Maintenance Manual

SL5000 r and T5000 r RFID Smart Label and Thermal PrintersTM TM

SL5000 r and T5000 r RFID Smart Label and Thermal Printers Maintenance Manual

Communication NoticesThis equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

Reorient or relocate the receiving antenna. Increase the separation between the equipment and receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/TV technician for help.

Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. Printronix is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by any unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the users authority to operate the equipment. This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Any change or modification to this product voids the users authority to operate it per FCC Part 15 Subpart A Section 15.21 regulations. CAUTION: This product should be positioned so that personnel in the area for prolonged periods may safely remain at least 23 cm (9 in) from the readers antenna surface in an uncontrolled environment. See FCC OET Bulletin 56 Hazards of radio frequency and electromagnetic fields. This product contains an intentional radiator with the following parameters: Operating Frequency: 902 to 928 MHz Typical RF Power: 25 to 100 milliwatts (SL5x04 MP) or 25 to 205 milliwatts (SL5x04 C1) Maximum RF Power: 1 Watt under abnormal conditions Printronix SL5000r and T5000r Tested To Comply With FCC Standards FOR HOME OR OFFICE USE

Canada This Class B digital apparatus complies with Canadian ICES-003 and RSS 210. Cet appareil numrique de la classe B est conforme la norme NMB-003 du Canada. CE Notice (European Union) Marking by the CE symbol indicates compliance of this Printronix system to the EMC Directive and the Low Voltage Directive of the European Union. Such marking is indicative that this Printronix system meets the following technical standards:

EN 300 220-1 (2000), Electromagnetic Compatibility and Radio Spectrum Matters; Short Range Devices; Radio equipment to be used in the 25 MHz to 1000 MHz frequency range with power levels ranging up to 500 mW. EN 55022 Limits and Methods of Measurement of Radio Interference Characteristics of Information Technology Equipment. EN 50082-1: 1992 Electromagnetic compatibilityGeneric immunity standard Part 1: Residential, commercial, and light industry. EN 60950 Safety of Information Technology Equipment.

This printer is a Class B product for use in a typical Class B domestic environment. CE Symbol

Declaration Of Conformity Manufacturer: Printronix, Inc. 14600 Myford Rd. Irvine, CA 92623 U.S.A. Information Technology Equipment, Printer Commercial and Light Industrial T5204r, T5304r, SL5204r, SL5304r, 5504-R40 with optional suffixes serial, parallel, coax, twinax, external LAN, Ethernet, Wireless Ethernet, RFID EN 60950-1: 2001, First Edition ETSI EN 301 489-1 ETSI EN 301 489-3 ETSI EN300 220 V1.3.1 Sec. 8.1, 8.2, 8.6, 8.7, 8.9 EN 55022: 1998 +A1 Class B EN 55024: 1998 EN 61000-4-2 EN 61000-4-3

declares that the product: Product Type: Equipment Class: Model Numbers: Configuration:

conforms to the following standards: Safety: EMC:

EN 61000-4-4 EN 61000-4-5 EN 61000-4-6 EN 61000-4-8 EN 61000-4-11 EN 61000-3-2: 2000 EN 61000-3-3: 1995 +A1 and complies with: The Low Voltage Directive 73/23/EEC and the EMC Directive 89/336/EEC. Taiwan

Lithium Battery Warning The controller PCBA contains a lithium battery sealed inside the real-time clock chip. Do not disassemble the chip to replace the battery. Do not dispose of the chip by incineration. Failure to comply may cause the battery to explode. Contact your local waste agency for the correct disposal procedure.

Printronix makes no representations or warranties of any kind regarding this material, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix shall not be held responsible for errors contained herein or any omissions from this material or for any damages, whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution, performance or use of this material. The information in this manual is subject to change without notice. This document contains proprietary information protected by copyright. No part of this document may be reproduced, copied, translated or incorporated in any other material in any form or by any means, whether manual, graphic, electronic, mechanical or otherwise, without the prior written consent of Printronix.

Trademark AcknowledgementsCompatibility Software Copyright 1989 Phoenix Technologies Ltd., All Rights Reserved. Alien and Alien Technology are registered trademarks of Alien Technology Corporation. Code V is a trademark of Quality Micro Systems, Inc. EIA is a registered service mark of the Electronic Industries Association. Epson is a registered trademark of Seiko Epson Corporation. HP is a registered trademark of Hewlett-Packard Company. IBM is a registered trademark of International Business Machines Corporation. IGP, LinePrinter Plus, PGL, Printronix, and PSA are registered trademarks of Printronix, Inc. Intermec is a registered trademark of Intermec Technologies Corporation. IPDS is a trademark of International Business Machines Corporation. J2SE, Java, and Solaris are trademarks of Sun Microsystems, Inc. LaserJet is a registered trademark of Hewlett-Packard Company. Linux is a registered trademark of Linus Torvalds. MS-DOS and Windows are registered trademarks of Microsoft Corporation. PCL is a registered trademark of Hewlett-Packard Company. PhoenixPage PCL 5 is a registered trademark of Phoenix Technologies Ltd. PostScript is a registered trademark of Adobe Systems. SL5000r, T5000r, IGL, STGL, TGL, and ZGL are trademarks of Printronix, Inc. Proprinter is a registered trademark of International Business Machines Corporation. QMS is a registered trademark of Quality Micro Systems, Inc. SATO is a registered trademark of SATO America, Inc. TEC is a registered trademark of the Toshiba TEC Corporation. UNIX is a registered trademark of Unix System Laboratories, Inc. Zebra is a registered trademark of Zebra Technologies Corporation.

COPYRIGHT 2005 PRINTRONIX, INC. All rights reserved.

Chapter

Table Of Contents

1 Maintenance Overview ....................................... 15Printronix Customer Support Center.................................................... 15 About This Manual............................................................................... 15 To Replace Parts .......................................................................... 15 To Order Parts .............................................................................. 16 Notes And Notices ........................................................................ 16 Manual Conventions ..................................................................... 17 Related Manuals ........................................................................... 17 The SL5000r/T5000r Series RFID/Label Printer.................................. 18 Standard Features ........................................................................ 19 Optional Features.......................................................................... 20 Thermal Printer Media................................................................... 21 Ribbons ......................................................................................... 21 Thermal Printer Technology .......................................................... 22 Controls And Indicators ....................................................................... 25 Control Panel ................................................................................ 25 Plugging In The Printer ................................................................. 29 Power Switch ................................................................................ 29 Operating Modes........................................................................... 29

2 Preventive Maintenance ..................................... 31Cleaning The Printer............................................................................ 31 Exterior .......................................................................................... 31 Interior ........................................................................................... 31 General Cleaning .......................................................................... 31 Cleaning The Printhead, Platen Roller And Media Sensors.......... 32 Printer Inspection................................................................................. 34

3 Troubleshooting .................................................. 35Introduction .......................................................................................... 35 What You Should Know About Print Quality ................................. 35 How To Maximize Printhead Life................................................... 35 Troubleshooting At A Glance ........................................................ 36 Start Here ............................................................................................ 37 How To Troubleshoot .......................................................................... 38 Printer Self-Tests And How To Verify Printer Operation ............... 39

9

Table of Contents

Troubleshooting Display Messages..................................................... 40 List Of Messages .......................................................................... 41 Troubleshooting Other Symptoms ....................................................... 75 General Symptom List................................................................... 75 Communications Failures .................................................................... 91 Troubleshooting A New Installation ..................................................... 94 Printer Configuration ..................................................................... 94 GAP NOT DETECTED.................................................................. 94 PRINT HEAD UP .......................................................................... 94 Ribbon ........................................................................................... 94 Documentation .............................................................................. 94

4 Replacing Parts................................................... 95About This Chapter.............................................................................. 95 Preparing The Printer For Maintenance ........................................ 95 Restoring The Printer To Operation .............................................. 96 Tools And Materials ...................................................................... 97 Torque Requirements ................................................................... 97 Removal And Replacement Procedures.............................................. 98 Belt, Platen .................................................................................... 99 Belt, Rewinder ............................................................................. 100 Coax/Twinax ............................................................................... 101 Control Panel Assembly .............................................................. 102 Controller PCBA (Printed Circuit Board Assembly)..................... 103 Cooling Fan, Power Supply......................................................... 106 Damper, Media............................................................................ 107 Frame Side Cover ....................................................................... 108 Gear, Ribbon Drive, Final............................................................ 109 Gear, Ribbon Drive, Intermediate ............................................... 110 Head Pressure Block Assembly .................................................. 111 Media Cover ................................................................................ 114 Media Hanger Beam ................................................................... 115 Media Sensor Assembly, Lower.................................................. 116 Memory Module, Flash SIMM ..................................................... 117 Memory Module, NVRAM And Real-Time Clock ........................ 119 Motor, DC Ribbon Drive .............................................................. 120 Motor, Stepper ............................................................................ 121 NIC, External............................................................................... 122 NIC, Internal, 10/100Base-T ....................................................... 125 NIC Configuration........................................................................ 126 Plate, Rear Panel ........................................................................ 127 Platen .......................................................................................... 128 Power Supply Assembly ............................................................. 129 Printhead Assembly .................................................................... 130

