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Monarch 9820TM Printer User Manual

1. 31 Platen Module 31 Platen Module 32 Bi Cell Sensor 32 Lower Supply Guide 32 Bi Cell Sensor Replacement 32 Lower Supply 33 aigu E 33 SUPPLY 33 Supply Holder 33 PLATEN 33 Platen Motor
2. 68 CONNECTORS AND 6 69 iv TC9830SM Rev B 7 98 Confidential List Of Tables Table 1 1 Daughter Board DIP Switches nnn nn EEEE 4 Table 1 2 Exterior Rear SW2 and SW3 DIP Switch 5 Table 4 140 TESS acta tao tana tie Rs Ts Se iss Te SA Ts Se Sas aS Ha Ss NaS Hi Ss SSR Ths Sa Sts Saat has Sees hes Sasa 21 Table D 1 Stacker Control eee 60 Table D 2 Jam Full Sensor enemas 61 Table D 3 Extended Motor Interface 817255 61 Table D 4 AC Power Harness eee eee eee nana 61 TableD 5 Power Supply Connector J2 enit Tene eee e A RR R RR RR al ln i a a ll ll i a i i ll 61 Table D 6 Power Supply 62 Table E 1 Knife Drive Board nana 66 Table E 2 Drive Board Connector J 69 Table E 3 Drive Board Connector 2 00 2 20000 00 0000000 Ta nh ALT
3. 9 2818 8110 10 353 9 Printhead Thermal Control eee o oe ree n ere e oo e 9 Print Imaging 9 Motion Control 9 Platen Drive 618 06 9 Ribbon Drive Interface eee aaa 9 Analog to Digital Conversion 9 Supply Detection amp Tracking System 9 Operator Control Panel 9 Communications
4. 28 Bridge Rectifier Removal 28 Inlet 28 Control Board Assy Removal 29 PRINT 55 29 Bi Cell Emitter 30 Upper Supply Guide Hemavan ges 30 Printhead Module 30 Ribbon Spool Assembly 2170 8 30 Ribbon Roller Assembly 30 DC Ribbon Motor 30 Print Assembly Ren de 31 FEED 55 31 Latch Fascia
5. 54 Figure EN TT 55 Figure Bib so NO annet 55 Figure B AGN al Oe cepe atten Ea d ti ML E I UM ULT EDT 55 Figure B 13 CN 19 to Daughter Board 55 Figure B 14 CN To MotherBoard CN 19 nt 55 Figure B 15 CN 10 Peel nenea nnn a aaa a aaa a 55 Figure B 16 CN 6 On Demand anna 55 Figure C 1 Control Board Assy Mother 57 Figure C 2 Control Board Assy Daugher 58 Figure D 1 Stacker Control Board 62 Figure D 2 Stacker Lubrication 222 4000 1 nana nana aan 62 Figure D 3 Model 928 Stacker Assembly _ anna 63 Figure D 4 Lower Transport eee eee eee aa eee eee 63 Figure D 5 Upper Transport Rollers 111000 eee eee nnm anna anna 63 Figure D 6 Power Supply Control 64 Figure E 1 Knife Lubrication 66 Figure E 2 Location of 66 Figure E 3 Knife
6. 7 OVERVIEW OF eee o eee oe eene n eee n ree n S 7 Power Transformer Assembly 8 Inlet Power Module 8 Power Transformer 8 Bridge Rectifier 8 CONTROL BOARD 5 eee o 8 Functional Description eee o eee o ere o ee o 8 Power Conversion eere eee n n eene n nee n eee n eee e s 9 Memory 9 Flash Memory 9 DRAM Memory 9 SRAM Memory 9 Printer Control
7. 60 62 MAINTENANCE 6 62 REPLACE ROLLERS 63 Replacing Transport Assembly 63 Replace DC Motor 64 Replace Stepper 1 64 Replace Stacker Sensors 64 Replace Power 64 Replace Control 64 APPENDIX 926 KNIFE ASSEMBLY 65 KNIFE SPECIFICATIONS 65 TAG CUT
8. 50 FLASH FAULTS 930 940 50 FAULTS 950 99 9 50 APPENDIX B CONNECTORS AND CABLES 51 Daughter Board 260171760016 55 APPENDIX C CONNECTOR LOCATIONS 57 APPENDIX D MODEL 928 5 59 SPECIFICATIONS 59 FUNCTIONAL DESCRIPTION 59 INSTALLATION 59 5 60 Error Messages 60 Alignment 60 CABLES AND 8
9. ee ee ee nana neam eee eee 67 Figure E 4 Drive Board Connector 68 vi TC9830SM Rev B 7 98 Confidential Safety Summary Warning and caution messages appear throughout this manual They alert you to potentially safety hazards or potential damage to equipment The messages and there meaning are shown below WARNING CAUTION Calls attention to practices that could cause Calls attention to improper practices that could oe result in a potentially serious even lethal injury minor injury or that could cause damage to equipment Familiarize yourself with proper procedures before operating or repairing the equipment Follow these precautions for your own safety Personal Safety Treat every circuit as if it is Live If in doubt check with a neon tester or voltmeter Know how to turn off power in the work area and how to obtain help in an emergency Don t work on equipment under power unless its absolutely necessary If you must use extreme caution Shock Don t under estimate the danger of shock 12 mA causes hand muscles to contract so you cannot free yourself 24 mA has proven fatal Tools Use the right tools for the job A tool which slips can cause a short or a shock When working on live circuits use tools with insulated handles Safety Devices Don t bypass safety devices particularly fuses If a hot wire shorts to an ungrounded fram
10. 23 Displaying Machine Service Totals 23 Print Contrast Adjustment 24 Platen Motor Gear Adjustment o ree 24 Ribbon Tension Adjustment 24 CHECKING SUPPLY 25 ii TC9830SM Rev B 7 98 Confidential CHAPTER 6 SERVICE PROCEDURES 27 MAINTENANCE 27 GENERAL SAFETY TIPS 27 CONTROL PANEL REMOVAL 27 COVER HOUSING REMOVAL 27 POWER TRANSFORMER ASSEMBLY 28 Transformer
11. 5 65 FUNCTIONAL DESCRIPTION 65 Functional Description 65 5 65 Evaluation of Error 760 65 VOLTAGE 6 5 66 66 MAINTENANCE 66 GENERAL SAFETY TIPS 66 Blade Assembly 909061 761 68 Drive Board Replacement 68 Motor
12. 19 POWER UP SELF TEST 19 NV RAM 19 Version String Mismatch 19 System Restart Condition 19 Printhead Dot Resistance 19 TEST LABEL LEVEL 1 gt 19 SERVICE DIAGNOSTICS 20 Accessing Diagnostic 1 400695 20 Data Dump Mode 20 Serial Loop 8 0 7651 21 Parallel Port 21 Diagnostics 16511
13. 9 RS 232 interface 10 Centronics IEEE 1284 Parallel 10 IEEE 1284 Bi Directional Parallel Interface 10 Contrast Control eee oe e eee o ee een nn e eee nn een ma 10 Hardware Power p Settings 1 5 10 Peel Module Assembly 10 PRINT ASSEMBLY 10 Thermal Printhead 10 Ribbon Supply amp Take up SpoolS 10 Ribbon Transfer Rollers 10 Ribbon Spool Drive Motors 11 Supply Deflector and Bi Cell Emitter IR LED 11 Ribbon Tr
14. 2 Remove poly bag 000543 01 3 Put all packing back in the carton and set carton aside 4 Inspect printer for damage Report any damage following established procedures 5 Open printer door and remove packing tape from the printhead assembly 6 Remove empty four inch core from ribbon take up spool 7 Install customer s ribbon roll 8 Install customer s supply stock July 1998 9820 9830 9835 Service Manual DOCUMENTATION The following Documentation Package TC9830DP or TC9835DP is provided with each printer e quick set Software Diskettes e Operators Handbook In addition these documents are available on your Service CD ROM as Adobe Acrobat Reader files pdf e Service Manual TC9830SM e Programmers Manual TC9800PM e TwinAx CoAx Manual TC9800TXCX The Operator s Handbook TC98300H or TC9835OH can be ordered separately SETTING DIP SWITCHES These printers have three sets of DIP switches Two sets are located on the back of the printer and accessed from outside of the printer They are designated SW2 Upper and SW3 Lower The third set is located on the Control Board Assembly daughter board and is designated SW1 The printer is delivered with the SW2 and SW3 DIP Switches set to the defaults shown in Table 1 2 SW1 switch setting are shown in Table 1 1 NOTE DIP switches are only read at power up Turn off the printer immediately after changing DIP switch settings To change the DIP s
15. Either adjustment moves the outside end of the ribbon roller to change the pressure on the ribbon The overall result of properly adjusted eccentrics is consistent ribbon tracking MATERIALS REQUIRED e 4 thermal transfer supply ex MMTP4055 900091 e 4 ribbon 24 TC9830SM Rev B 7 98 Confidential July 1998 Tests and Adjustments 1 Ensure printer is in Normal Mode with the printhead Wide Narrow detents set to Wide 2 Loosen locking screw and set eccentric at the nominal position vertical for take up roller horizontal for supply roller See Figure 5 3 3 Tighten both locking screws Parallel Flats Vertical for Nominal Position Figure 5 3 Eccentric And Locking Screw 4 Press Feed several times until the supply roller serrations are visible across the ribbon width 5 Turn supply eccentric clockwise until serrations are the same across the ribbon width 6 Hold eccentric and tighten locking screw to secure the adjustment 7 Press Feed several times until the serrations of the take up roller are visible across the ribbon width 8 Turn take up eccentric clockwise until serrations are the same across ribbon width 9 Hold eccentric and tighten locking screw 10 Press Feed and Pause to get test labels several times and watch for ribbon wrinkle 11 If wrinkles occur re check step 8 to ensure take up roller is properly adjusted If wrinkles occur repeat adjustment 12 Re che
16. MCB 12 MCB 10 MCB 08 06 04 MCB 02 BOARD GROUND MC 014 MC D12 MC D10 MC D08 MC D06 MC D04 MC D02 MC D00 VCC N C N C N C BOARD GROUND Figure B 9 CN 10 Board Interface TC9830SM Rev B 7 98 Confidential Connectors and Cables July 1998 Connectors and Cables 1 TDX ANODE 2 TDX COMM Figure B 10 CN 11 GND Two wire harness connect red wire to TP5 25 volts Figure B 11 CN 14 RT_MTR_1 2 2 Figure 12 CN 15 RS_MTR_1 RS_MTR2 Figure B 13 CN 16 12V GND 12 GND NO RAT 25V GND Figure B 14 CN 19 to Daughter Board CN3 July 1998 9830 9835 Service Manual Daughter Board Connectors RAT 25V Figure B 15 CN 3 To MotherBoard CN 19 PEEL MFTR 1 PEEL MFTR 2 Figure B 16 CN 10 Peel Motor Figure B 17 CN 6 On Demand Sensor TC9830SM Rev B 7 98 Confidential 55 9820 9830 9835ervice Manual Connectors and Cables 56 TC9830SM Rev B 7 98 Confidential July 1998 APPENDIX C CONNECTOR LOCATIONS 000000000 000000000 Dnm 1 CN20 jS o z nocooocooo ooooocno 000000000000000000000 100000000000000000000 00000000000 000000000000 10000000000000000000
17. Table D 1 Stacker Control Harness Control Board CN1 Pin N C N C 60 TC9830SM Rev B 7 98 Confidential July 1998 Model 928 Stacker 9820 9830 9835 Service Manual Table D 2 Jam Full Sensor Harness Control Board CN3 Pin Full Sensor S1 Pin Jam Sensor S2 Pin Table D 3 Extended Motor Interface Harness Soldered to Control Board Connector CN4 Power Switch SW1 mu __ 60 Table D 5 Power Supply Connector J2 Connector J2 Pin Signal Pin Control Board Connector CN2 Pin 1 Orange NGC _ FEE i S GreemYelow ND NO July 1998 TC9830SM Rev 7 98 Confidential 61 9820 9830 9835 Service Manual Model 928 Stacker Table D 6 Power Supply Connector J1 1 GND 2 NIC he es Sar OT Sach 4 NIC Mite AC Inlet Bearings ies 1 ES 99 om Figure D 2 Stacker Lubrication Points Figure D 1 Stacker Control Board MAINTENANCE LUBRICATION PROCEDURES The stacker should be lubricated whenever the idler shafts are replaced Use the illustrations provided and the Stacker Illustrated Parts Breakdown for assistance in NOTE Do not get lubricant on stacker rollers or performing maintenance Maintenance procedures for belts performance could be adversely the stacker are described below affected Note the following general safety reminders before Turn stacker and
18. B 7 98 Confidential 47 9820 9830 9835 Service Manual Printer Error Status Codes 427 Format name is invalid Valid name is 1 8 characters inside quotes or for a printer assigned name Press Clear and try to continue 428 Batch name is invalid or graphic not found Press Clear and try to continue 429 A field number appears more than once in a format 430 The format uses a graphic file that cannot be found 433 The batch references a field number that doesn t exist in format 497 An error occurred during loop back test on parallel port 499 An error occurred during loop back test on serial port DATA FORMATTING FAILURES 571 619 Formatting errors indicate that a field will print incorrectly After you have checked the data stream and corrected the data retransmit the batch The batch will still print but the field font bar code or density may be incomplete missing or contain incorrect data Code Description 571 UPC EAN data length is invalid The bar code data length in batch doesn t fit format 572 A field copy padded or incrementing length is invalid The field length in batch doesn t fit format or field contains blanks Or fixed length field doesn t contain specified number of characters 573 Price field length is invalid The price field length in batch doesn t fit format or field contains blanks 574 CD scheme or room for CD CD scheme in batch doesn t fit format or field contains blanks 5
19. some metal before touching the printer July 1998 TC9830SM Rev B 7 98 Confidential 27 9820 9830 9835 Service Manual POWER TRANSFORMER ASSEMBLY Maintenance of the Power Transformer involves e removing reassembling the power transformer e removing reassembling the bridge rectifier e removing reassembling the AC Inlet TOOLS REQUIRED e Longnose Pliers e Phillips Screwdriver Transformer Removal CAUTION You must remove several wires from the Bridge Rectifier AC Inlet module and the Control Board Assembly power connector It is crucial to reconnect the wires properly when replacing the transformer Connection to AC Inlet Bridge Rectifier Figure 6 1 Transformer Wiring Diagram 1 Remove four bridge rectifier wires as shown in Figure 6 1 2 Remove power connector CN6 from the Control Board Assembly See Appendix C for location of connectors 3 Remove six transformer wires from the AC Inlet module 4 Remove four transformer base screws 5 Laythe two grounding wires aside so they do not snag when replacing the transformer 6 Remove the transformer 28 TC9830SM Rev B 7 98 Service Procedures 7 Reassemble in reverse order Bridge Rectifier Removal yellow wire TRANSFORMER BRIDGE SE RECTIFIER Figure 6 2 Bridge Rectifier Four Wires CAUTION The bridge rectifier has four wire connections See Figure 6 2 Reconnect the black and red wires properly when replacing t
20. 2 Bridge Rectifier Four 28 Figure 6 3 Bridge Rectifier Four ls nnn n nnn neni rtis nnne nnn 28 Figiire 6 4 Print ASsembly rire tte dk x a tea a e eie E e EE teda 30 Figure 6 5 Bl Gell Emitter REMOVAL aucti te a a a ada a a aaa 30 Figure 6 6 Print Assembly Plate amp Printhead 31 igure 6 75 Lateh Removal 31 ligure 6 8 BOEl SENSO ei tr m E nannestad 33 Figure 8 1 BieCell Sensor Adjustment ter ERE EDGE abat Di a statala 40 Figure 8 2 Sensor Board auraen een 40 Fig re B 15 GN 1 IEEE 1284 Parallel POM eter ERE AEO a a d 51 Figure B 2 GN 2 Printhead Assembly RR annekterte THER 5 5 51 Figur B 3 GN3 Platen Stepper Motor asceza aaa a aadnk 52 TC9830SM Rev B 7 98 Confidential Figure B 4 CN 4 Control 0002 0000 52 Figure B 5 CN 5 Coax Twinax 2 04000 10100 nana aan 52 Figure 6 CN6 Transformer Output 53 Figure B 7 CN7 RS 232 Serial 53 Figure B 8 CN 8 Supply Sensor 53 Figure B 9 CN 10 Board
21. 59 CONTRAST POT 000 PH RESISTANCE 0869 BAD DOTS 000 MEMORY 1024KR 256KN OPTIONS M R P DIPSH 0000000000100000 Figure 4 1 Test Labels The first test label prints firmware version and current printer configuration in 1 packet format refer to the printer s Packet Reference Manual NOTE Some reported settings may not be configurable on a given printer System Setup E Control Characters B Supply Setup F Serial Comm Settings Print Control Backfeed Control D Monetary Formatting M Memory Allocation The second label prints basic diagnostic information Total Inches Printed No of Bad Dots s b lt 3 Current Inches Total RAM Max 512k 40 VDC Value s b 30 47 DIP Settings Dot Resist s b 832 Ohms Contrast Pot Installed Options M 256K memory expansion R RS 232 option Keypad V Verifer P Peel C Cutter S Stacker X V5 2 sensing system SERVICE DIAGNOSTICS Service Diagnostics is initiated by setting the Lower DIP switch 3 to the ON position before powering up At power up 000 is displayed on the control panel Two Service Diagnostic modes are available e Data Dump Mode e Diagnostics Test Mode Off line Diagnostics Tests Serial Loop Back Test 20 TC9830SM Rev B 7 98 Confidential Diagnostics Parallel Port Timeout Test Test Label Virgin Reset SENDFILE Diagnostic Tests Test Label Sensor Display Service Totals Immediate Commands Job Request Printer Interactive Mode Sup
22. Confidential 67 9820 9830 9835 Service Manual Model 926 Knife Os Ji To Motor J2 To Solenoid J3 To Printer Control Board To 928 Stacker To Printer Daughter Board Figure E 4 Drive Board Connector Locations Blade Assembly Replacement Turn printer off 2 Remove 928 Stacker Assembly See Appendix D 3 Remove three cover screws to gain access to the Blade Assembly 4 Note the position of the Blade Assembly in relation to its mounting frame This relationship is critical to provide a straight cut from left edge to right edge of tag 5 Using an Allen wrench remove two cap screws that attach the knife unit to its mounting frame 6 Disconnect solenoid at connector J2 on Drive Board 7 Remove the Knife Blade Assembly 8 Reassemble in reverse order NOTE Carefully align the edge of the knife assembly to the mounting frame There should be almost no variation side to side on cut tag 0 030 0 020 The mounting hole closest to the operator panel is slotted for this adjustment 9 Adjust Blade Assembly When a straight cut across the tag has been achieved lock down all adjustments 10 Run 50 100 tags to verify proper cut operation 11 Replace the knife cover 12 Attach the Stacker Assembly see Appendix D 13 Turn printer on and test for correct operation 68 TC9830SM Rev B 7 98 Confidential Drive Board Replacement Replace the Drive Board using the following procedure 1 Turn
