PM4i Service Manual

Service Manual
EasyCoder® PM4i
Bar Code Label
Printer
Intermec Technologies Corporation
Worldwide Headquarters
6001 36th Ave.W.
Everett, WA 98203
U.S.A.
www.intermec.com
The information contained herein is provided solely for the purpose of allowing customers to operate
and service Intermec-manufactured equipment and is not to be released, reproduced, or used for any
other purpose without written permission of Intermec Technologies Corporation.
Information and specifications contained in this document are subject to change without prior
notice and do not represent a commitment on the part of Intermec Technologies Corporation.
© 2005-2007 Intermec Technologies Corporation. All rights reserved.
The word Intermec, the Intermec logo, Norand, ArciTech, Beverage Routebook, CrossBar,
dcBrowser, Duratherm, EasyADC, EasyCoder, EasySet, Fingerprint, INCA (under license), i-gistics,
Intellitag, Intellitag Gen2, JANUS, LabelShop, MobileLAN, Picolink, Ready-to-Work, RoutePower,
Sabre, ScanPlus, ShopScan, Smart Mobile Computing, SmartSystems, TE 2000, Trakker Antares,
and Vista Powered are either trademarks or registered trademarks of Intermec Technologies
Corporation.
There are U.S. and foreign patents pending.
The name Centronics is wholly owned by GENICOM Corporation.
Microsoft is a registered trademark of Microsoft Corporation.
Torx is a registered trademark of Camcar Division of Textron Inc.
TrueDoc is a registered trademark of Bitstream, Inc.
TrueType is a trademark of Apple Computer Inc.
Unicode is a trademark of Unicode Inc.
Windows is a trademark of Microsoft Corporation.
ii EasyCoder PM4i Bar Code Label Printer Service Manual

Contents
Before You Begin................................................................................................................. vii
1 Models and Options

1.1 Identification ..................................................................................................................2
1.2 EasyCoder PM4i Printer Specifications ..........................................................................7
1.3 EasyCoder PM4i Printer Dimensions..............................................................................9
2 Front and Keyboard

2.1 Front..................... ........................................................................................................14
2.2 Keyboard ......................................................................................................................15
2.3 Console PCB ................................................................................................................16
3 Covers and Doors

3.1 Right-Hand Door .........................................................................................................20
3.2 Front and Left-Hand Cover ..........................................................................................21
3.3 Front Door ...................................................................................................................22
4 Chassis 4.1 Description........... ........................................................................................................24

4.2 Center Section ..............................................................................................................25
4.3 Bottom Plate .................................................................................................................25
5 Media Supply
5.1 Internal Supply .............................................................................................................28
5.2 Label Slack Absorber .....................................................................................................31
5.3 Print Mechanism Edge Guide .......................................................................................32
5.4 Internal Fan-Fold Guide................................................................................................33
6 Transfer Ribbon Mechanism

6.1 Description........... ........................................................................................................36
6.2 Ribbon Supply Unit ......................................................................................................37
6.3 Ribbon Rewind Unit.....................................................................................................38
6.4 Ribbon Sensor...............................................................................................................39
6.5 Ribbon Motor ...............................................................................................................41
6.6 Front Ribbon Break Shaft .............................................................................................42
6.7 Printhead Ribbon Break Shaft .......................................................................................43
7 Print Mechanism
7.1 Description............. ......................................................................................................46
7.2 Platen Roller ................................................................................................................49
7.3 Stepper Motor ...............................................................................................................51
7.4 Belts ..............................................................................................................................53
7.5 Label Stop Sensor ..........................................................................................................54
7.6 Printhead ......................................................................................................................60
7.7 Headlift Sensor .............................................................................................................66
7.8 Headlift Mechanism......................................................................................................68
7.9 Media Feed Principles ..................................................................................................72
EasyCoder PM4i Bar Code Label Printer Service Manual iii

8 Liner Takeup Unit
8.1 Description........... ........................................................................................................76
8.2 Takeup Unit Parts .........................................................................................................77
8.3 Fitting a Liner Takeup Unit...........................................................................................78
8.4 Replacing the Timing Belt.............................................................................................78
9 Label Taken Sensor

9.1 Description.. .................................................................................................................80
9.2 Replacement .................................................................................................................81
9.3 Activating the LTS ........................................................................................................81
9.4 Adjustment ...................................................................................................................82
10 Paper Cutter
10.1 Description .................................................................................................................84
10.2 Installation ..................................................................................................................85
10.3 Controlling the Cutter ................................................................................................86
10.4 Media Load .................................................................................................................86
10.5 Servicing .....................................................................................................................87
10.6 Cutter PCB .................................................................................................................89
11 Electronics Compartment
11.1 Introduction ...............................................................................................................94
11.2 Accessing the Electronics Compartment......................................................................94
11.3 Main Parts ..................................................................................................................95
12 Power Supply
12.1 Description .................................................................................................................98
12.2 Replacing the Power Supply Unit ..............................................................................100
12.3 Components .............................................................................................................102
12.4 Schematics ................................................................................................................104
13 CPU Board
13.1 Description ...............................................................................................................108
13.2 Circuits .....................................................................................................................109
13.3 Connections..............................................................................................................114
13.4 Test Points .................................................................................................................115
13.5 Startup ......................................................................................................................116
13.6 Components .............................................................................................................117
13.7 Schematics ................................................................................................................119
13.8 Replacing the CPU board .........................................................................................128
14 Interfaces
14.1 Introduction .............................................................................................................130
14.2 RS-232 Serial Communication Port ("uart1:") ..........................................................131
14.3 USB Interface ("usb1:") ............................................................................................132
14.4 Bar Code Wand Interface (wand:) .............................................................................133
14.5 Installing an Optional Interface Board ......................................................................134
14.6 Serial/Industrial Interface Board (not IPL) ................................................................138
14.7 Double Serial Interface Board (not IPL) ....................................................................148
14.8 RFID Serial Interface Board ......................................................................................158
iv EasyCoder PM4i Bar Code Label Printer Service Manual

14.9 IEEE 1284 Parallel Interface Board ...........................................................................166
14.10 EasyLAN Ethernet Interface Board .........................................................................170
14.11 EasyLAN Wireless Interface Board ..........................................................................175
15 RFID 15.1 Key Components of Intermec RFID Kits ..................................................................182

15.2 Verifying RFID functionality ....................................................................................187
16 Troubleshooting
16.1 Diagnosing................................................................................................................190
16.2 No Reaction at Power Up..........................................................................................192
16.3 Printer Stops Working After Startup..........................................................................193
16.4 CPU Board Failures ..................................................................................................194
16.5 Power Supply Unit Failures .......................................................................................195
16.6 Console Errors ..........................................................................................................196
16.7 Error Messages ..........................................................................................................198
16.8 No Communication (general) ...................................................................................200
16.9 No Serial Communication .......................................................................................201
16.10 Network Communication Troubles .........................................................................203
16.11 Sensor Malfunctions ...............................................................................................207
16.12 Printing Troubles.....................................................................................................210
16.13 Transfer Ribbon Troubles .......................................................................................214
16.14 Liner Takeup Troubles .............................................................................................216
16.15 Memory Card Troubles ...........................................................................................217
16.16 Paper Cutter Troubles..............................................................................................218
16.17 RFID Troubles ........................................................................................................220
A Program Overviews
Intermec Shell v8.0 Overview ...........................................................................................226
Setup Mode Overviews .....................................................................................................227
B Firmware Upgrading
Introduction............... ......................................................................................................244
General Principles .............................................................................................................244
Upgrading From a Memory Card .....................................................................................245
Upgrading From the Host .................................................................................................247
EasyCoder PM4i Bar Code Label Printer Service Manual v

vi EasyCoder PM4i Bar Code Label Printer Service Manual
Before You Begin
This section provides you with safety information, technical support infor-
mation, and sources for additional product information.
Safety Summary
Your safety is extremely important. Read and follow all warnings and cau-
tions in this document before handling and operating Intermec equipment.
You can be seriously injured, and equipment and data can be damaged if
you do not follow the safety warnings and cautions.
Do Not Repair or Adjust Alone
Do not repair or adjust energized equipment alone under any circum-
stances. Someone capable of providing first aid must always be present for
your safety.
First Aid
Always obtain first aid or medical attention immediately after an injury.
Never neglect an injury, no matter how slight it seems.
Resuscitation
Begin resuscitation immediately if someone is injured and stops breath-
ing. Any delay could result in death. To work on or near high voltage, you
should be familiar with approved industrial first aid methods.
Energized Equipment
Never work on energized equipment unless authorized by a responsible
authority. Energized electrical equipment is dangerous. Electrical shock
from energized equipment can cause death. If you must perform autho-
rized emergency work on energized equipment, be sure that you comply
strictly with approved safety regulations.
Sicherheitsübersicht
Ihre Sicherheit ist äußerst wichtig. Lesen und befolgen Sie alle Warn- und
Vorsichtshinweise in diesem Dokument, bevor Sie Intermec-Geräte ver-
wenden und betreiben. Falls die Sicherheitswarnungen und Vorsichtshin-
weise nicht befolgt werden, kann es zu ernsthaften Verletzungen sowie
Geräteschäden und Datenverlusten kommen.
Nicht alleine Reparaturen oder Einstellungen durchführen
Reparieren oder justieren Sie niemals alleine stromführende Geräte. Aus
Sicherheitsgründen muss eine zweite Person anwesend sein, die erste Hilfe
leisten kann.
Erste Hilfe
Nach einer Verletzung unverzüglich erste Hilfe oder medizinische
Betreuung aufsuchen. Verletzungen dürfen nicht vernachlässigt werden,
auch wenn sie noch so unbedeutend erscheinen.
Wiederbelebung
Wiederbelebungsversuche müssen unverzüglich eingeleitet werden, falls
jemand verletzt wird und die Atmung aussetzt. Verzögerungen können zum
Tod führen. Bei Arbeiten an oder in der Nähe von Hochspannung müssen
Ihnen die zugelassenen Erste-Hilfe-Methoden vertraut sein.
EasyCoder PM4i Bar Code Label Printer Service Manual vii

Stromführende Geräte
Niemals an stromführenden Geräten arbeiten, es sei denn Sie wurden von
einer verantwortlichen Stelle dazu berechtigt. Stromführende Geräte sind
gefährlich. Stromschläge durch stromführende Geräte können zu tödlichen
Verletzungen führen. Falls zugelassene Notreparaturen an stromführen-
den Geräten vorgenommen werden müssen, ist darauf zu achten, dass die
genehmigten Sicherheitsvorschriften strikt eingehalten werden.
Safety Information
Your safety is extremely important. Read and follow all warnings and cau-
tions in this document before handling and operating Intermec equipment.
You can be seriously injured, and equipment and data can be damaged if
you do not follow the safety warnings and cautions.
This section explains how to identify and understand dangers, warnings,
cautions, and notes that are in this document. You may also see icons that
tell you when to follow ESD procedures.
A warning alerts you of an operating procedure, practice, condition,
or statement that must be strictly observed to avoid death or serious
injury to the persons working on the equipment.
Warnung: Ein Warnhinweis macht Sie auf ein Betriebsverfahren,
eine Praktik, einen Zustand oder eine Anweisung aufmerksam,
die genauestens befolgt werden muss, um schwere oder tödliche
Verletzungen der an den Maschinen arbeitenden Personen zu
vermeiden.
A caution alerts you to an operating procedure, practice, condition, or
statement that must be strictly observed to prevent equipment damage
or destruction, or corruption or loss of data.
Vorsicht: Ein Vorsichtshinweis macht Sie auf ein Betriebsverfahren,
eine Praktik, einen Zustand oder eine Anweisung aufmerksam, die
genauestens befolgt werden muss, um Schäden oder eine Zerstörung
der Maschine bzw. die Zerstörung oder den Verlust von Daten zu ver-
meiden.
This icon appears at the beginning of any procedure in this manual
that could cause you to touch components (such as printed circuit
boards) that are susceptible to damage from electrostatic discharge
(ESD). When you see this icon, you must follow standard ESD guide-
lines to avoid damaging the equipment you are servicing.
Note: Notes either provide extra information about a topic or contain spe-
cial instructions for handling a particular condition or set of circumstances.
Global Services and Support

Warranty Information
To understand the warranty for your Intermec product, visit the Intermec
web site at www.intermec.com and click Service & Support > Warranty.
Disclaimer of warranties: The sample code included in this document
is presented for reference only. The code does not necessarily represent
complete, tested programs. The code is provided “as is with all faults.” All
viii EasyCoder PM4i Bar Code Label Printer Service Manual

warranties are expressly disclaimed, including the implied warranties of
merchantability and fitness for a particular purpose.
Web Support
Visit the Intermec web site at www.intermec.com to download our cur-
rent manuals (in PDF). To order printed versions of the Intermec manuals,
contact your local Intermec representative or distributor.
Visit the Intermec technical knowledge base (Knowledge Central) at
intermec.custhelp.com to review technical information or to request tech-
nical support for your Intermec product.
Telephone Support
These services are available from Intermec:
In the USA and Canada
call 1-800-755-5505 and
Services Description choose this option
Order Intermec prod- • Place an order. 1 and then choose 2.
ucts • Ask about an existing order.
Order Intermec Media Order printer labels and rib- 1 and then choose 1
bons.
Order spare parts Order spare parts. 1 or 2 and then choose 4
Technical Support Talk to technical support about 2 and then choose 2
your Intermec Product.
Service • Get a return authorization 2 and then choose 1
number for authorized
service center repair.
• Request an on-site repair
technician.
Service contracts • Ask about an existing 1 or 2 and then choose 3
contract.
• Renew a contract.
• Inquire about repair billing
or other service invoicing
questions.
Outside the U.S.A. and Canada, contact your local Intermec representa-
tive. To search for your local representative, from the Intermec web site,
click Contact.
Who Should Read This Document?
This Service Manual is for the person who is responsible for installing,
maintaining and troubleshooting the EasyCoder PM4i printer.
Please note that the operations described in this manual should only be
carried out by skilled and authorized personnel. The printers contain wires
and circuits with up to 380V, which implies the risk of fatal electrical
shock. Moving parts may also cause harm, if incorrectly manipulated.
It is assumed that the reader possesses reasonable skills in mechanics and
electronics and is familiar with the Intermec programming languages (Fin-
gerprint and IPL) and their related standard application programs. Note
that even if the printers are technically identical (with the exception of the
keyboard overlay), Fingerprint and IPL make the printer work quite differ-
EasyCoder PM4i Bar Code Label Printer Service Manual ix

ently and certain devices and options are not supported by IPL. It is also
assumed that the reader has access to the standard tools of an electronics
workshop.
Related Documents
This table contains a list of related Intermec documents and their part
numbers.
Document Title Part Number
EasyCoder PM4i User’s Guide (Fingerprint version) 1-960583-xx
EasyCoder PM4i User’s Guide (IPL version) 1-960584-xx
EasyCoder PM4i Spare Parts Catalog 1-960607-xx
Fingerprint Programmer’s Reference Manual 937-005-xxx
IPL Programmer’s Reference Manual 066396-xxx
In addition to the documents mentioned above, you may also find use for
Installation Instructions for various options.
The Intermec web site at www.intermec.com contains our documents (as
PDF files) that you can download for free.
To download documents
1 Visit the Intermec web site at www.intermec.com.
2 Click Support > Manuals.
3 In the Select a Product field, choose the product whose documentation
you want to download.
To order printed versions of the Intermec manuals, contact your local
Intermec representative or distributor.
x EasyCoder PM4i Bar Code Label Printer Service Manual

