operation/Function
Pressing and releasing the Feed/Pause button causes the printer to feed out one label or a minimum specified amount of media. Pressing and holding the button down causes media to feed continuously until the button is released. Pressing the Feed/Pause button twice takes the printer offline. Press the button once more to bring the printer online.
If the printer is printing:
Pressing and releasing the Feed/Pause button causes the printer to pause. Subsequent pressing and releasing of the button allows the printer to resume printing. Pressing and holding the Feed/Pause button down until the printer stops printing cancels the current print job.
When the printer is first powered on:
Pressing and holding the Feed/Pause button down when turning printer power on places the printer in the Test and Service mode and causes the hardware configuration label to print.
Checking the Printer Configuration
The factory default settings for the 3600 printer are listed with the 3600 specifications in this chapter. These parameters are set using a combination of DIP switch settings and downloadable printer commands, which are described in the user's manual. Remember, you can print out hardware and software configuration labels for statistics of the printer you are servicing.
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General Information
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DIP Switch Settings
The DIP switches on the rear panel of the printer control communications parameters, media type configuration, and test and service functions. To change settings, carefully position the plastic (breakable) switches to ON or OFF with a small straight-slot screwdriver. The printer is shipped from the factory in the standard configuration, with the 16 DIP switches set as shown in the following illustration. When changing switch settings, you must cycle the printer power from off to on for the changes to take affect.
Factory Default Settings
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AC power cord receptacle
Connecting the Printer to a Computer
To operate as intended, the 3600 must be interfaced with a computer (desktop or laptop PC, local area network, AS400 or similar mainframe) with its serial port configured for the communications protocol appropriate to the computer interface. It is assumed that the correct interface (point-to-point, non-switched modem, network, etc.) was achieved originally at installation and should have a history of correct operation. Refer to the 3600 User's Manual or contact an applications analyst for detailed information about the type of installation you are servicing.
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DIP switches
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OFF
Serial communications port
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OFF
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Serial Port Settings
Parameter
Baud Rate
Settings
1200, 2400, 4800, 9600, 19,200 Even, Odd, None Intermec, XON/XOFF, XON/XOFF with status
Description
The rate, in bits per second (bps) at which the host exchanges data with the printer. Checks each transmitted character for errors. The type of network used to connect the printer, the host, and the rest of the data collection system. Intermec protocol includes Standard, Polling Mode D, and Multi-Drop protocols. Unique address for each device connected using Multi-Drop protocol. Provides printer diagnostics to the host and prints test labels.
Parity Protocol
Device Address Test and Service
A to Z, 0 to 5 Test Prints, Data Line Print, Cloning, Selective Transfer, Memory Reset
Printing
Regardless of your computer setup, you can use several methods to download information to print labels. This section describes different ways you can communicate with the printer. Refer to the 3600 User's Manual for detailed information. Note: Remember that these factors affect print quality: correct media, media sensitivity setting, print speed, and correct bar code orientation.
Using Label Debut
If you are using a point-to-point (printer-to-PC) connection to communicate with the printer, the printer parameters can be easily set using the DOS-based software package Label Debut. The Label Debut prompting screens assist you in designing, printing, and editing labels. Refer to the Label Debut User's Manual for more detailed information.
Using Third-Party Software
Your customer may be using third-party software to create label formats and convert graphics into a UDC format that the 3600 printer can interpret. You can use the same software to set the printer parameters.
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Using the Printer Command Set
You can also create labels by downloading formats (designs) and data created with the printer command set. The commands in the printer command set can perform any function or activate any feature of the 3600 printer. You can use the following methods to download commands: · · · · · Downloading printer commands using DOS Using ASCII control characters or hexadecimal equivalents Using readable protocol/command characters Downloading printer commands with a PC communications program or host terminal Using a Novell network
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Preventive Maintenance
Preventive Maintenance
2
This chapter identifies scheduled maintenance actions and provides illustrated procedures for cleaning the 3600 printer.
Preventive Maintenance Actions and Intervals
Preventive maintenance consists primarily of scheduled cleanings, but also occassional performance checks and, possibly, adjustments based on those checks. When you perform preventive maintenance, you should also conduct the tests and adjustments described in Chapter 3, "Testing and Adjusting," that will ensure the printer continues to deliver the highest quality output. You need to perform preventive maintenance procedures at the intervals identified to ensure a printer remains in proper working condition. The following table is a schedule of recommended printer cleaning and checking. Detailed cleaning procedures follow. Chapter 4, "Troubleshooting," contains instructions for performing various tests and adjustments. Printer Component
Printer
Maintenance Action and Interval
Inspect the printer (and the rest of the data collection system) at every service visit. Your inspection should include the types of items listed in the following section. Inspect after every roll of media. Clean after every roll (or 6,000 inches) of media or more often if necessary. Inspect or test print quality every service visit. Make any necessary adjustments. Clean after every five rolls of media. Using hi-tack adhesive requires cleaning after every roll of media. If the customer uses tag stock or continuous media, you may want to clean after every five rolls of media, or more often if necessary. Harsh or dusty environments dictate the need to clean more frequently. Inspect or test the operation of these printer elements at every service visit. Make any necessary adjustments.