10

Table of Contents

Printhead Cover/Upper Media Sensor ........................................ 132 Resistors, Terminating ................................................................ 133 Rewinder (Option) ....................................................................... 135 Rewinder, Torque Check and Adjustment................................... 136 Security Key ................................................................................ 139 Security Key, Reprogramming .................................................... 140 Sensor, Head Up......................................................................... 142 Sensor, Label Taken ................................................................... 143 Spindle Assembly, Ribbon Supply Or Take-Up........................... 144 Support Assembly, Lower ........................................................... 145 Support Assembly, Upper ........................................................... 146 Tear Off Assembly ...................................................................... 147 Peel/Tear Assembly .................................................................... 148 Tear Bar Assembly, Adjustable ................................................... 149 Tensioner, Rewinder Belt ............................................................ 151

5 Illustrated Parts Breakdown .............................. 153Organization Of This Chapter ............................................................ 153 Illustrated Parts Breakdown............................................................... 153 Hardware Kit ............................................................................... 196 Hardware Kit, Cutter Options ...................................................... 197

A ASCII Codes ..................................................... 199 B Downloading Software ...................................... 203Loading Flash Memory ...................................................................... 203 Loading Software With The Firmware Download Utility .............. 204 Loading Through The Parallel Or Serial Port Using DOS ........... 205 Loading Software If Flash Contains Only Boot Code .................. 207 Loading Software Through The NIC............................................ 208 Downloading Optional Fonts to Flash Memory ........................... 210

C Wire Data .......................................................... 213Circuit Board And Cable Pinouts ....................................................... 213

D Media Cutters and Tray .................................... 237Introduction ........................................................................................ 237 Cutter Installation and Removal......................................................... 238 Cutter Tray Installation And Removal ................................................ 242 Cutter Assembly Replacement .......................................................... 244 Troubleshooting ................................................................................. 246 Maintenance ...................................................................................... 247 Specifications..................................................................................... 247 Spare Parts........................................................................................ 248

11

Table of Contents

E Online Data Validator ........................................ 253Contents ............................................................................................ 253 Safety Notices.................................................................................... 254 Overview............................................................................................ 255 Installation and Removal ................................................................... 256 Install The Ferrite ........................................................................ 257 Install The Brackets..................................................................... 262 Attach The Power/Data Cable To The Validator ......................... 264 Basic Setup........................................................................................ 265 Enabling And Disabling The Validator......................................... 266 Resetting Validator Data ............................................................. 266 Adjusting The Scanning Beam .......................................................... 267 Shifting The Scanning Beam....................................................... 271 Calibration.......................................................................................... 272 Bar Code Validation Demo Page ................................................ 274 Configuring The Validator .................................................................. 275 Bar Code Failures.............................................................................. 275 Bad Bar Code Error Detection .................................................... 275 Missing Bar Code Error Detection............................................... 275 Error Action ................................................................................. 276 Error Messages ........................................................................... 280 Troubleshooting ................................................................................. 284 Maintenance ...................................................................................... 286 Spare Parts........................................................................................ 287

F Wireless Interface ............................................. 289Installation and Removal ................................................................... 289 Install The RF Antenna Cable Assembly .................................... 290 Install The Wireless Interface Card ............................................. 293 Install The Radio Card, Protective Cover, And Antenna ............. 294 Spare Parts........................................................................................ 296

G RFID Encoder and Antenna Assemblies........... 297Installation And Removal ................................................................... 297 Prepare The Printer ........................................................................... 297 Remove The Frame Side Cover ........................................................ 298 Replace The RFID Encoder Assembly .............................................. 299 Remove The RFID Encoder Assembly ....................................... 299 Replace The RFID Antenna Assembly ....................................... 301 Install The RFID Encoder Assembly ........................................... 304 Route The Data Cable ................................................................ 307 Finish The Installation........................................................................ 308 Error Messages ................................................................................. 309

12

Table of Contents

Troubleshooting ................................................................................. 310 Spare Parts........................................................................................ 311

H General Purpose Input/Output (GPIO).............. 315Installation And Removal ................................................................... 315 Prepare The Printer ........................................................................... 315 Remove The Frame Side Cover ........................................................ 316 Install The GPIO Subassembly.......................................................... 317 Spare Parts........................................................................................ 319

13

Table of Contents

14

1

Maintenance Overview

Printronix Customer Support CenterThe Printronix Customer Support Center offers technical support with: Installation Configuration and setup Operation and supplies loading Specifications of the proper print media and ribbon Answers to post-sale service support questions

Call the Printronix Customer Support Center at: (714) 368-2686 in the Americas (31) 24 6489 489 in Europe, Middle East, and Africa (65) 654 84114 in Asia Pacific or visit the Printronix web page at www.printronix.com http://www.printronix.com/public/servicesupport/default.aspx

About This ManualThis is a field service maintenance manual for SL5000r/T5000r series RFID and thermal label printers. Refer to the Table of Contents or the Index to locate the maintenance information you need.

To Replace Parts1. Go to Chapter 4, page 95. 2. Find the removal procedure for the part. 3. Read the entire procedure before you start and make sure you understand all notes and notices, which are defined on page 16. 4. Gather the tools you will need. 5. Do the procedure.

15

Chapter

1

About This Manual

To Order PartsGo to the Illustrated Parts Breakdown (IPB) on page 153, which contains drawings of all printer assemblies. Next to each illustration is a list of the parts shown and their part numbers. When locating parts, note the following:

If a part number is listed you can order that part or assembly. If a component is part of a field kit, order the kit. Parts marked Ref (reference) are not spared or are part of another assembly. Part numbers are not listed for common fasteners. In illustrations, magnified details are shown with locator arrows and letters:

This arrow points to an area . . .

A

that is magnified here, on the same page or a subsequent page.

A80

Assemblies you can order as kits are shown in the following manner:

To get item 80, 85, or 87, for example, order item 90, which is a kit containing all these parts.

85 87 90

Notes And NoticesFor your safety and to protect valuable equipment, always read and comply with information highlighted under the following special headings:

WARNING CAUTION IMPORTANT

A warning describes conditions that can harm you as well as damage the equipment. A caution describes conditions that can damage the printer or related equipment. Information vital to proper operation of the printer. NOTE: Helpful and timesaving tips about printer operation and maintenance.

16

Manual Conventions

Manual Conventions Control panel keys are printed in bold, uppercase letters. Example: Press the PAUSE key to take the printer offline. Control panel keys are often shown by their symbol or icon (located on the control panel directly below the key). Example: Press the to select it. LCD fault messages display the specific fault in uppercase letters on the top line. A corrective action in upper and lowercase letters displays on the bottom line. Example: PAPER OUT Load Paper

Key combinations (pressing keys at the same time) are indicated by the + (plus) symbol. Example: Press + to unlock the key.

Related ManualsThis manual does not explain how to install, operate, configure the printer, or how to program application software for operation with the printer. That information is in the following manuals, available online at www.printronix.com:

SL5000r/T5000r Thermal Printer Users Manual SL5000r/T5000r Quick Setup Guide SL5000r/T5000r RFID Labeling Reference Manual Network Interface Card Users Manual Online Data Validator Users Manual IGP/PGL Emulation Programmers Reference Manual IGP/VGL Emulation Programmers Reference Manual IPDS Programmers Reference Manual LinePrinter Plus Emulation Programmers Reference Manual Printer Protocol Interpreter (PPI) ZGL Programmers Reference Manual Printer Protocol Interpreter (PPI) TGL Programmers Reference Manual Printer Protocol Interpreter (PPI) IGL Programmers Reference Manual Printer Protocol Interpreter (PPI) STGL Programmers Reference Manual

17

Chapter

1

The SL5000r/T5000r Series RFID/Label Printer

The SL5000r/T5000r Series RFID/Label PrinterNOTE: As used in this manual, the terms T5000r and printer refer to all models within the series. SL refers to all SmartLine RFID models. The T5000r series is a family of high quality, direct thermal and thermal transfer printers specifically designed to print labels and tags from any MS-DOS, Windows, ASCII, or EBCDIC (with the Coax/Twinax option) based compatible computer. Printronix Dynamic Print Control provides exceptional print quality. A circuit monitors the data to be printed and automatically adjusts the energy applied to the thermal printhead for maximum performance. The printer can communicate with the host computer via RS-232 and RS-422 serial, Centronics-compatible parallel, IEEE 1284 compliant parallel, USB 2.0 Universal Serial Bus, and (optionally) coax/twinax, ethernet 10/100Base-T, or wireless ethernet host connections. The interface cable needed to connect the printer to the host device is supplied by the user. The T5000r, Smart Ready, and SmartLine series are comprised of the products detailed in Table 1. NOTE: All 4 and 6 inch models are Smart Ready.