1 Models and Options
This chapter describes how to identify the various configurations of the

EasyCoder PM4i printer, provides comprehensive technical specifications,
and gives all important measurements.
EasyCoder PM4i Bar Code Label Printer Service Manual 1

Chapter 1—Models and Options
1.1 Identification
Main Model
The EasyCoder PM4i Printer comes in one main model, which can be
modified in regard of media handling, printhead density, interfaces, firm-
ware, etc. As standard, the printer has an 8 dots/mm (203.2 dpi) printhead
and is capable of both direct thermal and thermal transfer printing,
The printer runs either Intermec Fingerprint Programming Language (FP)
v8.10 (or later) or Intermec Programming Language (IPL) v2.10 or later.
Externally, the difference is visible on the keyboard overlay. Fingerprint
printers have 23 keys and IPL printers have 8 keys (see Chapter 2).
2 EasyCoder PM4i Bar Code Label Printer Service Manual

To identify the printer, start by reading the machine label attached to the
rear of the printer. The machine label contains type, part number, serial
number, and signs of approval.
The printer can use any 100 to 240 VAC, 50 to 60Hz voltage. There is no
manual voltage selector.
Machine label

Options for EasyCoder PM4i Printer

The EasyCoder PM4i Printer can be fitted with a number of options:
• Special Printheads (300 dpi and/or thick media) (see Chapter 7)
• Label Taken Sensor (see Chapter 9)
• Integral Liner Takeup Unit (see Chapter 8)
• Media Supply Hub (replaces supply post) (see Chapter 5)
• 3-inch Adapter (for media supply hub) (see Chapter 5)
• Media Roll Retainer (for media supply hub) (see Chapter 5)
• Paper Sensor (see Chapter 5)
• Fan-Fold Guides (see Chapter 5)
• Cutter with Tray (see Chapter 10)
• Side Door with Keylock (see Chapter 3)
• Real Time Clock Circuit (see Chapter 13)
• One or two interface boards of various types
(only one parallel board with IPL) (see Chapter 14)
• EasyLAN interface (Ethernet or Wireless) (see Chapter 14)
Side door with keylock
Cover Fan-fold guide

(replaces liner
takeup unit
Paper sensor
Label taken sensor
Rotating media
supply hub
Media roll
retainer
Cutter
Cutter tray Special printheads Liner takeup unit 3-inch adapter

Interfaces
As a standard, the printers are equipped with one serial RS-232 port, one
serial USB port, and one wand interface. The USB port and the wand
interface are not supported by IPL. In addition, one EasyLAN interface
and one or two extra interface boards can be fitted, see Chapter 14. IPL
only supports the EasyLAN interface and one parallel interface board.
Provision for Ether-

net connector
Provision for Easy-

LAN antenna
Provision for
one or two interface
boards (only the left
slot used with IPL)
Wand interface
(not used with IPL)
Serial Port (RS-232)
USB Port
(not used with IPL)

Checking Hardware and Firmware

Finally, you may want to inspect the electronics compartment. To do so,
carefully follow the instructions in Chapter 11.
The electronic compartment contains wires and components with
dangerous voltage (up to 380V). Always switch off the power and
unplug the power cord before you remove the cover over the electronics
compartment!
Im Elektronikfach gibt es Kabel und Komponenten, die hohe
Spannungen (bis zu 380 V) führen. Immer die Stromversorgung
abschalten und das Netzkabel abziehen, bevor die Abdeckung des
Elektronikfachs abgenommen wird!
In the electronics compartment, check:
• Type of CPU board
- Check number and size of Flash SIMMs.
- Check size of SDRAM SIMM.
• Any optional interface board fitted?
- Check type, straps, and optional circuits.
Refer to Chapters 13 and 14 for more information.
The PM4i printer comes with either Fingerprint v8.xx or IPL v2.xx firm-
ware. The firmware type and version can be changed with a firmware card
or special software. The keyboard overlay will also need to be changed. The
current firmware type is indicated in the display window.
Fingerprint Only
If the printer is working and possible startup program can be interrupted,
the type of program in the printer can be identified. Connect printer
and computer, open a suitable communication program, and start up the
printer in Fingerprint’s immediate mode. The instructions FILES, FONTS,
and IMAGES will return information about what files, fonts and images
are stored in printer memory. Use the VERSION$ function to check ver-
sion of the Intermec Fingerprint firmware.
You can read the setup in the Setup Mode or using Intermec Shell, which
also allows you to print test labels containing the present setup values. To
enter Shell if a custom-made autoexec-file prevents access, lift the printhead
and press and hold any key on the printer's keyboard (except the <Shift>
key) while you turn on the power. When the Shell countdown begins,
release the key and press <Enter> to start Shell. If you want to print test
labels, lower the printhead. Refer to the User’s Guide and to Appendix
A in this Service Manual for more information on Setup Mode and the
Intermec Shell startup program.
If the printer still does not work, you may need to interview the user.
IPL only
The Test/Service part of the Setup Mode allows several types of test labels
to be printed (see the User’s Guide and Appendix A). IPL also has a number
of commands that return valuable information on the printer’s status (see
IPL Programming, Reference Manual).

1.2 EasyCoder PM4i Printer Specifications

Printing
Print Technique Thermal Transfer and Direct Thermal
Printhead Resolution 8 dots/mm (203.2 dpi) Standard
11.81 dots/mm (300 dpi) Option
Print Speed (variable) 100 to 200 mm/sec. (approx. 4 to 8 in./sec.) 8 dots/mm (203.2 dpi)
100 to 150 mm/sec. (approx. 4 to 6 in./sec.) 11.81 dots/mm (300 dpi)
Print Width (max) 104 mm (4.095 in.) = 832 dots 8 dots/mm (203.2 dpi)
105.7 mm (4.161 in.) = 1248 dots 11.81 dots/mm (300 dpi)
Print Length (max) 32767 dots = 409.5 cm (161.25 in.)1
Media Width (min/max) 25 to 114.3 mm (1.00 to 4.5 in.)
Media Roll Diameter (max) 213 mm (8.38 in.)
Media Roll Core Diameter 38 to 40 mm (1.5 in.) or 76 mm (3 in.)
Ribbon Width (min/max) 25 to 110 mm (1 to 4.33 in.)
Ribbon Roll Diameter, Outer (max) 82 mm (3.2 in.) 450 m (1475 ft)2
Ribbor Roll Core Diameter, Inner 25.4 mm (1 in.)
Print Directions 4
Modes of Operation
Tear Off (Straight-through) Yes
Cut Off Option With paper cutter
Peel Off (Self-strip) Option With liner takeup unit
Firmware (Fingerprint)
Operating System Intermec Fingerprint v8.10 Incl. Direct Protocol
Smooth Fonts TrueDoc and TrueType fonts
Built-in scaleable fonts (std) 15 Unicode fonts3
Built-in bar code symbologies (std) 45
Startup Program (std) Intermec Shell v8.0
Firmware (IPL)
Operating System IPL v2.10
Built-in scaleable fonts (std) 13 scaleable + 21 simulated bitmap
Built-in bar code symbologies (std) 31
Startup Program (std) None
Physical Measures
Dimensions (W×L×H) 298×543×261 mm (11.7×21.4×10.3 in.)
Weight (excluding media) approx. 13.5 kg (30 pounds)
Ambient Operating Temperature +5°C to +40°C (+41°F to +104°F)
Humidity 20 to 80% non-condensing
Electronics
Microprocessor 32 bit RISC
On-board Flash SIMMs 2 sockets (for 4 or 8 MB each) Std. 1 × 4MB
On-board SDRAM SIMM 1 socket (for 8 or 16 MB) Std. 1 × 8MB
Power Supply
AC Voltage 90 to 265 VAC, 45 to 65Hz
PFC Regulation IEC 61000-3-2
Power Consumption Standby 15W; Peak 300W

Sensors
Label Gap/Black Mark/Out of Media Yes Variable position
Printhead Lifted Yes
Ribbon End/Ribbon Low Yes IPL only ribbon end
Paper Low Yes
Controls
Control Lamps 3
Display 2 × 16 character LCD with background light
Keyboard (Fingerprint) 22 keys membrane-switch type
Keyboard (IPL) 7 keys membrane-switch type
Print or Feed/Pause button 1
Beeper Yes
Data Interfaces
Serial 1×RS-232 + 1×USB
Bar Code Wand 1 Not supported by IPL
Connection for Interface Boards 1+2 1 EasyLAN + 2 other
Finisher Interface 1 For cutter etc.
Memory Card Adapter 1 CompactFlash cards
Accessories and Options
Special printheads 8 dots/mm: Thick media 203.2 dpi
11.81 dots/mm: Standard and Thick media 300 dpi
Paper Cutter Option For cut-off operation
Paper Cutter Tray Option For cut-off operation
Integral Self-strip Unit w. Liner Takeup Option For peel-off operation
Rotating Media Supply Hub Option Replaces supply post
3-inch Adapter Option For media supply hub
Media Roll Retainer Option For media supply hub
Internal Fan-fold Guide Option
Side Door with Keylock Option
Label Taken Sensor Option
Real Time Clock Option 10+ years life
RS-232 Interface Cable Option
Parallel Interface Cable Option
IEEE 1284 Parallel Interface Board Option
Double Serial Interface Board Option (not IPL)
Serial/Industrial Interface Board Option (not IPL)
EasyLAN Ethernet Interface Option Model EasyLAN100i2
EasyLAN Wireless Interface Option Model Wireless100i2
External Alphanumeric Keyboard Option (limited functionality in IPL)
CompactFlash Cards Option 8MB to 1GB. Not CF+
Compact Flash Card Protection Plate Option
1
/. The max. print length is also restricted by the amount of free SDRAM memory.
2
/. Max. ribbon length depends on ribbon thickness.
3
/. Latin, Greek, and Cyrillic fonts according to Unicode standard are included.

1.3 EasyCoder PM4i Printer Dimensions

Front View
539 mm (21.22 in.)
101 mm (3.98 in.)
Edge of cover to dot #0: Media path

145 mm (5.71 in.) 114 mm (4.49 in.)
Rear View
45 mm (1.77 in.)
325 mm (12.80 in.)
Paper input: 26 mm (1.02 in.)

Side View
23 mm
(0.91 in.)
261 mm (10.28 in.)
7 mm (0.28 in.)
69 mm (2.72 in.)
18 mm (0.71 in.)
543 mm (21.38 in.)
636 mm (25.04 in.)
Top View
298 mm (11.73 in.)

Bottom View 60 mm (2.36 in.) 430 mm (16.93 in.)
Dot #0: 16 mm (0.63 in.)
15 mm
245 mm (9.65 in.)
(0.59 in.)
6 mm (0.24 in.)
Ø 12 mm
(0.47 in.)
25 mm (0.98 in.)
250 mm (9.84 in.)
Hole: Ø 7.1 mm (0.28 in.)

Foot: Ø 16 mm (0.63 in.)
At least 60 mm (2.3 inches) of free space behind the printer is required for the connectors, and for inserting and removing a memory card.

Cutter with Tray, Side View

150 mm (5.91 in.)
100 mm (3.94 in.)
154 mm (6.06 in.) 593 mm (23.35 in.)
747 mm (29.41 in.)
Cutter with Tray, Top View

136 mm (5.35 in.)

Open Cutter, Side View

160 mm (6.30 in.)
644 mm (25.35 in.)

2 Front and Keyboard
This chapter describes the keyboard and display fitted at the front of the
EasyCoder PM4i Printer.

Chapter 2—Front and Keyboard
2.1 Front
The front and left-hand moulding is made as a single integrated unit which
covers the front of the printer and the electronics compartment. The entire
moulding is illustrated in Chapter 3.
The front contains:
• The membrane-switch keyboard with overlay and print or feed/pause
button.
• The console PCB (Printed Circuit Board)
Left-hand cover moulding
Self-adhesive
overlay
M3 nuts (x4)
Insert keyboard
cables here
Print button
layer
Membrane-switch
keyboard layer
Mounting plate
Console PCB
#T10 Torx screws (x3)

2.2 Keyboard
Keyboard Overlay
The keyboard overlay is fitted on the print button layer using a non-perma-
nent adhesive to allow easy replacement. Custom-made overlays could also
be printed and used to replace the standard overlays for customized appli-
cations or in areas, where the English text is not acceptable. There are two
standard overlays; one for Fingerprint and one for IPL.
Fingerprint overlay IPL overlay
Print Button Layer

The print button layer is permanently glued to the the membrane-switch
keyboard layer and contains a yellow print button dome that activates a
switch on the membrane keyboard layer. The print button dome protrudes
through a hole in the keyboard overlay.
Membrane Switch Keyboard Layer
The keyboard is of membrane switch type and is permanently glued to the
mounting plate. There are 23 switches including the print button switch.
The keys have fixed functions in the immediate and setup modes, but can
also be assigned various functions in Intermec Fingerprint programs. In
IPL, the keys are not user-programmable.
Two flat cables connect the membrane-switch keyboard to P2 and P3 on
the console pcb.
Mounting Plate
The mounting plate holds both the overlay/print button/membrane-switch
keyboard assembly and the console pcb. It is fitted to the left-hand cover
moulding using four M3 nuts accessible from the inside.

2.3 Console PCB

The console PCB contains an LCD (Liquid Crystal Display) and three
LED (Light Emitting Diode) control lamps. It also serves as a connec-
tion point between the keyboard and the I2C bus on the CPU board. It is
attached to the mounting plate using three #T10 Torx screws.
The display has 2 × 16 character with a 5 × 7 dots matrix and background
light. 8 characters are programmable.
The left-hand LED control lamp (marked “Power”) shines green when the
power is on. Power on is also indicated by the display’s background light.
The other two LEDs are programmable using the Fingerprint instructions
LED ON and LED OFF. There is no such facility in IPL. The center LED
(marked “Ready”) is green and blinks when data is received. The right-
hand LED (marked “Error”) is red.
Note: the console PCB is connected to J50 at the front of the CPU board
via a permanently fitted 10-p flat cable. This cable must be disconnected
from the CPU board before the cover can be entirely removed.