23. carriage to verify e Bi Cell Sensor Adjustment adjustment e Print Contrast Adjustment e Platen Motor Gear Adjustment e Ribbon Tension Adjustment July 1998 TC9830SM Rev B 7 98 Confidential 39 9820 9830 9835 Service Manual 20 Remove gray scale and test printer with customer s supplies 118705 Boe 118704 n ed 118706 Figure 8 1 Bi Cell Sensor Adjustment NOTE hood covers the adjusting screw on the back of the housing REPLACING A SENSOR Use these instructions for 9835 printers version 5 0 or earlier All of the harnesses are identified with part numbers and must be attached to the sensor board 8 118699 Follow the same cable routing that was used for the original system To replace a sensor 9 1 Remove the ferrite noise filter from the 10 old reflective object harness 118704 and install it on the new harness 118704 NOTE Be sure the Reflective Object Sensor is located in the middle of the sensor housing 117990 2 Locate the label that is applied to the top of the sensor board 118699 and make note of the Trans and REFL HEX values These values must be entered using Sendfile V 2 15 You must convert the HEX value to decimal using Microsoft Windows Scientific Calculator Once the parts have been installed you will need to power up the printer in Diagnostic Mode Set SW 3 on lower bank of switches to the ON position and turn on the 9835 printer 4 Start Sendfile and
24. current high value or lower than the current low value it replaces that value In this way the differential between minimum and maximum signal can be determined Sometimes this differential is referred to as the span This cycle is repeated for each motor step interval while the motor is running during calibration The first transition edge of software significance is the BOF This is defined as the leading edge of the feature It is based on an algorithm that on every step checks to see if the AD count is at a value that has passed through a calculated threshold moving from white into the feature Before the algorithm can be used the signal differential must be larger then a predefined minimum Once this criteria has been July 1998 Supply Sensing Systems meet the threshold count is calculated as the sum of half of the differential between the Low and Hi AD counts captured plus the Low count When a valid BOF has been found it is saved and used as the threshold for the TOF The next transition edge of importance is the TOF It is defined as the trailing edge of the feature Once the BOF has been found the software looks fora TOF In fact it uses the same AD threshold count calculated for the BOF The difference is that the TOF point is determined as the AD count passes through the NOTE 9820 9830 9835 Service Manual Field Service performs no electrical adjustments Bi Cell Sensor Adjustment 1 Turn Printer Off Load d
25. diagnostics tests and in information labels printed in response to a FEED command following a status code between 571 through 619 PROBLEM SUGGESTED ACTION Printer does not print test labels Check for status code on LCD Verify stock is installed correctly Verify ribbon is installed correctly Verify printer voltage measurements Verify printhead is installed correctly Verify printhead harness connection is on PCB Verify DIP switch settings Confirm supply feed operation Confirm ribbon feed operation Perform sensor display service test using SENDFILE Perform test label immediate command Replace control panel Replace printhead Replace Control Board Assy Printer only prints test labels Check for status code on LCD Verify comm DIP switch settings Perform serial parallel comm test Perform data transfer immediate commands Transfer format using Windows Terminal July 1998 TC9830SM Rev B 7 98 Confidential 15 9820 9830 9835 Service Manual PROBLEM Partially printed data Printing shadows or smears Light printing Heavy printing Voids in printing 16 Troubleshooting SUGGESTED ACTION Check for status code on LCD Verify wide narrow printhead adjustment Perform sensor display service test Verify ribbon installed correctly Confirm ribbon feed operation Clean printhead Confirm supply sensor operation Send a packet you know has no syntax errors Check status code on LCD Verify wide narrow pr
26. from the knife to the stacker Additional electrical power required by the stacker is provided by an on board power supply The power supply converts 115 VAC to 24 Vdc for the DC motor The Control Board contains the necessary circurity to provide control of the motors and sensors and has a daughter board to provide power to the stepper motor The DC motor drives the Lower Transport Assembly through a series of pulleys and gears The Lower Transport Assembly and Upper Transport Assembly move cut tags from the knife to the stacker belt A stepper motor drives the stacker belt As the stacker belt revolves the accumulating tags move with the belt toward the end of the stacker tray Belt movement is automatically stopped when the tags reach the end of the stacker tray and the Stacker full sensor sends a stop signal to the printer Belt movement can also be stopped by turning the printer off The purpose of the Stacker Full Sensor is to detect when the stacker tray has been filled with tags and to signal the Stacker Control Board to stop operations INSTALLATION 1 Unpack stacker from shipping carton Retain carton TC9830SM Rev B 7 98 Confidential 59 9820 9830 9835 Service Manual 2 Turn printer off 3 Lift the knife printer slightly and slide the knife on to the stacker mounting plate tabs 4 Attach stacker AC power cable to stacker and AC power outlet 5 Attach knife to stacker cable 6 Adjust cutter as necess
27. go to the Diagnostics section On the left side of the screen you will see a command that says Reset 98xx DAC values 5 Press to enter this function 6 Apop up menu appears This is where the Transmissive Trans and Reflective REFL values recorded from the board will be entered 7 Press 2 followed by the 3 digit decimal value converted using the scientific calculator 40 TC9830SM Rev B 7 98 Confidential 118718 7 Supply Sensing Systems TX 7B 8 Ref 4 0 C MONARCH MAR ASSY 11869 NG 9 Figure 8 2 Sensor Board Press 3 followed by the 3 digit decimal value converted using the scientific calculator You have now completed the sensor kit installation Exit Sendfile and take the printer out of Diagnostic mode Test the 9835 using the customers tags or labels to verify correct operation July 1998 Supply Sensing Systems SENSOR SETUP WITH VERSION 5 2 OR GREATER Manufacturing sets all three sensors before a printer is shipped Service needs to adjust the sensor if a sensor component fails in the field or for specific customer supplies Use Sendfile Version 2 21 or greater to set the sensor values The three sensors are aperture center black mark center and die cut edge WARNING You must follow these steps exactly Failure t
28. is relieved 7 Remove latch knob and spring 8 Remove the front exit door by lightly pressing one side until the hinge pin clears the platen frame 9 Reassemble in reverse order Platen Module Removal 1 Remove the backing paper deflector 2 Remove the three phillips screws that hold the feed module to the printer base 3 Lift up on the outboard side of the platen module to allow the platen roller gear to clear the printhead alignment bracket 4 Rotate the platen module counterclockwise to make room for removal of the platen assembly CAUTION The sensor harness limits platen rotation Be careful not to damage the harness Confidential 31 9820 9830 9835 Service Manual 5 Unlatch the bearing block latch on each side of the platen roller by inserting a small blade screwdriver between the latch and the platen frame While holding the latch out with the screwdriver push the bearing block up so the latch pawl clears the hole in the platen frame NOTE Remove the rivot from bearing block on printhead latch side 6 When both bearing blocks are unlatched push the platen assembly up and out of the platen frame CAUTION Do not run the platen roller into the printhead or the assemblies could be damaged Platen Module Replacement 1 Locate the left side of the platen frame by locating the cable harness exit hole 2 Turn feed assembly so the drive gear is on the same side of platen frame as cable exit hol
29. must be L from left or R from right Pad character is outside range 0 to 255 Check digit selection must be G to generate check digit Primary or secondary price format is outside range 1 to 15 Data type restriction is outside range of 1 to 6 Option is not valid for field Bar code Interchar gap must be 0 to 99 dots known as additional character gap with Option 50 Power up mode must be 0 online or 1 offline Language selection must be 0 Batch separator code must be 0 off or 1 on in the system setup packet Slash zero selection must be 0 standard zero or 1 slash zero Supply type must be 0 black mark 1 die cut or 2 continuous TC9830SM Rev B 7 98 Confidential 45 9820 9830 9835 Service Manual Printer Error Status Codes 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 282 283 284 285 286 287 288 289 290 291 292 310 311 314 46 Ribbon selection must be 0 direct or 1 transfer Feed mode must be 0 continuous or 1 on demand Supply position is outside range Contrast adjustment must be 390 to 156 dots Print adjustment must be 99 to 99 dots Margin adjustment must be 99 to 99 dots Speed adjustment must be 25 2 5 IPS 40 4 0 IPS or 60 6 0 IPS Primary monetary symbol is invalid Secondary symbol selection must be 0 none or 1 print secondary sign Monetary decimal places must be 0 to 3 Character string lengt
30. must use exactly six characters Action must be 0 disable or 1 enable for backfeed control packet Dispense position must be 50 to 200 dots Backfeed distance must be 10 to 200 dots Check digit scheme number must be 1 to 10 Modulus must be 2 to 11 Check digit algorithm must be D sum of digits or P of products TC9830SM Rev B 7 98 Confidential July 1998 Printer Error Status Codes 9820 9830 9835 Service Manual 325 327 328 340 350 351 352 380 400 402 403 404 405 409 Duplicating direction must be 0 insert after or 1 insert before in duplicate fields for graphics Amount of row adjustment must be 0 to 999 dots in duplicate fields for graphics Duplicate count must be 0 to 999 Bitmap line encoding must be H hex or R run length Font selector must be 1 to 9999 Font data length must be 68 to 16384 Insufficient font memory is available for downloaded font Job request is outside range 0 to 4 The character immediately following is invalid Field separator is not in expected location Field separator was not found The number or string that is currently being processed is too long Too many fields exist in format You cannot have more than 1000 fields in format Lines boxes and constant text fields count as fields The printer memory is full Delete unnecessary formats or graphics from memory If you are using a graphic file that is very large consider using another mapping method suc
31. peel module separates the supply from the backing paper It consists of an on demand sensor rollers and a 12Vdc motor drive Dip SW1 switch 2 located on the daughter board enables and disables the peel function PRINT ASSEMBLY This Print Module is a plastic casting located inside the printer s hood It is attached to the mid frame by two bearing blocks which capture studs on the module back plate Components of the Print Module are 10 TC9830SM Rev B 7 98 Confidential Functional Description Figure 2 1 Print Assembly Thermal Printhead The printhead is located at the bottom front of the module It is held in place by a plastic carrier which acts as an interlock to a formed metal bracket The bracket is center mounted and pivots to ensure an even pressure on the supply The printhead bracket has two alignment loops which slip over the platen roller to assure dot row to platen roller alignment The printhead mount also has two spring loaded adjustment knobs to adjust printhead pressure for wide or narrow supplies A 30 pin ribbon cable connects the printhead to the Control Board Assy Ribbon Supply amp Take up Spools The ribbon supply and ribbon take up spools are located on the supply side of the module Each spool shaft extends through the module wall and connects to its own DC drive motor The spools are designed to handle a detented ribbon core so when ribbons of various widths are installed they maintain center ju
32. the frame 2 Toreplace the supply holder guides e Remove screw from the washer and gear e Pull front guide up and out of frame and replace e Pull back guide up and out of frame and replace e Move front and back guides to the center and install supply gear and washer with the screw 3 Insert the supply holder into the main frame and push downward PLATEN MOTOR Disconnect the wires from the AC Inlet to gain access to the stepper motor connector If you have problems removing the motor access is difficult you must remove the Control Board Assy TOOLS REQUIRED e Phillips Screwdriver Magnetic July 1998 9820 9830 9835 Service Manual Platen Motor Removal Remove Control Board Assy Remove four screws from platen motor housing Reassemble in reverse order Adjust platen motor gear See Chapter 5 PEEL MODULE Maintenance to the Peel Module includes replacement of the motor and peel roller POL c NOTE The peel roller is removed in the same manner as the platen rollers TOOLS REQUIRED e Phillips Screwdriver e Flat head Screwdriver Peel Module Removal Remove printer housing Unload supply Raise Printhead and retain it in the up position Disconnect Peel Motor wiring connector at motor 5 Remove On Demand Sensor wiring connector at sensor and release wiring from the door assembly 6 Remove supply backing exit door assembly 7 Remove peel module paper exit chute 8 Remove thr
33. with the stand offs or the board could be damaged 9 Remove three stand off retainer screws located in connectors CN1 CN7 and below CN4 10 Carefully pull the Control Board off the stand off detents while lifting it past the transformer wires to clear the large slot in the rear frame wall CAUTION There is a large metal thermal heat sink on the bottom of the board Snagging it on the AC inlet module boot or transformer wires can damage the equipment 1 Remove stepper motor connector CN3 2 Reassemble in reverse order except before seating the Control Board e Reconnect stepper motor connector CN 3 e Feed the wire latches through the printer frame opening e Reconnect the ground wire PRINT ASSEMBLY Maintenance of the Print Assembly involves removing and replacing of the following assemblies e bi cell emitter upper supply guide and printhead module e ribbon spool and ribbon roller assemblies TC9830SM Rev B 7 98 Confidential 29 9820 9830 9835 Service Manual e ribbon motors and print assembly Figure 6 4 Print Assembly TOOLS MATERIALS REQUIRED e Phillips Screwdriver e Flat head Screwdriver e Ribbon spool intermediate gear retaining clip Bi Cell Emitter Removal Figure 6 5 Bi Cell Emitter Removal 1 Using fingers release emitter cover from the emitter housing Slide the emitter out of the housing See Figure 6 5 2 Remove the connector from the sensor circuit board 3 C
34. 0 whena knife jam is detected The following checks are suggested to correct the problem 1 Turn printer off 2 Check supply path for jammed tags or obstruction in path TC9830SM Rev B 7 98 Confidential 65 9820 9830 9835 Service Manual 3 Check Blade Assembly alignment and ensure assembly mounting screws are tight 4 Verify supply type cutter only cuts tags Labels should not be cut 5 Check to ensure tags being used do not exceed 0 010 inch 0 25 mm thickness VOLTAGE TESTS Before replacing the Drive Board check for the static voltages shown in Table E 1 to determine if the board has failed If all voltages are correct troubleshoot the 9835 printer control board See Chapter 3 1 If 25Vdc is not detected at J3 1 the printer is not providing power to the knife drive board Troubleshoot the printer 2 f 25Vdc is detected at J3 pin 1 but not at both pins of J1 and J2 replace Knife Drive Board 3 If 25Vdc is detected at J1 but not at J2 replace solenoid 4 f 25Vdc is at J2 but not J1 replace knife drive motor Table E 1 Knife Drive Board Voltages Connector Voltage 25v on both pins 25v on both pins 25v on pin 1 only J5 Connector Pin Voltage 5v 5v 5v 5v 5v LUBRICATION To prevent excessive wear the knife should be lubricated every 100 000 cuts Approximately every 10 rolls of 1 2 supply A Knife Lubrication Kit Part Number 118782 is available 66 TC983
35. 006 21 Performing a Virgin Printer Reset 21 Printing a Test Label 21 CHAPTER 5 TESTS AND 5 23 SERVICE TESTS 23 6 23 Continuity Tests 23 Transformer Primary Side 23 Transformer Secondary 5106 23 Bridge Rectifier eee eo eee o eee nr e e 23 Head Open Sensor
36. 0SM Rev B 7 98 Confidential Model 926 Knife NOTE Lubricate with multi purpose grease using a long cotton swab Do not over lubricate Do not get grease on knife blade or performance could be affected 1 Turn printer off NOTE The knife unit has two cam surfaces that should lubricated with multi purpose grease 2 Using along cotton swab lubricate the knife cams 3 Turn printer on and test for correct operation Cam Cam hidden from view Figure E 1 Knife Lubrication Points MAINTENANCE OVERVIEW This section describes removal and replacement procedures for the knife assembly See Figure E 2 for printer to knife connector locations See Figure E 3 to identify parts and assist in performance of maintenance procedures Figure E 4 shows the location of connectors on the drive board GENERAL SAFETY TIPS Observe these general safety precautions before servicing the knife Additional Warnings and Cautions appear in this document as they apply to specific procedures Knife Assembly Figure E 2 Location of Connectors July 1998 Model 926 Knife 9820 9830 9835 Service Manual Blade Assembly Connector J4 To 928 Stacker Knife Assembly Mounting Screws 3 Motor Mounting Screws 2 Allen Head Cap Screws e Drive Motor Drive Belt cid Cover Cover 4 Mounting Screws 3 Figure E 3 Knife Assembly July 1998 TC9830SM Rev B 7 98