Table 1. The T5000r, Smart Ready, and SmartLine Series Model T5204r T5204r DT* SL5204r MP T5304r T5304r DT* SL5304r MP T5206r T5306r T5208r T5308r Max Print Speed (ips) 10 10 10 8 8 8 10 8 8 6 Printing Density (dpi) 203 203 203 300 300 300 203 300 203 300 Max Print Width (inches) 4.1 4.1 4.1 4.1 4.1 4.1 6.6 6.6 8.5 8.5

* DT = Direct Thermal only 4 inch models (no ribbon transfer support)

18

Standard Features

Standard FeaturesEmulations:

Printronix LinePrinter Plus (LP+). Provides direct compatibility with Printronix P-series printers. Epson FX-1050, Proprinter IIIXL, and Serial Matrix printers. Printronix IGP/PGL and IGP/VGL. Provides printer system commands for text, barcodes, graphics, lines, and boxes.

Thermal Transfer and Direct Thermal Printing: On all printers (except 4 inch DT models, which print only in direct thermal mode) Standard Interfaces:

Serial: RS-232 USB 2.0 Universal Serial Bus Parallel: Centronics-compatible parallel, IEEE 1284 compliant parallel

NOTE: The interface cable needed to connect the printer to the host device is supplied by the user.

Bar Codes: Support for over 20 types of bar codes Download: Fonts, forms, and graphics into printer memory Resident Fonts: Letter Gothic Bold (#93779), Courier Bold (#93952), CG Triumvirate Bold Condensed (#92250), OCR-A (#90993), OCR-B (#91409), CG Triumverate (#92244), CG Triumverate Bold (#92248), and CG Times (#92500) High Resolution Printhead: For sharp graphics and text Label Taken Sensor: For detecting removal of labels in Tear-Off mode (and in Peel-Off mode when the optional rewinder is installed) Tear-Off Mode: For positioning the label at the tear-off position and detecting its removal before printing the next label Tear-Off Strip Mode: For printing a specified number of labels and positioning the last label at the tear-off position 32MB DRAM memory (fixed) 8MB Flash memory (SIMM) Auto Label Mapping: For compatibility with programs written for Printronix line matrix printers. Ventless System: For operation in environments with airborne particulate matter without compromising performance ZGL, TGL, IGL, and STGL Interpreters: PPI/ZGL (Zebra), PPI/TGL (TEC), PPI/IGL (Intermec), and PPI/STGL (SATO) interpreters are powerful integration tools that allows the SL5000r/T5000r to function in virtually all legacy ZPL, TEC, IPL, and SATO application environments without requiring modification to host data stream.

19

Chapter

1

The SL5000r/T5000r Series RFID/Label Printer

Optional FeaturesThe following options are also available for SL5000r/T5000r printers:

Fonts: A selection of fonts can be loaded from the host computer into printer memory. Once loaded, these fonts are accessed in the same way as the resident fonts. See Table 9 on page 210 for a list of optional fonts. Memory Expansion: 16MB Flash SIMM replaces standard 8MB Flash SIMM to provide additional memory for fonts, forms, and logos. Media Cutter: Automatically cuts up to 0.010 thick printed tag stock as the media exits the printer. Available for 4, 6, and 8 inch printers. Media Cutter Tray: Used with the media cutter option to catch and collect the cut media in a bin. Internal Label Rewinder: In label peel-off mode, prints and peels off labels one at a time before printing the next label and rewinds the liner into a discardable roll. In batch rewind mode, rewinds printed labels into a removable roll up to 5 inches maximum diameter. Peel-Off Mode: Used with the optional label rewinder to peel off labels one at a time, before printing the next label. Batch Rewind Mode: Used with optional label rewinder to wind printed labels into a removable roll. Coax/Twinax Host Interface: Provides connection to a host computer system using a coaxial or twinaxial interface. NIC (10/100BaseT) Internal or External: The NIC (Network Interface Card) 10/100BaseT connectivity option provides wired networks in either an internal or external option that allows you to attach the printer to a LAN (Local Area Network) instead of directly to a host computer. The remote management software is standard with this option. IPDS: Available for coax/twinax, a NIC, or a combination of both. The printer may be ordered with this option installed and the required hardware to support it, or it can be field installed by an authorized service representative at a later date. The printer must have a coax/twinax interface or NIC, and 300 dpi printhead installed to support this fieldinstalled option. TN5250/TN3270: Enables your printer to communicate with an IBM host through a NIC using the 5250/3270 datastream. This feature allows you to use an application generated for the coax/twinax emulation to be printed through the NIC.

NOTE: IPDS is not supported by SL/RFID models.

NOTE: TN5250/TN3270 is not supported by SL/RFID models.

20

Thermal Printer Media

Online Data Validator: Analyzes each bar code to ensure it meets stringent scanning standards. This 100-percent inspection, commenced immediately after the label is printed, validates the symbology specifications of both linear and PDF417 bar code images. Bad bar code labels are cancelled and good replacement labels are printed automatically. RS-422: Serial interface option. GPIO (General Purpose Input/Output): This option enables a T5000r printer to interface with an external device such as a label applicator system. GPIO is available as a factory option or field installable kit that also includes a mating connector for field interface, installation instructions, and operation manual. Wireless NIC: This card provides wireless 802.11b connectivity without expensive cabling and reconfigurations required from a wired network. Power Cart: The power cart is an ergonomically designed cart with a durable steel frame and battery support systems for maximum maneuverability. The combination of the wireless T5000r and the rugged power cart delivers a mobile on demand bar code printing system.

Thermal Printer MediaBecause there are two modes of operation, there are two kinds of thermal printer paper:

Direct thermal paper: This paper is coated with chemicals that act as accelerators, ink, and ink binders. In direct thermal mode, the heat from the thermal printhead contacts the paper and causes a chemical reaction on the surface of the paper. Thermal transfer paper: This film or synthetic paper substitute is designed to accept transferred images well and to resist scratching. Most thermal transfer papers can be die-cut for easy label applications. Printronix offers a selection of thermal transfer paper sizes and face stocks, which ensures high print quality and long life when used with Printronix ribbons.

NOTE: Thermal transfer is not supported on 4 inch DT model printers.

RibbonsUse only Printronix Genuine Thermal Ribbons in this printer. Printronix thermal ribbons are engineered to enhance thermal printing capabilities and to prevent premature wear of the printhead.

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Chapter

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The SL5000r/T5000r Series RFID/Label Printer

Thermal Printer TechnologyUnlike a dot matrix, laser, or LED printhead printer, a thermal printer has a printhead containing heating elements that are used with paper or a ribbon specially designed for use with a heated printhead. The T5000 printer uses an inline thermal printhead, which produces high resolution output quickly and efficiently. The architecture of the T5000 is shown in Figure 1.

The Printing ProcessThe thermal printhead allows two modes of operation:

Direct Thermal Mode: The thermal printhead selectively heats tiny rectangular dots on its surface. When the heated dots contact specially coated thermal paper, the dyes and developers in the coating react to the heat and develop an image. This mode of printing is often used for shortterm labeling applications. Thermal Transfer Mode: The heated dots contact a thermal ribbon; the thermal ribbon reacts to the heat by bonding the image to the paper. This method is especially suitable for print applications requiring long-term storage, abrasion resistance, durability in extreme environmental conditions, and resistance to tampering. (Models designated -DT do not print in this mode.)

Dynamic Print ControlPrint quality in thermal printers depends on how well the thermal ribbon and thermal transfer paper respond to the heat of the thermal printhead. The thermal printhead must reach a specific temperature to print, then must cool down in the shortest possible time after printing. Print quality therefore depends on precise control of the energy supplied to the thermal dots. If uneven print density occurs, it is usually caused by the stored heat from dots printed previously. The T5000 printer uses Dynamic Print Control technology to ensure even print density. Dynamic Print Control is printer software that monitors and adjusts printhead temperatures. Based on stored results of previously printed dots, the printer predicts the amount of heat required to print subsequent dots and regulates the electrical energy applied to the printhead. This prevents uneven print density and permits the printing of narrow-ladder bar codes and vertical grid lines that are absolutely straight.