1-971651-26 Console PCB; Components
Component Side
Soldering Side

18
IN-CIRCUIT SERIAL PROGRAMMING
VCC
P4
VPP 1
2
3
4
5
VCC VCC
VCC VCC R7
VCC
R8
R15
R4
R6
VCC
15
16
DISP1
3 VDISP A K 2 VCC
R17
R18
R19
R20
R21
R22
5
C3
R/W
4 RS GND 1
6 E
R13
DISPLAY
R5
IC1 P3
PIC16F872
D0
D1
D2
D3
D4
D5
D6
D7
D4
9 CLKIN INT/RB0 21 COLSH R23 1
7
8
9
10 CLKOUT 22 COL0 R24 2
RB1
10
11
12
13
14
23 COL1 R25 3
RB2
1 MCLR/VPP 24 COL2 R26 4
RB3
25 COL3 R27 5
RB4
26 COL4 R28 6
RB5
D4 2 RA0 27 ROW4
RB6
D5 3 RA1 28 ROW3
RB7 P2
D6 4 RA2
D7 5 RA3/VREF
E 6 RA4/T0CKI 11 ROW2
RC0
RS 7 12 ROW1 R29 1
RA5 RC1
13 ROW0 R30 2
VCC RC2
14 SCL R31 3
RC3
15 SDA R32 4
RC4
20 VCC 16 NOTIFY R33 5
RC5
T3 17 R/W 6
RC6
8 GND RC7
18
VCC 19 GND
VCC
C7
C9
P1
C11
C13
C15
R35
P5
C6
C8
C10
C12
C14
C16
1 1
2 2
3 RESET R1
R14
R16
4 LED2 R2
5 LED1 R3
6 I2C_NOTIFY R34
7
8 SDA
9
10 SCL
VCC
1-971651-26 Console PCB; Schematics
D2
R10
D1
T1 R11
VCC
D3
T2 R12
+
C5
C4
EasyCoder PM4i Bar Code Label Printer Service Manual

3 Covers and Doors
This chapter describes the covers and doors used on the EasyCoder PM4i
printer. It covers the following topics:
• The right-hand doors, that is the doors that cover the print mechanism
and media compartment.
• The front and left-hand cover that contains the console and protects the
electronics compartment.
• The front door, that protects the front of the print mechanism.

Chapter 3—Covers and Doors
3.1 Right-Hand Door

The EasyCoder PM4i printer comes as standard with a large door that
covers the print mechanism and the ribbon and media supplies. It has
an inspection window that allows the operator to check the remaining
amount of ribbon and media without having to open the door. The door
swings upwards using two hinges fitted between the center section and the
door by means of four #T20 Torx screws each.
The rear part of the right-hand door has an inlet for external media sup-
plies, such as fan-folded tickets and tags.
The standard door can be replaced by an optional door fitted with a key-
lock that engages the bottom plate. When replacing the right-hand door,
remove the screws that hold the hinges to the door. This preserves the
adjustment of the hinges.
The right-hand door is quite heavy. To avoid injury, make sure you
keep your fingers out of the way when you close the door.
Die rechte Tür ist sehr schwer. Verletzungen vermeiden! Die Finger
beim Schließen der Tür vom Türspalt fernhalten.
Optional keylock
Inspection window
Hinge (x2)

3.2 Front and Left-Hand Cover

The front/left-hand cover is fitted with a number of user interface devices,
see Chapter 2.
Removing the front/left-hand cover gives access to:
• The electronics including CPU board, AC connection, power supply,
and any optional interface PCBs.
• The motor, belts, and pulleys of the media feed and the optional liner
takeup unit and ribbon feed motor.
The left-hand cover plate is fitted to the center section using eight #T20
Torx screws; four are accessible from the media compartment and the other
four from the underside of the bottom plate.

To remove the cover

1 Disconnect the power cord.
dangerous voltage (up to 380V). Always switch off the power
and unplug the power cord before you remove the cover over the
electronics compartment!
2 Tip the printer over so it rests on its left cover. Place it on a soft cloth or
similar to avoid scratches.
3 Open the right-hand door.
4 Using a #T20 Torx screwdriver, remove the four screws that holds the
cover along the lower left edge of the bottom plate and the four screws
that hold the cover to the center section (see illustration).
5 Put the printer back on its feet and remove the cover while
disconnecting the console cable from the CPU board.
6 Put the cover aside taking care to avoid scratches.
Install the cover like this:
• Put back the left-hand cover in reverse order. Route the cable from the
console unit above the ribbon motor to prevent it from being entagled
in the headlift mechanism. Connect the cable to connector J50 at the
upper right corner of the CPU board. Make sure that the lower edge of
the cover is pressed inwards as far as it goes before tightening the screws.
3.3 Front Door

The front door protects the print mechanism and is affixed with two
#T20 Torx screws to the upper side of the bottom plate. It cannot be used
together with a cutter.
The door can be tilted down to facilitate media and ribbon load.
#T20 Torx screw (x2)

4 Chassis
This chapter describes the center section, bottom plate, and rubber feet, of
the EasyCoder PM4i printers.

Chapter 4—Chassis
4.1 Description
The printer’s chassis consists of two main parts:
• The center section
• The bottom plate
Center section
Bottom plate

Plastic dampeners (x2)
Rubber foot (x4)

(enlarged)
Provision
for cutter or
front door

Chapter 4—Chassis
4.2 Center Section

The center section is where most parts are fitted, such as the print mecha-
nism, the transfer ribbon mechanism, the liner takeup unit, and the media
supply. The center section is fitted to the bottom plate by a total of four
#T20 Torx screws.
In the electronics compartment, the CPU board and power supply unit are
fitted to the center section. The power supply unit is also attached to the
bottom plate using two screws.
compartment!
4.3 Bottom Plate

The bottom plate is fitted with four easily replaceable rubber feet. These
feet could be removed and the holes be used to bolt the printer to a frame,
table or similar. The holes have a diameter of 7.1 mm (0.28 inches). To
reduce noise, fit rubber dampeners between the table and the printer if you
bolt it in place.
When fitting a replacement foot, insert it through the bottom plate and
firmly press the pin so the rivet expands on the upper side of the plate.
The two keyholes should not be used to bolt the printer to a frame, or the
bottom plate may be bent. These holes are only used for fixtures during
manufacturing.

Chapter 4—Chassis
There are two self-adhesive plastic dampeners attached to two tabs along
the right edge of the bottom plate to reduce noice when the right-hand
door is closed.

5 Media Supply
This chapter explains the media supply roll post and the two types of
adjustable media edge guides. It also covers the rotating media supply hub
with the 3-inch adapter, the media roll retainer, and the paper low sensor.
Finally, it describes how an external media supply can be used in a standard
EasyCoder PM4i printer and in a printer fitted with an internal fan-fold
guide.

Chapter 5—Media Supply
5.1 Internal Supply

Being of a modular design for maximum flexibility, the EasyCoder PM4i
printer can use either a media supply roll post or a rotating media supply
hub inside the media compartment. Alternatively, an external media
supply (for example a box of fan-folded tickets) behind the printer can be
used, preferably in connection with an internal fan-fold guide.
Media Supply Roll Post

The media supply roll post fits both 38 to 40 mm (1.5 inch) and 76 mm
(3 inches) media roll cores because the post can be moved vertically in a
slot in the center section. The bottom position is used for small cores and
the top position is used for large cores. The post is locked by a straight-slot
screw.
There are two edge guides delivered with the EasyCoder PM4i printer; a
low guide is fitted as standard and a high guide is packed with the other
accessories. The operator can switch between the two guides at will. Just
pull out the guide as far as it goes and twist it carefully to release it from
the post.
Both guides can be tilted down to a horizontal attitudes when they are
in their extreme outer positions. In case of the low edge guide, this is not
necessary when 76 mm (3 in.) media cores are used.
After the media roll has been loaded, it is important that the edge guide is
adjusted so the roll becomes flush with the center section.
m
76 m )
.
(3 in
E
COR m
0m
38-4 in.)
(1.5
Straight-slot screw
(hidden)
Low edge guide
Media supply roll post
High edge guide

Media Supply Hub

The rotating media supply hub consists of four bobbin modules on
threaded shaft that is fitted to the center section. To remove the bobbins
from the shaft, remove the #T20 Torx screw and washer and pull out the
bobbin modules. When fitting or removing the shaft, protect it using a
piece of tape or similar to avoid dents and marks.
The hub is designed to fit media roll cores with an internal diameter of 38
to 40 mm (1.5 inches). 76 mm (3 inches) cores can also be accepted by
fitting an optional 3-inch adapter on the hub. Secure the adapter on the
hub using the locking screw. Make sure that the screw hits an even plastic
surface on the hub (not a metal leaf-spring).
Some media rolls have a tendency to become unwound in an outward
spiraling direction. Thus, Intermec offers an optional media roll retainer,
that can be pressed onto the media supply hub after the media has been
loaded and keeps the media in place even if the printer is tilted sideways.
The retainer restricts the media width to a maximum of 100 mm (3.94
inches).
Hub
#T20 Torx screw

and washer
Locking
screw
Paper sensor
cover
Media roll retainer

3-inch adapter

Paper Sensor (Fingerprint Only)

The paper sensor can only be used in connection with a media supply hub
and allows the firmware to detect when the diameter of the remaining
media becomes less than a value set in the Setup Mode (Media/Paper/Low
Diameter). This affects SYSVAR(46) which switches from 0 to 1. Thus, a
Fingerprint program can be created, that reads SYSVAR(46) and uses it to
issue for example audible alarms or error messages to notify the operator of
a pending out-of-media condition.
The sensor detects a pattern of dark and light sectors at the back of the disk
at the inner end of the media supply hub. By comparing the rotation speed
of the hub and the print speed, the firmware can calculate the diameter of
media roll.
The paper sensor assy is snap-locked to the center section below the media
supply hub and is connected to J57 on the CPU board (see Section 13.3).
The cover is always fitted regardless whether it contains a sensor or not.
To adjust the paper sensor
1 Enter Setup mode and navigate to Media > Paper > Paper Sensor.
2 In the Paper Sensor menu, press <Enter> to perform a Testfeed.
The printer will feed out a few labels and feed the ribbon accordingly.
3 While the media feed mechanism is operating, the paper sensor is
autoadjusted and the resulting adjustment value is shown in the lower
line of the menu (read-only).
Sensor inside
Cover
Snap-lock (x4)
Cable
Connect to J57 on CPU board

5.2 Label Slack Absorber

The EasyCoder PM4i printer is provided with a spring-loaded slack
absorber between the media supply and the print mechanism. The slack
absorber compensates for jerks in the media when the printing starts and
stops in order to make the media feed as smoothly as possible. The label
slack absorber body is snap-locked to a threaded shaft attached to the
center section. One end of the spring is attached to the center section using
a #T10 Torx screw and the other to the body of the absorber.
A green plastic edge guide is fitted to the body of the label slack absorber
and can be adjusted for various media widths.
To remove the slack absorber, disengage the snap-lock inside the body
and pull it away from the shaft. Protect the shaft from scratches using for
example insulating tape and remove it using a pair of pliers. Assemble in
reverse order.
#T10 Torx screw
Spring
Snap lock
Shaft Body
Edge guide

5.3 Print Mechanism Edge Guide

To the rear of the print mechanism is an adjustable edge guide. The guide
is fitted onto a shaft affixed to the center section. The same shaft also holds
the upper part of the media guide. The edge guide can be moved along the
shaft to fit various media widths and be locked using a knurled nut.
Before removing the edge guide, remove the upper media guide as
described in Section 7.5.
Edge guide
Knurled nut
Shaft
Upper media guide

5.4 Internal Fan-Fold Guide

For temporary use of an external supply, the media can be routed through
the slot in the rear part of the right-hand door and use the existing edge
guides. However, for permanent use of an external supply of, for example,
fan-folded tickets or tags, it is recommended to use the optional internal
fan-fold guide.
The internal fan-fold guide is a factory-installed option. The fan-fold guide
is fitted to the bottom plate and center section. The S-shaped guide behind
the print mechanism, the label slack absorber, the internal liner rewind
unit, and the media supply roll post or hub are omitted.
The fan-fold guide can be adjusted from full media width down to 40 mm
(1.57 in.) by untightening two knurled nuts and moving the outer guide
inwards or outwards accoiding to the media width. Then tighten the nuts.
The fan-fold guide cannot be used in connection with peel-off (self-strip)
operation.
As the media will be not be fully protected by the printer cover, the user
should take care to protect the exposed media supply from dust, dirt, and
so on. Direct thermal media should also be protected from heat, direct
sunlight, moisture, oil, plasticizers, and fat.
Outer guide Knurled nut (x2)

(adjustable)


6 Transfer Ribbon Mechanism
This chapter describes the mechanism that drives the thermal transfer
ribbon in the EasyCoder PM4i printer. It covers the following topics:
• Description
• Ribbon supply unit
• Ribbon rewind unit
• Ribbon sensor
• Ribbon motor
• Front ribbon break shaft
• Printhead ribbon break shaft

Chapter 6—Transfer Ribbon Mechanism
6.1 Description
The thermal transfer ribbon mechanism is standard in EasyCoder PM4i
printer. The mechanism consists of seven main parts:
• Ribbon supply unit (see Section 6.2)
• Ribbon rewind unit (see Section 6.3)
• Ribbon sensor (see Section 6.4)
• Ribbon motor assembly with gearbox (see Section 6.5)
• Adjustable front ribbon break shaft (see Section 6.6)
• Rear ribbon break shaft intergrated with the print mechanism
• Printhead ribbon break shaft (see Section 6.7)
Ribbon Supply Unit
Ribbon Rewind Unit
Ribbon Motor assy.

Ribbon Sensor
(hidden)
(hidden)
Front Ribbon Break

Shaft
Printhead Ribbon Break Shaft Rear Ribbon Break Shaft

6.2 Ribbon Supply Unit

Description
The ribbon supply unit accommodates the supply of thermal transfer
ribbon. For troublefree printing, use ribbons recommended by Intermec.
Ribbon Specifications
Width: 25 to 110 mm (1 to 4.33 in.)
Roll diameter (outer), max.: 82 mm (3.2 in.)
Roll core diameter (inner): 25.4 mm (1.00 in.)
Ribbon length, max.: approx. 450 m (1,475 ft)
The unit is designed to keep the ribbon tight all the time in order to avoid
wrinkling and creases, which would ruin the printout. It consists of a shaft,
screwed into the center section, on which a bobbin is snap-locked. Inside
the bobbin is a hub with a tab that engages a hole in the center section and
a spring clutch. The bobbin is fitted with a plate that holds the cardboard
core of the ribbon roll.
Inside the inner end of the bobbin is a pattern of reflecting and non-
reflecting sectors by means of which the ribbon sensor can detect the
rotation of the bobbin.
When the bobbin is rotated, the spring clutch is unwound and tries to pull
the ribbon back onto the roll. As the pulling force increases, the clutch
starts to slip and the ribbon can be unwound while still being kept tight.
The bobbin can rotate in both directions. Thus, ribbons wound with the
ink-coated side facing either inwards or outwards can be used.
Detection Pattern
Spring Clutch
Hub
Tab
Ribbon
Sensor
Bobbin
Bobbin Plate
Shaft
Replacement
1 Pry the two legs of the snap-lock in the bobbin apart using a pair of flat-
tipped screwdrivers while pulling out the bobbin with the spring clutch
and hub. Avoid removing the hub and spring clutch from the bobbin.
2 If the shaft needs to be removed, use a piece of insulating tape to protect
the shaft from being scratched by the tool.
3 Reassemble in reverse order.

6.3 Ribbon Rewind Unit

Description
For logistic reasons, the ribbon rewind unit consists of the same parts as
the ribbon supply unit (see Section 6.2) with the exception that there is no
spring clutch.
The ribbon rewind bobbin winds up the used ribbon on its cardboard
core after printing. It is driven via a gearbox by the ribbon motor. A gear
wheel in the gearbox engages the cogs along the rim of the inner part of
the bobbin. The bobbin rotates counterclockwise to wind up the ribbon
during printing or clockwise to allow the ribbon to follow the media when
it is pulled back.
Bobbin
Hub
Tab
Shaft
Bobbin Plate
Replacement
1 Pry the two legs of the snap-lock in the bobbin apart using a pair of
slotted screwdrivers. At the same time, pull out the bobbin.
2 Remove the hub from the shaft, if necessary.
3 If the shaft needs to be removed, use a piece of insulating tape to protect
the shaft from being scratched by the tool.
4 Reassemble in reverse order. Take care so the cogs along the rim of the
bobbin engage the gear wheel in the gearbox properly.