Printhead
Drive roller and tear bar Media path, edge, and guides TTR drive roller Liner drive roller Media supply post Label and ribbon sensors Pinch roller
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Inspecting the Printer
You should routinely inspect the printer and the rest of the data collection system. Your inspection needs to address the following and similar concerns:
· · · · ·
Make sure the printer is properly grounded. Make sure the printer's AC power source is within tolerance. Make sure the printer is clean. Make sure the printer is away from liquids. Inspect the work environment for cleanliness and arrangement. Large electric motors, welders, and switching equipment can negatively affect printer performance. Check the data collection network regularly for loose wires or poorly installed connections. Be sure to replace corroded wires.
·
Cleaning the Printer
Use these procedures to access the printer parts and clean them. Heed the warnings and cautions to prevent harm to yourself or damage to the printer. You will need the following items to clean the printer correctly:
· · · · · ·
Isopropyl alcohol Cotton swabs Clean lint-free cloth Soft bristle brush Vacuum cleaner Soapy water/mild detergent
WARNING
Warning Energized electrical equipment is dangerous. Switch off the printer power and remove the power cord before cleaning any part of the printer. Failure to comply can result in injury or death.
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Removing the Media Cover
Most of the cleaning procedures require that you remove the media cover. To remove the media cover 1. Place your fingers in the space at the lower center edge of the media cover and pull the bottom of the cover away from the base of the printer. 2. Grasp the front of the media cover and lift the front of the cover upward.
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Media cover
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Media cover release (between the two notches)
3600M.010
3. Lift the media cover away from the printer.
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Cleaning the Printhead
Since the printhead must maintain close contact with the media to provide good print quality, cleaning media debris from the printhead is very important. Clean the printhead after every roll (or 6,000 inches) of media or whenever necessary. Caution Do not use sharp objects such as knives or screwdrivers to scrape the printhead clean. Cleaning with sharp objects will damage the printhead. Clean with only a cotton swab, or a clean, lint-free cloth or tissue moistened with isopropyl alcohol.
CAUTION
To clean the printhead 1. Remove the media cover. 2. Raise the printhead by rotating the head lift lever clockwise until the printhead releases.
TTR/ ribbon
Media roll
Printhead lift lever
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3. Remove the media from the paper path and the ribbon (if installed) from the TTR supply and takeup hubs. 4. Use a cotton swab moistened with alcohol to remove any dirt, adhesive, or debris from the print surface on the bottom of the printhead.
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Thermal printhead
3600M.012
5. Wait 5 to 10 seconds for the print surface to dry. Reload the media (and ribbon if used). 6. Engage the printhead by rotating the head lift lever counterclockwise until it locks in place. 7. If you are finished cleaning, install the media cover.
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Cleaning the Rollers and Tear Bar
Cleaning the platen roller and the tear bar preserves print quality by ensuring close contact between the media and the printhead. The TTR roller, liner roller, and media roller are cleaned in the same fashion to minimize general debris and to maximize their efficiency. To clean the rollers and tear bar 1. Remove the media cover. 2. Raise the printhead by rotating the head lift lever clockwise until the printhead releases. 3. Remove the media from the paper path and the ribbon (if installed) from the TTR hubs. 4. Clean the rollers with a lint-free cloth moistened in isopropyl alcohol. Wipe the cloth over the rollers, rotating each roller so that you clean all of it.
Media roll roller
TTR roller
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Platen roller Tear bar
Liner roller
3600M.013
5. Clean both sides of the tear bar with a lint-free cloth moistened in isopropyl alcohol. Remove all traces of dust, paper, and adhesive. 6. Reload the media (and ribbon if used) and then engage the printhead by turning the head lift lever counterclockwise until the printhead locks. 7. If you are finished cleaning, install the media cover.