22

Thermal Printer Technology

RFID Encoder

Antenna Board

P2 J2

Cutter PCBA Option

J1 P1

P301 J301

Validator Option

Control PanelP13 P9 J9 J31 Flash SIMM P11 J11 P18 J18 J21 P21 J P 1 1 5 5 J16 P16

P12 J7 RS422 J12

J13

Cutter Option

RJ11 J3 Diagnostic Port Serial J2 Port DB9 P10 J10 J4 J112 P112 USB J203 Parallel Port

PCI Expansion Ports J25 J24

ControllerJ14 P14

Ribbon Supply Motor

Upper Media Sensor

Stepper Motor Head Up Sensor Label Taken Sensor

Real Time U9 Clock/ NVRAM J6 P6 J5 P5 J17 P17

J8 P8

Ribbon Take-up Motor

Lower Media Sensor P401 J401 P403 CN403

PCI Bus Expansion Connector

AC Power Line 1 Line 2/neutral Ground (green/ yellow wire)

P402 J201 Fan

Thermal Print HeadJ402

Power Supply

Ethernet NIC Option

Wireless Option

Figure 1. Functional Block Diagram, SL5000r

23

Chapter

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The SL5000r/T5000r Series RFID/Label Printer

RFID Encoder

Antenna Board

P2 J2

Cutter PCBA Option

J1 P1

P301 J301

Validator Option

Control PanelP13 P9 J9 J31 Flash SIMM P11 J11 P18 J18 J21 P21 J P 1 1 5 5 J16 P16

P12 J7 RS422 J12

J13

Cutter Option

RJ11 J3 Diagnostic Port Serial J2 Port DB9 P10 J10 J4 J112 P112 USB J203 Parallel Port

PCI Expansion Ports J25 J24

ControllerJ14 P14

Ribbon Supply Motor

Upper Media Sensor

Stepper Motor Head Up Sensor Label Taken Sensor

Real Time U9 Clock/ NVRAM J6 P6 J5 P5 J17 P17

J8 P8

Ribbon Take-up Motor

Lower Media Sensor P401 J401 P403 CN403

PCI Bus Expansion Connector

AC Power Line 1 Line 2/neutral Ground (green/ yellow wire)

P402 J201 Fan

Thermal Print HeadJ402

Power Supply

Ethernet NIC Option

Wireless Option

Figure 2. Functional Block Diagram, T5000r

24

Control Panel

Controls And IndicatorsControl PanelMost of the controls and indicators for the printer are on the control panel at the top left of the printer. The control panel contains an LCD and the control keys shown in Figure 3. The functions of the keys are summarized on the following pages. NOTE: Two control panel overlays are available: the international overlay uses graphic symbols to indicate key function, the English language overlay adds English labels to the blue keys, as shown in Figure 3. The overlays are otherwise identical.

Online Status Indicator

OFFLINELiquid Crystal Display (LCD)

Job In Process Indicator

Figure 3. Control Panel

25

Chapter

26 Description Indicates when the printer is online, offline, or when there is a fault condition. Flashes during a fault condition. A backlit Liquid Crystal Display (LCD) with two rows of 16 characters each. During a fault condition, displays the specific fault message and the corrective action. Indicates when the printer is receiving or processing data. Stays lit when data has been processed and is waiting to be printed. Off when no data is being received or when no data remains in the buffer. Flashes when receiving data. During a fault condition, displays the specific fault message and the corrective action. Flashes when receiving data. Stays lit when data has been processed and is waiting to be printed. Off when no data is being received or when no data remains in the buffer. Displays ONLINE, the interface type, and emulation in use. Displays OFFLINE. Flashes during a fault condition. Stays lit when the printer is online, ready to print, and accept data from the host. Off when the printer is offline. Off. Function in Online Mode Function in Offline Mode Function in Menu Mode Flashes during a fault condition. Displays OFFLINE and a main menu, submenu, or option. During a fault condition, displays the specific fault message and the corrective action. None

Indicator

1

Online Status

Controls And Indicators

Status and Display Indicators

Liquid Crystal Display (LCD)

Job In Process

Button PAUSE Key Toggles the printer between online and offline modes. JOB SELECT Key None Selects a pre-stored printer configuration. Sets printer to Offline Mode. Sets printer to Online Mode.

Description

Function in Online Mode Sets printer to Offline Mode.

Function in Offline Mode

Function in Menu Mode

Scrolls left through main menus.

Control Panel Keys

DECREMENT Key in Menu mode FEED Key Advances the media one label length.

Decrements option values within submenus. Advances the media one label length.

UP Key in Menu mode

Scrolls the current menu selection one level up. None Scrolls through the Test Print patterns. Scrolls right through main menus.

TEST PRINT Key Pressing the (ENTER) key with a Diagnostic Test displayed initiates the test. Pressing the (ENTER) key again terminates the test. INCREMENT Key in Menu mode

+

Increments option values within submenus.

Control Panel

27

Chapter

28 Description CANCEL Key When the CANCEL key is enabled, pressing it will clear all data in the printer buffer and prevent printing of that data. Note: The factory default is Disable. However, when the Coax/Twinax interface option is installed, the factory default is Enable. DOWN Key in Menu mode Scrolls the current menu selection one level down. Takes the printer Offline and selects the Menu mode. None None Selects the Menu mode. Scrolls between main menu selections. Selects the current menu value and displays an asterisk (*) next to the value. Clears all data in the printer data buffer when enabled. Clears all data in the printer data buffer when enabled. Function in Online Mode Function in Offline Mode Function in Menu Mode

Button

1Controls And Indicators

Control Panel Keys (continued)

MENU Key

ENTER Key Pressing the (ENTER) key in Menu mode selects the displayed option or value. An asterisk (*) then appears next to the option or value indicating it has been selected. Note: If the ENTER key is locked, ENTER SWITCH LOCKED displays on the LCD for one second. Press the (DOWN) and (ENTER) keys at the same time to unlock the ENTER key and select an option or value.

Plugging In The Printer

Plugging In The PrinterIn compliance with international safety standards, this printer is equipped with a three-pronged electrical plug on the power cord. When this power cord is plugged into a correctly wired power outlet, the ground conductor ensures that the printer chassis is at ground (earth) electrical potential.

WARNING

Failure to properly ground the printer can result in electrical shock to the operator. Do NOT use adapter plugs or remove the grounding prong from the power cable plug. If an extension cord is required, make sure it is a three-wire cable with a properly grounded plug.

Power SwitchIMPORTANTAfter powering off the printer, always wait at least two seconds before powering it back on. The power switch is a rocker switch located on the bottom back panel of the printer. To apply power, set the switch to the | (On) position. When you first power on the printer, a series of initialization messages will appear on the control panel LCD. To remove power, set the power switch to the O (Off) position.

Operating ModesThe operating mode is selected with control panel keys or results from certain operations, such as powering on the printer. There are four operating modes: Online The printer is ready to receive data and will immediately print data sent from the host. Pressing the PAUSE key toggles the printer between online and offline modes. The ONLINE status indicator is lit when the printer is in online mode. Communication with the host computer is suspended so you can load media, navigate through the printer configuration menus to make changes or verify option settings, or do other operator tasks. Pressing the PAUSE key toggles the printer between online and offline modes. The ONLINE status indicator is off when the printer is in offline mode. Pressing the MENU key takes the printer offline and into Menu mode. In this mode you can navigate through all configuration and status menus and change printer configuration. A fault condition exists that must be cleared before printing can continue. The ONLINE status indicator flashes, the alarm beeps if configured to do so, and a fault message displays.

Offline

Menu

Fault

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Controls And Indicators

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2

Preventive Maintenance

Cleaning The PrinterThe T5000 thermal printer is a simple, reliable device, designed to require very little maintenance. Aside from the normal replenishment of print media and ribbons, the only preventive maintenance required is periodic cleaning and inspection for damage. Because operating conditions vary widely, the user must determine how often to clean the printer. Since there is no guarantee that the user will clean the printer regularly, you should clean it whenever you are called to service it. Depending on the media used, the printer may accumulate residues (media dust, adhesives, etc.) as a by-product of normal printing. To maintain top printing quality, you should remove these residues by cleaning the printer periodically.

CAUTION

Do not use abrasive cleaners. Do not drip liquid into the printer. Damage to the equipment will result. Do not spray directly onto the printer if you use spray solutions. Spray a cloth, then apply the dampened cloth to the printer.

ExteriorClean the exterior surfaces with a clean, lint-free cloth. If necessary, use a mild detergent or desktop cleaning solution. NOTE: Do not use abrasive cleaning agents or solvents.