6.4 Ribbon Sensor

Description
The ribbon sensor is snap-locked to the center section from the media
compartment side and is completely enclosed by the ribbon supply unit
(see Section 6.2). The sensor consists of a plastic housing with a LED and a
photoelectric sensor.
The light from the LED is alternately reflected or absorbed by black and
silver-colored sectors on a label fitted at the inner end of the ribbon supply
bobbin. The signals from the sensor allow the firmware to detect the speed
with which the bobbin rotates and compare it with the speed of the media
feed.
If no bobbin rotation is detected during media feed, the Fingerprint
firmware assumes an error condition (error 1027 “Out of transfer ribbon”)
provided the printer is set for thermal transfer printing. In IPL, the error
message “Ribbon out” is displayed.
When the printer is set for direct thermal printing, the ribbon motor
is switched off and the takeup will not work. If a ribbon is nevertheless
loaded, it will be pulled out in front of the printer by the advancing media
without any warning.
The ribbon sensor is connected to J56 on the CPU board (see Section
13.3).
Housing
Snap-Locks
LED and Sensor

Replacement
1 Open the media compartment door.
2 Remove the cover over the electronics compartment as described in
Section 10.2, taking all precautions against electric shock.
3 Remove any transfer ribbon from the ribbon supply unit.
4 Remove the ribbon supply bobbin with hub and spring clutch as
described in Section 6.2.
5 Disconnect the sensor’s cable from J56 on the CPU board.
6 From inside the electronics compartment, compress the snap-locks and
pry out the sensor into the media compartment.
7 Install a replacement sensor unit in reverse order.

Adjustment (Fingerprint)
Low diameter
In the Setup Mode, it is possible to specify the diameter (in millimeters) of
the ribbon supply roll, where a ribbon low condition should be detected.
By default, this parameter (Media/Paper Type/Transfer/Low Diameter, see
Appendix A) is set to 0, which disables the function. To enable it, enter the
desired value.
By reading SYSVAR(26) in a Fingerprint application program, the status of
the ribbon low sensor can be polled. SYSVAR(26) returns 0 if the diameter
of the ribbon supply roll is greater and 1 if it is less than the value entered
in the Setup Mode.
Note that a full forward rotation of the supply bobbin must have been
completed. If not, 0 will be returned.
Note: When the ribbon low function is enabled, error condition 1083
“Ribbon low” is reported every tenth time SYSVAR(26) = 1 is detected in
connection with a PRINTFEED.
Sensitivity
1 Enter Setup Mode and navigate to Media > Paper Type > Transfer/
Ribbon Sensor.
2 In the Ribbon Sensor menu, press <Enter> to perform a Testfeed.
3 The printer will feed out a few labels and feed the ribbon accordingly.
4 While the ribbon mechanism is operating, the ribbon sensor is
autoadjusted and the resulting adjustment value is shown in the lower
line of the menu (read-only).
Adjustment (IPL)
There is no facility for adjusting either the low diameter or the sensitivity
of the ribbon sensor in IPL.

6.5 Ribbon Motor

Description
The ribbon motor assembly consists of a 24 VDC motor with a gearbox.
The gearbox engages the cogs along the rim of the ribbon rewind bobbin
and rotates it in either direction according to the polarity of the power.
The power comes to the ribbon motor via a cable connected to P6 on the
Power Supply Unit (see Section 12.3).
The ribbon motor assembly is a complete unit and should not be taken
apart. It is fitted to the electronics compartment side of the center section
using three #T20 Torx screws.
DC Motor
Gearbox
#T20 Torx Screws (×3)

6.6 Front Ribbon Break Shaft

Description
The front ribbon break shaft serves two purposes: to keep the ribbon away
from the print mechanism and to compensate for any lack of parallelity
in the other parts of the ribbon mechanism. The shaft is screwed into a
plate inside the center section. The shaft and the plate can be tilted using
a straight-slot screw from the media compartment (also see last illustration
in Section 7.1).
Before you attempt to adjust the break shaft, make sure that the ribbon
wrinkling is not caused by something else (see Section 16.13).
Bevor versucht wird, die Bruchwelle einzustellen, sicherstellen, dass es
keinen anderen Grund für das zerknitterte Band gibt (siehe Abschnitt
16.13).
• If the ribbon tends to slide outwards, turn the screw carefully clockwise
(fw) to move the outer end of the break shaft forward.
• If the ribbon tends to slide inwards, turn the screw carefully
counterclockwise (bw) to move the outer end of the break shaft
backward.
Adjustment Screw
Front Ribbon Break Shaft

6.7 Printhead Ribbon Break Shaft

Description
The printhead ribbon break shaft keeps the ribbon away from the front
edge of the printhead and minimizes the friction. The shaft is fitted
between the two gables of the printhead bracket. The inner gable has a D-
shaped hole and the outer gable has a round hole. The shaft is held in place
by a plastic clip inside the outer gable.
Inner Gable
D-plane
Break Shaft
Plastic Clip (hidden)
Outer Gable
Replacement
1 Pry away the plastic clip, taking care not to lose it.
2 Pull the shaft in the direction towards the outer gable until it disengages
from the inner gable.
3 Tilt out the inner end so it can bypass the inner gable and pull it out of
the outer gable.
4 Reassemble in reverse order taking care so the D-plane on the shaft fits
into the D-shaped hole in the inner gable.


7 Print Mechanism
This chapter describes the print mechanism of the EasyCoder PM4i printer
and explains how to adjust the various functions and replace part subject to
wear. It covers the following topics:
• Description
• Platen roller
• Stepper motor
• Belts
• Label stop sensor
• Printhead
• Headlift sensor
• Headlift mechanism
• Media feed principles

Chapter 7—Print Mechanism
7.1 Description
The print mechanism is fully integrated with center section (see Section
4.2), the transfer ribbon mechanism (see Chapter 6), and optional liner
takeup unit (see Chapter 8).
The main parts of the print mechanism are:
• The rubber-coated platen roller drives the media past the printhead and
provides counter-pressure.
• The liner drive roller is used for peel-off operation and helps pulling the
liner towards the takeup unit.
• The stepper motor drives the platen roller and the liner drive roller via
two timing belts inside the electronics compartment. It also drives the
optional liner takeup unit via a third belt running inside the center
section. The liner drive roller and the takeup unit belt are always fitted.
• The tear bar makes it easier to tear-off continuous stock. It also helps
separate labels and liner during peel-off printing.
• The label stop sensor (LSS) controls the media feed and checks for out-
of-media conditions.
• The printhead produces the heat that blackens the direct thermal media
or melts the ink of the transfer ribbon in bitmap patterns that make up
letters, graphics, or bar codes.
• The headlift mechanism presses the printhead against the direct thermal
media or thermal transfer ribbon, or raises the printhead to allow media
and ribbon replenishment.

The parts of the print mechanism, as seen from the media compartment
side of the center section, are illustrated below.
Pressure arm Headlift lever
Headlift mechanism
(partly hidden
behind center
section)
Belts, and pulleys
Printhead
Printhead bracket
Guide
Upper media guide

Tear bar
Lower media guide assy
with LSS adjustment screw
Platen roller
(barely visible)
Liner drive roller

Guide link
Printhead cable
(data)

The parts of the print mechanism fitted inside the electronics compartment
in an EasyCoder PM4i printer are illustrated below.
Headlift Linkage
Ribbon motor
and gear box
Pulley & belt

(platen roller)
Pulley & belt

(liner drive roller)
Headlift sensor
Stepper motor

7.2 Platen Roller

Description
The platen roller is coated with silicon rubber. It is imperative that the
roller is kept clean and is free from uneven wear or dents. The platen roller
is identical to the liner drive roller, so these rollers could be switched. The
same applies to the pulleys and belts. It is normal that the platen roller
needs to be replaced after a period of time depending on print volume and
other circumstances. The roller is supported by two permanently lubricated
plain bearings pressed into the center section.
Be careful not to rotate the platen roller manually when the power is
switched on, as this may damage the stepper motor driver on the power
supply unit (see Chapter 12). Always turn off the power to the printer
before you remove labels or label residue that is stuck on the platen
roller!
Darauf achten, dass die Druckwalze nicht von Hand gedreht wird,
wenn die Stromversorgung eingeschaltet ist. Dadurch kann der
Schrittmotorantrieb im Netzteilmodul beschädigt werden (siehe
Kapitel 12). Immer die Stromversorgung des Druckers abschalten,
bevor Etikette oder Etikettrückstände entfernt werden, die auf der
Druckwalze festkleben!
Replacement
This procedure also applies to the liner drive roller.
1 Turn off the power and disconnect the power cord.
2 Remove the front/left-hand cover, see Section 3.2.
3 Raise the printhead to open position.
4 Remove the tear-off bar by pulling the plate upwards. Avoid bending
the hooks, which will make it loose-fitting.
5 Press down the snap-lock at the bottom of the guide link and pry the
guide link away from the shafts of the platen roller and the liner drive
roller.
6 Using a 1.5 mm hexagon key, loosen the grub screw in the pulley of the
roller.
7 Hold the pulley and belt while pulling out the roller.
8 Reassemble in reverse order, making sure that the tear bar snaps at the
inner end of the liner drive roller.
When fitting back the pulley, check that the grub screw hits the flat side
of the D-shaped end of the roller shaft. Tighten firmly. Check that the
belts are fitted properly over the pulleys on both the two rollers and the
stepper motor.

1.5 mm hexagon key
Liner drive roller
Tear bar
Platen roller
Guide link
Snap-lock

7.3 Stepper Motor

Description
The stepper motor drives the platen roller and the liner drive roller
using a double-belt pulley and two timing belts inside the electronics
compartment. It also drives the optional liner takeup unit using a pulley
on the opposite side of the motor and a long belt that runs inside a recess
in the center section. The pulleys are permanently fitted and cannot be
replaced.
The stepper motor is driven in micro-stepping mode with 8 steps/dot at 8
dots/mm (203.2 dpi), which means that the theoretical feed error will be
negligible. However, mechanical conditions such as a worn platen roller or
a slippery liner may adversely affect the accuracy.
The stepper motor is fitted using four #T20 Torx screws and rubber noise
dampeners inside a moulding protruding from the center section.
Replacement
1 Switch off the power and disconnect the power cord.
3 Disconnect the stepper motor cable from P10 on the Power Supply
Unit.
4 Dismantle the stepper motor from the bracket by removing the four
#T20 Torx screws.
5 If the printer has a liner takeup unit (see Chapter 8), remove the media
guide assembly (see Section 7.5) to gain access to the belt running from
the stepper motor to the liner takeup unit.
6 Remove the belts from the stepper motor pulleys. If no liner takeup unit
is fitted, you can leave its timing belt in the recess in the center section.
7 Loosen the 1.5 mm hexagonal grub screws that hold the pulleys of the
platen roller and liner drive roller and remove the pulleys and belts.
8 Remove the stepper motor.
9 Replace the rubber dampeners with a fresh set.
10 Put back the stepper motor. If there is an optional liner takeup unit,
start by fitting its belt to the motor’s inner pulley. If no takeup unit is
fitted, make sure that the pulley does not engage the belt. Then fit the
belt and pulley to the liner drive roller and finally the belt and pulley to
the platen roller.
11 Fit the four screws that hold the flange of the stepper motor.
12 Connect the cable of the stepper motor to P10 on the Power Supply
Unit.
13 Put back all remaining parts.

The dampeners, the belts, and the pulleys are identical. Normally, there is
no need to separate the flanges and the pullies.
#T20 Torx
screws (×4)
Rubber
dampeners (×4)
Flange Stepper motor

Platen roller belt
Liner drive roller belt
Platen roller pulley
Liner drive roller pulley
Flange

7.4 Belts
Description
The print mechanism has two timing belts, one that drives the platen roller
and another that drives the liner drive roller. The belts are subject to wear
and may need periodic replacement.
Replacement
Replace a worn out or broken belt using the same method as when
replacing the stepper motor, see Section 7.3.
Adjustment
The tension of the belts cannot be adjusted.

7.5 Label Stop Sensor

Description
The label stop sensor (LSS) controls the media feed. It consists of two sets
of sensors and diodes fitted in a fork-shaped sensor housing. One part runs
on top of the upper media guide and the other part runs inside the lower
media guide assembly. Each part has one light-emitting diode and one
photoelectrical receiver. The sensor housing slides along a shaft fitted to the
lower media guide when the straight-slot adjustment screw is rotated. The
LSS can be moved laterally from the inner edge of the media and 57 mm
(2.24 in.) outwards, which corresponds to the center of a full width media.
The sensors are protected from the media by the two transparent media
guides. The upper media guide can be removed to facilitate cleaning. The
sensor are connected to the CPU board.
Upper media guide

Adjustment screw
Lower media guide
Connectors
Shaft
Sensor housing

Working Principles
The label stop sensor serves a number of purposes, depending on how
the printer is set up in regard of media type in Fingerprint and IPL
respectively:
Label (w gaps)/Gap
A beam of light is emitted from the diode in the lower part and received
by the sensor in the upper part. The firmware detects the front of each
label, that is, when the light is completely interrupted by the opaque
label, as opposed to the semi-transparent liner in the gaps between labels.
If no label has been detected during a media feed corresponding to more
than 150% of the set label length, a “next-label-not-found” condition is
assumed. If a renewed print operation gives the same result, an “out-of-
paper” condition is assumed.
Ticket (w mark)/Mark
Normally, a beam of light is emitted from the diode in the lower part. The
beam is reflected back to the sensor in the lower part by the white media,
or is absorbed by a black mark. The firmware detects when the front edge
of a black mark passes the sensor, that is, when light starts to be absorbed.
If no mark has been detected during a media feed corresponding to more
than 150% of the set ticket length, a “next-label-not-found” condition is
assumed. If a renewed print operation gives the same result, an “out-of-
paper” condition is assumed.
By switching the cables from the upper and lower part of the LSS on the
CPU board, black marks on top of the media can be detected.
Ticket (w gaps)/Gap
The light is emitted from the diode in the lower part and received by the
sensor in the upper part. The light will either pass uninterrupted through
a detection gap in the media or be blocked by the non-transparent ticket.
The firmware detects the rear edges of detection gaps, that is, when the
light starts being interrupted. If no ticket has been detected during a media
feed corresponding to more than 150% of the set ticket length, a “next-
label-not-found” condition is assumed. If a renewed print operation gives
the same result, an “out-of-paper” condition is assumed.
Var. Length Strip and Fix Length Strip/Continuous
The light is emitted from the diode in lower part and received by the
sensor in the upper part. The beam will either be blocked by the media
or be completely uninterrupted when the printer runs out of continuous
stock. The firmware assumes an out-of-paper condition if the light has not
been interrupted within a media feed corresponding to 150% of the set
length.