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Preventive Maintenance
2
Cleaning the Media Guides and Media Path
Clean the media guides and media path regularly to keep debris off the media surface and printhead where irregularities can spoil print quality or damage the printhead. Cleaning the guides also helps prevent media skewing or improper tracking as it travels through the paper path, which can result in print problems. Always clean the media guides immediately after any label jam in the printer. Media debris may accumulate around the printer mechanism and along the media path during normal operation of the printer. Clean debris away using a soft bristle brush or vacuum cleaner. Remove all traces of dust, paper, and adhesive. Clean the flat surfaces of the media path (including the edge guide) with a lint-free cloth and isopropyl alcohol. Also remove all traces of dust, paper, and adhesive from the pinch rollers on the media access door. To clean the media guides and media path 1. Remove the media cover. 2. Remove the media from the paper path and the ribbon (if installed) from the TTR hubs. 3. Pull down and hold the spring-loaded lower media guide to open up the media path. 4. Clean the lower media guide with a lint-free cloth moistened in isopropyl alcohol.
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Upper media guide Lower media guide Media path
3600M.014
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5. Use a lint-free cloth moistened with isopropyl alcohol to clean the upper media guide. Be sure to remove all traces of debris. 6. Reload the media (and ribbon if used). 7. If you are finished cleaning, install the media cover. To clean the pinch rollers 1. Open the media access door. 2. Use a cotton swab moistened with isopropyl alcohol to clean the pinch rollers. Rotate the rollers to get any debris out of all of the grooves.
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Pinch Roller Media access door
3600M.015
3. If you are finished cleaning, install the media cover.
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Preventive Maintenance
2
Cleaning the Label and Ribbon Sensors
There are three label sensors and a ribbon sensor on the 3600 printer that require cleaning: the label taken sensor, the label mark sensor, the label gap sensor, and the ribbon motion sensor. To clean the sensors 1. Remove the media cover. 2. Raise the printhead by rotating the head lift lever clockwise until the printhead releases. 3. Remove the media from the paper path and the ribbon (if installed) from the TTR hubs. 4. Clean the label taken sensor and the label mark sensor with a cotton swab moistened with isopropyl alcohol.
Ribbon motion sensor
Encoder decal Main PCB
Cotton swab
Label taken sensor Label mark sensor
Drive roller Upper media guide (underside) Cleaning brush Lower media guide
Label gap sensor
3600M.016
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5. Pull down on the lower media guide to expose the label gap sensor. Using a soft bristle brush, remove all debris and dust from the label gap sensor. 6. Clean the label gap sensor with a cotton swab and alcohol. 7. Remove the electronics cover. 8. Very carefully clean the small ribbon motion optical sensor on the main PCB and the black and white encoder decal on the TTR supply clutch/encoder assembly with a cotton swab moistened with alcohol. 9. Install the electronics cover. 10. Reload the media (and ribbon if used). 11. Engage the printhead by rotating the head lift lever counterclockwise until it locks in place. 12. If you are finished cleaning, install the media cover.
Cleaning the Printer Covers
Clean the 3600 printer covers with a general purpose cleaner (soapy water/mild detergent). Do not use abrasive cleansers or solvents. Be sure to clean the transparent panel on the media cover so that you can see the media supply inside the printer when the cover is closed.
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Testing and Adjusting
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Testing and Adjusting
3
This chapter contains procedures for testing the printer's performance as a quality check during preventive maintenance, as a functional check when troubleshooting, and as part of the repair process after replacing a printer component. This chapter also contains procedures for making adjustments and alignments that ensure the printer is operating normally.
Testing the Printer
If you are on site for preventive maintenance or are following up a corrective action and the printer is working, start conducting quality checks from the Test and Service mode. If you are on site for corrective maintenance, determine if the problem lies with setup and process or the printer itself. Use the Test and Service mode to determine if the printer can print. If it can, perform the communications test. The quality and efficiency of producing labels reveals if a printer is operating correctly. In addition to analyzing labels to evaluate printer performance, the 3600 printer Test and Service mode allows you to conduct printer tests that include printing test labels (illustrated in this section) with a fixed look so you can compare them to an expected standard. The test labels can be used for checking printhead alignment, printhead bias, dots out of specification, label tracking, and ribbon wrinkling. Test and Service mode functions can be run at the printer or from a host terminal through the use of commands. If you find a printer lacking in performance after running your tests, check and make the adjustments and alignments necessary to return the printer to normal service. If you cannot get a printer working properly with an adjustment or alignment, troubleshoot for a component failure. Note: Making the alignments out of order can introduce, not solve printing problems. Review the section about printer alignments before making any changes.
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Running Test and Service Mode at the Printer
Note: When the printer is placed in Test and Service mode, it prints out a hardware configuration label, regardless of its initial DIP switch settings, and remains in Test and Service mode until the power is switched off and the DIP switches are reset. Momentarily pressing the Feed/Pause button during a test will cause the test to halt. Holding the Feed/Pause button down will start a new run of whichever test you select. To enter Test and Service mode and select test functions at the printer 1. Switch off the printer power. 2. Set the DIP switches to select the function that you want to run. 3. Press down and hold the Feed/Pause button while powering on the printer. The printer prints out a hardware configuration label. 4. Hold the Feed/Pause button down for 1 second. The test begins immediately. 5. If you wish to perform another function, repeat Steps 1 through 4. The function currently being executed is terminated and the new function begins. To exit Test and Service mode 1. Switch off the printer power. 2. Return all DIP switches to their original settings. 3. Switch on the printer power.