37. 2 Verify that the magnet is present and inserted properly 3 Verify that sensor is functioning properly EVALUATION OF A 765 ERROR PRINTHEAD FAILURE This error occurs if a dot is out of specification This error can occur even if print quality is not visibly affected Operation can be continued until the problem is corrected Perform the following procedure 1 Check connections to the printhead 2 Check the printhead harness 3 Check the printhead itself and replace if necessary EVALUATION OF THE CONTROL BOARD ASSY The following status codes indicate the Control Board Assembly has a fault 900 RAM Test Failure 905 Illegal Interrupt 901 ROM EPROM Test Failure 906 Power Failure 902 Timer Failure 907 No Application Memory 903 Interrupt Test Failure 908 NVRAM Checksum Failure 904 No Kernel Memory 910 Warm Restart 1 To determine if this fault is permanent or temporary turn the printer off wait 15 seconds then turn the printer on again If any of these status codes are repeated turn off the printer and replace the Control Board Assy Print a test label See Test Label Level 1 in Chapter 4 for instructions on printing a test label Place the printer in Data Dump mode and send data to the printer EVALUATION OF COMMUNICATIONS If the printer functions properly off line examine communications There are two communication paths for the printer The RS 232 serial path uses a 25 position connector The IEEE 1284 parallel path co
38. 3 layers thick Turn printer off and unplug power cord 2 Raise cover and ensure printhead is latched in the down position 3 Remove printer housing Confidential Tests and Adjustments Bearing Clearance Must Be 0 006 0 008 Figure 5 2 Platen Motor Gear Adjustment 4 Using the paper shimstock check clearance between the bearer on the platen motor gear and the bearer on the platen gear See Figure 5 2 Clearance should be between 0 006 and 0 008 5 If clearance is less than or greater than the specification perform steps 7 thru 11 6 With printhead fully latched loosen four Phillips head screws holding platen motor 7 With paper shimstock in place move platen motor housing to adjust for specification clearance 8 Tighten all four screws 9 Rotate platen by hand 360 to check for binding or excessive backlash 10 Repeat steps 7 thru 10 as necessary Ribbon Tension Adjustment There are two Ribbon Tension Adjustments The Ribbon Supply Roller Eccentric and the Ribbon Take up Roller Eccentric Rotation of the supply roller eccentric provides even tension across the width of the ribbon on the supply side of the printhead Typically the factory setting for the supply eccentric is primarily horizontal Rotation of the take up roller eccentric adjusted after the supply eccentric provides even tension across the width of the ribbon on the take up side of the printhead
39. 33 PEEL 33 Peel Module Removal 33 Peel Motor Replacement 33 CHAPTER 7 USING 35 FLASH DOWNLOADING PROCEDURES 35 CHAPTER 8 SUPPLY SENSING SYSTEMS 37 SUPPLY DETECTION TRACKING SYSTEM 37 SUPPLY DEFLECTOR BI CELL EMITTER IR LED 37 LOWER SUPPLY GUIDE BI CELL SENSOR 38 SUPPLY 38 SUPPLY 38 MECHANICAL ADJUSTMENTS 39 Bi Cell
40. 75 The graphic included in your format could not be found 611 Font bar code or density is invalid The font bar code or density in batch doesn t fit format 612 The data in this line of batch is either missing or doesn t match format 613 Reference point off tag 614 Field is off tag or there is an invalid character in packet Make sure you did not enter O for 615 Bar code width is greater than 16 inches or number of keywords for your PDF417 bar code exceeds 928 Decrease density or shorten amount of data to print bar code 616 Dot shifting failed A bad dot falls on a bar code that cannot be shifted 618 Magnification must be 1 to 7 or 4 to 90 for the scalable font 619 The JIS 16 bit code for Kanji is invalid MACHINE FAULTS 700 766 Errors 700 to 766 occur when there is a problem with the printer Code Description 703 The printer sensed a calibration of different sized black marks Make sure correct supply is loaded 704 Printer has not sensed a supply mark within specified number of inches or out of supplies 750 Printhead is overheated Turn off printer to let printhead cool 751 Printer did not sense a mark when expected 48 TC9830SM Rev B 7 98 Confidential July 1998 Printer Error Status Codes 9820 9830 9835 Service Manual 752 Printer sensed a mark in wrong place 753 Printer sensed a mark that is too long 754 The printer is either out of ribbon or ribbon is jammed 755 Printhead is open Close printhea
41. 9835 printer with a 926 Knife attached SPECIFICATIONS Height Base Width Tag Bed Depth Weight Shipping Weight Power Capacity 14 4 inches 366 mm 25 6 inches 650 mm 29 6 inches 752 mm 7 9 inches 201 mm 18 pounds 8 2 kg 30 pounds 13 6 kg 115 VAC 60 Hz 100 VAC 50 60 Hz 230 VAC 50 Hz Up to 1 500 tags with tag thickness of 0 010 inches 25 mm thick Operating Limits Storage Limits Relative Humidity Operating and Thermal Transfer 40 to 95 degrees F 4 to 35 degrees C Direct 40 to 104 degrees F 4 to 40 degrees C 15 to 120 degrees F 9 to 49 degrees C 5 to 90 percent non Storage condensing Speed Up to 6 0 inches 152 mm Minimum Stackable Tag Sizes Width Length Printed widthwise 1 63 inches 1 2 inches 41 mm 30 mm Printed Lengthwise 1 2 inches 1 57 inches 30 mm 40 mm Header Length NOTE Supply roll must be wound printed side in July 1998 3 66 inches 93 mm FUNCTIONAL DESCRIPTION The 928 Stacker consists of the following modules e Upper Transport Assembly e Upper Drive Shaft Assembly e Lower Transport Assembly e Stepper Motor e DC Motor e Stacker Full Jam Sensors e Power Supply e Control Board The Model 928 Stacker is attached to a 9835 Printer which has the Model 926 Knife Assembly installed The printer and knife attaches to tabs on the stacker mounting plate wiring harness carries electronic signals and 12 Vdc
42. 998 Batch mode must be N new or U update Batch separator must be 0 Off or 1 On in the batch control field Print multiple is outside range 1 to 999 Cut multiple is outside range 0 to 999 Only valid for printers with a knife Multiple part supply is outside range 1 to 5 Reserved for knife usage Only valid for printers with a knife Option number must be 1 4 30 31 42 50 51 52 60 or 61 Copy length is outside range 0 to 2710 Copy start position must be 1 to 2710 Destination start position must be 1 to 2710 Source field must be 0 to 999 Copy type must be 1 copy after rules or 2 copy before rules Increment Decrement selection must be I increment D decrement Incrementing start position must be 0 to 2710 Incrementing end position must be 0 to 2710 The incrementing amount must be 0 to 999 Security value for a PDF417 bar code must be 0 to 8 Correct and resend format to printer Narrow element value is less than 1 or greater than 99 Correct and resend format to printer Wide element value is less than 1 or greater than 99 Correct and resend format to printer Dimension must be 1 to 30 for a column or 3 to 90 for a row on a PDF417 bar code Truncation code must be 5 standard or truncated bar code Aspect code must be C columns or R rows Option definition must be S set or T template Input device must be D Default H Host K Keyboard N None or S Scanner Pad direction
43. E Ld 243 656 69 Table E 4 Knife Drive Board Connector 3 0000000 0 0 0 0 00 0 00000000100 eee 69 Table E 5 Drive Board Connector J4 To 928 Stacker 69 Table E 6 Knife Drive Board Connector 00000 2 000000 00 000000000 69 List of Figures Figure 1 1 9830 Printer Housing nnns 1 Figure 1 2 Printer Unpacking itd certet EE ERRRRRRER takket 3 Figure 1 SW2 SW3 DIP Switch 4 Figure 2 1 Print Assembly item rcd EY RR a DER 10 Figure 2 2 Feed Assembly tait tet t tr ae dt lt da aaa 11 Figure 2 Supply Holder Assembly nenea anemie 12 Figure 2 4 Control Panel 12 Figiire 4 1 Test Eabels initiiert sn LIP ATE SERE 20 Figur 4 2 Loop Back Plug WINN Sunt seat t rad de ta e t tate at tat radiata 21 Figure 5 1 Print Contrast 2242 000 24 Figure 5 2 Platen Motor Gear 24 Figure 5 4 Eccentric And Locking nenea nenea nana nsn n TERETE 25 Figure 6 1 Transformer Wiring ari aia aaa a ada 28 Figure 6
44. Figure 1 Control Board Assy Mother Board Legend CN10 Sensor Connector Assy 2 wire pigtail from CN8 CN1 IEEE 1284 Parallel Port CN11 Index Sensor Emitter Assy Printhead Assy CN12 Daughter Board Connector CN3 Platen Stepper Motor CN13 Daughter Board Connector Control Panel CN14 DRAM Expansion Not Shown Gor OT CN15 Ribbon Take Up Motor CN6 Transformer Output Power CN16 Ribbon Supply Motor ONE 85 232 Port CN17 CN18 Engineering Use Not Shown CN8 Index Sensor Receiver Assy CN19 Daughter Board Connector CN9 Not Used CN20 Engineering Use July 1998 TC9830SM Rev B 7 98 Confidential 57 9820 9830 9835 Service Manual Connector Locations BRRRRERRRRR O O O Auxillary keypad connects to CN9 le dd Re gt CNT 0000000000 E O 0000000000 2 O 0000000000 0000000000 O 0000000000 0000000000 OO 5 wire knife harness 4 wire knife harness Figure C 2 Control Board Assy Daugher Board Legend CN7 Reserved CNS3 Mother Board CN19 CN8 Reserved CN4 Cutter Option 9 Reserved CN5 Stacker Option CN10 Peel Motor CN6 On Demand Sensor SW1 See Chapter 1 for settings 58 TC9830SM Rev B 7 98 Confidential July 1998 APPENDIX D MODEL 928 STACKER The 928 Stacker only works with a
45. Monarch 9820 9830 9835 Printers Monarch Table of Contents CHAPTER 1 PRINTER OVERVIEW amp INSTALLATION 1 PRINTER 5 1 PRINTER OPTIONS 3 1 PRINTER 1 1 5 1 STOCK SPECIFICATIONS 2 UNPACKING THE PRINTER 3 DOCUMENTATION 3 SETTING DIP SWITCHES 3 FUSE 4 CONNECTING TO HOST 4 CHAPTER 2 FUNCTIONAL
46. OUND O UI PUN 9830 9835 Service Manual Figure B 6 CN6 Transformer Output Power CHASSIS GROUND 1 RXD bar 2 CTS 4 CHASSIS GROUND 6 N C 8 N C 10 N C 12 N C 14 N C 16 N C 18 N C 20 N C 22 N C 25 24 Figure B 7 CN7 BIPOLAR SIGNAL BP GUARD GROUND UNIPOLAR SIGNAL UP GUARD GROUND 12 VDC 12 V RIN GROUND 12 VDC NOD oR WD TXD bar RTS DSR N C N C N C N C N C N C DTR N C N C RS 232 Serial Port Figure B 8 CN 8 Supply Sensor Bi Cell TC9830SM Rev B 7 98 Confidential 53 9820 9830 9835ervice Manual Connectors and Cables Manual 54 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 BOARD GROUND N C RSWE bar MCB A13 11 MCB 09 MCB 07 MCB 05 MCB A03 RSWE bar Mc D15 Mc D13 Mc D11 D09 007 005 003 001 2 4 6 BOARD GROUND 8 D17 10 Mc D19 12 MC D21 14 D23 16 D25 18 MC D27 20 ROMCS1 bar 22 ROMCS1 bar 24 BOARD GROUND 26 MC D30 28 RSWE bar 30 N C 32 MC A21 34 19 36 17 38 MCB 15 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 VCC ROMOE bar RSWE bar MC D16 MC D18 MC D20 MC D22 MC D24 MC D26 MC D28 ROMCS1 bar ROMCS1 bar MC D29 D31 20 18 16 MCB 14
47. Sensor 39 REPLACING A SENSOR 40 SENSOR SETUP WITH VERSION 5 2 OR 41 POWER UP SENSOR 41 Performing a sensor Display 42 TC9830SM Rev 7 98 Confidential APPENDIX PRINTER ERROR STATUS CODES 43 READING AN ERROR LABEL 43 DATA ERRORS 001 499 43 COMMUNICATION FAILURES 410 499 47 DATA FORMATTING FAILURES 571 619 48 MACHINE FAULTS 700 766 48 HARD PRINTER FAULTS 900 910
48. Supply guides are used to capture the supply and maintain center justified tracking The supply must be positioned between the platen and printhead to feed properly The printhead applies pressure to the supply to hold it against the platen roller As the platen roller rotates the supply is forced to move between it and the printhead The stepper motor engages the platen drive gear located behind the inner feed module wall and drives the platen roller The function is controlled by the Control Board Assembly SUPPLY SENSING Supply sensing begins when the IR Emitter in the supply deflector emits an IR beam through the supply The Bi Cell sensor located in the supply guide receives the beam and changes it into corresponding voltage level As the beam intensity changes the associated voltage output of the Bi Cell also changes Voltages are reported to the Control Board Assy 38 TC9830SM Rev B 7 98 Confidential Supply Sensing Systems where they are compared to a known base line voltage When the input characteristics match relative to predefined times voltage levels and expected supply position a gap or black mark is sensed For the 9820 9830 printers SENDFILE provides volts relating to the sensor s activity as stock moves past the sensor Two points are of interest high point must be approx 176 and low count must be approx 79 Two sensor channels are used One measures the paper s presence The other detects the transi
49. and the feed module frame Lower Supply Guide and Bi Cell Sensor See Chapter 8 Supply Sensing Systems for more information Printhead Latch The printhead latch is spring loaded and mounted on the outside of the feed module frame within the latch fascia It locks the printhead in position Functional Description The feed module transports supply through the printer and across the printhead It also maintaining proper alignment tension and speed This is accomplished by sensing the stock position while securing the printhead down onto the platen roller Major functions are supply feeding and supply sensing See Chapter 8 Supply Sensing Systems for more information TC9830SM Rev B 7 98 Confidential 11 9820 9830 9835 Service Manual Functional Description Printhead Locking Printhead release knob is used to release the print module from its open position SUPPLY HOLDER ASSEMBLY Inner Guide wee Figure 2 4 Control Panel Assembly Functional Description LEDs The three LEDs indicate general printer status and activity LCD The three character LCD identifies specific printer conditions through the use of numeric codes These codes are listed and described in Appendix A Feed In Normal mode advances a label from y E the printer In Offline mode or Online Functional Description Diagnostic mode prints a test label Pause Stops the current batch from printing Printing resumes when Pause is pressed a
50. ansfer Rollers 11 Functional Description 11 Ribbon Drive Operation 11 11 FEED ASSEMBLY 11 Platen Module ec eco ee er eo n ere en e ee m 11 24VDC Stepper Motor 11 Lower Supply Guide and Bi Cell Sensor 11 Printhead 107 11 Functional Description 11 Printhead Locking 12 SUPPLY HOLDER 5 5 12 Functional Description 12 CONTROL PANELASSEMBLY no 12 F
51. are re allocates all available memory as blocks of working storage Then the routine performs an integrity check on the working storage to verify that itis accessible When the version string mismatch test passes the firmware begins the printhead dot resistance test Printhead Dot Resistance The printhead resistance routine is a hardware test of all 832 individual dots for correct resistance value If the test passes the printer switches to online ready mode If the test detects any dots that are open or have high resistance gt 852 Ohms error 765 appears on the LCD Failure does not halt printer operations TEST LABEL LEVEL 1 Test Label can be performed in Normal or Diagnostics Test mode When the printer finishes printing the two test labels it returns to the ready state MATERIALS REQUIRED Installed supply stock at least 1 wide X 2 long 1 If the printer is in Normal Mode press Feed Pause at the same time If the printer is in Diagnostics Test mode press Feed Two test labels print See Figure 4 3 If the test fails an error appears on the LCD Press Clear to reset the printer 2 Examine the test labels for smearing image washout print uniformity contrast missing dots or out of specification readings TC9830SM Rev B 7 98 Confidential 19 9820 9830 9835 Service Manual rrrommooor M LECH MABKTN MODEL M9835 S H Version 5 1 TOTAL INCHES 0001234 HI ENERGY INCHES 0000012 VOLTAGE 39
52. arefully work the sensor harness through the upper supply guide openings and through the print assembly opening 4 Laythe sensor circuit board and harness aside 30 TC9830SM Rev B 7 98 Confidential Service Procedures Upper Supply Guide Removal 1 Remove bi cell emitter from the upper supply guide 2 Gently pry the supply guide from the pin and remove it Printhead Module Removal 1 Remove the printhead ribbon cable connector at the printhead end 2 Remove three printhead module screws as shown in Figure 6 4 3 Remove the printhead module and lay it aside to prevent it from being damaged 4 Carefully work the printhead cable back through the exposed cable slot and lay it aside Ribbon Spool Assembly Removal 1 Remove the C clip at the outer shaft end 2 Slide spindle off shaft 3 Reassemble in reverse order Ribbon Roller Assembly Removal 1 Remove the screw at the end of the roller shaft 2 Slide the serrated roller and eccentric adjuster off the end of the shaft 3 Reassemble in reverse order 4 Adjust ribbon tension See Chapter 5 DC Ribbon Motor Removal 1 Locate the two patterns of three recessed screws on the front side of the print module casting 2 Mark each motor so they aren t interchanged when reassembling 3 Remove the three screws from each pattern while holding the ribbon motor so it doesn t fall 4 Unplug the single wire from the Control Board Assy July 1998 Serv
53. ary Refer to Operating Instructions 0928 CAUTION To avoid damage to the motor the stacker rollers and front of knife must not be in direct contact NOTE When installing make sure the stacker is properly aligned with the knife The stacker tray should angle down and away from the 926 Align the stacker by lowering the stacker s feet turn them in to lower and out to raise the stacker Lock the legs in place by tightening the locking nut provided TROUBLESHOOTING 1 Check AC inlet fuse and power switch Model 928 Stacker 2 Ensure the stacker to knife harness is properly connected 3 Inspect stacker drive belts for proper adjustment 4 Check all wiring harness connector for proper connection Error Messages Error Message 761 is shown on the printer display if a stacker fault or jam is detected Stacker Full Empty the tray Press Clear to clear the error and resume printing Stacker Jam Clear the jam Press Clear to clear the error and resume printing If the jam is not inside the stacker check inside the knife or printer Alignment The stacker s bed must slant slightly down away from the knife Raise or lower the stacker s feet by turning them Tighten leg nuts to lock into place For additional alignments refer to the Operating Instructions 0928 CABLES AND CONNECTORS The following tables provide pinouts for stacker connectors Connector locations are shown in Figure D 1