General
The information on where the gaps or marks are presently positioned
relative the LSS (and thereby also relative the dot line on the printhead)
is saved as an “invisible” file in the flash memory’s file operating system
(see Section 12.2). However, if the printhead is raised, or if the power is
interrupted during printing, this file may be cleared, which will affect any
labels between the LSS and the dot line. In this case, readjust the LSS by a
TESTFEED operation (Fingerprint) or by pressing the Feed/Pause button
(IPL).
Note (Fingerprint only): It is possible to decide if the media feed data will
be cleared or not when the printhead is raised by means of the Fingerprint
instruction SYSVAR(28). By default, the media feed data are not cleared.
The LSS checks for gaps or marks at every dot of positive media feed (feed
out/print), but gaps or marks are ignored at negative media feed (retract).
Gaps and black marks up to 170 dots (21.3 mm/0.84 inches) are allowed.
Adjustment of the Sensitivity
The LSS should always be adjusted when the user changes to another
brand (sometimes even a new batch) of media, and when a defective sensor
has been replaced. This is especially the case with self-adhesive labels on
liner, because the transparency of the liner may vary and the difference
between labels and gaps may be too small. Before starting the adjustment,
check that both the upper and lower sensor are clean and free from
obstructions and that the edge guides are adjusted so as to guide the media
with a minimum of play. Also check that both parts of the LSS are in the
same lateral position and aligned with any gaps or black marks.
Fingerprint Only
As standard, there are four ways to adjust the LSS:
• Performing a TESTFEED by simultaneously pressing the “Shift” and
“Feed” keys on the printer’s built-in keyboard.
• Selecting the TESTFEED option in Intermec Shell.
Four values are displayed showing how the sensor has been adjusted.
1. A measured value lower than the displayed value is interpreted as
media detected.
2. A measured value higher than the displayed value is interpreted as no
media detected.
3. Gain, that is, the sensitivity of the sensor.
4. Drive, that is, the intensity of the light-emitting diode.
• Selecting the TESTFEED option in the Setup Mode.
• Executing a TESTFEED statement in a Fingerprint program.
The printer feeds out 1.5 times the set label length or less while testing
all levels of the LSS at each millimeter of media feed. The LSS is adjusted
according to the result of the check and a full label is fed out according to
the present feedadjust setup.
The label stop sensor/black mark sensor can be turned off for a specified
amount of media feed using the LBLCOND statement, see Intermec
Fingerprint v8.xx Programmer’s Reference Manual.

IPL Only
The sensitivity of the LSS is configured at startup. To force adjustment of
the sensitivity (corresponding to a TESTFEED in Fingerprint), raise and
close the printhead and then press the Feed/Pause key.
Adjustment of the LSS Lateral Position
The LSS can be moved continuously across the media path. Use a straight-
slot screwdriver or a similar tool to turn the adjustment screw.
• Rotate the screw clockwise to move the detection point towards the
center section. The extreme position is aligned with the inner edge of
the media path.
• Rotate the screw counterclockwise to move the detection point
outwards, away from the center section. The extreme position is 57
mm (2.24 in.) outward the inner edge of the media path (that is, at the
center of a full width media).
When using irregularly shaped labels, align the LSS with the front tips of
the labels.
Point of detection
Upper LSS
OUT
IN
Adjustment screw

Cleaning the Media Guide

The upper part of the media guide assembly can be removed for occasional
cleaning.
1 Raise the printhead.
2 Loosen the screw on the edge guide.
3 Pull both the upper media guide and the edge guide straight out along
the shaft.
4 Clean both the upper and lower media guides where the LSS runs using
a cleaning card or a soft cloth moistened with isopropyl alcohol.
5 Assemble in reverse order making sure that the LSS shaft fits into the
holder on the upper media guide.
Isopropyl alcohol [(CH3)2CHOH; CAS 67-63-0] is a highly flammable,
moderately toxic, and mildly irritating substance.
Isopropylalkohol [(CH3)2CHOH; CAS 67-63-0] ist extrem brennbar,
moderat giftig und leicht reizend.
Media guide
(lower part)
Edge guide shaft
Clean here! Upper LSS
Edge guide
Holder
Clean underside
here!
Media guide
(upper part)

Replacing the Sensors

To replace the LSS sensors, proceed as follows:
3 Remove the tear bar and the guide link, see Section 7.2.
4 Pull out the S-shaped guide at the rear of the print mechanism.
5 Pull out the upper media guide and the edge guide, see “Cleaning the
Media Guide” on the previous page.
6 Pry out the printhead lift lever, remove the two #T20 Torx screws that
hold the housing, and remove the housing.
7 Disconnect the cables from connectors J54 and J55 on the CPU board.
8 Remove the three #T20 Torx screws that hold the lower media guide
assembly and pull it out while carefully manipulating the cables and
connectors through the slot in the center section. Release the snap-
locks on the part that covers the timing belt to the liner takeup unit. Be
careful not to lose the grounding spring.
9 Remove the E-ring that locks the LSS adjustment screw to the wall of
the lower media guide (see the first illustration in this chapter).
10 Replace the sensor assembly with a new set and lock it with the E-ring.
11 Connect the cable from the lower part (marked “BM”) to J54 on the
CPU board and the one from the upper part (marked “GAP”) to J55.
(The cables can be switched in order to detect black marks on top the
media instead of at the back.)
12 Reassemble in reverse order making sure that the grounding spring is
fitted straight up. When pressing back the printhead lift lever, lower the
printhead, lock the pressing arm and hold it forcefully so as to prevent
the headlift mechanism from coming apart.
Grounding spring
LSS cables
Edge guide
Tear bar Guide
Lower media guide assy.
#T20 Torx screws (×3)

Guide link Printhead lift lever
Housing
Upper media guide

7.6 Printhead
Description
The printing is produced by the thermal printhead, which consists of a
line of very small, closely spaced resistors on a ceramic tile fitted across the
media path. When a current is led through the resistors, commonly called
“dots,” these will be heated very quickly. When the current is shut off, the
dots cool down just as fast.
As the media is fed past the dots, the hot dots will produce a number
of black spots on heat sensitive (direct thermal) media, or on other face
materials via a thermal transfer ribbon. The spots can be combined into
bitmap patterns, which make up characters, bar codes, images, lines, and
boxes.
The direct thermal printing method requires special media coated with a
thin layer of heat-sensitive chemicals. As the media is fed past the dots, the
heat from the dots will make the chemicals react, producing a dark salt,
which makes up the imprint under each dot.
In the thermal transfer printing method, a special “ink”-coated transfer
ribbon is used. When the ribbon is heated by a dot on the printhead,
the ink melts and sticks to the receiving face material, where the ink
immediately becomes solid again, producing a black spot. Transfer ribbons
normally do not smear at room temperature, neither before nor after
printing. Nor do the printed labels smear, even if the printout may be
smudged by extensive rubbing if an unfortunate combination of ribbon
and face material is used. The thermal transfer method makes it possible to
use a wide range of face materials for printing, for example papers, boards,
plastics, foils, etc. However, an original transfer ribbon from Intermec
should always be used.
The basis for all measures and positioning in both the Fingerprint and IPL
programming languages is the size of printhead dots.
In an 8 dots/mm (203.2 dpi) printhead, which is standard, each dot has a
nominal size of 0.125 mm (4.92 mils). This means that a heated dot under
standardized conditions will produce a black spot which has a diameter of
0.125 mm (4.92 mils).
In an 11.81 dots/mm (300 dpi) printhead, which is an Fingerprint-only
option, each dot has a nominal size of 0.086 mm (3.33 mils). This means
that a heated dot under standardized conditions will produce a black spot
which has a diameter of 0.086 mm (3.33 mils).
Depending on dot temperature, exposure time, media and ribbon
characteristics, etc., the spot may actually be somewhat smaller (weak
print) or larger (black print), but that does not affect the calculation of
distances, sizes, and positions.
At startup, the printer auto-detects the printhead density as well as the
head resistance. The printhead can also be checked using the Fingerprint
instructions HEAD, FUNCTEST, and FUNCTEST$. In IPL, the
number and size of the dots in the printhead is returned to the host by the
command <STX><ESC>H<ETX>.

Print Window
The EasyCoder PM4i printer has as standard an 8 dots/mm (203.2 dpi)
printhead or as an Fingerprint-only option an 11.81 dots/mm (300 dpi)
printhead. In addition to the normal printheads, which are designed for
a media thickness up to 175 μm (7 mils), there are also 8 dots/mm and
11.81 dots/mm printheads for media thicknesses from 170 to 220 μm (6.6
to 8.7 mils).
8 dots/mm Printhead
Density 8 dots/mm (203.2 dots per inch)
Print width 104 mm (4.095 inches)
Number of dots 832
Dot size 0.125 mm (4.92 mils)
10.3 mm (0.41 in.)
Print Width
max. 104.0 mm (4.095 in.)
Dot-line
on printhead
FEED Dot #831

Dot #0 DIRECTION
Media Width
25-114.3 mm (1-4.5 in.)

11.81 dots/mm Printhead

Density 11.81 dots/mm (300 dots per inch)
Print width 105.7 mm (4.161 inches)
Number of dots 1248
Dot size 0.085 mm (3.33 mils)
8.6 mm (0.34 in.)
Print Width
max. 105.7 mm (4.161 in.)
Dot-line
on printhead
FEED Dot #1247

Dot #0 DIRECTION
Media Width
25-114.3 mm (1-4.5 in.)

The printhead is fitted to a bracket using two screws. The printhead, the
printhead ribbon break shaft, and the bracket are always delivered as a
complete assembly. Two hooked fingers at the rear of the bracket are fitted
over the headlift shaft so as to hold the printhead in place. A U-shaped tab
on the outer side of the bracket engages the guide link when the printhead
is closed, making sure that the printhead becomes properly aligned with
the platen roller. There are no facilities for adjusting the position of the
printhead relative the platen roller, neither longitudinally nor laterally.
There are two cables from the printhead to the CPU board:
• The innermost cable is used for the power to the printhead and is
connected to P5 at the front of the Power Supply Unit.
• The outermost cable is used for data to the printhead and is connected
to J40 on the CPU board.
“Finger”
Cable from power

supply unit (P5)
Bracket
“Finger”
Printhead
Cable from CPU

Printhead ribbon
board (J40)
break shaft

Replacing the Printhead

The printhead is a consumable part subject to wear from both the direct
thermal media or the thermal transfer ribbon and from the rapid heating
and cooling process during printing. Thus, it will require periodic
replacement depending on print volume, type of media or ribbon, amount
of energy to the printhead, print speed, ambient temperature, and several
other factors.
Never use printheads that were designed for the EasyCoder F4 or F4
Compact Industrial. Using one of these printheads will cause a short
circuit or even a blown fuse.
Niemals Druckköpfe benutzen, die für die Modelle EasyCoder F4
oder F4 Compact Industrial vorgesehen sind. Wenn einer dieser
Druckköpfe benutzt wird, verursacht dies einen Kurzschluss oder eine
durchgebrannte Sicherung.
To replace a defective or worn printhead
1 Switch off the power.
3 Turn the printhead lift lever clockwise to raise the printhead.
4 Remove any media and ribbon from the print mechanism.
5 Carefully pull the printhead bracket away from the magnet in the
pressure arm.
6 Disconnect the printhead bracket from the print mechanism and pull
out the printhead while twisting it outwards as far as the cables allow.
7 Disconnect the two cables from the printhead. Note the snap-lock on
the inner connector. Pull at the connectors, not at the cables!
8 Connect the two cables to the replacement printhead.
9 Put back the printhead in reverse order and check that the printhead
cables run freely.

10 Lower the printhead so the magnet engages the printhead bracket.

11 Switch on the power. The printer’s firmware automatically measures the
printhead resistance and density at startup.
12 Load the media and ribbon again.
Precautions
Some simple measures can be taken by the user to prevent premature wear-
out:
• Clean the printhead regularly, as described in the User’s Guide. Not only
will a dirty printhead produce an inferior printout, but any residue on
the dots will prevent heat from dissipating through the media.
• Follow the Intermec’s recommendations regarding Paper Type or Media
Sensitivity setup. Too much energy to the printhead will wear it out
rapidly.
• Do not use higher Print Speed setting than necessary.
• Low ambient temperature requires more energy to the printhead
dots than room temperatures and will therefore cause more wear to
the printhead. High print speed accelerates the wear. Thus, at low
temperatures, select as low a print speed as acceptable.
• In Fingerprint, do not use a higher Contrast setting than necessary,
especially not in combination with the highest Label Constant or
Ribbon Constant settings.
• In IPL, do not use a higher Darkness setting than necessary.
• Do not use a higher printhead pressure than necessary.
• Never print outside the media path. Dots that are not in contact with
the media will not be cooled properly.
• When using media with less than full width, be careful to adjust the
printhead lift arm so there is an even pressure across the media. Not
only will an uneven pressure impair the printout quality, but it may also
prevent the dots from being properly cooled. Moreover, a sharp outer
media edge in direct contact with the printhead may cause excessive
mechanical wear on some dots, which may be visible when printing on
wider media later.
• When using preprinted labels or labels with some type of varnish or
non-standard top coating for direct thermal printing, use original
Intermec labels or inks recommended by leading manufacturers of direct
thermal media. The labels must not contain any aggressive substances
such as chloride or grinding substances such as titanium dioxide.
• Only use transfer ribbons recommended by Intermec.

7.7 Headlift Sensor

Description
The purpose of the headlift sensor is to detect whether the printhead is
raised or lowered. To avoid the risk of overheating the printhead dots,
printing cannot be performed when the sensor detects that the printhead
is raised (the media serves to cool the printhead). An ever so slightly raised
printhead would also impair the printout quality. Thus, it is important that
the printhead is properly engaged and a sufficient pressure is applied before
the sensor detects a “Closed” condition.
The sensor is fitted using a barbed shaft that is pressed into a hole in
the center section. The sensor consists of a light-emitting diode and
a photoelectric sensor with housing and cables. The headlift sensor is
connected to J58 (marked “HEADLIFT”) on the CPU board.
A beam of light is constantly transmitted from the diode. When the
printhead is in closed position, the light beam is interrupted by an angular
plate at the end of the crank shaft. As soon as the headlift lever is activated,
and even before the printhead starts to raise, the plate is moved out of
the sensor gap and the sensor can detect the light beam. This condition
is managed by the firmware. In Fingerprint, an error message (1022
“Head Lifted”) will be returned if you try to print a label. In IPL, the error
message “Print Head UP/Press Feed” is displayed.
Plate on Crank Shaft
(printhead lowered)
J84
Headlift Sensor
Connect here!
HEADLIFT
J58

Sensor Replacement
Before deciding to replace the sensor, check that the sensor is free from
dust, and other objects that can block the light.
To replace the sensor
1 Switch off the power, remove the power cord, and remove the front/
left-hand cover.
3 Disconnect the sensor’s cable from the CPU board.
4 Pull the sensor straight out using a pair of pliers. The sensor has a barbed
shaft inserted into a hole in the center section moulding and requires
some force to come out.
5 Make sure the hole is clear from any remnants of the old sensor.
6 Reassemble in reverse order. The sensor’s cable should be connected to
J58 (marked “HEADLIFT”) on the CPU board.
7 In Fingerprint, check that the sensor works properly using a PRSTAT
statement, see Intermec Fingerprint v8.xx, Programmer’s Reference
Manual.
8 In IPL, check that the sensor works properly using the Label Path
Open Sensor Value (<STX>L<ETX>), see IPL Programming, Reference
Manual.