Setting DIP Switches
Use the information provided in the following tables and examples to set the DIP switches for the Test and Service mode function that you wish to perform. The "0"s indicate that the switch is in the OFF position and the "1"s indicate that the switch is in the ON position.
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Testing and Adjusting
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Test and Service Switch Settings
Top Bank Bottom Bank
O = OFF 1 = ON TESTS Test Prints Configurations Hardware Software Test Labels Print Quality Pitch Page Single Page All Pages Format Single Format All Formats UDC Single UDC All UDCs Font Single Font All Fonts Data Line Print Cloning Receiver Sender Selective Transfer Receiver Send Pages Single Page All Pages Send Format Single Format All Formats Send UDC Single UDC All UDCs Send Font Single Font All Fonts Send Configuration Send Tables Send All Memory Reset Page/Format UDC/Font Configuration Tables All
OFF ON
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
O O O O O O O O O O O O O O 1 O O O O 1 O O O 1 O O O O O O 1 O
O O O O O O O O B B 1 1 B B 1 1 B B 1 1 B B 1 1 O O
O O O O O A O O O O O A O O O O O A O O O O O A B B B O O A 1 1 1 O O A B B B O O A 1 1 1 O O A B B B B B 1 1 1 1 1 A A
O O O O 1 O O O O O O 1 O 1 1 O O O O 1 O O O 1 1 1 O O O O 1 O O O 1 O O O 1 O
O O O O O 1 O O O O O 1 O O O 1 O O O 1 1 O 1 O 1
B B B B O O 1 1 1 1 O O O O O O O O
O O O O O O O
O 1 O 1
O O O O O O O 1 O O O O
O O O O
O O O O O O O O O O O O
1 1 1 1 1 1 1 1 1 1 1 1 O O O O O
1 1 1 1 1 1 1 1 1 1 1 1 O O O O O
O O O O O O O 1 O 1 O O C C O O 1 1 O O O O 1 1 O C C O 1 1 1 1 1 1 1 O O O O 1 C 1 O O O O O O O O C 1 O O O O O O O O
O O C C 1 1 O O 1 1 C C 1 1 C 1 O O O O O O O O C 1 O O O O O O O O
O O O O O O C D D D D D 1 1 1 1 1 1 O D D D D D 1 1 1 1 1 1 C C C C O O 1 1 1 1 O O C 1 O O O O O O O O D 1 O O O O O O O O D 1 O O O O O O O O D 1 O O O O O O O O D 1 O O O O O O O O O 1 O O O O O O O O
O O 1 O O 1 O 1 O 1 O O O O O 1 1 1 1 1 O O 1 O 1 O 1 O 1 1 1 1 O O O 1 1 O O 1 O 1
A: OFF = Batch of 1. ON = Batch of 100. B: Page/Format/UDC/Font number. Least significant bit first. C: Source Page/Format/UDC/Font number. Least significant bit first. D: Destination Page/Format/UDC/Font number. Least significant bit first.
3600M.020
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Test and Service Configuration Settings
Top Bank Bottom Bank
O = OFF 1 = ON
OFF ON
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Label Rest Point Adjust Forward Adjust Backward 86XX Emulation Advanced Mode 10 Mil 15 Mil X Forms Adjust Adjust Forward Adjust Backward Y Forms Adjust N: Number. Least significant bit first.
O
1
1 O 1 N N N N N N N N N N
1
O
1 O O 1 O 1 1
1
1
1
1 O 1 N N N N N N N N N N N N N N N
1
1
1 O
3600M.021
Dot Increment Switch Settings
Bottom Bank
OFF
0 = OFF 1 = ON # of dot increments 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
ON
1 2 3 4 5
1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O 1 O
O 1 1 O O 1 1 O O 1 1 O O 1 1 O O 1 1 O O 1 1 O O 1 1 O O 1
O O O 1 1 1 1 O O O O 1 1 1 1 O O O O 1 1 1 1 O O O O 1 1 1
O O O O O O O 1 1 1 1 1 1 1 1 O O O O O O O O 1 1 1 1 1 1 1
O O O O O O O O O O O O O O O 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3600M.022
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Testing and Adjusting
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Printing Test Labels
The test labels can be used for checking printhead alignment, printhead bias, dots out of specification, label tracking, and ribbon wrinkling. The examples show the DIP switch settings that select the illustrated label.