54. asing or decreasing the speed of the digital pulse that make up the four phased signals Ribbon Drive Interface Electronically controlled DC motors drive the ribbon over the printhead The motors and associated control software control the tension of the ribbon web as the ribbon spools from the supply side to the take up side A speed detection method using BEMF Back Electromagnetic Motor Force provides accurate ribbon tension control Analog to Digital Conversion An ML2255 A D converter in conjunction with the microcontroller monitors system functions The A D converter combines an 8 Bit A D converter 8 channel analog multiplexer and a microcontroller compatible 8 bit parallel interface and control logic The A D converter monitors various system functions and provides information to the printers firmware to control the supply motion print quality etc Supply Detection amp Tracking System See Chapter 8 Supply Sensing Systems for more information Operator Control Panel Printer Control Board uses a Peripheral Interface Unit PIU to control the operator control panel interface comprised of a three digit display three push button keys and three LEDs An optional 917 Keypad is available for the 9835 printer offline batch entry Communications RS 232 interface and the Centronics IEEE 1284 compliant parallel interfaces are mounted on the Control Board Assy Both are located on the left edge of the board an
55. at has a temporary prompt box in the center of the screen that requests a password NOTE If a password is not given totals are displayed but can not be changed 3 To modify totals enter the applicable number 1 2 3 4 4 Before clearing a totals number the routine prompts another response Pressing Y causes a reset to 0 Any other entry results in an abort July 1998 TC9830SM Rev B 7 98 Confidential 23 9820 9830 9835Service Manual 5 Following a totals number the routine prompts another response Any entry other than Y results in an abort 6 Press D to return to the Sensor Display screen or press L to exit the Sensor Display test sequence Print Contrast Adjustment Adjust print contrast if printing is too light or too dark TOOLS REQUIRED e Small Flat head Screwdriver Using a small flat head screwdriver turn print contrast knob clockwise for darker print counterclockwise for lighter print Figure 5 1 Print Contrast Adjustment NOTE Adjustments may also be made via immediate commands Refer to the Packet Reference Manual for information on proper syntax Platen Motor Gear Adjustment This procedure adjusts the backlash in the platen drive gear train It should be performed each time a Platen Assembly or a Platen Motor Assembly is replaced TOOLS MATERIALS REQUIRED e Phillips Screwdriver e Paper Shimstock 0 006 to 0 008 thick or Label Backing Paper Liner folded
56. bar TPH STB B bar 22 TPH STB A bar TPH STB B bar 24 TPH STB A bar TPH STB A bar 26 N C V TM 28 VREF 5 VDC 30 5 VDC Figure B 2 CN2 Printhead Assembly TC9830SM Rev B 7 98 Confidential 51 9820 9830 9835ervice Manual 13 15 Noo 13 15 17 19 21 23 25 27 29 31 33 35 37 39 52 Figure B 3 CN3 LED 1 CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND KEY1A KEY2A KEY3A LED 2 F PP STROBE bar LC PDOO LC PDO1 LC PD02 LC PD03 LC PD04 LC PD05 LC PD06 LC PD07 N C F MC BUSY F MC PERROR F MC SELECT N C N C N C N C 4 5 VDC N C N C O UI PUN 25 VDC SM PH A SM PH A bar 25 VDC SMPHB SM PH B bar Figure B 4 CN4 1 39 PMN Connectors and Cables Platen Stepper Motor 1 8 10 12 14 16 5 VDC DISPLAY CLK DISPLAY LATCH DISPLAY DATA CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND LED 3 Control Panel 16 18 20 22 24 26 28 30 32 34 36 38 40 CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND F MC INIT bar N C N C N C N C CHASSIS GROUND N C N C Figure B 5 CN 5 Coax Twinax Interface TC9830SM Rev B 7 98 Confidential July 1998 Connectors and Cables Now 13 15 17 19 21 23 25 July 1998 15 VAC 1 N C CHASSIS GROUND 15 VAC 2 40 VDC CHASSIS GR
57. board to the standoffs Disconnect power supply harness at control board connector CN1 Remove control board Reassemble in reverse order Figure D 6 Power Supply Control Board 64 TC9830SM Rev B 7 98 Confidential July 1998 APPENDIXE 926 KNIFE ASSEMBLY The 926 Knife only works with a 9835 printer KNIFE SPECIFICATIONS Height 8 5 inches 216mm Width 9 3 inches 236mm Depth 7 6 inches 193mm Weight 9 0 pounds 4 1 Kg Shipping Wgt 9 5 pounds 4 3 Kg Power Input Voltage 24 0 Vdc From 9835 Printer Output Voltage 12 0 and 5Vdc to Stacker Assembly 40 to 104 degrees F 4 to 40 degrees C 15 to 120 degrees F 10 to 49 degrees C 5 to 90 percent non condensing Operating Limits Storage Limits Relative Humidity Speed Up to 6 0 inches 152mm per second TAG CUT DIMENSIONS Width 1 2 to 4 0 inches 30 mm to 102 mm Lengths 1 2 to 16 inches 31 mm to 406 mm Thickness 0 007 inch to 0 010 inch 0 18 mm to 0 25 mm NOTE Supply roll must be wound printed side in Labels should not be cut FUNCTIONAL DESCRIPTION The 926 Knife Assembly consists of the following modules e Blade Assembly Drive Board e DC Drive Motor e Solenoid The Knife Assembly is attached to the front of the 9835 Printer beneath the print module It is fastened to the printer base with three fasteners and has two wiring harnesses that connect to the 9835 Feature July 1998 Board a
58. cation values and existing supply See Chapter 1 for DIP Switch settings and procedures 2 Ensure that the proper fuse has been installed See the Operator s Handbook 3 Inspect printhead to ensure it is locked in place 4 Ensure stock and ribbon are properly loaded Refer to the Operator s Handbook for printer loading instructions ANALYZING FAILURE DURING POWER UP Each time the printer is turned on it runs Power up Diagnostics These Level 0 Diagnostic Tests are described in detail in Chapter 4 If any of the first eight tests result in a fault condition a three digit status code is indicated on the Control Panel LCD As shown in Figure 4 2 if any of the following status codes are indicated the printer will stop operating and remain in a hold mode until CLEAR is pressed 909 Memory Failure 765 Printhead Test Failure 911 Virgin Reset NOTE These error codes only appear during a power up test sequence If a 765 status code is indicated during the power on tests the printer is still operational but may not be able to print all of the commanded label images The Control Panel is tested during the power up tests by blanking the three digit LCD display momentarily This is the final Level 0 test and would be noticed only if a 765 status code were previously indicated EVALUATION OF A 616 ERROR DOT SHIFTING FAILED This error occurs if at least one dot element is non functional Shifting the image pattern will not work You mu
59. ching stacker full sensor to stacker bed 3 Remove 2 clips holding sensor wiring harness to the stacker bed 4 Thread sensor cable through frame to control board 5 Loosen set screws and remove belt speed adjustment knob 6 Remove 4 retaining screws and electronics cover Model 928 Stacker 7 Remove 4 screws holding control board to standoffs 8 Slide sensor out of transport mounting and thread sensor cable through frame back to control board 9 Move control board back to expose sensor wiring harness connector 10 Disconnect wire harness from control board connector CN3 and remove sensor 11 Reassemble in reverse order Replace Power Supply 1 Unplug stacker power and stacker to knife cable 2 Loosen set screws and remove belt speed adjustment knob 3 Remove belt adjustment potentiometer mounting nut and washer 4 Remove 4 retaining screws and electronics cover 5 Remove four power supply mounting screws 6 Tilt power supply up to disconnect wiring harness at connectors J1 and J2 7 Remove power supply 8 Reassemble in reverse order Replace Control Board Unplug stacker power and stacker to knife cable Loosen set screws and remove belt speed adjustment knob Remove belt adjustment potentiometer mounting nut and washer Remove 4 retaining screws and electronics cover Disconnect harness connectors at control board connectors J1 J2 and J3 Remove the four screws holding the control
60. ck that printhead Wide Narrow detents are set to Wide button locked down 13 Press Feed several times and observe the smoothness of the ribbon as it enters the printhead platen roller area Readjust the supply roller eccentric as required 14 If wrinkles occur loosen the take up eccentric screw with the printer running and rotate the eccentric to eliminate wrinkle 15 Hold eccentric and tighten the screw July 1998 Confidential 9820 9830 9835 Service Manual CHECKING SUPPLY QUALITY The printer continuously stores data from the most recent 16 supplies printed This checks the reflectivity of the sensor marks on the supply Before you check your supply quality print a batch of supplies or test labels Use Sendfile version 2 19 to check your supply quality This test can also be performed using the optional 917 Keypad To check your supply quality from the optional keypad 1 From the Diagnostics menu press lt or gt until you see DIAGNOSTICS lt User Diag gt 2 Press Enter You will be at the User Diagnostics menu Press lt or gt until you see USER DIAG Supply Quality gt 3 Press Enter If you have not printed any labels the message No data Press Enter appears If you have printed labels since turning on the printer you will see Len Min Max OK 1568 034 124 Y gt The Len listing is the length of the loaded supply in dots The Min listing should be greater than the Ma
61. contains interfaces for controlling all printer functions including Ribbon Supply and Take up motors Stepper Motor Peel motor Knife motor and the Printhead A single microcomputing unit consisting of a 32 bit RISC processor 256K OTPROM 16 bits and 256K 16 bits of Dynamic RAM DRAM controls the interfaces Major functions of the Control Board Assy are e Power Conversion e Memory e Printer Control e Operator Panel Control e Communications e Contrast Control e Hardware Power up Settings DIP Switches e Peel Motor Control e On Demand Sensor Interface Knife Motor July 1998 Functional Description Power Conversion Power conversion interface receives AC and DC voltage from the Power Transformer assembly 35VAC is converted to 12VDC and 12VDC while the 40VDC input is converted to 25VDC and 5VDC Memory Control Board Assebmly contains three types of memory Flash DRAM and SRAM Flash Memory Flash memory contains the necessary BOOT code and Operating System functions for I O routines used for communications the application program fonts formats and the Kernel Library functions DRAM Memory DRAM is used for variable storage buffers and image memory The base memory configuration for the printer is 256K 16 bits SRAM Memory SRAM 32K of non volatile static RAM is used to store system parameters and machine totals All relevant information is automatically stored in the SRAM when th
62. controlled by the Control Panel and DIP Switch settings and include Printer On Off Diagnostics On Demand Mode Error Fault Condition Indication and Clear PRINTER OPTIONS These options are available for all printers e TwinAx CoAx Interface e Memory Expansion Board e Ethernet Adapter Plug 117531 01 10BaseT e Ethernet Adapter Plug 117532 02 10Base2 The following options are available for the 9835 printer e 917 Keypad for offline batch entry e 926 Knife e 9287 Stacker must be used with knife The 9835 printer also supports 9445 emulation connection for an optional keyboard and a verifier Service can install the above options on site NOTE knife and stacker attachments be installed by the customer or Field Service technicians Ethernet Adapter Plugs are not factory installed PRINTER SPECIFICATIONS Height 12 5 inches 318 mm Width 12 inches 305 mm Depth 13 inches 330 mm Weight 29 pounds 13 kg Shipping Wgt 33 pounds 15 kg Power 115 VAG 60 Hz 9820 9830 9835 Service Manual Fuse Inlet Module Fuse Main PCB Tear Bar Programming Communications Operating Limits Storage Limits Relative Humidity Display Thermal Printhead Printing Methods Supply Types Ribbon Types Ribbon Length Ribbon Widths Max Ribbon Roll O D Ribbon Storage 4 0 amp 250 V Slo Blow 1 required 7 0 amp 125 V Slo Blow Soldered radial lead
63. d by grasping the harness by the connector Lower Supply Guide Removal Turn printer off and unplug AC cord Remove bi cell sensor Remove sensor harness from two retainer loops Open print module until it latches Locate locking tabs on either side of the guide frame which lock into the platen frame 6 With asmall straight blade screwdriver gently pry latches in towards the feed path while pushing up on guide frame until latch releases from frame Repeat for latch on the other side REN Bi Cell Sensor Replacement 1 Connect sensor harness to the sensor board 2 Insert sensor board in holder on an angle to engage board in holder tabs 3 Apply light pressure on the opposite side of the board to seat board into holder 4 Ensure sensor window is showing through the hole in sensor holder 5 Insert top holder tab into guide frame 6 Pivot sensor holder assembly down and latch the back tabs Use your thumb to support the under side of the guide frame Latch Bi Cell Sensor Figure 6 8 Bi cell Sensor July 1998 Service Procedures Lower Supply Guide Replacement Reinstall sensor harness through retainer loops 2 Align guide frame with notches in platen frame 3 Press down on guide frame until latches engage the platen frame SUPPLY HOLDER TOOLS MATERIALS REQUIRED e Phillips Screwdriver e Flat head Screwdriver Supply Holder Removal 1 Pull upward on supply holder and lift it away from
64. d accessed by the user at the rear of the printer near the supply roll 9820 9830 9835 Service Manual RS 232 interface This interface allows connection to devices capable of RS 232 communications The interface is incorporated in the microcontroller and has DIP switches to set communications parameters The DIP switches can be set manually by the user or through software control Centronics IEEE 1284 Parallel Interface This interface accommodates high data rates up to 2M Bits Second IEEE 1284 Bi Directional Parallel Interface An IEEE 1284 High Speed Bi directional Parallel interface provides parallel communications The microcontroller directly controls the port The interface allows compatibility with the Centronics interface as well as allowing for High Speed Bi directional communications NOTE Third party LAN devices are connected through the parallel interface to allow the printer to interface different LAN networks Contrast Control A manual contrast control located at the edge of the Control Board Assy extends out of the rear cover It is used for fine adjustments to the print contrast values Hardware Power up Settings DIPS Two 8 switch DIP switches located on the back panel of the printer above the contrast adjustment control the default power up configuration of the printer Settings include the serial port settings diagnostics ribbon setup printer mode and supply type Peel Module Assembl The
65. d before continuing 756 The printer is out of supplies Load supplies 757 Load supplies The calibrated supply length differs by or 25 inches from format Press Feed NOTE For errors 751 753 check supply tracking supply marks black mark sensor position supply roll for binding Then press Clear If error continues to appear change supply Code Description 758 Either on demand sensor is broken supply is not seen or continuous unit set to on demand mode Adjust sensor so it is over a white area on supply or set unit to continuous mode This error may occur if you remove a label too quickly in on demand mode The printer does not recalibrate after this error 759 Knife is not moving 760 Knife jam 761 Stacker is full or jammed Empty stacker before continuing The printer does not recalibrate after this error 762 Low battery Recharge battery 763 Waiting to dispense label Press Feed 764 Verifier failure Check verifier by referring to your verifiers manual The printer does not recalibrate after this error 765 Printhead failure You need a new printhead 768 Printhead is not present Make sure the printhead is connected and closed 770 Print motor not ready Call Technical Support 771 Format specified by application not found Reload application and format If problem continues call Technical Support 790 Printer busy Press Clear Resend packets If problem continues call Technical Support 791 Printer has an er
66. d to the printer frame base left of the power transformer It has wire attachments to ground the power transformer and the Control Board Assy The bridge rectifier accepts the AC from the power transformer and converts it to DC This voltage is then supplied to the Control Board Assembly for further conversion 8 TC9830SM Rev B 7 98 Confidential Functional Description CONTROL BOARD ASSEMBLY The Control Board Assembly is located on the back side of the printer frame wall beneath the printer s back cover It consists of a mother board and a daughter board The two boards are replaced as a single assembly The board assembly is mounted on six quick release aluminum standoffs Three of the standoffs are threaded for retainer screws The board has three connectors serial port parallel port and bar code verifier the print contrast control and three DIP switch assemblies Two are mounted on the long vertical side allowing for external access The third DIP switch is located on the daughter board There is a connector across the top of the board and a hall effect sensor at the top right corner of the board to sense Head Open condition Eight additional connectors accept cabling to other printer assemblies The daughter board has a connector for cabling to the mother board and two connectors for functional expansion Functional Description The Control Board Assy controls all electrical requirements for the printer and