7.8 Headlift Mechanism

Description
The headlift mechanism is used to raise and lower the printhead to allow
media and ribbon load and also to apply a proper printhead pressure
against the media. See Section 7.1 and the next page for illustrations!
The headlift is operated by the green headlift lever in the print mechanism.
The lever is snap-locked at the end of the crank shaft, which runs inside
the pressure shaft. At the other end of the crank shaft and inside the
electronics compartment is an angular plate, which is used by the headlift
sensor to detect whether the printhead is lowered or raised (see Section
7.7).
A small eccentrically fitted knob on the angular plate runs in a crescent-
shaped slot in the lifting arm. A coil spring presses the knob down in the
slot and helps lifting the printhead. The lifting arm is connected by a link
to the pressure link, which pivots in extensions from the center section.
Thereby the rotating movement of the crankshaft is transformed into a
lateral movement.
The upper part of the pressure link is spring-loaded in relation to the
center section. Thus, when the lever is turned towards lowered printhead
position, the pressure is increased. The pressure is factory-adjusted by
means of two screws inside the electronics compartment and fine-adjusted
by the operator using a straight-slot screw accessible through a hole in the
center section.
The lifting arm is connected to the pressure shaft by a lever. The pressure
shaft runs through the center section to the print mechanism, where the
pressure arm is fitted on the shaft. A magnet at the tip of the pressure arm
holds the printhead bracket. The arm can be moved laterally to apply its
pressure at the center of the media, regardless of media width.
The printhead bracket hangs loosely on the pressure shaft in two hooked
“fingers.” When the printhead is lowered, semicircular guides at both sides
of the bracket engage the inner part of the platen roller and a slot in the
guide link, ensuring that the printhead will be properly aligned with the
platen roller.
When the printhead lift lever is activated from lowered position, the
printhead will not start to move immediately, but the angular plate on
the crank shaft will start to rotate out of the gap in the headlift sensor,
indicating a “printhead lifted” condition. When the lever has reached
a more or less vertical position, a clicking noise will be heard and the
printhead is raised from the platen roller. Now the coil spring between
the angular plate and the lifting arm will help the operator finish the
movement of the lever and hold the printhead firmly in raised position.

When the printhead lift lever is turned from raised to lowered position,
the operator has to overcome a slight pressure from the coil spring until
the lever passes a vertical position. Then the printhead snaps into place and
the spiral spring applies its pressure. In the final part of the movement,
the angular plate is rotated into the gap of the headlift sensor indicating a
“printhead closed” condition.
This exploded view shows the parts of the headlift mechanism. Also refer
to illustrations in Section 7.1 for assembled views.
Fine-adjustment screw
Printhead
lift lever
C
Pressure spring
Shoe
Nut
Pressure arm
#T10 Torx screws
Pressure Shaft
A
B
Pressure
link
Lever
Printhead
Lifting arm with
Link bracket
Coil spring
Angular plate Crank shaft
The transfer ribbon mechanism have been omitted in the illustration above to improve visibility.

Printhead Pressure Adjustment

A skilled service technician can use the procedure described below to adjust
printhead pressure. Operators should only use the fine-adjustment screw
accessible from the media compartment.
1 Slit a piece of plastic tube lengthwise and put it on the tear bar in order
to minimize the friction. On the thermal transfer-capable printers, the
tube must not interfere with the printhead ribbon break shaft.
2 Fit a 300 g (0.66 lb) weight at the end of a full width strip of liner.
3 Loosen the upper #T10 Torx screw (A) in the electronics compartment.
Note: The designations “A”, “B”, and “C” refer to the illustration on the
previous page.
4 Using a 5.5 mm spanner, loosen the nut on screw (B).
5 Loosen the lower #T10 Torx screw (B) in the electronics compartment
until the nut almost comes off.
6 Tighten the fine-adjustment screw (C) until it comes as far into the shoe
as possible and the spiral spring becomes compressed.
7 Lower the printhead.
8 Tighten screw B until it meets the end of screw C.
9 Raise the printhead and put the liner strip between the printhead and
platen roller so the weight hangs freely over the tear bar. Lower the
printhead.
10 Loosen screw B until the strip starts to slip and tighten it again until the
strip stops to slip.
11 Tighten screw B two (2) full turns and lock it with the nut. Now the
printhead has a pressure of approximately 4.2 kgs.
12 Loosen screw C four full turns to decrease the pressure (each turn
represents approximately 0.5 kp of pressure).
Do not use a higher printhead pressure than necessary. High
printhead pressure increases the wear on the printhead and shortens
its life.
Keinen höheren Druckkopfdruck benutzen als erforderlich. Ein
hoher Druckkopfdruck bedeutet mehr Druckkopfverschleiß und
eine kürzere Lebensdauer des Druckkopfs.
13 Tighten screw A until it has a play of ±0.1 mm (4 mils) to the lifting
link and lock it with blue Loctite. The tightness of this screw affects the
resistance in the printhead lift lever.
14 Fine-adjust using screw C according to printout samples (preferably test
labels). Differences in media thickness, stiffness, width, etc. may require
slightly higher or lower pressure. Generally, thicker and/or stiffer media
requires more printhead pressure. However, a very high pressure setting
on screw C may require readjustment of screw A or there will be no
printhead pressure at all.
15 If necessary, lubricate moving parts with MolyKote P6 30 L Plastislip or
a similar grease.

Printhead Pressure Alignment Adjust

The printer is factory-adjusted for full media width. When using media
less than full width, it is recommended to adjust the pressure arm so it
becomes centered in relation to the media. Thereby, an even pressure across
the media is obtained.
A poorly adjusted pressure arm may be detected by a weaker printout on
the inner part of a less than full width media. Similarly, when reverting to a
wider media, the arm should be adjusted, or the printout on the outer part
of the media could be weak.
To adjust the pressure arm
1 Loosen the straight-slot screw that holds the pressure arm. Move the
arm inwards or outwards until the arrow on the tip of the arm becomes
centered in relation to the media.
Note: While moving the arm, push at the part where the screw is
situated, not at the tip. If the arm is hard to move, raise the printhead
and pull the printhead bracket free from the magnet in the pressure
arm.
2 After having centered the arm, lock it by tightening the screw.

3 Adjust all edge guides (print mechanism, label slack absorber, and media
supply roll post.
Knurled nut
Center of media
Tip of pressure arm
Edge guide

7.9 Media Feed Principles

Fingerprint only
The Start and Stop Adjust parameters in the Fingerprint Setup Mode
control how the media will be positioned in relation to the printhead when
the printing starts and after the printing is completed, respectively. By
default, the Start and Stop Adjust parameters are both set to 0, which is
suitable for tearing off the media against the tear bar, for example between
labels or at the perforation in a pre-perforated continuous stock. However,
because the dot line on the printhead is situated 14.7 mm (0.58 inches)
back from the tear bar, the printing will not start at the top of the label but
further back along the media path.
14.7 mm Default (tear-off):
(0.58 in.) Start Adjust: 0
Stop Adjust: 0
Dot line on printhead
Tear bar
Note: Due to several factors, media feed measurements are not exact and
may vary somewhat between applications and individual printers. There
is inevitably a small amount of slippage between media and platen roller,
which in its turn is affected by printhead pressure, type of media or liner,
thickness of the media, roll size, type of media supply device, etc. The
platen roller may be worn, giving it a slightly smaller diameter and/or less
friction. There is also a certain amount of inexactness in the media feed
mechanics and belts and so on. Therefore, the operator cannot expect to
reach exact Start and Stop Adjust values simply by calculation. Use the
measurements given in this chapter to calculate rough starting points and
use the trial-and-error method to find values that give the desired result.
Note: All calculations and feed adjust values in this chapter refer to 8 dots/
mm (202.3 dpi) printheads.

In many cases, it is desired to start the printing immediately at the top

of the label. Actually, what you want to do is to pull back the edge of the
media to the dot line. You can do this by means of a negative Start Adjust
value (for example -100 dots = 12.5 mm/0.49 inches). Be careful not to
enter too large a value, or the media may come loose from platen roller.
14.7 mm Tear off (print at top of label):
(0.58 in.) Start Adjust: -100
Stop Adjust: 0
Tear bar
When using peel-off operation, the labels would drop from the liner and
get stuck on for example the desk if you use the default Start Adjust value
0. Use a Stop Adjust value of around -44 (= 5.5 mm/0.22 inches) instead:
that is, after the printing is completed 5.5 mm/0.22 inches less of media
feed than normal will be performed. However, if you still want to print
from the top of the label, you must compensate by a Start Adjust value
of around -56 (= 7.0 mm/0.28 inches). Note that the sum of the Start
and Stop Adjust values always is 100 dots (12.5 mm/0.49 inches), which
corresponds to the distance between dot line and tear bar minus a margin
for the gap between labels and certain slippage.
14.7 mm Peel off (print at top of label):
(0.58 in.) Start Adjust: -56
Stop Adjust: -44

Tear bar

A special case is tickets with black marks. It is recommended to place the

black mark adjacent to the perforation or the intended tear-off line. If the
black mark is placed further down the media, this must be compensated
for by a negative Stop Adjust setting.
IPL Only
In IPL, the media feed is affected by the mode of operation. There are
three such modes:
• Tear-off (straight-through)
(default)
• Peel-off (self-strip)
(enabled/disabled by <STX><SI>tn<ETX> command)
• Cut-off
(activated/deactivated when the cutter is enabled/dispabled in the Setup
Mode or by <STX><SI>cn<ETX> command)
Each mode has a fixed amount of media feed, which can be fine-adjusted
using the Label Rest Point parameter in the Setup Mode (See Appendix A,
Setup/Media/Lbl Rest Point) or an <STX><SI>fn<ETX> command.
The type of detection is decided by the Media Type parameter in the Setup
Mode (See Appendix A, Setup/Media/Media Type).

8 Liner Takeup Unit
This chapter descibes the optional liner takeup unit and covers the follow-
ing topics:
• Description
• Takeup unit parts
• Fitting a liner takeup unit
• Replacing the timing belt

Chapter 8—Liner Takeup Unit
8.1 Description
The liner takeup unit is a factory installed option that is used for peel-off
(self-strip) operation. Peel-off means that self-adhesive labels are automati-
cally separated from the liner (backing paper) after printing and the liner
is wound up on a hub inside the printer’s media compartment. Peel-off
operation cannot be combined with fan-fold guides. The rewind unit is
made up by the following main parts:
• The takeup hub assy (see Section 8.2 for details)
• The timing belt (fitted in all printers)
• The guide shaft Center section
Stepper motor
Belt
Pulley
Shaft
Pulley
Spring clutch
Guide shaft
Takeup hub
The takeup hub is driven by a pulley on the right side of the stepper motor
via a timing belt, which runs in a recess in the center section behind the
media guide assy. (To simplify manufacturing, the timing belt is fitted in
all printers, but when there is no takeup unit it does not engage the pulley
of the stepper motor). The dimensions of the pulleys make the takeup hub
rotate somewhat faster than the media is being fed out, thus providing a
certain tension to the liner. A wrapped spring clutch inside the takeup hub
allows it to slip so as to limit the tension. An extra guide shaft fitted to the
center section separates the liner from the media path.
The liner drive roller (standard) underneath the platen roller helps pulling
the liner (see Section 7.1).
The tension of the timing belt cannot be adjusted.

8.2 Takeup Unit Parts

The liner takeup unit consists of the following parts:
• Timing belt pulley (with flange and bearing)
• Hub (with spring clutch, bearing, and brace)
• Shaft Return Spring
Shaft
Bearing
Brace
Hub
Spring Clutch
Pulley
Bearing
The threaded shaft is screwed into the center section. The timing belt
pulley is fitted on the shaft and the timing belt is fitted around the pulley.
The spring brake is mounted inside the bobbin and fits around the outer
end of the pulley. It provides the necessary friction to keep the liner tight
without pulling it too hard.
The brace collapses when being pulled out. The plastic spring inside the
brace returns and expands the brace when it is released. Thus, the wound
up liner can easily be removed at media replenishment.
The bobbin is held on the shaft by a snap-lock of the same type as the
ribbon supply and rewind hubs (see Sections 6.2 and 6.3).
When no rewind unit is fitted, the recess in the center section is covered
by a circular cover plate, which can be removed using a #T20 Torx screw-
driver.

8.3 Fitting a Liner Takeup Unit

Even if the liner takeup unit is intended to be factory-fitted, it is quite easy
to upgrade a printer with such a device:
1 Remove the cover plate from the center section using a #T20 Torx
screwdriver.
2 Pull out the rear part of the timing belt from inside the media guide
assembly.
3 Fit the takeup pulley into the recess in the center section and wrap the
timing belt around it. When you pull the timing belt, it will engage the
pulley of the stepper motor.
4 Screw the takeup shaft through the rewind pulley and into the center
section using a pair of pliers. Then screw the takeup guide shaft into
the center section. Use tape or similar to protect the shafts from being
scratched by the tool.
5 While rotating it, press the takeup hub onto the shaft and the pulley.
Press until the snap-lock engages the groove in the shaft.
8.4 Replacing the Timing Belt

To replace a broken or worn-out timing belt
1 Remove the media guide assy. as described in Section 7.5, “Label Stop
Sensor/Replacing the Sensors.”
2 Pull out the rewind bobbin from the shaft. You will need two straight-
slot screwdrivers or a special tool to pry the two legs of the snap-lock out
of the groove in the shaft.
3 Separate the pulley from the takeup hub while taking care so the spring
clutch stays inside the hub.
4 Fit a new timing belt over the pulley of the stepper motor.
5 Put back the takeup pulley and rewind hub as described in Section 8.3.
6 Reassemble remaining parts in reverse order.

9 Label Taken Sensor
This chapter describes the optiona label taken sensor and covers the
following topics:
• Description
• Replacement
• Activating the LTS
• Adjustment

Chapter 9—Label Taken Sensor
9.1 Description
The Label Taken Sensor (LTS) is a factory-installed or field-installable
optional device, which enables the printer’s firmware to detect if the latest
printed label, ticket, tag, etc. has been removed before printing another
copy. It cannot be used in conjuction with a paper cutter, see Chapter 10.
The label taken sensor consists of a photoelectric sensor with a connection
cable. The sensor is fitted to a lug at the front tip of the center section
using a #T10 Torx screw and a washer. The cable is secured to the bottom
plate inside the electronics compartment using two self-adhesive cable
clips.
Cable to J53 on the CPU board
Mounting lug
#T10 Torx screw

and washer
Sensor
A LED (light-emitting diode) in the LTS emits a narrow beam of light,

which will be reflected back to a photoelectric sensor by any label, ticket,
tag, piece of strip, or liner, that has not been removed from the outfeed
area. A prerequisite is that the media is fed out along the center section of
the printer.
The LTS is connected to J53 on the CPU board. The sensitivity is adjusted
in the Setup Mode, see Section 9.3.
The theoretical point of detection of the LTS is situated 20.7 mm (0.81in.)
outside the inner edge of the media path and immediately in front of the
tear bar.