InteriorClean the interior of the printer by removing any dirt and lint with a softbristled, non-metallic brush. Use a vacuum cleaner to remove the residue.

General CleaningPeriodically clean all rollers, guides, and assemblies. Use low pressure air to remove dust in the printer. Use isopropyl alcohol and a cotton swab to clean any areas where media dust, adhesives, etc. have accumulated.

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Cleaning The Printer

Cleaning The Printhead, Platen Roller And Media SensorsNOTE: You do not need to turn off the printer before cleaning the printhead, platen roller, or media sensors.

Printhead CleaningAs you use your printer, the printhead may become dirty which can result in poor print quality. Clean the printhead each time you install new ribbon (thermal transfer print mode) or install new media (direct thermal print mode). Clean the printhead with the cleaning pen supplied with the printer. By keeping your printhead clean, you will help maintain its life.

Platen Roller CleaningMedia dust and adhesive residue on the platen roller can degrade print quality and cause voids in your label image. Clean the platen roller at the same time as the printhead. Use a small amount of isopropyl alcohol on a cloth to clean the platen roller. With the pivoting deck up the platen roller can be rotated forward by hand to access and clean its entire surface area.

Media Sensor CleaningThe upper and lower media sensors should be cleaned to ensure reliable TOF and Paper Out sensing. Clean the media sensors at the same time as the printhead. The upper media sensor (located in the horizontal slot of the printhead cover) can be wiped clean using a soft cloth. The lower media sensor, easily seen by its visible red light, is located in the horizontal slot of the media guard. Remove media dust by vacuuming or blowing air across the lens cover.

Media Damper CleaningThe media damper (see Figure 24, page 166) and media width guide can begin to collect adhesive and paper dust residue that can prevent proper guiding of labels. Use a small amount of isopropyl alcohol on a cloth to remove label adhesive and dust from the underside of the media damper and its fixed (inbound) guide and from the adjustable (outbound) width guide.

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Cleaning The Printhead, Platen Roller And Media Sensors

Printhead Heating Elements

Pivoting Deck

APeel/Tear Door

Platen Roller

Lower Media Sensor (with visible red LED) Printhead Cover/ Upper Media Sensor

Deck Lock Lever

APrinthead Heating Elements Upper Media Sensor

1. Rotate the deck lock lever clockwise to open the pivoting deck and remove any media and ribbon (if loaded) to gain access to the printhead assembly heating element area. 2. Gently rub the felt tip of the cleaning pen or a cotton swab with isopropyl alcohol across the printhead heating elements (light brown area). 3. Allow the printhead to dry for one minute before reloading the media and ribbon. 4. Clean the platen roller. 5. Clean the upper and lower media sensors.

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Printer Inspection

Printer InspectionAfter cleaning the printer, inspect all wear items and electromechanical components, as outlined below. 1. Remove the frame side cover (page 108). 2. Inspect the EMI clips on the frame side cover for damage. Replace any clip that is damaged or missing. (Figure 20, page 154.) 3. Inspect the platen belt and the rewinder belt for cracks, cuts, fraying, and wear. (Figure 22, page 160.) Replace any damaged or worn belt. 4. Inspect the ribbon drive gears and intermediate gears for cracks, chipped or missing teeth. (Figure 23 on page 164 and Figure 33 on page 190.) Replace any damaged gear. 5. Inspect all cable assemblies and electrical cords for cracks, cuts, fraying, or exposed conductors. Replace any damaged or worn cables. 6. Install the frame side cover. 7. Open the media cover. 8. Open and close the media cover, checking that the cover closes completely. Adjust as required. (Figure 20, page 154.) 9. Check that the media hanger guide assembly operates correctly and the spring is not broken. Replace if damaged. (Figure 20, page 154.) 10. Inspect the ribbon spindles, rewinder, and media damper for damage and smooth operation. (Figure 23, page 164.) Replace a damaged spindle or bail. 11. Inspect the printhead and platen assemblies for obvious damage. (Figure 25, page 168.) Replace damaged assemblies. 12. Inspect the media sensor assemblies for paper dust, sufficient horizontal travel, smooth horizontal movement, and damaged or frayed ribbon cable. 13. Restore the printer to operation (page 96).

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3Introduction

Troubleshooting

This chapter lists fault messages and symptoms, and gives procedures for troubleshooting printer malfunctions. You must operate the printer to check its performance and you may have to reconfigure it. This manual does not cover printer operation or configuration, so always have the Users Manual handy when you troubleshoot.

What You Should Know About Print QualityThe print quality of a thermal printer is affected most by the amount of heat applied by the printhead to the media and by the location of the printhead in relation to the print media. Low-cost direct thermal media often have very high reaction temperatures, which means that it takes a great deal of heat to make a clear image. Resin ribbons and film media may also require higher print intensity for a quality image. You can increase the heat applied by the printhead in three ways: 1. Set the Print Intensity configuration parameter to a higher numerical value with a command from the host computer or by accessing the MEDIA CONTROL menu with the control panel. (Refer to Configuring the Printer in the Users Manual.) This causes more heat to be transferred to the print media, thus generating a darker image. 2. Run the printer slower. 3. Do both 1 and 2.

IMPORTANT

Keep the printhead clean. Foreign material on the printhead interferes with heat transfer. If smears, voids, or white lines appear on printed forms, clean the printhead (page 32).

How To Maximize Printhead Life1. Remind the customer to clean the printhead with a cleaning pen after each roll of ribbon (thermal transfer) or media roll (direct thermal). The cleaning pen (P/N 203502-001) will last for eight printhead cleanings. Refer to the Users Guide.

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Introduction

2. Avoid excessive printhead pressure, usually indicated by white wear spots on the printhead element. Reduce the pressure until you see print quality problems, then increase the pressure slightly until you have good print quality. 3. Avoid excessively high Intensity settings. Intensity is the burn temperature that the printhead operates at. Lower temperatures will increase the life of printheads. Reduce the Intensity setting until you see print quality problems, then increase the setting slightly until you have good print quality. 4. Clean and inspect the platen roller for excessive wear (light print) and gouges (repeating voids). 5. Customer responsibilities: configuration, printhead installation, and preventative maintenance. Refer to the Users Guide.

Troubleshooting At A GlanceStart Here.......................................................................................... page 37 How To Troubleshoot........................................................................ page 38 Troubleshooting Display Messages .................................................. page 40 Troubleshooting Other Symptoms .................................................... page 75 Troubleshooting A New Installation................................................... page 94

36

Troubleshooting At A Glance

Start HereAre you here because of an YES error message? NO Power on the printer and observe the control panel for the following sequence of events (retry as required): 1. TESTING HARDWARE PLEASE WAIT appears on display. 2. DIAGNOSTICS PASSED appears on display. 3. LOADING FONTS FROM FLASH appears on display. 4. Printer goes ONLINE or OFFLINE, depending on users configuration. Did steps 1 through 4 occur? YES NO Go to Troubleshooting Display Messages, page 40.

Make a configuration YES printout. (Refer to the Users Manual.) Does machine configuration print? NO

Is this a newly installed printer? YES NO

Go to LCD message display is illuminated and the printer appears to be working, but nothing is printed, page 78.

IML was successful. Other symptoms are listed in Table 3, page 76. Go to Troubleshooting A New Installation, page 94.

Is the control panel display backlit? YES NO

Is there a faint horizontal bar on the YES display? NO

Go to Printer does not initialize, the display is backlit and a faint horizontal bar appears on the top line. No message displays, page 79.

Go to Printer fails to turn on, the display is not backlit, and the fan is not running, page 79.

1. Power down, remove frame side cover, and reseat control panel cable. 2. Replace control panel and cable. 3. Troubleshoot using HalfSplit Method outlined on page 38.

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How To Troubleshoot

How To TroubleshootYou will be more successful in troubleshooting printer problems if you use standard fault isolation techniques, which are summarized below: 1. Ask the operator to describe the problem. 2. Verify the fault by running a diagnostic printer test or by replicating the conditions reported by the user. 3. Look for a matching message or symptom in Table 2 on page 41 or Table 3 on page 76. If you find a match, follow the troubleshooting instructions. 4. If you cannot find the symptom in either troubleshooting table, use the Half-Split Method to find the malfunction: a. Start at a general level and work down to details. b. Isolate faults to half the remaining system at a time, until the final half is a field-replaceable part or assembly.

WARNING

ALWAYS disconnect the AC power cord from the printer or the power outlet before doing any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure. 5. Replace the defective part or assembly. Do not attempt field repairs of electronic components or assemblies. Most electronic problems are corrected by replacing the printed circuit board assembly, sensor, or cable that causes the fault indication. 6. Test printer operation after every corrective action. (See Printer SelfTests And How To Verify Printer Operation below.) 7. Install any parts you replaced earlier that did not solve the problem. 8. Stop troubleshooting and return the printer to normal operation when the reported symptoms disappear.