67. die cut butt cut black mark only with aperture and non indexed supplies The supply detection and tracking system detects the document edge position and out of stock condition The infrared emitter is located above the web path and is positioned to allow the bi cell sensor detector to serve as a receiver for recognizing die cut supplies Version 5 2 or greater The software uses an adaptive threshold algorithm that has successfully been used in the M9446 printer This method provides the benefit of accurately processing apertures die cut gaps and black marks even though the electronic signal response may vary greatly between supply types It consists of measuring the difference between the minimum and maximum A D Analog to Digital converter values captured from the sensor The amplitude of this signal range represents the sensor response to the feature The minimum value captured plus half the height of the signal range constitutes the threshold level for both the Top of Form TOF and Bottom of Form BOF This means that on the leading edge of the feature when the threshold value is crossed the BOF is marked Likewise when the feature is departing the sensor and the trailing edge threshold is crossed the TOF is marked TOF BOF Threshold Low value High Value Low Value 2 The paragraph above describes how the algorithm is developed on one feature For V5 2 the threshold will July 1998 be an average threshold val
68. e 3 Position bearing blocks in the slot on each side of frame then push down on roller until bearing block latches snap into place 4 Rotate platen module clockwise to locate it in its original position The platen module must be lifted up to allow the platen gear to clear the printhead alignment bracket Detents in the base plate assure alignment of the platen frame 5 Reinstall the three phillips screws and tighten 6 Verify clearance between platen drive gear and the stepper gear bearer this should not have changed for this procedure Nominal gap for this adjustment is factory set at 0005 Bi Cell Sensor Removal 1 Grasp the bi cell sensor holder at its base squeeze together to release the latch tabs and lift the back of the sensor holder upwards 2 Release latch tabs by pulling back and up on sensor holder 3 Rotate sensor holder back to expose sensor circuit board 4 Insert the blade of a small screwdriver through the sensor holder on the left side about 3 8 down from the top and pushs the sensor board away from the sensor housing apply thumb pressure to the cover to gain leverage 32 TC9830SM Rev B 7 98 Confidential Service Procedures CAUTION The recommended pushing location minimizes the possibility for damaging the circuit card 5 Carefully remove sensor board from sensor holder NOTE Use caution not to damage the circuit board 6 Unplug sensor harness from sensor circuit boar
69. e edge sensor Black Mark center sensor Continuous no sensor Center Aperture center sensor EE qned Transfer JP or Transter Loa 580 Tn E Feed Mode ie 2 Femme TTR On Demand n 1 lof NOTE DIP Switches for Version 5 2 or greater are shaded 6 TC9830SM Rev B 7 98 Confidential July 1998 CHAPTER 2 FUNCTIONAL DESCRIPTION OVERVIEW OF MODULES Power Transformer Assembly Power Supply and Distribution e Control Board Assy Data Handling and Control e Peel Module Supply Backing Separation e Print Assembly Thermal Control and Motion Synchronization e Feed Assembly Supply Alignment Tension e Supply Holder Assembly Supply Guide e Control Panel Assembly Operator Interface Control Board Print Assembly Assy Fe n T Supply Holder Assy 2 A Ans y A 5 AC Inlet Module Power Transformer Assy Peel Module Rectifier inside door of 9830 Control Panel Assembly Mounted to printer housing not shown July 1998 TC9830SM Rev B 7 98 Confidential 9820 9830 9835 Service Manual Power Transformer Assembly The power transformer assembly is located beneath the printer s back cover and includes three components Inlet Power Module The power module is attached to the printer s rear panel just in fro
70. e the frame itself becomes hot and potentially dangerous Electrical Fires Use Type C BC or ABC extinguishers only Equipment Safety Your body is a giant capacitor It can store several thousand volts of electricity Digital equipment is easily damaged or destroyed by this static electricity You don t have to see a spark to ruin an IC 50 volts is enough To protect the equipment from static damage follow these guidelines Ground yourself before reaching into the equipment or touching any circuit board or other electrical component The Monarch Static Ground Kit contains everything you need Re ground whenever you have walked away and returned to the equipment Be especially careful around carpet Carpet is a major source of static buildup in the body Even a few steps can recharge you The smaller the object the greater the precautions must be A board in the machine is better protected than one which is not plugged in a chip on a board is better protected than one in your hand Avoid touchings pins coming out of a chip or the connector edge of circuit boards These metal parts have signal and data lines which are connected directly to fragile circuits TC9830SM Rev B 7 98 Confidential vii viii TC9830SM Rev B 7 98 Confidential CHAPTER 1 PRINTER OVERVIEW amp INSTALLATION PRINTER FEATURES The 9820 9830 9835 printers are on line table top printers that accepts Monarch Printer Control Language II MPCLII da
71. e acceptable range is 0 10 The word Calibrating appears on the screen The process is complete when Calibrating disappears To set adjust the die cut edge sensor 20 Load a minimum of 4 inch long die cut liner stock with the labels removed Close printhead 21 Press 2 to set the die cut sensor 22 Press A to automatically set adjustment The ideal setting is 4 00 The acceptable range is 0 10 The word Calibrating appears on the screen The process is complete when Calibrating disappears To set adjust the black mark center sensor 23 Remove the liner stock from the printer 24 Load a minimum of 4 inch long piece of tag stock into printer Make sure the black mark is not over the center sensor Close the printhead 25 Press 3 to set the black mark sensor 26 Press A to automatically set adjustment The ideal setting is 4 00 The acceptable range is 0 10 The word Calibrating appears on the screen The process is complete when Calibrating disappears 27 Press S to save the adjustments The printer displays 909 Turn off the printer Wait three seconds and turn the printer back on POWER UP SENSOR RECOGNITION During power up initialization the software checks a reserved area in flash to see if the printer has the V5 2 sensor system hardware installed If it does then the V5 2 sensing is activated If not then the daughter board is checked to see if the model
72. e printer is turned off Printer Control Control Board Assembly controls all printer functions It use a high performance 32 bit RISC based integrated microcontroller The microcontroller performs imaging and provides interfaces to printer control operations Major functions of the board are Data Handling During operation communication with both the RS 232 port and the High Speed parallel port is maintained MPCL data received is transferred to Dynamic RAM DRAM Printhead Thermal Control Printhead thermal control operation is a dynamic closed loop servo circuit that adjusts the on off duty cycle in response to a continuously monitored Printhead operating temperature and resistance Print Imaging The Thermal Printhead Interface is controlled by the microcontroller Page image data is transferred from Dynamic RAM to the thermal printhead as a serial data stream July 1998 TC9830SM Rev B 7 98 Confidential 9820 9830 9835 Service Manual Motion Control Motion control sub system controls four DC motors Two DC motors drive the Ribbon control a stepper motor controls the platen drive and a fourth motor drives the Peel Module Platen Drive Interface Control Board Assembly controls the platen drive motor s torque speed and direction through the use of four phased 25Vdc output signals Motor torque and direction is controlled by changing the sequence and pattern of the four signals Motor speed is controlled by incre
73. ee screws attaching the peel module to the platen module 9 Remove Peel Module through the end of the printer 10 Reassemble in reverse order BJ RN oc Peel Motor Replacement 1 Remove Peel Module 2 Carefully pry peel motor gear from shaft 3 Remove three motor mounting screws and remove motor 4 Reassemble in reverse order TC9830SM Rev B 7 98 Confidential 33 34 TC9830SM Rev B 7 98 Confidential July 1998 CHAPTER 7 USING FLASH 12 Turn printer off for 10 seconds and then back on FLASH DOWN LOADING After printer powers up print a test label to confirm correct operation PROCEDURES 13 Test printer with SENDFILE formats or the The following information should be used as a customer s data stream guideline for programming a 9800 series printer using DOS Flash Download Utility NOTE Close all applications to prevent any conflicts with the communications ports on your PC CAUTION Follow these steps exactly failure to do so will result in an unsuccessful attempt that may require board replacement 1 Open the ZIPPED file 98XXVXX zip into a directory called FLASH NOTE The PC should be capable of communicating at 38 4 baud Make sure the printer is powered down Connect Serial Cable to PC and printer Cable must support DTR flow control 4 Note DIP switch settings so printer can be returned to its original configuration 5 Move ALL DIP switches to the ON position 6 Turn pri
74. er reading across both Yellow wires 0 1 ohms e All other combinations must read infinite open resistance Bridge Rectifier 1 Set Ohm meter to 2000K scale 2 Remove wires from device 3 Black lead on Red wire terminal labeled on device at the notched corner and leave attached while moving red lead to other terminals of the device should yield e Red lead on either yellow wire 90 from that corner should read approx 500 ohms e Red lead on black wire diagonal from red wire terminal should read approx 1000 ohms Switch Red lead to red wire terminal and move Black lead to all other positions The result should be infinite ohms Head Open Sensor Hall Effect Sensor 1 is located at the top of the board and must be within 6 mm of the magnet Top leg of chip closest to the top edge of the board changes between 5VDC and ground in response to the magnet in the Print Module It should be at OVDC with respect to frame ground when head is closed If magnet is bent operation may be affected Displaying Machine Service Totals This test is performed online using SENDFILE Only the Service Totals test sequence requires an intermediate step to access It requires the operator to run Diagnostics D from the SENDFILE Format Page screen resulting in the Sensor Display format and then run Service Totals S from the Sensor Display Screen 1 Press M for Modify Service Totals 2 Theinitial Service Totals form
75. er length Cut Length Stock Thickness Stock Roll Stock Output Stock Type Version 5 2 or greater stock type TC9830SM Rev B 7 98 Confidential 16 inches 405mm max 12 inches 305mm max 9820 75 inches 19mm min 1 2 inches 31mm min with optional knife installed 0 007 inches min 0 18mm 0 010 inches max 0 25mm Outside Diameter 9 375 inches 229 mm Inside Core Diameter 3 4 inches 102 mm 8100 inches 200 m long Roll or Fanfold Die cut without Black Mark Black Mark Continuous Coated Supplies Die Cut Edge Black Mark Continuous Center or Edge Aperture July 1998 Printer Overview and Installation UNPACKING THE PRINTER Clear a work area approximately four feet wide 2 Open shipping carton top flaps 3 Remove the Documentation Package and top pad 000655 05 DOCUMENTATION 0 PACKAGE MANUAL amp DISKETTES PAD TOP P 000655 05 IN POLY BAG 000543 01 POWER CORD m m PAD SCORED T we 000655 03 7 PAD SCORED 000655 02 PAD BOTTOM 000655 04 000655 01 Figure 1 2 Printer Unpacking 4 Remove scored pad 000655 02 and scored pad 000655 03 Figure 1 2 5 Remove power cord from scored pad 000655 03 NOTE The power cord is not included with some models 1 Grasp printer at base by inserting hands into cutouts in bottom pad 000655 04 Lift printer out of box and set on solid surface
76. h as run length encoding to reduce required memory COMMUNICATION FAILURES 410 499 Errors 410 to 414 are usually caused by a hardware failure by an incorrect SETUP option or by the host PC ignoring flow control XON XOFF CTS RTS or DTR The serial communication settings are Baud rate 1200 2400 4800 9600 19200 38400 Word length 7 or 8 Stop bits 10r2 Parity Odd Even None Flow control None XON XOFF CTS RTS DTR Code Description 410 Parity on printer doesn t match parity on host Check parity setting under SETUP options 411 Framing error The printer cannot communicate with host Make sure host is turned on communication cables are connected correctly port settings are correct and communications are active Check baud rate word length and stop bits to make sure they match those at host Do not toggle between Microsoft amp Windows amp and MS DOS while using COPY command or you will receive a framing error Exit Windows before using COPY command Re transmit data 412 There is a problem with flow control between printer and host Make sure printer and host flow control settings match both are DTR or both are XON XOFF 413 Online receive queue is full Check your printer s XON XOFF or DTR SETUP values to be sure there isn t a flow control problem 414 The internal keyboard buffer is full or you need a new keypad 415 The buffer size you defined exceeds total available in your machine July 1998 TC9830SM Rev
77. h in control characters packet must be 5 MPCL control characters or 7 ENQ IMD command character Baud rate selection must be 0 1200 1 2400 2 4800 3 9600 4 19200 or 5 38400 Resend communication settings packet or check DIP switch settings Word length selection must be 0 7 bits or 1 8 bits Resend communication settings packet or check DIP switch settings Stop bits selection must be 0 1 bit or 1 2 bits Resend communication settings packet or check DIP switch settings Parity selection must be 0 none 1 odd or 2 even Resend communication settings packet or check DIP switch settings Flow control selection must be 0 none 1 DTR 2 CTS RTS or 3 Resend communication settings packet or check DIP switch settings Internal code page selection must be 0 Internal 1 ANSI 2 DOS 437 or 3 DOS 850 Cut adjustment must be 99 to 99 dots RS232 Trailer string is too long Use a maximum of 3 characters ENQ Trailer string is too long Use a maximum of 3 characters The storage device type in memory configuration packet must be N non volatile RAM or R volatile RAM The buffer type must be Transmit Receive Image F Format or D Downloadable Fonts The buffer size is invalid The printhead width must be 244 to 812 dots The battery voltage must be 0 15 volt battery or 1 12 volt battery The printer address specified in communication settings packet
78. hese wires or the printer could be damaged voltages vary 1 Remove the four wires and single retainer screw located in the center of the rectifier 2 Remove the bridge rectifier 3 Reassemble in reverse order AC Inlet Removal AC INLET MODULE solid black wire striped black wire solid brown wire solid orange wire striped brown wire striped orange wire striped green wire 6 3 Bridge Rectifier Four Wires The AC Inlet has six wires coming from the transformer and one ground wire Reconnect the wires properly when replacing this part voltages vary Confidential July 1998 Service Procedures Release wires from loop holder 2 Remove six wires leading to the transformer 3 Remove flange screw fastening green wire from the AC Inlet to the Control Board Assembly 4 Slide AC Inlet boot back and disconnect seven spade connectors wires 5 Depress top and bottom retaining detents on the AC Inlet and remove it through the back of the printer 6 Reassemble in reverse order Control Board Assy Removal The Control Board Assembly has eight connectors to interface with external assemblies A single connector CN5 is used with the TwinAx CoAx interface option as an external interface The other seven connectors are used with board mounted option assemblies The daughter board also has three connectors which must be disconnected for board assembly removal CAUTION CN15 and CN16 are identical in a
79. hillips Screwdriver e Flat head Screwdriver 1 Turn the printer off and unplug the power cord 2 Place printer flat uncluttered surface 3 Remove Control Panel by applying light downward pressure on the latching tab on the top of panel fascia 4 Remove ribbon harness assembly by grasping the connector applying slight force away from the control panel circuit board 5 Remove single line ground wire 6 Set Control Panel aside and place the ribbon harness and ground wire back into the printer to prevent snagging on Cover Housing 7 Reassemble in reverse order COVER HOUSING REMOVAL The cover housing is attached to the printer frame by five Phillips head screws Two screws are located near the printer base one is behind the Control Panel and two are on the supply spool frame wall TOOLS REQUIRED e Phillips screwdriver e Flat head Screwdriver WARNING 1 Remove two screws at printer base NEVER perform maintenance on the printer with the 2 INO scons one wall power cord connected Doing so exposes points where 3 Remove screw from under control panel AC voltages are present Reattach the power cord 4 Lift cover housing to clear the frame walls only when test procedures indicate that power is required 5 Reassemble in reverse order CAUTION Static electricity can damage printer parts Use a static ground wrist strap whenever possible If a wrist strap is not available ground yourself by touching