9.2 Replacement
The LTS comes as a complete assembly of sensor and cable. To replace a
faulty LTS, proceed as follows.
2 Remove the left-hand cover as described in Section 3.2.
3 Remove the front door as described in Section 3.3.
4 Disconnect the LTS cable from the CPU board.
5 Remove the #T10 Torx screw nad washer that hold the sensor.
6 Pull the LTS through the hole in the center section into the electronics
compartment.
7 Fit a new LTS assembly in reverse order.
8 Start up the printer, enter the Setup Mode and adjust the sensitivity of
the new LTS as described in Section 9.3.
9.3 Activating the LTS

In Fingerprint, the label taken sensor is enabled using the instruction
LTS& ON.
In IPL, the self-strip mode must be enbled. This can also be done by
executing the following commands:
<STX>R<ETX> (Enter print/configuration mode)
<STX><SI>t1<ETX> (Enable self-strip)

9.4 Adjustment
The sensitivity of the Label Taken Sensor (LTS) may need to be adjusted
according to the ambient light conditions and the reflective characteristics
of the back side of the media.
Fingerprint
The sensitivity can be adjusted in the Setup Mode (see Appendix 1),
or by using setup files or setup strings (see Intermec Fingerprint v8.xx,
Programmer’s Reference Manual). In the Setup Mode, the LTS setup options
are only displayed if an optional label taken sensor is installed in the
printer.
• LTS Adjust:
Press <Enter>. A label is fed out. Remove the label and press <Enter>
again. A menu shows the sensitivity automatically selected by the
firmware and the range in which the LTS will work. Press <Enter> again
and you will proceed to the LTS Test menu.
• LTS Test:
Press <Enter>. A label is fed out. Remove the label and a new label
should be fed out automatically. Repeat until you are sure the LTS
works properly. Then press <Enter> to stop and exit.
• LTS Value:
Press <Enter>. You can enter a new value in the range indicated in the
LTS Adjust menu (see above). Min/max values are in the range 0-10.
IPL
The sensitivity can be adjusted in the Setup Mode (see Appendix 1).
1 In Setup Mode, select the Configuration option.
2 Select LTS Calibration and press the T key.
3 Press <Enter>
4 A number of labels are fed out. Remove the labels and press <Enter>.
5 The sensor has now been automatically adjusted and the resulting
sensitivity is displayed as a numeric value in the range of 8 to 14.

10 Paper Cutter
This chapter descibes the optional paper cutter for EasyCoder PM4i
printer. The chapter covers the following topics:
• Description
• Installation
• Controlling the cutter
• Media load
• Servicing
• Cutter PCB

Chapter 10—Paper Cutter
10.1 Description
The cutter is a factory-installed or field-installable option for the
EasyCoder PM4i printer. The cutter automatically cuts off the media after
printing according to instructions in the controlling firmware. The cut
off portions of media are presented at the front of the cutter and can be
collected on a removeable tray.
The cutter can be tilted forward to facilitate media load. As a safety
measure, the cutter can only operate when being completely closed.
The cutter prevents an optional label taken sensor from working, even if it
is not necessary to remove it before fitting the cutter.
Cutter
Removable Tray
Outfeed Slot
The cutter is primarily intended to cut paper-based media in the form

of continuous stock. It is also possible to cut through the liner between
labels, but be careful not to cut through the labels themselves, because the
adhesive will stick to the cutting blade and may cause malfunction.
Avoid cutting soft plastic-based media.
Minimum media thickness: 78μm
Maximum media thickness: 175μm
For measures, refer to Sections 1.6 and 1.7.
The weight of the cutter is approximately 1.8 kg (4.0 lb).

10.2 Installation
The cutter is easy to install and requires no modification of the printer
itself.
The installation kit contains:
• Cutter unit (1)
• Tray (1)
• #T20 Torx screws (3)
• Installation Instructions (1)
The only tool required is a #T20 Torx screwdriver.
To install the cutter
1 Turn the printer upside down on a soft piece of cloth or similar.
2 Remove the front door, see Section 3.3.
3 Insert the cutter bracket between the printer’s bottom plate and print
mechanism so the three thread bushings on the bracket fits into the
corresponding holes in the printer’s bottom plate. Fit it using the three
#T20 Torx screws included in the kit.
4 Turn the printer back on its feet.
6 Connect the cutter cable to the Finisher interface connector underneath
the print mechanism.
7 Restart the printer.
Bracket
Connect to Finisher
interface

10.3 Controlling the Cutter

Fingerprint
The cutter is activated by CUT or CUT ON statements, see the
Fingerprint or Direct Protocol manuals. Application programs may have
related facilities for operating the cutter.
The edge will cut through the media approx. 33 mm (1.3 inches) in front
of the printer’s dot line. The following values are recommended for cutting:
Type of Cutting 8 dots/mm printhead 11.81 dots/mm printhead
Cut between labels w. gaps
Start adjust: - 325 dots - 480 dots
Stop adjust: + 240 dots + 354 dots
Cut fix and variable length strip (no liner!)
Start adjust: - 340 dots - 502 dots
Stop adjust: + 340 dots + 502 dots
IPL
The cutter can be enabled/disabled in the Configuration part of the
setup mode or using the command <STX><SI>cn<ETX>, where n=
0 disables the cutter and n=1 enables it. When the cutter is enabled, the
media feed is automatically adjusted for cut-off operation.
When the cutter is not enabled, a cut operation (advance label and cut)
can be executed using the command <STX><SO><ETX>.
Also see the IPL Programmer’s Reference Manual.
10.4 Media Load

Load media following the descriptions in the User’s Guide for Media Load/
Cut-Off operation (optionally with Quick-Load guides). The cutter is held
by a snap lock and can be tilted forward to facilitate media load. Always
engage the printhead in order to hold the media before closing the cutter.

10.5 Servicing
The cutter mechanism and the circuit board becomes accessible when
the cover is removed. The cover is held by one #T20 Torx screw. It is not
necessary to remove the entire cutter unit.
The cutter shears will need to be cleaned from adhesive residue if the cutter
has been used for cutting through labels, something that is not advisable.
Use isopropyl alcohol (see warning text on the container). The extreme
positions of the moving cutting shear (that is, the shear is in top or home/
bottom position) is detected by a sensor at the tip of the circuit board and
a microswitch at the right side of the cutter assembly.
Fingerprint
If the following errors occur, clean the shears from adhesive residue and the
sensor from dust.
• 1701 “Cutter error1”
A cut has been performed but the shear has stopped on its way back to
home (bottom) position.
The cutter has failed to cut after several attempt (3 is default) and the
shear has returned to home (bottom) position.
The cutter has failed to cut and the shear has stopped before returning
to home (bottom) position.
If the cutter cable connector has come loose from Finisher interface, Error
37, “Cutter device not found” or Error 1059, “Cutter does not respond” will
occur.
If the “cutter open/closed” microswitch on the cutter assy is faulty, Error
1704, “Cutter open” will occur, even if the cutter in fact is closed.
IPL
IPL reports if the cutter has failed to return to home position by displaying
the message “Open&shut cutter.” Follow that instruction. If the error
persists, clean the shears from adhesive residue and the sensor from dust.

Lubricated Parts
Do not use isolpropyl alcohol!
Bracket
Circuit board
Top position
sensor S1
#T20 Torx screw

Cable
Cutter bottom
(home) position
sensor S2
(hidden)
Cutter open/
Cover closed sensor S4
Tray Cover fitted/removed

sensor S3
Media intake
Latch

10.6 Cutter PCB

1-971650-50 Cutter Circuit Board assembly

1-971650-25 Cutter Circuit Board; Components
Primary Side Secondary Side

1-971650-25 Cutter Circuit Board; Schematics


11 Electronics Compartment
This chapter describes how to access the electronics compartment and

shows the main parts.
The electronics compartment contains wires and components with
compartment!

Chapter 11—Electronics Compartment
11.1 Introduction
The Electronics Compartment is off limits to the normal user, but for
the authorized service technician, it contains a number of parts of great
interest:
• The stepper motor and timing belts of the platen and liner drive rollers.
• The ribbon feed motor.
• The headlift mechanism and sensor.
• The CPU board.
• The power supply unit.
• Optionally one or two extra interface boards and/or one EasyLAN
board.
11.2 Accessing the Electronics Compartment

To gain access to the electronics compartment, remove the front/left-hand
cover as described in Section 3.2. To completely remove the cover, you
will need to disconnect the cable to the console pcb from J50 on the CPU
board.

11.3 Main Parts

This is what you may see when you remove the front/left-hand cover from
an EasyCoder PM4i printer.
Power supply Optional EasyLAN board Connect console pcb here Ribbon motor
(behind CPU board)
Headlift
mechanism
Optional CPU board Stepper motor Platen roller Liner drive roller
interface board(s) belt and pulley belt and pulley


12 Power Supply
This chapter describes the power supply unit (PSU) which is fitted in the
electronics compartment, see Chapter 11.
compartment!
Double Pole/Neutral Fusing. Parts may remain live after fuse
operation.
Zweipolige/Neutralsicherung. Teile können nach Ansprechen der
Sicherung noch stromführend sein.
The chapter covers the following topics:
• Description
• Replacement
• Components
• Schematics

Chapter 12—Power Supply
12.1 Description
The Power Supply Unit (PSU) is identical in all EasyCoder PF2/4i- and
PM4i-series printers. It is situated inside the electronics compartment
between the CPU board and the center section.
No attempt to repair this unit is allowed. Never replace a blown fuse, but
replace the entire PSU.
The power supply unit is primary-switched with power correction factor
controller so as to comply with the CE regulations, which require a sinus-
shaped load curve. It is designed for input voltages in the range of 90 to
265 VAC, 45 to 65Hz. There is no manual switch.
The unit requires 15W at standby and 300W peak. It produces 24VDC
only; all other voltages are transformed from 24VDC by the CPU
board. The CPU board controls the PSU over the I2C bus, where also
identification and error signals are transmitted to the CPU board. Voltage
and temperature are monitored and the unit is over-current protected.
The PSU consists of the following main parts:
Stepper Motor Stepper Motor

Controller Output
Power Supply Board
Input Voltage:
90 to 265 VAC 15W standby 24 VDC 6A
45 to 65Hz
(approx. 300W peak)
P24 Enable
Power Fail
Input
Booster Forward
Converter Converter
Rectifier 24V
Pulse Width Pulse Width Stepper Motor

Modulator Modulator
(w. Power Factor Contr.) Forward Controller
Temperature Control
&
Power Fail Interrupt
Control Vout
(24V)
I2C-bus

Power Factor Control

The power factor control transforms the AC input voltage to 385 VDC
by sensing the shape of the curve of the input voltage and chopping it to
short pulses, where the pulse amplitude follows the shape of the curve. The
booster is protected by two 4A fuses.
Forward Converter
The forward converter transforms 385 VDC to 24 VDC 0-6A. The
24VDC is the bulk voltage and is used for all parts of the printer. Other
voltages needed for internal devices are locally transformed from 24VDC.
Connections
P1 24VDC to CPU board, control lines, and I2C bus communication
between PSU and CPU board.
P5 24 VDC to printhead
P6 Ribbon motor
P7 Not used
P8 ISR connector (not used)
P10 Stepper motor
X1 Input voltage 90 to 265 VAC, 45 to 65Hz
Overheating Protection
The power supply unit is fitted with a sensor that will shut down the
unit in case of overheating (Power Fail Interrupt or PFI) and another
sensor that will warn the main CPU if the power supply is getting hot
(Notify). A Power Fail Interrupt (PFI) signal will warn the logics so
valuable data can be saved before power is lost. Before a print operation is
executed, the Notify signal is checked. If the Notify signal is activated, a
warning is shown in the display and the main CPU will reduce the power
consumption to avoid shutdown by detaining the printing until the Notify
signal is deactivated.
Primary switched power supply units are generally difficult to troubleshoot
and repair. If one component fails due to aging or overload, a number of
other components will also break as a consequence. If a fuse blows, do not
attempt to repair the PSU, but replace the entire unit!
The power supply unit contains wires and circuits with dangerous
voltages. For safety reasons, it is strictly forbidden to try to repair a
power supply unit or to replace a blown fuse. Whenever a fuse blows,
always replace the entire power supply unit.
Das Netzteilmodul enthält Kabel und Schaltkreise, die gefährliche
Spannungen führen. Aus Sicherheitsgründen ist es streng untersagt,
ein Netzteilmodul zu reparieren oder eine durchgebrannte Sicherung
auszutauschen. Falls eine Sicherung durchbrennt, muss das gesamte
Netzteilmodul ausgetauscht werden.

12.2 Replacing the Power Supply Unit

The PSU comes as a complete unit consisting of a large metal bracket to
which the following parts are factory-fitted:
• Plastic protection sheet
• Power supply pcb (attached to the bracket using four #T10 Torx screws
and washers)
• AC power cord socket (attached to the bracket using two #T10 Torx
screws and nuts)
• On/off switch (attached to the bracket using snap-locks)
• Label
• Heatsink (attached to bracket using doublesided tape)
The bracket and heatsink are fitted to the center section using six #T20
Torx screws.
Label Bracket
Protection Sheet
On/Off Switch
Power cord
socket
#T10 Torx
screws
and nuts
(x2)
PSU Board
Tape
#T10 Torx screws and washers (x4)

Heatsink
Power supply unit without heatsink (simplified drawing)

Replacement Procedure
1 Take precautions to avoid any electrostatic discharge.
2 Switch off the printer and disconnect the power cord and all interface
cables on the rear plate.
3 Remove the front/left-hand cover as described in Section 3.2.
4 Remove any interface bord connected or attached to the CPU board.
5 Disconnect all cables from the CPU board and remove it (see Section
13.3). The CPU board is held to the PSU bracket using four #T20
screws and one hexagonal spacer.
6 Remove the six #T20 Torx screws that hold the PSU bracket/heatsink
assy to the center section.
7 Do not dismantle the PSU. Replace the entire unit!
8 Assemble in reverse order.