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Printer Self-Tests And How To Verify Printer Operation

Printer Self-Tests And How To Verify Printer OperationThe printer automatically performs a sequence of self-tests when it is powered on. If the self-test software detects a fault, an error message displays on the LCD. Always verify printer operation before returning it to normal operation: 1. Access the Print Mode option in the QUICK SETUP or MEDIA CONTROL menu and make sure the printer is set for the type of print media installed. (Refer to Configuring the Printer in the Users Manual.) a. Direct indicates direct thermal printing, which uses no ribbon and requires heat-sensitive media. b. Transfer indicates thermal transfer printing, which requires a ribbon. 2. Access the printer test patterns in one of two ways: a. Select the Printer Tests option under the DIAGNOSTICS menu. Press + or to cycle through the different tests. OR b. Press PAUSE to take the printer offline. Then press TEST PRINT to cycle through the different tests. Press (ENTER) to print one of the test patterns, described below.

Printer TestsThis menu item selects the test pattern to be printed. Use these patterns to check the print quality and operation of the printer.

Auto Calibrate: Senses paperout, gap, notch, hole, or mark, and calibrates the printer for the currently installed media. Checkerboard: Prints a pattern that helps identify marginal printhead elements, quality of edge sharpness, and uneven print quality. Grey: Prints a pattern that helps identify burned out printhead elements and uneven print quality. Grid: Prints a pattern that helps identify edge sharpness and uneven print quality. Current Config: Prints the current printer configuration and helps identify the text print quality. Left Test: Prints a pattern containing a series of ladder-type bar code symbols, starting with four and decrementing by one symbol on each print until a single symbol prints on the left side. This pattern helps identify ribbon wrinkle problems. Right Test: Prints a pattern containing a series of ladder-type bar code symbols, starting with four and decrementing by one symbol on each print until a single symbol prints on the right side. This pattern helps identify ribbon wrinkle problems. E-Net Test Page: Prints the ethernet statistics stored on the NIC. This menu item appears only if the NIC is installed.

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Troubleshooting Display Messages

Barcode Demo: Prints one demo page containing some text and two good bar codes (Code 39 and Code 128) positioned at the left and right margins of the label media. The test automatically produces output for 4, 6, and 8 inch printers at 203 and 300 dpi.

NOTE: The Barcode Demo will stop automatically. This demo uses the Label Length and Label Width settings to adjust the page automatically.

Valid. Report: Prints a report of the validation statistics since the printer was turned on or since the last data reset. (This item appears only if the validator is installed.)

When you have selected the desired test pattern, press (ENTER) to begin printing the pattern. In the case of the Checkerboard, Grey, and Grid test patterns, the number of times the pattern repeats is determined by the setting of the Test Count menu item. If the Test Count menu item is set at Continuous, you can stop printing by pressing again.

Troubleshooting Display MessagesThe printer uses built-in test equipment to monitor its operation and the condition of the print media. Various messages display indicating the status of the printer and media stock levels. Three kinds of messages can appear on the LCD:

Status messages Configuration menus and menu options Fault messages

Most fault messages are cleared from the LCD by correcting the fault condition and then pressing the PAUSE key. Fault messages that can only be cleared by shutting down and restarting the printer are indicated by an asterisk (*) appended to the message. When printer logic detects a fault condition, three things happen:

The status indicator on top of the printer flashes on and off. The audible alarm beeps if it has been enabled in the PRINTER CONTROL menu. Press PAUSE to silence the alarm. The control panel LCD displays a fault message.

40

List Of Messages

List Of MessagesFind the message in the Message List below and follow the suggested procedure. After correcting an error, press the PAUSE key to erase the message and put the printer in the offline mode. If an error is not cleared, the printer will try to print again but will display the error message until the error is cleared. Table 2. Message List MessageI I I I I I I I I I I I I I I I

Explanation 1. The Flash SIMM (Single In-line Memory Module) is not installed. 2. The Flash SIMM has corrupt boot code.

Solution 1. Install the Flash SIMM. 2. If the message reappears, replace the Flash SIMM with a new Flash SIMM. 3. Download the latest level of software. 4. If the message reappears, replace the control panel and cable. 5. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. Proceed to the next step. 6. Download the latest level of software.

OR I I

06 HOST REQUEST

Status message in the CT emulation: the host computer or print controller requires attention. Status message in the CT emulation: the printer was offline more than 10 minutes and the Intervention Required parameter is set to Send to Host.

Not a printer problem.

08 HOLD PRINT TIMEOUT

Press PAUSE to put the printer online.

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Table 2. Message List Message 15 COMM CHECK Explanation Communication message that appears in the CT emulation and means the line is not active on a twinax interface. Solution 1. Reseat the twinax host data cable connection and the twinax I/O cable connection at the coax/twinax board, and then press PAUSE to clear the message. 2. Disconnect the twinax autotermination (Smart T) cable from the printer. Test the cable for these resistances: Pin 1 - 2 = 110 Pin 3 - 4 = 110 Pin 1, 2, 3, 4 - Shield = 55 Pin 5 - Shield = 0 Pin 14 - 1, 4 = 0 Pin 7 - 2, 3 = 0 If resistances are not correct, replace the twinax auto-termination cable. 3. Power on the printer. Send a print job to the printer. If the message reappears, replace the Flash SIMM. 4. Power on the printer. Send a print job to the printer. Verify that all other devices are working properly. (Refer to line problem determination procedures, as recommended by the host system.) If the message is gone, the host has reestablished communication with the printer. If all other twinax devices work properly and the message still appears, replace the coax/twinax board. Write down the message and return it with the defective board. 22 INVALID ADDR Invalid address: poll time-out on the twinax interface, indicating the unit address is not recognized by the printer. Have the system administrator make sure the printer address is correct.

42

List Of Messages

Table 2. Message List Message 27 CU TIMED OUT Explanation Controller Unit Timed Out: Poll time-out error. The printer was not polled for one minute across a coax interface. Controller Unit Not Enabled: The printer was not enabled for one minute or more on a coax interface. Status message in the CT emulation: the printer was offline more than 10 minutes and the Intervention Required parameter is set to Send to Host. +40VDC Power Failed: an internal power failure. NOTE: The power supply delivers +24VDC and +40VDC. The controller PCBA uses the +24VDC to develop +5VDC and +3.3VDC for its logic circuits. Solution Check cable connection and host system. (Refer to line problem determination procedures, as recommended by the host system.) Check cable connection and host system. (Refer to line problem determination procedures, as recommended by the host system.) Close and latch the pivoting deck. Press PAUSE to put the printer online.

28 CU NOT ENAB

33 HEAD OPEN TIMEOUT

40V POWER FAIL

1. Power off the printer. Remove the side frame cover. Check that the power supply cable is fully seated in connector J17 on the controller PCBA. 2. Using a voltmeter, test between TP4 GND and TP1 +40VDC (+35 to +45VDC). If the voltage is not in this range, unplug the ribbon motors and stepper motor one at a time and cycle power each time. If the message persists, replace the power supply assembly. 3. Power on the printer. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board.

203 DPI Head Installed

Normal power-up message. The printer is running its initialization routine and indicating the DPI resolution of the installed printhead.

No action required.

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Table 2. Message List Message 300 DPI Head Installed Explanation Normal power-up message. The printer is running its initialization routine and indicating the DPI resolution of the installed printhead. The user tried to use an undefined VFU channel. This message appears when at least one label in a batch of labels has a data validation error. NOTE: This message appears only when Validator Action is set to Grade&Report. Bar Code Improper Data Format Data validation error: the bar code is not properly encoded. For example, a check sum is incorrect, a required number of characters is not met, or the required terminator characters are not included. This problem is almost always caused by incorrect form or host application design. Data validation error: the blank zone(s) left or right of the bar code is not big enough to meet the minimum requirement. Typically, this occurs in forms where bar codes are placed too close to other elements, the bar code is too close to an edge of the media, or the medias position is shifting. The minimum quiet zone on each end of the bar code should be ten times the minimum element width or 1/4 inch, whichever is greater. In addition, between bar codes, the validator requires a minimum distance of 20 times the minimum element width or 1/2 inch, whichever is greater. Solution No action required.

BAD VFU CHANNEL Bar code fails Job has errors

Use defined channels. 1. Press PAUSE to clear the message. 2. Manually scan all the bar codes in the label batch, then reprint the bad labels.

Fix the application so it sends data in the correct bar code format.