80. ice Procedures Print Assembly Removal 1 Remove two screws holding pivot retainers to the frame 2 Lift the upper supply guide and remove the retainer pins from the upper supply guide 3 Remove the magnet from the tunnel housing on the side facing the Control Board Assy See Figure 6 6 Save the magnet Figure 6 6 Print Assembly Plate amp Printhead Module 4 Reassemble in reverse order 5 Adjust ribbon tension See Chapter 5 FEED ASSEMBLY Maintenance of the Feed Assembly involves e removing the latch fascia and platen module e replacing the platen module e removing the sensor and lower supply guide e replacing the bi cell sensor and supply guide TOOLS MATERIALS REQUIRED e Phillips Screwdriver e Flat head Screwdriver e Ribbon spool intermediate gear retaining clip July 1998 TC9830SM Rev B 7 98 9820 9830 9835 Service Manual Latch Fascia Removal 1 Remove cover housing 2 Remove snap pin from rear latch fascia by prying gently outward with a screwdriver WARNING Leave the printhead latched to hold the latch knob in place or it may fly off and cause harm OG Spring Figure 6 7 Latch Removal 3 With the printhead latched remove the latch fascia See Figure 6 7 4 Carefully unlatch and raise printhead 5 Pull latch knob away from platen frame until the stop tab disengages from the frame 6 Rotate latch knob counterclockwise until all spring tension
81. ie cut supply and turn off printer Connect laptop computer to printer s serial port laptop must have SENDFILE V2 07 installed threshold from the feature back to white 4 a do Switch 3 bottom set to ON Diagnostics The threshold value used for this first feature is not Set DIP switch 6 bottom set to OFF Die Cut saved in the averaging array because it only represents the minimum span distance as defined by Turn printer on Printer will feed two labels and the algorithm criteria However by the time the TOF display 000 position is reached a full representation of the signal 7 Start SENDFILE as follows profile has been captured and this actual profile is P M for Model E what is used for BOF TOF on the second feature 8 Press M for Model number and press Enter When the second feature passes by the sensor the 9 de 22 ENE la e 5 supe valid BOT and TOF are those points that were IAC IDLE lagnesice wu Spay calculated from the first feature The threshold points calculated based on the signal profile captured from 10 After SENDFILE displays IDLE press D for this feature are saved as the second entry in the array Diagnostics For the third feature the threshold points become an 11 Remove Die Cut labels from the printer average of the first two features Here after the array is continually updated containing the last two threshold 12 Check the emitter for operation using an Infrared values Detector Probe The calib
82. inthead adjustment Perform contrast sensor display service test using SENDFILE Verify supply installed correctly Verify ribbon installed correctly Confirm stock feed operation Confirm ribbon feed operation Clean printhead Check status code on LCD Verify wide narrow printhead adjustment Perform contrast sensor display service test using SENDFILE Adjust contrast Verify ribbon installed correctly Confirm ribbon feed operation Check platen roller surface Clean printhead Check status code on LCD Perform contrast sensor display service test using SENDFILE Adjust contrast Verify correct stock ribbon installed correctly Clean printhead Check status code on LCD Confirm test label printhead operation Perform printhead sensor display service test using SENDFILE Replace printhead Confirm fault via immediate command service test Confirm test label printer config parameters Verify communication DIP switch settings Send a corrected format packet Perform terminal data transfer tests Replace Control Board Assy TC9830SM Rev B 7 98 Confidential July 1998 CHAPTER 4 DIAGNOSTICS If you have any problems using SENDFILE refer to the Sendfile Manual on your Service CD ROM The following diagnostics are resident in the 9820 9830 9835 printer s firmware ROM e Power Up Self Test e Test Label e Service Diagnostics Level 1 Data Dump Mode Diagnostics Test Mode Off line Diagnostics Tests L
83. ng RAM Communications parity error Communications framing error Communications buffer overran Invalid record type specified Invalid ASCII hex data in record Invalid checksum Invalid record count recorded FLASH address being programmed FAULTS 950 999 Errors 950 999 indicate circuit board failure Call Technical Support 50 TC9830SM Rev B 7 98 Confidential July 1998 APPENDIX B CONNECTORS AND CABLES This appendix contains charts of the pinouts for the Control Board Assembly connectors 13 15 17 19 21 23 25 27 29 31 33 35 13 15 17 19 21 23 25 27 29 July 1998 F PP STROBE bar 1 2 LC PDOO LC PDO1 4 LC PD02 LC PD03 6 LC PD04 LC PD05 8 LC PD06 LC PDO7 10 F MC ACK bar F MC BUSY 12 F MC PERROR F MC SELECT 14 F MC AUTOFD bar N C 16 CHASSIS GROUND EMI GROUND 18 N C CHASSIS GROUND 20 CHASSIS GROUND CHASSIS GROUND 22 CHASSIS GROUND CHASSIS GROUND 24 CHASSIS GROUND CHASSIS GROUND 26 CHASSIS GROUND CHASSIS GROUND 28 CHASSIS GROUND CHASSIS GROUND 30 CHASSIS GROUND F MC INIT bar 32 F MC FAULT bar N C 34 N C N C 35 36 F MC SELIN bar Figure B 1 CN 1 IEEE 1284 Parallel Port CHASSIS GROUND 1 VTPH CHASSIS GROUND VTPH CHASSIS GROUND VTPH CHASSIS GROUND 8 VTPH CHASSIS GROUND 10 VTPH BANK ENABLE OUTPUT 12 CHASSIS GROUND VDAT bar 14 CHASSIS GROUND LATCH bar 16 CHASSIS GROUND TPHCLK 18 CHASSIS GROUND 29 1 TPH STB B bar 20 TPH STB A
84. nsists of an external 36 position connector CN1 and an internal 40 position connector CN5 that is used to support the Coax TwinAx Interface CN1 also supports an external Ethernet adapter 14 TC9830SM Rev B 7 98 Confidential July 1998 Troubleshooting 9820 9830 9835 Service Manual The external Coax TwinAx Interface is a 15 position connector into which is plugged either a Coax adapter cable or a TwinAx adapter cable All electronic activity for the serial port is limited to the Control Board Assembly All electronic activity through CN1 is limited to the Control Board Assy There is a small circuit board mounted on the inside rear printer wall that interconnects the 15 position external connector with the internal CN5 Both CN1 and CN5 share common PCB electronics 1 Make sure the printer is plugged in and connected to a host with the proper cables See Connecting to a Host in Chapter 1 2 Compare host communication values to values reported on the test label See Test Label Level 1 in Chapter 4 for instructions on printing a test label 3 Check printer ports using SENDFILE to send an ENQ GENERAL TROUBLESHOOTING SUGGESTIONS There are a number of printer self reporting fault detection fault isolation avenues built into the 9820 9830 9835 printers Three digit status codes detailed in Appendix A all help to pinpoint the problem In addition the printer provides status information in the two test labels in the SENDFILE service
85. nt of the Control Board Assy Its face plate partially extends through the rear panel to allow users access to the power receptacle fuse box power selector and the on off switch It has wire attachments to ground the Power Transformer This module includes the following components e International line cord receptacle e 4 0 Amp 250VAC Slo Blow fuse Line voltage enters at the cord receptacle and passes through a slow blow fuse The slow blow fuse protects the system from damage by power surges Line ground is provided to the printer via a ground harness connected to the bottom frame Power Transformer The power transformer is available in three voltages 110V 115V or 220V It is attached to the frame base just below the print module The transformer gets AC line voltage from the inlet power module and converts it to two AC output voltages The first is sent directly to the Control Board Assembly for futher conditioning The second output is sent to the bridge rectifier for additional conversion The power transformer assembly outputs the required AC and DC voltages for operation of the printer and sends both voltages directly to the Control Board Assy Further conversion and or distribution is made by the Control Board Assy Major functions of the power transformer include providing power to the Inlet Power Module Power Transformer and to the Bridge Rectifier Bridge Rectifier The bridge rectifier is a 1 x 1 assembly fastene
86. nter on The Operator panel will display 001 ok to download Flash From FLASH directory type GO and press Enter The program will prompt you for COM 1 or COM 2 Select the appropriate port Once you select the COM port the application begins transfer of data and the green LED will lite The download takes approximately five minutes at 38 4 baud The below listed download status codes will be displayed during the download process e 002 Transient Programmer now erasing flash e 003 Transient Programmer now ready to accept download 9 When the application is finished it will return the to the DOS prompt CAFlash Turn printer off 10 Return DIP switches to original setting noted in step 4 11 Turn printer on Display should read 909 July 1998 TC9830SM Rev B 7 98 Confidential 35 9820 9830 9835 Service Manual Using Flash 36 TC9830SM Rev B 7 98 Confidential July 1998 CHAPTER 8 SUPPLY SENSING SYSTEMS Several supply sensing systems have been used for the 9800 series printers This chapter contains Supply detection and tracking for each printer e Adescription of the supply deflector Bi cell emitter lower supply guide and Bi cell sensor e Sensor tests and adjustments for each sensing system e Information about the version 5 2 sensing system SUPPLY DETECTION TRACKING SYSTEM An electro optical system consisting of a single infrared emitter and a bi cell sensor allows the printer to support
87. o disable ENQ This July 1998 Diagnostics applies only when you are in Data Dump mode Serial Loop Back Test This test evaluates serial port circuits on the Control Board Assembly nothing external to the Control Board so communication setting DIPs 1 through 10 do not affect this test TOOLS REQUIRED e Loop Back Plug 114271 1 printer off and disconnect host serial port connector from CN 7 2 Install Loop Back Plug into RS 232 Serial Port CN 7 See Figure 4 4 for plug wiring 3 Turn the printer on and go into Diagnostics Test Mode 2 002 This is accomplished by pressing the Feed or Clear key from Mode 1 001 4 Press PAUSE Jumper Pins Signal 2 3 TXD RXD 4 20 5 7 12 TI OI IOD 4 6 RTS DSR 5 20 DTR CTS Figure 4 2 Loop Back Plug Wiring 5 The test runs automatically once initiated and takes approximately two seconds 6 If the test passes 222 is displayed If the test fails Loopback Plug not installed installed incorrectly or bad Control Board Assy components error 499 is displayed 7 Press Feed and Clear to exit Parallel Port Test The parallel port timeout test can be used with version 3 1 or greater firmware When the parallel port is in flow control the printer continues to accept data one character at a time until the entire receive buffer is full The rate that data is accepted can be set through this diagnostic mode The default is one character
88. o do so may cause the printer to lock up and not be able to recover Set switch on bottom row position 43 on CPU board to diagnostic mode Remove any supply from printer Close the printhead Make sure printer is turned OFF Connect the correct printer voltage 115 or 230 Connect the serial cable to printer and computer Start Sendfile version 2 21 or greater QU Ni SO Be GI Turn on printer Press Clear if error 792 is displayed Press D to go into diagnostics 10 For standard 9820 9830 9835 printers set print contrast to 2 50 02 For linerless 9830 set print contrast to 1 25 02 11 Press X for sensor adjustments 12 Press C to get to the screen on the right hand side It should show version 5 0 at the top right and the center should show aperture die cut black mark Toggle C until you see this screen 13 Press S this saves the virgin settings 14 Press D to go into diagnostics 15 Press X for sensor adjustments 16 Press C to get to the screen on the right hand side It should show version 5 0 at the top right and the center should show aperture die cut mark Toggle until you see this screen July 1998 9820 9830 9835 Service Manual To set adjust the aperture center sensor 17 Remove supplies if any are loaded and close printhead 18 Press 1 to set aperture sensor 19 Press A to automatically set adjustment The ideal setting is 4 00 Th
89. o seconds and release NOTE Using Virgin Reset Command in SENDFILE requires the Service Password Printing a Test Label Print a test label by pressing the Feed while in Data Dump mode or Diagnostics Test mode For more information on printing a test label see Test Label earlier in this chapter TC9830SM Rev B 7 98 Confidential 21 9820 9830 9835 Service Manual Diagnostics 22 TC9830SM Rev B 7 98 Confidential July 1998 CHAPTER 5 TESTS AND ADJ USTMENTS SERVICE TESTS The following tests are described in this section e Voltage Tests e Continuity Tests e Supply Quality NOTE Sensor tests are described in Chapter 8 Supply Sensing Systems CN6 Power Supply Pin numbers are read from left to right including empty positions e Transformer secondary non rect AC output Pin 1 amp 3 15VAC Pin 3 amp 4 15VAC e Transformer secondary rect DC output Pin 5 amp Pin 6 Grnd 40VDC Continuity Tests WARNING Failure to turn off and unplug printer for these test could result in electrical shock Transformer Primary Side Should be tested at AC Inlet under the boot Black amp Brown 0 2 ohms Black White amp Brown White 0 2 ohms e Orange amp Orange White 0 2 ohms e All other combinations must read infinite open resistance Transformer Secondary Side Ohm reading must be taken with power off e At CNO all combinations of Pins 1 3 amp 4 0 1 ohms e At bridge rectifi
90. oopback Test Level 2 Parallel Port Test Level 3 POWER UP SELF TEST When the printer is turned on a test sequence is initiated The diagnostics routine initializes the Control Board Assembly and evaluates the Printhead The test sequence is e Non Volatile RAM Byte Test e Version String Mismatch e Printhead Dot Resistance A failure in any of the test sequences results in the display of an error code on the 3 digit Control Panel Display An error during the printhead dot test indicates that bar code scan quality may be compromised However such a failure may not be evident in text printing NV RAM ByteTest The Non Volatile RAM test checks the first two bytes of NVRAM If the test passes the next test begins If the test fails error 909 appears on the display Version String Mismatch The version string test compares the software version in ROM to the version in RAM If the versions match the current software is in RAM and the software clears storage RAM Then the software clears the working storage routine If the versions in ROM and RAM do not match error 911 appears on the LCD System Restart Condition The three conditions that cause a system restart are July 1998 e Different versions of software installed e Clearing memory with the Reset NVRAM function in service diagnostics e Memory corrupt due to a hardware software error If the restart flag was set during these diagnostic tests the softw
91. per every 10 seconds This value prints out on the test label July 1998 9820 9830 9835 Service Manual To change the parallel port timeout 1 Set lower DIP switch 3 to ON The display reads 000 2 Press Feed and Clear at the same time until the display reads 003 Mode 3 3 Press Pause to enter the parallel port timeout mode 4 Press Clear to increase the timeout and press Feed to decrease the timeout The display changes to show the amount of the timeout 5 Press Feed and Clear at the same time to exit data dump mode The display reads 000 The amount of data the application processes from the communication driver is 128 bytes at a time Flow control is now activated when there is 512 bytes left available in the buffer and flow control is now deactivated when there is 1024 bytes available in the receive queue Diagnostics Test Mode There are two types of Diagnostics Tests those performed off line by pressing some keys and those performed using SENDFILE Table 4 1 lists the tests and procedures that can be performed in Diagnostics Test mode Table 4 1 Diagnostics Tests DIAGNOSTICS OFF LINE TEST ONLINE KEYS Loop Back Test off line Pause Feed Clear Pause Virgin Printer Reset off line Performing a Virgin Printer Reset A Virgin Printer Reset sets the printer to its original factory settings and erases all data in RAM To initiate a virgin reset hold down Feed Clear Pause for approximately tw
92. porting Hardware Accessories Required e SENDFILE and Flashloader requires a laptop or PC connected to the printer via a serial cable PC should be capable of communicating at 38 4 baud e Serial Loop Back Test requires Loop Back Plug 114271 Accessing Diagnostic Modes To use the different modes available in Service Diagnostics you must have lower DIP switch 3 turned on and the display reads 000 From the 000 display press Feed and Clear at the same time until you see 001 data dump mode 002 serial loop back test or 003 parallel port test Each mode is activated by pressing Pause Data Dump Mode To use data dump mode 1 Set lower DIP switch 3 to ON The display reads 000 2 Press Feed and Clear at the same time The display changes to 001 Mode 1 3 Press Pause to enter data dump mode Two blank labels feed and the display reads 111 4 Download the data stream you want to dump print on a label 5 Press Feed and Clear at the same time to exit data dump mode The display reads 000 Data dump mode captures all data being sent to the printer and holds it in a buffer No data is acted upon ex Immediate commands or Job request packets Once the buffer is full a label automatically prints with the downloaded data printed on it You must press Feed to print a label if the amount of data sent does not fill the buffer to the required level NOTE If you are sending data down through SENDFILE be sure t