Hardware Configuration The hardware configuration label is the first label printed when you enter Test and Service mode. This label serves as a configuration reference as well as an alphanumeric and alignment print test. This label contains the following information and uses:
· · · · · Printer memory including both storage and image RAM. Printer mileage including inches processed and inches burned. Printhead settings including width, dot size, and burn pot setting. Firmware checksum, program, and version number. Vertical lines for evaluating printhead alignment.
To achieve the highest quality label, print the hardware configuration label at a speed of 3 ips (inches per second).
1
3600 Hardware Configuration
Memory Installed Storage RAM Image RAM Flash RAM Mileage Inches Processed Inches Burned Labels Cut Printhead Width Dot Size Burn Pot Setting Hardware Options I/O Option Internal Option External Option Firmware Checksum ROMO (U9) ROM1 (U8) Program Version : 128 kilobytes : 382 kilobytes : none : 540 : 204 :0 : 1344 dots : 5.0 mil : 213 : none : none : Self Strip : FAC3 : OC3E : 062198 : 1.1
2 3 4
ON
5 6 7 8 1 2 3 4
OFF
ON
5 6 7 8
OFF
3600M.023
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Software Configuration This three-label set lists current configuration parameters that are set from the host computer. It also lists defined pages, formats, graphics, fonts, and installed options. This label serves as a configuration reference as well as an alphanumeric and multiple label alignment and print test.
1 2
Program Version : Pages Defined : Formats Defined : Fonts Defined :
1.1 0 0, 19 0, 1, 2, 7, 20 21, 22, 23, 24, 25, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41
PRINT SPEED - 3.0 IPS IMAGE BANDS - 3
RIBBON SAVE - Disabled SELF STRIP - Disabled
BAUD RATE - 9600 DATA BITS - 7
3 4
ON
5
OFF
6
MAX LABEL LENGTH - 4 inches CUTTER - Disabled LABEL STOCK - Inter- label gap DARK ADJUST - 0 MEDIA TYPE - Direct Thermal MEDIA LENGTH - 0 inches CHARACTER SET - US ASCII TRANSLATION - Disabled EMULATION - Disabled LABEL RETRACT - Enabled X FORMS ADUST - 0 Y FORMS ADJUST - 10 LABEL REST POINT - 0 SENSITIVITY - 420
MESSAGE LENGTH - 255 PARITY - Even
7
STOP BITS - 1 PROTOCOL - Xon/Xoff No Status
8
Graphics Defined : none
1
DEVICE ADDRESS - A INTERNAL OPTIONS - none EXTERNAL OPTIONS - Self Strip
2 3 4
ON
5 6 7 8
OFF
3600M.024
Print Quality This label contains bar codes and human readable fields that you can use to determine whether the printer you are testing is attaining the best print quality possible. If you notice problems with the print quality, check and perform the adjustment and alignment procedures provided in this chapter to achieve optimum printer performance.
1
3-8
CODE,39,3.0./1 CODE,39,3.0./1
CODE 39 2.5 / 1
CODE 39 3.0 /1
2
MODEL 3600
CODE 39 3.0 / 1
Prog 062198 Version 1.1 CODE 39 *PICKET FIELD* *PICKET FIELD*
3 4
ON
5 6 7
OFF
*PICKETFIELD* *PICKET FIELD* INTERMEC INTERMEC Corporation
Everett, WA 98203
8
*PICKETFIELD*
*SUPPLIER*
*PICKETFIELD*
*SUPPLIER*
1 2 3 4
ON
5 6 7 8
OFF
3600M.025
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Testing and Adjusting
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Format This label, which can be a test of a single format or can provide a two-label sample of all the formats, has bar codes and human-readable fields that you can use to determine whether the printer you are testing is attaining the best print quality possible using a particular format.
*
3600 TEST LABEL
CODE,39
3600 TEST LABEL
*
CODE 39
CODE,39
5670
1234
Pitch This label is a gray scale printout of every third dot. The test label should present a regular pattern with dots that line up diagonally when held at an angle. Look for irregularities that may signal a problem with the platen roller or the media path. If the printhead is uneven or the print path is skewed, it will be reflected in this label. Use this label to determine whether the printhead is printing evenly, but use the actual customer format to pass/fail the printhead.