Bar code quiet zone too small

1. Fix the application. 2. Disable Quiet Zone in the VALIDATOR menu.

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List Of Messages

Table 2. Message List Message BATT HIGH VOLT Explanation This is the High Volt Alert that can be set by the user (factory default = 16.0 Volts). This fault detection is only supported when the power cart ICP (Intelligent Control Panel) option is connected to the printer serial port and Battery Monitor = Enable in the BATTERY CONTROL menu. This is the Low Volt Alert that can be set by the user (factory default = 8.5 Volts). This fault detection is only supported when the power cart ICP (Intelligent Control Panel) option is connected to the printer serial port and Battery Monitor = Enable in the BATTERY CONTROL menu. Solution 1. Raise the value in the High Volt Alert option in the BATTERY CONTROL menu. 2. If High Volt Alert = 16.0 Volts and fault message remains, call your authorized service center.

BATT LOW VOLT

1. Plug the power cart cable into an AC receptacle to recharge the battery. 2. If recharging the battery fails to clear the fault, replace the battery or batteries. NOTE: Follow the battery manufacturers safety precautions when installing a new battery. Make a configuration printout. Verify that the printer matches the host serial interface configuration settings for Data Protocol, Baud Rate, Data Bits, Stop Bits, Parity, Data Terminal Ready, and Request to Send. Set printer serial interface parameters to match those of the host. 1. Make a configuration printout. Verify that the printer matches the host serial interface configuration settings for Data Protocol, Baud Rate, Data Bits, Stop Bits, Parity, Data Terminal Ready, and Request to Send. 2. Send a print job to the printer. If the message reappears, go to Communications Failures, page 91.

BUFFER OVERFLOW

The host computer sent data through a serial interface after the printer buffer was full.

BUFFER OVERRUN

The print buffer has overflowed on a serial interface.

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Troubleshooting Display Messages

Table 2. Message List Message Calibration warning Explanation The validator has detected that it needs calibration. This message is a reminder and does not halt printing. Run Calibrate procedure was attempted with Peel-Off Media Handling selected. NOTE: You can perform Auto Calibrate in Peel-Off mode if Cal in Peel Mode = Enable. Be prepared to catch labels during the calibrate procedure. Checksum Failure The bar code data fails the checksum check or is missing the checksum digit. The program successfully loaded into printer RAM and the checksum matched. The old program is now being deleted from flash memory. Data validation error: the contrast between bars and spaces is not sufficient. This can be caused by too little heat in the thermal transfer or by use of colored media or ribbons. Solution Press PAUSE to clear the message. Calibrate the validator. See Calibration on page 272. 1. Select another Media Handling option in the QUICK SETUP or MEDIA CONTROL menu. 2. Enable Cal in Peel Mode in the CALIBRATE CTRL menu. NOTE: Admin User must = Enable. Verify that the checksum digit exists in the bar code and that it is the correct value. No action required.

CANNOT CALIBRATE Disable Peel-Off

CLEARING PROGRAM FROM FLASH

Contrast too low Check media

Increase Print Intensity or reduce Print Speed in the QUICK SETUP menu or via host software, change media, or disable Symbol Contrast in the VALIDATOR menu.

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List Of Messages

Table 2. Message List Message CUTTER FAULT Jam or Cut Fail Explanation 1. The cutter option was not able to complete a full cut cycle due to a jam. 2. The cutter PCBA detected current overload and opened circuit breaker on the cutter PCBA. 3. The cutter is open (in the down position). 4. On a later model cutter, the upper cutter enclosure is not installed. Solution 1. Clear obstructions from the cutter assembly. 2. Check that the thickness of the media does not exceed 0.01 inch (0.254 mm). 3. Wait a few minutes for the cutter circuit breaker to automatically reset. Press PAUSE to clear the fault message and resume printing. 4. Make sure the cutter assembly is closed and locked in the operating position with the upper cutter enclosure installed. 5. Make sure the two interlock switches are enabled and not damaged. If damaged, replace the cutter assembly. 6. Replace the cutter driver PCBA. DEACTIVATING HOST SERIAL Normal message that displays when you set Validator Funct. = Enable in the VALIDATOR menu or Battery Monitor = Enable in the BATTERY CONTROL menu. The printer passed its memory and hardware initialization tests. This is the normal reminder message when you change the Print Mode setting from Transfer to Direct in the QUICK SETUP or MEDIA CONTROL menu. No action required.

DIAGNOSTICS PASSED DIRECT THERMAL Remove Ribbon

No action required. 1. Remove ribbon from the ribbon supply and ribbon take-up spindles in the printer. 2. If ribbon is required for printing, change the Print Mode back to Transfer. Do not power off the printer until downloading is complete.

DO NOT POWER OFF

This is a standard warning message that displays while the printer is downloading software.

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Table 2. Message List Message DOWNLOADING TO VALIDATOR Explanation Normal message when the printer is downloading emulation software with a validator option installed. NOTE: Many software builds contain updates to the validator option. E-NET INIT E-NET READY E-NET RESET EC SOFTWARE FAIL* See Manual The NIC is initializing. The NIC has finished initializing. The NIC is being reset. The printer cannot find the engine controller program or the validation checksum is corrupt. Solution No action required. NOTE: The validator software update can be verified in the F/W Revision menu option of the VALIDATOR menu. It displays as: Version: X305. No action required. No action required. No action required. 1. Cycle power: power down the printer, wait 15 seconds, then power the printer on. 2. If the message reappears, download the emulation. If the message reappears, replace the Flash SIMM. 3. Download the emulation. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. ENTER to Stop 1. A diagnostic test pattern has been selected and is running. 2. A diagnostic test pattern is selected, but will not print. Peel-Off or Tear-Off Media Handling method is selected. ERROR: DC PROGRAM NOT VALID The printer cannot find the data controller program or the validation checksum is corrupted. 1. This is a normal message. Press the (ENTER) key to stop printing the test pattern. 2. Remove the frame side panel. Make sure the label taken sensor cable is connected to J18 on the controller PCBA. 1. Download the emulation software again. 2. If the message reappears, replace the Flash SIMM.

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List Of Messages

Table 2. Message List Message ERROR: DRAM AT ADDRESS XXXXXXXX Explanation The printer found a defective memory location. Solution 1. Cycle power: power down the printer, wait 15 seconds, then power the printer on. 2. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. ERROR: FLASH DID NOT PROGRAM The printer encountered an error trying to program flash memory. 1. Download the emulation software again. 2. If the message reappears, replace the Flash SIMM. 3. Download the emulation. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. ERROR: IPDS needs 300 DPI Head! The printer has detected a 203 DPI printhead installed, with IPDS software downloaded. NOTE: IPDS software supports only the 300 DPI printhead. ERROR: NO DRAM DETECTED The printer could not find any DRAM. 1. Cycle power: power down the printer, wait 15 seconds, then power the printer on. 2. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. ERROR: PROGRAM NEEDS MORE DRAM The program exceeds the memory limitations of the printer. Download a smaller program. Power off the printer and replace the 203 DPI printhead with a 300 DPI printhead.

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Table 2. Message List Message ERROR: PROGRAM NEEDS MORE FLASH Explanation The printer requires more flash memory in order to run the downloaded program. Solution 1. Install a 16MB Flash SIMM at J31. 2. If the message reappears, replace the Flash SIMM. 3. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. ERROR: PROGRAM NOT COMPATIBLE ERROR: PROGRAM NOT VALID ERROR: SHORT AT ADDRESS XXXX The printer is not compatible with the downloaded program. The printer does not see a program in flash memory. Hardware failure in DRAM on main PCBA controller circuitry. Use the correct emulation software option(s) for this model printer. There is no program in printer memory. Download the program again. 1. Cycle power: power down the printer, wait 15 seconds, then power the printer on. 2. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. ERROR: WRITING TO FLASH Hardware or software fault in flash memory. 1. Download the emulation software again. 2. If the message reappears, replace the Flash SIMM. 3. Download the emulation. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board.

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List Of Messages

Table 2. Message List Message ERROR: WRONG CHECKSUM Explanation The printer received the complete program but the checksum did not match. The data were corrupted during download. Solution 1. Download the program using a new software CD. If the message reappears, replace the Flash SIMM. 2. Download the emulation. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. Wait. When the asterisk (*) stops rotating, a different fault message will appear; troubleshoot the final message. (This message can also appear if the printer does not have enough flash memory.) 1. Verify that the fan rotates when the printer is first powered up and when the printer moves media or prints. 2. Ensure that the fan cable is properly connected to JP401 on the power supply PCBA. 3. Verify that the correct power supply is installed in the printer. 4. Replace the power supply fan. 5. Replace the power supply. 6. Replace the controller PCBA. Write down the message and return it with the defective board. FILE EXISTS Enable Overwrite The printer operator tried to save a file using the name of an existing stored file. Enter the PRINTER CONTROL menu and enable the Overwrite Files feature to overwrite an existing file. (Refer to the Users Manual.)