93. ppearance but are oriented differently Reversing the two connectors could damage the printer 1 Remove the following connectors from the Control Board e CN2 Printhead e CN3 Stepper Motor e CN4 Operator Panel e CN6 Power e CN8 Bi Cell Sensor detector e CN11 Bi Cell Emitter e CN15 Ribbon Take Up Motor e CN16 Ribbon Supply Motor NOTE CNS not readily accessible in its installed position It is removed with the board partially lifted free 2 Remove wiring at connectors CN3 CN6 and CN10 from the daughter board 3 Move harness cables aside to allow clearance for board removal 4 Slide AC inlet module boot back to access connectors 5 Disconnect seven spade connectors at back of inlet July 1998 9820 9830 9835 Service Manual 6 Release the AC inlet retaining tabs and slide the AC inlet out the back of the printer 7 Remove the AC inlet s green ground wire from the frame to allow the module to clear the back frame 8 Before removing the Control Board Assembly e Verify the print assembly is in the closed and latched position e pull the two yellow AC supply wires to the front side of the transformer e reposition the parallel port latch wires inside the frame opening CAUTION e Do not bend the hall effect sensor HALL1 located in the upper right corner of the board The leaded device is fragile and can be bent or broken easily e Use care not to scratch the back side of Control Board
94. printer off 2 Remove the Stacker Assembly see Appendix D 3 Remove three cover screws to gain access to the Drive Board 4 Note the positions of all wiring harness connections Disconnect each harness from the Drive Board Lift the Drive Board off its standoffs Reassemble in reverse order Attach the 928 Stacker Assembly and test for correct operation Motor Replacement Turn printer off 2 Remove 928 Stacker Assembly See Appendix D 3 Remove three cover screws to gain access to the motor 4 Remove two motor mounting screws and remove motor 5 Remove knife motor wiring at motor connector 6 Loosen the pulley set screw and remove pulley Make sure set screw is on flat of shaft 7 Reassemble in reverse order July 1998 Model 926 Knife 8 Adjust belt tension 9 Squeeze halfway between pulleys When distance from outside of one side of belt to outside of opposite side is approximately 1 0 tighten screws on motor 10 Turn printer on and test for correct operation 11 Replace the knife cover 12 Attach the Stacker Assembly to the Knife Assembly see Appendix D CONNECTORS AND CABLES The following tables provide pinouts for the Knife Assembly cables and connectors Table E 2 Drive Board Connector J1 To Motor Terminal Table E 3 Drive Board Connector J2 To Motor Solenoid Terminal Printer CN11 Pin Julyl 1998 TC9830SM Rev B 7 98 Confiden
95. printer off servicing the stacker Additional Warnings and Remove stacker from knife assembly Cautions are provided where appropriate as they apply to specific procedures Remove the stacker rear and side covers P P Apply silicon lubricant to the two bearing on the WARNING rear frame and two bearings on the front frame See Figure D 2 P mmo Never perform maintenance on the stacker with the power cord connected Doing so exposes points 5 Replace the stacker covers where AC voltages are present Reattach power cord 6 Reattach stacker to knife only when test procedures indicate that power is required 7 Turn on printer and stacker and test for correct operation CAUTION Static electricity can damage stacker parts Use a static ground wrist strap 62 TC9830SM Rev B 7 98 Confidential July 1998 Model 928 Stacker Rear Frame Full Sensor Front Frame Electronics Cover Side Cover Figure D 3 Model 928 Stacker Assembly 6 9820 9830 9835 Service Manual Unplug stacker power and stacker to knife cable Remove side rear and back covers as necessary to access rollers being replaced From front main frame side remove E ring holding the shaft containing the rollers being replaced Withdraw the shaft from the rear frame side Remove rollers from the shaft while withdrawing the shaft from the frame Reassemble in reverse order If replacing serrated rollers make sure teeth face up
96. ration function is complete when the second 13 Cover the Bi Cell switch with a piece of black valid feature is found and measured The existing electricians tape Completely block all light software has processed the physical aspects of the DO NOT TOUCH THE SENSOR LENS WITH label such as print length feature length and TOF to YOUR FINGERS TOF distance into the tracking system The software 14 With all light blocked from Bi Cell note the can now track the label just seen by the sensor so that reading on SENDFILE This is the reference it hie bci in Vnde position ae value for the sensor Range is 2 35V to 2 55V If printhead Knowing label length provides the ability to reading is out of range replace Bi Cell Sensor predict when the next feature can be expected Therefore the only time the sensor will be enabled is 15 Remove electrical tape after calibration during the window of time when the 16 Place gray scale over sensor glossy side down feature should pass by the sensor The reason in HANDLE FILTER BY EDGES ONLY SKIN using a small window is to minimize detection of OILS CAN ALTER THE BI CELL READING extraneous pulses that may adversely affect the accuracy of the algorithm 17 Close print module and note the Bi Cell reading in SENDFILE 18 From back of Bi Cell housing turn adjusting M ECHANICAL ADJ USTM ENTS screw to obtain the reference value observed in Step 14 This section describes 19 Open and close printhead
97. ror pending Turn printer off Wait 15 second and turn printer on Resend packets If problem continues call Technical Support 792 Check daughter board switches or configuration Reset sensor kit or values 793 Printer job queue is full Turn printer off Wait 15 seconds and turn printer on Resend packets If problem continues call Technical Support July 1998 TC9830SM Rev B 7 98 Confidential 49 9820 9830 9835 Service Manual HARD PRINTER FAULTS 900 910 Errors 900 to 910 are hard printer faults If a 900 series error is displayed turn the printer off then cycle on again If the error occurs again the Main PCB has probably failed and needs to be replaced Printer Error Status Codes Errors 905 906 and 907 can occur at any time the printer is powered The other 900 series errors are only indicated at Level 0 initial power up test Code 900 901 902 903 905 906 907 908 909 910 911 Description RAM test failure ROM EPROM checksum failure Software timer failure Software interrupt failure Illegal interrupt Non maskable interrupt Low RAM error Non Volatile RAM checksum failure RAM corrupted Warm restart Version string mismatch FLASH FAULTS 930 940 Errors 930 940 are errors that may occur during the loading of flash memory Code 930 931 932 933 934 935 936 937 938 938 940 Description Error occurred erasing FLASH Error occurred writing FLASH Error occurred writi
98. s 9830 9835 Service Installed Flash Parallel Port IEEE 1284 compliant or Centronics Mode With Ribbon 40 to 95 degrees F 4 to 35 degrees C Without Ribbon 40 to 104 degrees F 4 to 40 degrees C 15 to 120 degrees F 10 to 49 degrees C 5 to 90 Non Condensing Liquid Crystal Display 3 numeric digits Light Emitting Diodes POWER green SUPPLIES amber PAUSED amber Thin Film 4 15 inches 105mm wide 832 dots 203 dots inch 8 dots mm 0 0049 inch dot width 0 1245 mm center center Thermal Transfer Thermal Direct 9820 labels only 9830 labels only 9835 labels or tags Roll Non Cartridge Standard Smudgeless Durable Steam Resistant High Energy 9830 9835 23 600 inches 600 m 1 3 inches 83 mm 1 6 inches 41 mm 2 16 inches 55 mm 3 15 inches 80 mm 4 13 inches 105 mm 3 6 inches 91 mm 41 to 95 degrees F Print Speed Max Print Image Max Print Tolerance Feed Method Printer Overview and Installation 5 to 35 degrees C 2D Bar Code 2 5 4 or 6 inches sec Serial Bar Code 2 5 inches sec 4 inches wide 102 mm 16 inches long 405 mm 0 050 inches 1 3 mm side to side On Demand Continuous and optional Peel Mode STOCK SPECIFICATIONS Ribbon Thermal Transfer Requirements Stock Width 1 2 inches 81mm 4 25 inches 108mm max Version 5 2 or 75 inches 19mm min greater width Stock Length 1 inch 25mm min Version 5 2 or great
99. second time Figure 2 3 Supply Holder Assembly The supply holder module holds the supply roll in a center justified position to ensure optimum supply tracking The guides are gently pushed inward until they center the roll and back off to the next detent Clear Cancels the current batch from being position when released printed if pressed for only a moment Cancels all batches associated with the The front guide pivots down for supply current format if pressed and held for loading unloading When loading fanfold supply the two seconds Cancels some error stack is placed behind the printer or under the table codes that appear on the LCD and fed through the supply holder guides Feed Pause n Normal mode prints a test CONTROL PANEL ASSEMBLY label Feed Clear Diagnostics mode places the printer in data dump mode See Chapter 4 Diagnostics for more information The Control Panel Assembly is mounted on the front of the printer The associated electronic components are mounted on a circuit board behind the panel fascia A ground wire connects the board to the chassis ground and a single wire harness connects it to the Control Board Assy 12 TC9830SM Rev B 7 98 Confidential July 1998 CHAPTER 3 TROUBLESHOOTING This chapter contains suggestions for diagnostic and repair actions PRELIMINARY CHECK The following checks should be made before going further 1 Are the DIP switches set properly to match communi
100. st replace the printhead EVALUATION OF A 704 ERROR OUT OF SUPPLY This error occurs when the sensor is not sensing the supply This can happen if there is a problem with the supply or with the sensor Perform the following procedure 1 Verify stock is loaded and properly aligned in the supply guide 2 Verify that DIP switches and online settings are set for proper supply type 3 Check Bi cell alignment using gray scale and check operation using diagnostic procedures be sure to check the harness See Sensor Tests and Bi Cell Sensor Adjustment in Chapter 8 for instructions 4 Verify Emitter is operational including the harness by using an infrared detector probe July 1998 TC9830SM Rev B 7 98 Confidential 13 9820 9830 9835 Service Manual Troubleshooting EVALUATION OF A 754 ERROR OUT OF RIBBON This error occurs whenever the ribbon stops turning This can happen if the motors are not working the stock is binding the platen is sticky or if any condition is present that prevents ribbon rotation Perform the following procedure 1 Verify Ribbon Motors are turning If they not check connectors to the Control Board Assy and the connections to the motors 2 Verify Platen Motor is feeding If is is not check the connections EVALUATION OF A 755 ERROR PRINTHEAD OPEN This error occurs if the printhead is not functioning properly Perform the following procedure 1 Ensure the printhead is properly latched
101. status codes are organized into Data Errors Communications Failures Data Formatting Failures Machine Faults and Hard Printer Faults To clear an error status code press Clear If a data formatting error 571 through 619 occurs press Feed The label prints but data may be missing READING AN ERROR LABEL An error label queues and prints when you press FEED after a data error occurs The error label contains the packet type field type line number and error number The packet and field type return the first letter after the or If the letter cannot be determined is returned The line number refers to which line in the packet the error occurs The error number is the three digit error code Use this information to correct the format batch font check digit graphic or online configuration packet MODEL M9830 S W Version 2 0 MODEL M9830 S W Version 2 0 FORMAT NAME 40200 FORMAT NAME BATCH NAME BATCH NAME Bch14002 PACKET TYPE F PACKET TYPE B FIELD TYPE FIELD TYPE B LINE 8 LINE 1 ERROR 1 8 ERROR 101 The first label shows an error in line 8 which is a constant text field within the format packet The error number is 18 The second label shows an error in line 1 of the batch packet The error number is 101 DATA ERRORS 001 499 Error Status Codes 001 to 499 are data errors They indicate that incorrect data was received from the external PC causing the printer to ignore the en
102. stification Ribbon Transfer Rollers Two ribbon transfer rollers are located on the supply side of the module The rollers are ribbed and attached to metal shafts by retainer screws One sits at the very front of the module wall above the printhead while the other is positioned just above the supply deflector July 1998 Functional Description Ribbon Spool Drive Motors wo DC ribbon drive motors are mounded to the back of the module wall Each motor drives a ribbon spool The motors are connected directly to the Control Board Assembly via separate two wire harness Supply Deflector and Bi Cell Emitter IR LED See Chapter 8 Supply Sensing Systems for more information Ribbon Transfer Rollers The two ribbon transfer rollers allow ribbon tension adjustments Each roller has an eccentric which allows slight skew adjustments to each which in turn affects the ribbon tension Functional Description The print module performs ribbon drive operations provides mechanical ribbon tension adjustments performs print functions helps maintain supplies tracking and houses half of the sensor assembly It is controlled by the Control Board Assembly Ribbon Drive Operation The ribbon drive operation is made up of two ribbon spools two 25Vdc drive motors and two ribbon transfer rollers It is controlled by the Control Board Assy Each drive motor sends continuous information to the Control Board Assy where it is used to e
103. switch is set to the 9835 sensing system If no daughter board is installed then the 9820 9830 sensor system control software is enabled For the 9820 30 and for the M9835 the selectable modes are transmissive reflective and non index continuous which currently exists in these models TC9830SM Rev B 7 98 Confidential 41 9820 9830 9835 Service Manual Version 5 2 or greater For the new V5 2 system there will be transmissive reflective non index continuous and center aperture The center transmissive sensor is intended only for supplies that have an aperture hole located in the middle of the web It is referred to as the aperture mode The transmissive edge sensor is used for both die cut and edge aperture supplies The reflective sensor is used with center web black marks The aperture sensing mode is enabled when the software selects the overhead center of web LED as the emitter and the black mark detector located beneath the web and directly under the LED If the transmissive mode is selected then the edge sensor assembly will be used For reflective mode the black mark sensor assembly located under the web will be selected Lower DIP switches 5 and 6 control the supply type sensing system Description 5 6 Die Cut or Edge Aperture Supplies edge sensor OFF OFF Black Mark Supplies center sensor OFF ON Non indexed Continuous Supplies no sensor ON OFF Center Aperture supplies center sensor ON ON The software has
104. t be 1 to 7 or 4 to 90 points for scalable font Horizontal magnification must be 1 to 7 or 4 to 90 points for scalable font Color must be A B D E F N O R S T or W Intercharacter gap must be 0 to 99 dots Field justification must be B balanced C centered E end L left or R right String length is outside range 0 to 2710 Bar code height must be at least 20 English 51 Metric 40 Dots and within supply dimensions Human readable option must be 0 default 1 no CD or NS NS at bottom no CD CD at bottom no NS 5 6 7 CD and NS at bottom 8 no text Bar code type is invalid Bar code density is invalid Line thickness must be 0 to 99 dots Line direction must be 0 90 180 or 270 End row is invalid Line segment or box end row is defined outside of printable area End column is invalid Line segment or box end column is defined outside of printable area Dot pattern for line or box must be Line length is defined beyond maximum length Line type must be S segment or V vector Imaging mode in graphic header must be 0 The format referenced by batch is not in memory Print quantity is outside range 0 to 32000 TC9830SM Rev B 7 98 Confidential July 1998 Printer Error Status Codes 9820 9830 9835 Service Manual 104 105 106 107 108 109 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 251 252 253 254 255 July 1
105. t connectors CN4 and CN5 A separate harness carries power to the knife from printer control board connector CN11 The knife drive board also has a connector to attach cabling to the 928 Stacker Assembly Functional Description The Knife Assembly is controlled by the Feature Board installed in the 9835 Printer All power to the knife is provided by the printer via cabling from the printer control board The rotary knife has a helical blade positioned below the supply path and is activated by the knife solenoid The knife is driven by a DC motor controlled via software by the printer When the knife is enabled by software the motor is turned on and a solenoid located on the Blade Assembly is energized and the knife blade completes one rotation producing a cut tag The motor runs constantly as long as there is power to the knife The Knife Assembly also has circuitry to provide 12 Vdc power and necessary control signals to the attached 928 Stacker Assembly The functionality of the stacker is explained in Appendix D TROUBLESHOOTING Drive Board circuits generate two error codes to assist in the detection of knife failures Error 759 indicates that the knife is not moving and Error 760 indicates a knife jam The following paragraphs contain suggestions for troubleshooting the two conditions Voltage tests are also included to further isolate a knife failure Evaluation of Error 760 The printer software reports an Error 76