1
OOOOOOOOOOOOOOOOOO
1
CODE,39
CODE 39
0123456789
0123456789
2 3 4
0123456789
CODE 39 3600 TEST LABEL
ON
5 6
OFF
3600 TEST LABEL 3600 TEST LABEL
7 8
3600 TEST LABEL
1 2
3600 TEST LABEL
3 4
3600 TEST
CODE,93,TEST,PRINT,BARCODE
CODE,93,TEST,PRINT,BARCODE
ON
5 6 7
OFF
DT / TTR PRINT QUALITY SAMPLE
3600M.026
8
2 3 4
ON
5 6 7 8 1 2 3 4
OFF
ON
5 6 7 8
OFF
3600M.027
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Font This is a multiple-label test of the available fonts. You can test a single font (Font 20 shown) or all of the fonts. An all-font test will use a lot of media. It is better that you test one font at a time to make your determinations.
1
|
Á
A
Ë
D
2
FONT 20
0 4 8
12 16 2
124 128 132 136 140
}
192 196 200 204
Á Å È Ì
3 4
1 5 9 13 17 2 2 6 10 14 18 2 3 7 11 15 19 23
125 129 133 137 141
_
193 197 201 205
Â Æ Ê Î
ON
5 6 7
OFF
26 130 134 138 142 7 131 135 139 143 14
194 198 202 206
Â
Ç Ë Ï
8 1
95 199 203 207
ON
Page These labels test the ability to download and correctly print single or multiple pages (a group of labels always printed together) of label data from a host. The data can be yours or the customer's, but you should include a test of the customer's labels to determine whether the printer you are testing is attaining the best print quality possible with the customer's data. UDC This label tests the ability to download and correctly print single or multiple user-defined characters (bitmap graphic) from a host. The data can be yours or the customer's, but you should include a test of the customer's labels to determine whether the printer you are testing is attaining the best print quality possible with the customer's data.
2 3 4
OFF
5 6 7 8
3600M.028
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Testing and Adjusting
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Running Test and Service Mode From a Host Computer
When conducting Test and Service mode functions from a computer, hardware diagnostic information is uploaded to the host from the printer. The following table describes the commands you would issue from a host terminal to run the Test and Service mode. To select Test and Service mode from Print mode, send T from the host terminal. Note: All commands in Test and Service mode end with the command terminator (;), except the last command in a message.
Test and Service Mode Command Descriptions
Command Code
A B
Test
Transmit Ambient Temperature* Printhead Resistance Test* Print Pitch Label Reset Printer Configuration Transmit Transmissive Sensor Value Dark Adjust* Transmit Paper Path Open Sensor Value* Transmit Reflective Sensor Value Transmit Printhead Temperature Sensor Value Print Quality Label Exit Test and Service
Description
Transmits the ambient temperature sensor output back to the host. The value ranges from 00 to FF. Causes the printer to begin the printhead resistance test. The printer will respond with the ASCII character string "pass" or "fail." Causes the printer to print the pitch label. Sets the printer configuration to the factory defaults. Transmits the label gap output back to the host. Values ranges from 00 to FF. This command changes the darkness of the print on your labels. It is for fine-tuning only. Transmits the Paper Path Open switch value back to the host. A value of 0 indicates the paper path is open and a value of 1 means it is closed. Transmits the label mark reflective sensor output back to the host. The values range from 00 to FF. Transmits the Printhead Temperature Sensor output back to the host. Values range from 00 to FF. Causes the printer to print out the print quality program and model number label. Causes the printer to exit Test and Service mode.
C D G
K L
M P
Q R
* The printer ignores this command.
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Test and Service Mode Command Descriptions (continued)
Command Code
S
Test
Transmit Printhead Resistance Values* Transmit Label Taken Sensor Value Transmit 40V Supply Value* Transmit 24V Supply Value*
Description
Transmits the average, maximum, or minimum printhead dot resistance value back to the host. Each value is a numeric data string separated by a comma. Transmits the label taken sensor output back to the host. Values can range from 00 to FF. Transmits the 12V supply output back to the host. The values range from 00 to FF. Transmits the 24V supply output back to the host. Values can range from 00 to FF.
T U V
* The printer ignores this command.
Testing Printer and Host Communications
This is a simple test of host-to-printer communications. If this test fails, there may be a problem with the printer serial port receiver circuitry or the setup. To test host-to-printer communications 1. Switch the printer power off. Return the DIP switch settings to the standard configuration if they have been changed. 2. Press and hold the Feed/Pause button while powering on the printer. The printer presents the hardware configuration test label. 3. Release the Feed/Pause button after the hardware configuration label is printed. You are now in data line print mode within the Test and Service mode. 4. Send down some characters from the host. At this point the printer does not attempt to interpret any printer commands, but simply prints each character and its hexadecimal equivalent as it is received. If you are using a PC running DOS, send down the following strings of commands from the DOS prompt: Note: ^Z is [Ctrl] [Z]. \MODE COM1: 96,E,7,1,N [Enter] (to configure the serial port) \COPY CON COM1: [Enter] (tells the PC to copy the following text to the COM1 port) ABCDEF^Z [Enter] (these characters are sent to the printer)
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Testing and Adjusting
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5. A good test will result in the following printout :
3600M.029
6. To enter normal print mode again, switch the printer power off and then on again. If this test does not work, recheck after you make sure that the DIP switches are set to the default configuration and that the printer cable is securely plugged into COM1 of your PC. Note: If you are using a different platform to communicate with your printer, refer to your host computer user's manual and the 3600 Bar Code Printer User's Manual for more detailed information about downloading commands.