ERROR OCCURRED FLUSHING QUEUES*

An interim message that displays while the printer discards host data it cannot use because a fault condition exists. While this message displays, the asterisk (*) rotates. The printer detected that the power supply fan did not rotate for at least a 45 second period when it is was supposed to. NOTE: This is a warning message and will not halt printing. When too high of internal temperature is detected, the printer will stop printing and display PWR SUPPLY HOT, PRINTER HOT, or PRINT HEAD HOT, based on the source.

FAN WARNING

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Table 2. Message List Message FILE SYS FULL Add Flash FILE SYS FULL Delete Files Explanation There is not enough flash memory to store a file. There is not enough flash memory to store the file. Solution Install a 16MB Flash SIMM and download the emulation software again. Enter the PRINTER CONTROL menu. Use the Delete Files selection to delete unwanted files. (Refer to the Users Manual.) Enter the PRINTER CONTROL menu and use the Optimize & Reboot feature. (Refer to the Users Manual.) 1. Install the Flash SIMM that was removed. 2. Enter the PRINTER CONTROL menu and use the Optimize & Reboot feature. (Refer to the Users Manual.) 1. Reseat Flash SIMM at J31. 2. If the message reappears, replace the Flash SIMM. 3. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. FPGA FILE NOT FOUND The program file was not downloaded successfully. 1. Download the program file again. 2. If the message reappears, replace the Flash SIMM. 3. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. FRAMING ERROR Serial framing error over a serial interface. Match the serial interface settings of the printer to those of the host computer.

FILE SYS FULL Optimize & Reboot

There is no flash memory left in which to store files.

FILE SYS INVALID Optimize & Reboot

The file system was not detected. The flash memory was corrupted or the Flash SIMM was removed.

FILE SYS WRITE Check Flash

Problem writing to flash memory.

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List Of Messages

Table 2. Message List Message GAP NOT DETECTED Check Media Explanation The printer is set for Mark, Gap, Advanced Gap, or Advanced Notch sensing, but a mark, gap or notch is not being detected. This can occur if: 1. Media with no gap or black mark is installed, and Gap or Mark is selected in the CALIBRATE CTRL menu. 2. The media sensor is not horizontally positioned relative to the gap, notch, hole, or black mark on the media, or the media width guide is not set correctly, causing the media to be misaligned. 3. If Advanced Gap or Advanced Notch is selected in the CALIBRATE CTRL menu, the upper media sensor may not be positioned over the lower media sensor. 4. An Auto Calibrate was not performed using the installed media. There is not enough contrast between the label and liner. Solution 1. If the customer is not using die-cut labels, set the Gap/Mark Sensor to Disable in the QUICK SETUP or CALIBRATE CTRL menu. 2. Inspect the horizontal position of the media sensor. Check the paper path. Clean the sensor assembly. 3. Position the upper sensor directly over the lower sensor if the customer is using either Advanced Gap or Advanced Notch. 4. a. Do the Auto Calibrate procedure. (Refer to the Users Manual.) This procedure improves the ability of the sensor to detect the type of media in use. Save your calibration after you calibrate. b. Run a Profile Printout from the CALIBRATE CTRL menu to obtain a visual indication regarding the contrast difference between the label and the gap, notch, or mark. c. If the Gap Threshold is too high or the Paper Out Threshold is too low the sensor may not detect the gap. Lower the Gap Threshold or raise the Paper Out Threshold value. (Refer to the Users Manual.)

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Table 2. Message List Message GAP NOT DETECTED Check Media Explanation Solution d. Make sure the media sensor cables have good connections to J15 and J21 on the controller PCBA. e. Verify that the media is within the specification of the printer. Refer to the Users Manual. f. GRF CHK ERROR PRESS PAUSE In the CT emulation over a twinax interface, the printer received a non-printable character. The printhead or power supply is approaching a hot state. Half Speed Mode aids the cooling process and should permit completion of print jobs. Half Speed Mode helps prevent a PRINT HEAD HOT or PWR SUPPLY HOT fault, which will stop the printer. Replace the media sensor(s).

Press PAUSE twice.

Half Speed Mode

1. Allow printer to continue printing. Full speed will resume automatically when a lower printhead or power supply temperature is achieved. 2. Let the printer cool down. Full speed will be restored when printing is resumed. 3. Lower Print Intensity and Print Speed to reduce frequency of Half Speed Mode.

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Table 2. Message List Message HEAD POWER FAIL Call For Service Explanation The printhead lost power. Solution 1. Check the connection of the phone-style power supply control cable at J5 on the controller PCBA and CN403 on the power supply. Disconnect the power supply control cable and check continuity. Replace the cable if it fails continuity test. 2. Check connections of other cables going from the controller PCBA to the power supply. Reseat all cables. Replace damaged cables. 3. If printing in Direct Thermal mode (i.e., no ribbon), check the voltage between TP4 GND and TP1 +40VDC (+35 to +45VDC) on the controller PCBA. If voltage is out of tolerance, replace the power supply assembly. 4. Power on the printer. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. IGP/PGL ERROR Appears when the Fault option is selected from Error Report on the control panel. Tear-Off or Peel-Off Media Handling selection (in the MEDIA CONTROL menu) was attempted with the cutter option installed. These modes require that the front door assembly be installed to use the label taken sensor. 1. Clear the IGP/PGL error. 2. Deselect Fault from Error Report on the control panel. 1. Select a different Media Handling mode. 2. Power off the printer and remove the cutter option, install the front door assembly, power on the printer and select Tear-Off or Peel-Off mode.

INCOMPATIBLE WITH CUTTER

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Table 2. Message List Message INSUFFICIENT RAM Reboot/Add RAM Explanation There is not enough RAM available for certain printer functions or emulations. Solution 1. Cycle power: power down the printer, wait 15 seconds, then power the printer on. 2. If the message reappears, increase the Glob Mem Adjust size in the PRINTER CONTROL menu and reboot the printer. 3. If the message reappears, replace the controller PCBA. Write down the message and return it with the defective board. LABEL MISSING Check Paper Path The label taken sensor did not detect the label present over the tear bar with Tear-Off or Peel-Off Media Handling mode enabled. 1. The label was removed before the printer stopped printing or before the Remove Label message was displayed. 2. The label slipped behind the platen roller. 3. The label wrapped around the platen roller. 4. Tear-Off or Peel-Off Media Handling mode was mistakenly selected. 1. Press PAUSE to continue printing and then wait for the Remove Label message to display before removing the label. 2. Open the pivoting deck, reinstall the label, close the deck, press PAUSE and continue printing. 3. Open the pivoting deck and remove wrapped labels from the platen. Clean all adhesive from the platen. Reinstall labels, close the deck, press PAUSE and continue printing. 4. Select the correct Media Handling mode in the QUICK SETUP menu. No action required.

LOADING PROGRAM FROM PORT XX%

The new program is loading into printer RAM. XX indicates how much of the program has loaded. The printer has deleted the previous program from flash memory and is loading the new program into flash memory.

LOADING PROGRAM INTO FLASH

No action required.

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Table 2. Message List Message MENU MODE QUICK SETUP Explanation Normal message that displays when you first press the MENU key to place the printer in Menu mode. A job was printed that had no RFID commands on at least one form of the job while RFID tags were installed in the printer and the Non-RFID Warning menu item is set to Enable. The printer assigns a certain amount of simulated NVRAM for storage of saved configurations. Large emulations reduce the amount of space available for saving configurations, which means that sometimes fewer than 8 configurations can be saved. If this message appears at powerup, it means the Flash SIMM is defective. Solution No action required.

NON-RFID DATA On Rfid Tag

Press PAUSE to clear the message. Set Non-RFID Warning to Disable, print a job with RFID commands on every form, or install non-RFID labels in the printer. 1. If the message appears at power-up, replace the Flash SIMM. 2. If the message appears while saving a configuration, the printer is out of memory and will not save the current or subsequent configurations. (Previously saved configurations remain available.)

NON VOLATILE MEMORY FAILED

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Table 2. Message List Message OPTION NOT INSTALLED Explanation 1. A cutter option must be installed and in the up (operating) position with the upper enclosure installed when the printer is powered on for the controller to detect it. 2. The media cutter option was not detected. The RJ11 plug from the cutter assembly to the cutter PCBA in the bottom-left front opening of the frame is disconnected. 3. Cut Media Handling in the MEDIA CONTROL