106. ta structure They use a 203 dpi thermal printhead for printing The printhead supports both thermal transfer heat activated ribbon and thermal direct heat activated stock printing Figure 1 1 9830 Printer Housing removed The printers have a hinged print assembly for ease in loading and unloading the supply The supply spool lower paper guide and ribbon spool are center justified and can be adjusted by the user to handle various supply widths The printers support fanfold or roll supply The 9835 supports tag stock to 10 mil thickness Standard smudgeless durable and steam resistant ribbon types are supported by all printers Ribbon length is 600 meters and is available in core widths of 1 3 1 6 2 16 3 15 and 4 13 Used ribbon is collected on a take up spool by taping the ribbon leader to an empty core One empty core is supplied with the printer The 9830 9835 models offer a Service installed tear bar Flash ROM programming and an optional Peel Module for separation of supply and backing The Peel Module is standard on the 9830 optional for the 9835 but not available on the 9820 The 9835 supports either a Peel Module or a knife but not both July 1998 TC9830SM Rev B 7 98 Confidential 9820 9830 9835 printer operation is controlled online via an RS 232 port a Centronics parallel port Ethernet adapter or a CoAx TwinAx port Local operation is
107. th Peel ON ON OFF OFF OFF ON 9835 With Knife ON OFF OFF OFF OFF ON 9835 No Peel Knife ON OFF OFF OFF OFF ON FUSE REPLACEMENT Refer to the Operator s Handbook for fuse replacement procedures CONNECTING TO A HOST For instructions on connecting the printer to a host refer to the Operator s Handbook 4 TC9830SM Rev B 7 98 Confidential July 1998 Printer Overview and Installation 9820 9830 9835 Service Manual Table 1 2 Exterior Rear SW2 SW3 DIP Switch Settings Upper DIP Switches ins 38400 ON OFFOFFL 980 poe L 8DaaBits 8DataBis Stop Bis 11111 2StopBis 11 ONStopBit jor tStpBt Pl 7 Even l None Os TT July 1998 TC9830SM Rev 7 98 Confidential 9820 9830 9835 Service Manual Printer Overview and Installation Lower DIP Switches SELECTION 1 2 3 4 5 6 7 a DEFAULT Flow Control EE or XONIXOFF RTSICTS Pere ERIE DTR EM iagnost EE Normal RunMode for oma Diagnostics Mode font Verifier ERE ENEA No Verifier TT dem T 1 1 RN Verifier Installed upply Type Sensing Die Cut or Edge Apertur
108. th for the power ground LED power and sensor output signals NOTE The new supply guide mechanisms are not backward compatible TC9830SM Rev B 7 98 Confidential 37 9820 9830 9835 Service Manual LOWER SUPPLY GUIDE BI CELL SENSOR The supply guide assembly spans the feed module frame just behind and below the platen roller It sits within two d tentes on each frame edge to maintain proper positioning It is held in place by individual plastic tabs engaging square holes on both sides of the frame Two center justifying supply guides sit on top of a guide frame and are interlocked A guide lock arm is positioned on the outside guide The Bi Cell supply sensor and housing are attached to the middle of the supply guide frame so that it is lined up with the IR emitter in the upper supply guide The sensor wiring harness attaches to the sensor housing and runs along the bottom of the guide frame and through the feed module frame to the Control Board Assembly Version 5 2 or greater The center justified reflective sensor is mounted on the lower supply guide support and provides an index signal when using black mark butt cut labels and black mark tags The reflective sensor is surface mounted to the reflective sensor junction PCB assembly NOTE The new supply guide mechanisms not backward compatible SUPPLY FEEDING The main components of supply feeding are the platen roller 25VDC stepper motor and supply guide
109. the capability of identifying both the Main Processor circuit board level and the sensor system installed in a printer The V5 2 software is compatible with combinations of previous main processor boards and sensor systems It also supports the new main processor board with V5 2 and earlier sensor systems installed Use Sendfile to save in flash the code that identifies that the V5 2 sensor hardware is installed 42 TC9830SM Rev B 7 98 Confidential Supply Sensing Systems Performing a Sensor Display Test This test is performed online using SENDFILE with version 5 0 or earlier printers 1 To display Analog to Digital static values minimum and maximum A D dynamic values or information on options press D To see the min max range of each of the A D channels highlight each sensor output and press Enter SENDFILE displays the following channels e e Head Temp Head Volt e Dot Test e Back EMF e High Volt e Contrast e Bi cell Version 5 2 or greater To perform a sensor test with version 5 2 or greater see Sensor Setup With Version 5 2 or Greater earlier in this chapter July 1998 APPENDIX A PRINTER ERROR STATUS CODES This section contains the error status codes used with the 9800 series printers These same codes are called status codes when they are displayed on the Control Panel LCD and error codes when they are part of Diagnostics Status Polling test sequences These error
110. tial 9820 9830 9835 Service Manual Table E 5 Drive Board Connector J4 To 928 Stacker Assembly Pa seme DT 3 2 p nk E 52 NET MET 2 2 3 fo p pl p Table E 6 Knife Drive Board Connector J5 From Printer Daughter Board CN5 PIN 5 CN5 PIN 1 CN5 PIN 2 CN5 PIN 3 CN4 PIN 6 CN4 PIN 1 CN4 PIN 3 CN4 Pin 2 GROUND 1 STKR_PRESENT STKR_ERROR 2 5 GROUND CUT_PRESENT CUT_ENABLE CUT_ERROR CN5 PIN 5 CUT_CONTROL EN 69 9820 9830 9835 Service Manual Model 926 Knife 70 TC9830SM Rev B 7 98 Confidential July 1998
111. tion from stock to gap and back These transitions produce an analog waveform which changes from reference typically 2 5 VDC or approx 128 A D counts These voltages are continually monitored and adjusted by the microprocessor Because of this microprocessor control no meaningful static measurements can be made to the sensing circuitry Paper to Gap is a negative waveform whose active threshold is 41 75 VDC or 89 A D counts waveform must drop approx 10 A D counts to be acted upon as a valid transition Gap to Paper is a positive waveform whose active threshold is 3 25VDC or 166 A D counts The 9835 uses a new sensing system that is optimized for black mark sensing while still having the ability to detect die cut supplies All 9835 printers contain a set of matched components that are factory adjusted Our intent is to produce a sensing system that does not require physical alignment in the field If a sensor fails order a Sensor Kit 11879801 The kit contains a matched set of components that must be installed and configured using Sendfile Version 2 14 or later Version 5 2 or greater When a label advance command is received the software checks to see if the supply has been calibrated If not Resync resets the A D signal measuring parameters When the supply starts moving forward the A D signal value is captured It is matched against the highest value saved and the lowest value saved If the new value is larger then the
112. tire print job After checking the packet and correcting the problem transmit the print job again The following is a list of data errors These errors occur because data in the format batch check digit font or graphic packet is invalid Code Description 001 Packet ID number must be 1 to 999 002 Name must be 1 to 8 characters inside quotes or a printer assigned name 003 Action must be A add or C clear 004 Supply length is invalid 005 Supply width is invalid 006 Storage device must be R volatile RAM 007 Unit of measure must be E English M Metric or G Dots July 1998 TC9830SM Rev B 7 98 Confidential 43 9820 9830 9835 Service Manual Printer Error Status Codes 010 011 012 013 014 015 016 017 018 020 021 022 023 024 025 030 031 032 033 040 041 042 043 044 045 046 051 101 102 44 Field ID number is outside range 0 to 999 Field length exceeds 2710 Row field position is greater than maximum stock dimension Column field position is greater than maximum stock dimension Font style must be 1 2 3 4 10 11 15 16 17 18 or 50 Character rotation must be 0 0 degree 1 90 degree 2 180 degree or 3 270 degree Field rotation must be 0 0 degree 1 90 degree 2 180 degree or 3 270 degree Field restriction must be V variable or F fixed Code page selection defined in field must be 0 Internal 1 ANSI 2 DOS 437 or 3 DOS 850 Vertical magnification mus
113. toward end of stacker bed Replacing Transport Assembly 1 Disconnect the power 2 Remove the upper transport lockshaft or BAIL and set aside REPLACE ROLLERS 3 Remove transport covers 118480 118479 118532 4 Remove aluminum support plate 110590 to E Clips acess the lower drive shaft pulley and spur gear 5 Loosen the set screws from the lower drive shaft pulley 110594 and spur gear 098330 6 Remove aluminum pulley 098367 to allow lower exit drive shaft s spur gear clearance for removal 7 Remove the pulley and spur gear 8 Remove the lower drive shaft pulley 110594 and white spur gear 098330 9 Remove the remaining four white spur gears 098330 10 Remove the four black idler gears 098373 and keep the attaching screws and nylon washers 11 Remove the E Ring from the gear train side of the rear main frame 118475 on the upper exit drive shaft 098320 12 Pull out the old drive shaft from the front main frame 118476 operator side of 928 13 Turn the 928 upside down and remove the front mounting plate 118467 to allow access to the front main frame 118476 mounting screws 14 Remove the two front main frame screws 15 Turn the stacker upright and remove all of the E rings and screws holding the front main frame 118476 attaching assemblies 16 Disconnect the spring from the tamper plate to allow the front main frame 118476 to be Figure D 5 Upper Transport Rollers J
114. ue calculated from the previous two features TOF BOF Average BOF TOF Threshold1 BOF TOF Threshold2 2 SUPPLY DEFLECTOR BI CELL EMITTER IR LED The supply deflector is attached to the bottom of the print module and pivots up and down to load labels and ribbon The IR Emitter is mounted in the center of the deflector which positions it in the middle of the paper path and above the supply sensor located in the supply guide Version 5 2 or greater The sensing system consists of three sensing systems an edge justified transmissive sensor a center justified reflective sensor and a center justified transmissive sensor which contains an LED positioned directly over the phototransistor of the reflective sensor The edge justified transmissive sensor provides an index signal when using die cut labels and edge justified aperture tags It is mounted on the inside supply guide and moves with the guide depending on the supply width This sensor is connected with an integral harness to the reflective sensor junction board The center justified overhead LED is mounted in the upper supply guide flapper and the phototransistor of the reflective sensor located below the web and provides an index signal when using center justified aperture tags The overheard LED is connected with a harness to the reflective sensor junction board A wire harness connected between the main PCB and the reflective sensor junction board provides the pa
115. uly 1998 TC9830SM Rev B 7 98 Confidential 63 9820 9830 9835 Service Manual removed from the stacker Be careful not to lose the spring 17 Slide the front main frame off the tamper plate shaft and gently pull it clear of the stacker 18 The old lower transport assembly should now be held in place by the four remaining plastite screws on the rear main frame 118475 19 Remove 4 screws holding the assembly in place and remove the lower transport assembly 20 Install the replacement kit 21 Reassemble in reverse order Replace DC Motor Unplug stacker power and stacker to knife cable Remove rear back and side covers Disconnect motor wiring harness at motor terminals 1 and 2 4 Remove four motor mounting screws belt and motor assembly 5 Reassemble in reverse order Hepiace Stepper Motor Unplug stacker power and stacker to knife cable 2 Remove rear back and side covers 3 Loosen set screws and remove belt speed adjustment knob 4 Remove belt adjustment potentiometer mounting nut and washer 5 Remove four screws and electronics cover 6 Disconnect motor wiring harness at control board connector P1 7 Remove four motor mounting screws belt and motor assembly 8 Reassemble in reverse order Replace Stacker Sensors The stacker full and stacker jam sensors share the same wiring harness so replace as an assembly Unplug stacker power and stacker to knife cable 2 Remove screw atta
116. unctional Description 12 CHAPTER 5 13 PRELIMINARY 13 ANALYZING FAILURE DURING POWER UP 13 EVALUATION OF A 616 ERROR DOT SHIFTING FAILED 13 EVALUATION OF A 704 ERROR OUT OF SUPPLY 13 EVALUATION OF A 754 ERROR OUT OF 14 EVALUATION OF A 755 ERROR PRINTHEAD 14 EVALUATION OF A 765 ERROR PRINTHEAD 14 EVALUATION OF THE CONTROL BOARD ASSY 14 EVALUATION OF COMMUNICATIONS 14 GENERAL TROUBLESHOOTING SUGGESTIONS 15 CHAPTER 4 DIAGNOSTICS
117. valuate ribbon conditions maintain optimum ribbon tension and sense the end of ribbon condition This system eliminates the need for ribbon sensors Printing The printhead has a line array of 832 dot elements sized to produce 203 dots per inch Printing occurs by sending image data to the printhead one line at a time Each time a line of data is received corresponding dots on the printhead are heated to create an image line on the stock Successive image lines generated across moving stock make up the total image The Control Board Assy controls all image data sent to the printhead and regulates the energy level of the printhead Energy levels are raised and lowered to create darker or lighter print respectively FEED ASSEMBLY The feed module components are mounted on a metal frame positioned beneath the Print module and July 1998 9820 9830 9835 Service Manual fastened to the printer base Components of the feed module are Spring Figure 2 2 Feed Assembly Platen Module The platen rollers are on top of the feed module frame just beneath the printhead It is held in place by two bearing blocks latched on the frame sides The inner side of the platen roller shaft extends through the inside wall of the feed module where a drive gear is attached 24V DC Stepper Motor The stepper motor is located behind the mid frame of the printer Its drive shaft and gear extends through to the space between the printer mid frame
118. witch settings TOOLS REQUIRED Small Flat Blade Screwdriver NOTE If software control is enabled by setting rear DIP switches 1 thru 3 to OFF all rear communications switches are ignored Downloaded communications settings remain in effect until a new packet is sent or until software control is disabled by setting rear DIP switches 1 thru 3 to a valid baud rate Downloaded communications settings remain in memory and take effect when software control is again enabled DIP Switches for Version 5 2 or greater are shaded TC9830SM Rev B 7 98 Confidential 3 9820 9830 9835 Service Manual Printer Overview and Installation m 1 Locate Upper or Lower DIP Switch block as Upper DIP Switches shown in Figure 1 3 2 Turn printer off and change individual DIP switches as required Use Table 1 1 as a guide 3 Daughter board SW1 settings are factory set However when replacing the Control Board Assembly the new board must be set as shown in Table 1 1 Lower DIP Switches ibe Figure 1 3 SW2 SW3 DIP Switch Location Table 1 1 Daughter Board DIP Switches SW1 SW2 SW3 SW4 SW5 SW6 Model Peel Not used Fox IV Paxar CL Memory 9820 OFF OFF OFF OFF OFF OFF 9820 with new ON OFF OFF OFF OFF OFF sensing system 9830 No Peel OFF OFF OFF OFF OFF ON 9830 With Peel OFF ON OFF OFF OFF ON Fox IV OFF ON OFF ON OFF ON printer applicator Paxar CL OFF ON OFF OFF ON ON 9835 Wi
119. x listing when white is under the sensor e adie cut label gap is under the sensor The Max listing should be greater than the Min listing when e black is under the sensor e solid black area of a die cut label is under the sensor The OK listing tells whether the sense mark on the supply passed a detection test Press gt to see the other readings If you are not using a Version 5 2 sensing system and you try to check the supply quality the message HW not supported appears TC9830SM Rev B 7 98 Confidential 25 9820 9830 9835Service Manual Confidential Tests and Adjustments 26 TC9830SM Rev B 7 98 Confidential July 1998 CHAPTER 6 SERVICE PROCEDURES MAINTENANCE OVERVIEW This chapter describes removal and replacement procedures for the following assemblies Operator Control Panel Cover Housing Power Transformer Assembly Power Transformer Bridge Rectifier AC Inlet Control Board Assembly Print Assembly Bi Cell Emitter Upper Supply Guide Printhead Module Ribbon Spool Assemblies Ribbon Roller Assemblies DC Ribbon Motors Feed Assembly Platen Module Bi Cell Sensor Lower Guide Assembly Supply Holder Assembly Supply Holder Supply Holder Guides Platen Motor Peel Module GENERAL SAFETY TIPS Note these general safety reminders before servicing the printer Additional cautions and warnings appear in this document as they apply to specific procedures CONTROL PANEL REMOVAL TOOLS REQUIRED e P

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