Adjusting the Printer
The following procedures provide instructions for adjusting the print bias, the print intensity (darkness), the label mark sensor, the label gap sensor, the label taken sensor, and the printhead fine adjustment lever on the 3600 printer. Warning Always disconnect the power cord before removing the electronics cover unless a procedure requires the unit to be energized. Failure to disconnect the power cord may result in injury or death due to electric shock. Caution The printhead and integrated circuits on printer circuit boards in this equipment are sensitive to damage by electrostatic discharge (ESD). Prevent ESD by always wearing skin contact ground straps firmly attached to the equipment metal base assembly when working inside of the equipment housing. Failure to comply can result in damage to components or the printhead.
WARNING
CAUTION
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Adjusting the Print Bias for Print Quality
Adjust the bias with a straight-slot screwdriver if the printhead is not making even contact with the media. Using different width media, especially narrow media, can result in uneven contact or a spot where there is no media between the printhead and the platen roller. Extra wear and damage can occur if narrow media is used for extended periods with incorrect bias. To adjust the bias adjust screw 1. Remove the media cover and locate the bias adjust screw.
Printhead bias adjust screw
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Em pt y/ Pa us
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Inte rmec
36 00
3600M.030
2. Turn the bias adjust screw counterclockwise to compensate for light print on the right side of the label; turn the bias adjust screw clockwise to compensate for light print on the left side.
If printing is light on the right side of label, turn the bias adjust screw counterclockwise.
If printing is light on the left side of label, turn the bias adjust screw clockwise.
*N AR RO WL E*
N* RA OR LW *E
3600M.031
3. Install the media cover.
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Testing and Adjusting
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Adjusting the Print Intensity
Note: Before you adjust print intensity, verify the sensitivity rating for the media matches the rating set in the printer. Use the darkness adjust control in combination with the darkness adjust command d to fine-tune the intensity of print on your customer's labels. The fine adjustments compensate for variations in the media ("lot to lot"), the printhead, or the printer. Set the darkness adjust control with a small straightslot screwdriver after entering the proper sensitivity number. To adjust the print darkness control 1. Locate the darkness adjust control on the back of the printer. Make adjustments with a small straight-slot screwdriver.
Turn the darkness adjust control clockwise for darker density. Darkness adjust control Turn the darkness adjust control counterclockwise for lighter density.
2. Increase the darkness by turning the darkness adjust control clockwise or decrease the darkness by turning the control counterclockwise. Run a test print to evaluate the print quality.
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
I
1 2 3 4 5 6 7 8
O
1 2 3 4 5 6 7 8
Screwdriver
3600M.032
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Adjusting the Printhead Adjustment Lever for Print Quality
The printhead adjustment lever is located at the end of the printhead pivot bracket. It allows fine-tuning of the printhead fore/aft position. The printhead adjustment lever provides three stops forward movement of the printhead and three stops backward movement from center position in 0.006-inch increments. To achieve the best print quality, raise the printhead with the printhead lift lever and position the printhead adjustment lever as shown in the illustration: from the rear, adjust clockwise/left to move the printhead forward, or adjust counterclockwise/right to move the printhead backward.
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
I
O
Printhead adjustment lever ad he int ard r s p rw ve fo
nth pri s ve rd mo kwa c ba
ea
d
mo
3600M.033
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Testing and Adjusting
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Adjusting the Label Mark Sensor
The mark sensor detects the mark on the back of continuous media stock. The output is then used to determine the start of print point. This sensor is located under the label pathway across from the platen roller. Two adjustments affect the performance of this sensor, its physical position and sensitivity. To perform this procedure, you need the following tools: · · · Digital multimeter #2 Phillips screwdriver Small straight-slot screwdriver
To position the label mark sensor 1. Remove the media cover. 2. Use your finger to reach underneath the lower guide.
Platen roller Locate the label mark sensor behind the platen roller near the inboard edge of the printer. Use your index finger to adjust the label mark sensor.
Inboard edge of printer. The platen roller is not shown for clarity only.
Label mark sensor
3600M.034
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3. Slide the mark sensor into a position that centers it over the label mark as the media passes by. It is adjustable from the inboard edge of the extrusion to one half of the paper path width toward the outboard edge. To adjust the label mark sensor potentiometer sensitivity 1. Remove the electronics cover 2. Switch on the printer power. 3. Enable the printer for mark sensing using the T{2} command. 4. Connect the positive lead of a digital voltmeter to TP18 (MARK) and the negative end to TP14 (GND) on the main PCB.
TP18 TP14 R191
3600M.035
5. Place the white portion of a label under the mark sensor. 6. Adjust R191 on the main PCB so the voltage at TP18 is 1V ± 0.2V. 7. Place the black mark portion of the label under the mark sensor. 8. The voltage at TP18 should now be greater than 2.5V. 9. Install the printer electronics cover and the media cover. 10. Check the printer for proper operation.
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Testing and Adjusting
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Adjusting the Label Gap Sensor
The label gap sensor output enables the software to determine the leading edge of a label by detecting the label gap. The label gap is the space between labels on the backing material. This reading enables the printer to properly position the start of print point. To perform this procedure, you need the following tools: · · · Digital multimeter #2 Phillips screwdriver Small straight-slot screwdriver
To adjust the label gap sensor potentiometer 1. Remove the media cover and the electronics cover. 2. Connect the positive lead of a multimeter to TP15 (GAP) and the negative lead to TP14 (GND) on the main PCB.
TP15 TP14
R124
3600M.036
3. Switch on the printer power. 4. Insert the label backing only in the label gap sensor. Adjust R124 on the main PCB so that the voltage at TP15 (GAP) is 1V ± 0.2V. 5. Insert both the label and the label backing in the sensor. Verify that the voltage at TP15 (GAP) is greater than 3V. 6. Install the printer electronics cover and the media cover. 7. Check the printer for proper operation.
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Adjusting the Label Taken Sensor
The label taken sensor output enables the software to determine that a label has been taken by detecting the label's presence. To perform this procedure, you need the following tools: · · · Digital multimeter #2 Phillips screwdriver Small straight-slot screwdriver
To adjust the label taken sensor 1. Remove the media cover and the electronics cover. 2. Connect the positive lead of a multimeter to TP19 (TAKEN) and the negative lead to TP14 (GND) on the main PCB.
R190 TP19 TP14
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3. Switch on the printer power. 4. Feed one label out of the printer so that it rests under the label taken sensor in a correct orientation. 5. Adjust R190 on the main PCB until the voltage at TP19 is 1.2V + 0.2V. 6. Remove the label from under the label taken sensor. 7. The multimeter reading at TP19 should now read above 4.5V. 8. Install the printer electronics cover and the media cover. 9. Check the printer for proper operation.
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Aligning the Printer
The following procedures provide instructions for aligning the rollers, aligning the printhead, and aligning the ribbon supply hub on the 3600 printer. Note: These alignments should be made in the sequence given. Performing them out of order can introduce and not solve printing problems. Warning Always disconnect the power cord before removing the electronics cover unless a procedure requires the unit be energized. Failure to disconnect the power cord may result in injury or death due to electric shock. Caution Integrated circuits on printer circuit boards in this equipment are sensitive to damage by electrostatic discharge (ESD). Prevent ESD by always wearing skin contact ground straps firmly attached to the equipment metal base assembly when working inside of the equipment housing. Failure to comply can result in damage to components. Caution Align only one outboard plate at a time (either upper or lower) to put the rollers back into factory alignment. If both plates are loosened, it may not be possible to align the rollers outside of the factory.
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Aligning the Rollers
You should perform this procedure every time an outboard plate is removed or replaced. To perform this procedure, you need the following tools: Note: If the printer you are servicing has upper outboard plate Intermec Part No. 062476-002 installed, you need to replace it with a new upper outboard plate Intermec Part No. 063225-001 before you can perform the following roller alignment. · · Roller alignment tool, Intermec Part No. T43150 #2 Phillips screwdriver
To align the rollers 1. Switch off the printer power and remove the power cord. 2. Remove the media cover, the electronics cover, and the front bezel cover (refer to Chapter 5, "Remove and Replace Procedures,"for detailed instructions). 3. Raise the printhead with the printhead lift lever. Remove media and ribbon if loaded. 4. Loosen the Phillips screws on the outboard plate that you are aligning. Note: Align only one outboard plate at a time (either the upper or the lower) to put the rollers back into factory alignment. If both plates are loosened, it may not be possible to align the rollers outside of the factory. 5. Align the three holes in the roller alignment tool with the platen roller, the liner roller, and the TTR roller. The fourth hole in the roller alignment tool fits over the black plastic cap closest to the front of the printer.
UP
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