102
P6 R131A R131C
D33
C95
C98
R131B
C102
D D
Q12 Q13 T1
G S G S
C93
C90
R127
U13 C8 C7
R106
C92
R102
C101
C100
R126
R105
R101
R104 R103
THR2
THR1
C91
R125
R124
R60
C104
P10 C94 R61 R59
C2
D28
R53
R58
R57
Q11 B C E
U4 R56 C4 C3
C97 R130A R55
R62
R76
D26 D25 C47
12.3 Components
R130B
A
E
D31 D32
SW1
R100
R63
R82
R81
D27
U5
NC
C78 R130C
C83
D30 D29 D16 Q4
C84 Z3 R65
NC A T2
P8 U10 K R64 U6 R52
C5
R54 C6
D24
C1
C52 C48
U11
R94
P1
Z2
A
R90 NC A
K
C76 C77 C75
R68
K
R71
NC
R87 R84 TY1
R80
R83
B
R88 R70
R67
C
R85 R89
E
C68
U8
Q14 D23
R114
R113
R112
R86
R118
R122
U7 K
C27
R51
A NC Z1 D14 C46
L2 L1
C87
NC
Q15
C51
R69
K
K
D15
E
R115
A
NC
1
C
R91 U12
R119
R123
R66
R116
B
C45
R92
R117
3 .
R110
R111
R120
R121
D12
D13
POT1
L5 T4
U3
VAR1
R93
TR1
L12 L10
PT2
PT1
C61
X1
R95
F1
F2
P4
C44
L13 L11
P7
C81 RB1
NC A C56
K
D22 F10 C34

U15 Z5
NC
K
C70 K C12
A
A NC
Z6
R98 C71 C59 R77
R78
R99 R97
NC
K
D18 C58 C33 8 1
A
Q10
8
7
8
7
C32
P5
1-971631-25 Power Supply Unit; Component side

C15
T3
C62 C20 L3
L4
R30
R33
C21
C24
D5
C22
C31 R37
R31
C18
C29
D11
D10
U2 U1 CHASSIE
D4
1
C19
14
C26
1
R36 C28
14
C10 R38 9 16
C36
D8
D3
R79 C9 D9
CHASSIES R41 D6 R14
K K
D D A NC D R39 K D A NC
R75 R42 A NC R15
R40 D2
S
D17 G S Q3 G S Q2 G D7 S Q1 G D1

R3 R2 R1
C13 R13
R12
C11
R11
R4 R5 R6
C23 R32
R8
R7
R10G
R10H
R10D
R10C
R10E
R10B
R10A
R10F
R10J
R10I
C25
R35
R26
R9
R27
C30
R29
R28
R18 R17 R16

C14
C42
C35
R21 R20 R19
C40 R45 R46 R47

R22 R23 R24
C43
R25
C41 R48 R49 R50
R43 C37
R44C
R44D
R44A
R44B
C50
C54
C53
C55
R74C
R73C
R74B
R74A
R73A
R73B
C85
C57
C103
C96
C99
C60
R129
R128
C63
C64
C65
C66
C80 C67
R96
C69
C88
1-971631-25 Power Supply Unit; Soldering side

104
R74A
L3 HV
6 10
7 11 R74B
D1 D18 24V POWER OUT
8 12 A C R78 R77
R74C C54
D
VGATE
C13
C14 R39
+
C15 C35 G
+
C34 Q2
1
L4 C59
+
24VP
C58
RB1 24V
R16
R19
R22
+ D7
S
2 3 R40 G 1 5
D6
AC AC C12 D 2 6
R13
C11 D17
-
S 3 7
12.4 Schematics
L5
C32
C33
1 3
4
C57
C56
1
C55
B
B
R17
R20
R23
D
11
12
13
14
R10A C53 2 4
C36
C
C
R12
G R14
Q1 15V
R10B T3
D10
D11
D2 U2
PT1
PT2
R15 R38
84-14
1 LIN VB 8
R10C
A
A
2 7
R18
R21
R24
A
A
R73A
R73B
R73C
HIN HVG
2
8
9
R11
SURGE PROTECTOR
SURGE PROTECTOR
3 6 CHASSIES
10
R10D D3 VCC OUT D9 R42
4 GND LVG 5
VARISTOR C31
R10E SHD PFIV L6385 R75 R79
D
A B
R41
C40
C41
G C9 C10
VAR1 R10F Q3
R29
R28
R27
R26
R25
R10G
R4
D8
270K
R45
R48
R43
L1
L2
R10H
R7
1K6
R10I
C37
C5 C6 U1
R5
24VP
R44A
R44B
R44C
R44D
R46
R49
R10J R9 UCC38503DW
R30
R71 C52
4 OVP/ENBL GT1 12 15V
C21
C
R8 3 VSENSE GT2 10
3
4
C20
R47
R50
R6
1 VAOUT VCC 9 Z2
R70
T2 C29
A
16 ISENSE1 CT 5
D4
C18
C19 R31
C30
17 MOUT RT 2 R37
U7
1
2
15 CAOUT GND 6 4 1
R69
R68
C2 18 IAC PWRGND 11 C51

C28 3 2 R67
19 VFF SS2 13
C3 C4 14 PKLIMIT VERR 7 LVT817 C50
R33 R36
C
R66
20 VREF ISENSE2 8
REF
C22
R32
U8
C26
C27
1
2
R35
15V POT1
3
4
TL431CLP
D5
A
1 2 3
C24
C23
C25
3
T1
SECONDARY 24VP
OVERVOLTAGE
R51
C
D15 15V SHUT DOWN
1
2
SHD 2 1 R52
U6 Z3
A
C7 C8 HV 15V 4 1 R65
15V
D13 3 2
C48
R54
10 T4 6 2
1 TY1 3
R64
LVT817
1-971631-25 Power Supply Unit; AC to 24VDC

3
+
1 5 C43 C44
R53
128-46
C
SW1 R59
Z1 D16 80 DEG 5-80 DEG
TR1 D12 PFIV
1
2
A
OVERHEAT 15V TEMPERATURE
C
C1 U4 R60 SENSOR SENSOR
8
U3
3
C42 B R56 1 THR1 THR2 PSU CTRL
D14
5
TOP221G08A Q4
2 5V
R1 R2 R3 CONTROL 4 R55 LM393M T T
4
TEMP_MON
E
C46
+
C45
1
2
3
6
7
8
R61
CHASSIE 15V
R57
R76 R62 15V
F1
F2
R63 U5
C47
R58 1 4 5V
1
U4
3
2
5
AC1 AC2
7 2 3 PFI_DET
X1 6
LM393M LVT817
GND

24 V POWER IN TPH 24V SWITCH 24 V TPH OUT
VGATE
C70
24V Z5 24V_PH P5
1
2
+
+
C61 C62 C63 3
C60
4 TT-MOTOR DRIVER
C69
5 24VS
6
D
Q10
7
G 8
R106
R96
S
D33
S
R97
3A
R104 R105
C
G
F10
5V R103 B Q12 P6
D
Z6
C71
Q11
1
C104
R98
2
R100
U12 Q13
R99 13 12 R101 G
AHCT14
C66 C65
R102
4
3
R129 MOUNTED IF STEPPER MOTOR DRIVER
U15 EXTERNAL DIODES 5V
L12
L13
L11
L10
ELSE R128
D22
LVT817
R129 24VS
1
2
CPU CON C67 C64 5V C103 C101 C100
+
+
P1 C68 C102
STEPPER MOTOR CURRENT CONTROL R128
C99
C96
C97
R95
C98
1 24VS 5V
2 +
32
16
37
38
36
43
25
3 P24ON
4
VDD
CP1
CP2
VCP
VBB
VBB
5
VREG
6 STEPPER MOTOR
7 TPHV RESET_N 27 RESET_N OUT1A 6
TT_PWM 42 SLEEP_N
R110
R111
R112
R113
8
D29
D30
D31
D32
9 U12 41 ENABLE_N
10 STMC4 11 10 R114 OUT1B 40 P10
AHCT14 HOME_N 4 HOME_N

11 STMC3 MS1 20 1
STMC2 5V MS1
12 MS2 19 MS2
2
13 STMC1 A3977 OUT2A 18 3
R118
14 U12 STEP 31 STEP 4

15 PIC_RESET 5V 9 AHCT14
8 R115 DIR 5 DIR U13
DIR 28
R122
16 26 OUT2B
SR_N
D25
D26
D27
D28
R124
17 STEP U12
STEPPER3 R94 HOME_N 14
18 REF
R119
19 U12 SENSE1 3
ISR CONNECTOR 1 AHCT14
2 9 PFD
R90
20 STEPPER4 5 AHCT14
6 R116
21 STEPPER5 10 RC1 SENSE2 21 C94
22 STEPPER6 5V 15 RC2
STEPPER7 P8
R130A
R130B
R130C
23
D23
R120
U12
R88
D
10K
24 1
R125
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
C92
C93
25 STEPPER8 2 3 AHCT14
4 R117
R123
1
2
26 STEPPER9 B 3
11
12
13
22
23
24
33
34
35
44
27 P24EN Q14 5V C 4 C95

28 PSU_INT_N B 5
R126
R127
C90
C91
E
PSU_NOT_N
R121
R131A
R131B
R131C
29
R87
30 U10 24VS U11 5V
31 SDA D24
R89
PIC16F87204 1 VIN VOUT
3
32 5.0V
SCL 9 21
+
+
33 24VS CLKIN INT/RB0

10 22 PFI_DET GND/ADJ
34 CLKOUT RB1 C83
PSU_NOT_N
2
5V RB2 23
C75
5V PSU_INT_N
C85
C88
C87
C84
1 MCLR/VPP RB3 24
CPU P41 RB4 25 P24ON
R86
5V? 2 RB5 26
R85 P24EN
1-971631-25 Power Supply Unit; Driver and CPU Interfaces

AD24V 2 RA0 RB6 27 B
3 RA1 RB7 28 C
R80
R81
STMC2 4 RA2
PSU CTRL 5 RA3/VREF
R84
FAN DRIVER
C76
STMC3 6 RA4/TOCKI RC0 11 STEP
STMC4 7 RA5 RC1 12 DIR 24VS
RC2 13 FAN_PWM P7
TEMP_MON 5V RC3 14 SCL
15 R93 FAN+
RC4 SDA 1
C
20 VCC RC5 16 RESET_N 2 FAN-

R91
RC6 17 MS1
C77
R83
8 GND RC7 18 MS2 B
C78
Q15
PFI_DET 19 GND
+
C81
C80
R92
R82
105

13 CPU Board
This chapter describes the CPU board which is fitted in the electronics
compartment (see Chapter 11).
compartment!
Before touching the CPU board, take precautions to avoid any
electrostatic discharge.
The chapter covers the following topics:
• Description
• Circuits
• Connectors
• Test points
• Startup
• Components
• Schematics
Note: Devices and file systems, such as "/c:" or "uart1:", are only used in
Fingerprint. Some may also exist in IPL, but are hidden to the user.

Chapter 13—CPU Board
13.1 Description
The CPU board is a four-layer board with most of its circuits surface-
mounted. Inside the laminate are a combined VCC layer (5V/3.3V/2.5V)
and a GND layer. The front and back sides are signal routing layers.
The hardware contains of the following main functions:
• Processor core
• Thermal printhead driver
• Stepper motor control logic
• Sensor drivers
• Communication, such as UART, USB, etc.
• Flash memory SIMM for the firmware and non-volatile storage
• SDRAM SIMM for working memory
• A/D converter for sensor adjustment, etc.
• Compact Flash memory card expansion
• Expansion bus
• PCI bus (custom)
Network
card
6
PCI bus 8
UART
(custom) 5 3 5
Wand iButton Beeper
1 3 5
Sensors
CPU PSA 3
A/D converter
RISC core 1 TPH logic 4
Memory controller SDRAM Stepper logic TPH
PCI interface Interrupt 5
1 Console
Clock I2C master
5
48 MHz Finisher
5
2 CPU board I2C bus 5
Bus isolation EEPROM PSU/Motor
interface
2 2 2 6 6
Flash memory Compact Flash CLIC Exp. interface USB
Stepper control signals
Support logic
Board id Optional board 7
Reset
Power conversion 24V In
(Optional board) 5V
3.3V
(only one optional 2.5V
board in PF-series)
1-971630-25 CPU board; Block Diagram

(numbers refer to schematics in Section 13.7)

13.2 Circuits
Components mentioned in this chapter are marked with gray in the
drawing below.
1-971630-00 PO2 J10
J21 J20
J30
RTC & PROGRAM KEY

COMPACT FLASH
U13
Processor
U30
P35 Support
Chip
BOOT-FLASH
Processor (U13)
The processor is a 32-bit RISC offering about 125 MIPS at the internal
clock speed 96MHz. The internal bus speed is twice the external bus speed
at 48MHz. The processor has several features, such as integrated SDRAM
controller, PCI bridge, DMA, UART, timers, etc.
Support Chip (U30)
The PSA (Processor Support ASIC) is a programmable logic device, which
is programmed by the firmware at each startup. It contains most of the
printer-specific and other logic functions, such as:
• Printhead data and strobe control
• Stepper and DC motor logic
• Sensor interface
• Timers and interrupt control
• Control logic for bar code wand and the electronic key/RTC
• I2C master
• Beeper signal generation
• Interface to A/D converter, console, finisher, etc.

Flash Memory (J20 and J21)

There are two sockets for Flash SIMMs (marked “BOOT FLASH” and
“EXP FLASH”). A SIMM (Single Inline Memory Module) must always
be fitted in J20 since this bank is the Bootbank. As standard, a single 4MB
flash SIMM is fitted. It contains the following sectors:
Device1 Size Type Used for
– 128K Boot Startup
1
/c 2048K User file system or Kernel FP: Customer’s programs, files, images
IPL: Formats, images, fonts
/c 1856K User file system FP: Customer’s programs, files, images
IPL: Formats, images, fonts
– 32K TMP area Media feed info, odometer value, etc.
– 32K Parameters Media feed info, odometer value, etc.
1
/. Devices are used in Fingerprint, but are hidden in IPL.
2
/. This sector can be used for the kernel or for the file system (/c). If it is used for the file
system, the kernel is placed in the file system under the /c/boot directory, which is the
normal configuration, enabling the size difference between 2048K and the real kernel
size to be used in /c. Refer to the Intermec Fingerprint v8.xx, Programmer’s Reference
Manual for a complete list of files stored in /c and /rom by default. The kernel includes
Fingerprint or IPL firmware, bar codes, standard fonts, standard images, Intermec Shell,
auxiliary programs, default setup values, and the EasyLAN home page files.
The flash memory retains its content at power off without any battery
backup. It consists of sectors that can be erased and written to over and
over again. This is done automatically in the background. At power-up,
the flash memory is reorganized to avoid fragmentation. Before a sector is
erased, its content will be copied to a temporary area as a safety measure
if something should go wrong, for example a power failure. For the /c file
system in Fingerprint, this area is 64K and is included in the sectors in the
table above. For the parameters, it is the 32K TMP sector.
The Boot sector is necessary for Intermec Fingerprint or IPL to start.
There is a boot sector in all flash SIMMs at delivery, but the firmware will
only accept the boot sector of a SIMM fitted in J20 (marked “BOOT
FLASH”). The boot sector is only protected when the flash SIMM is fitted
in socket J20 (”BOOT FLASH”). If you move flash SIMMs from one
CPU board to another, make sure that the SIMM containing the boot
sector is fitted in J20 (“BOOT FLASH”) on the other board, or the boot
sector will be overwritten.
Note: The Intermec Fingerprint firmware is either stored in the /c file

system or in a dedicated area on the boot flash (2MB large). If it is stored
in the file system, removing or exchanging an EXP FLASH in the J21 loca-
tion may render the printer inoperable. To cure this condition, use a Com-
pactFlash card containing an upgrade file (kernel) to reload the firmware.
As illustrated in the table above, a total nominal capacity of 3904K is used

for the /c file system (MIFS, or FOS) and fonts. In Fingerprint, practically,
around 2 MB are available to the user (about 200-400K less if the kernel is
in the dedicated area).

Exactly which fonts, images, files, and programs are stored in the
Fingerprint file system may vary between customers and applications.
The parameters sectors store the PFSVARs (see SETPFSVAR Fingerprint
statement), odometer values, and a few other “invisible” files with data,
that are required for the printer to start up with the same settings as when
it was shut off, for example information on the position of label gaps in
relation to the LSS.
The printer’s permanent memory can be expanded by fitting a second
4MB or 8MB flash memory SIMMs in sockets J21. 4MB and 8MB flash
SIMMs can be mixed at will. Flash SIMMs are custom-made and can only
be ordered from Intermec.
Note: The first time the printer is started with a SIMM in J21 (“EXP
FLASH”), the memory is not increased to enable cloning the first SIMM.
The expansion is not done until the second time the printer is started.
Flash Memory Available to the User

J20 (Boot) J21 (Exp) J20 (Boot) J21 (Exp) SUM
4MB SIMM – 1.8MB – 1.8MB
4MB SIMM 4 MB SIMM 1.8MB 4MB 5.8MB
8MB SIMM – 5.8MB – 5.8MB

SDRAM Memory (J10)

The SDRAM memory (Synchronous Dynamic Random Access Memory)
is the printer’s temporary memory (Fingerprint device "tmp:"). It will lose
its content when the power is switched off or at a power failure. Thus, it
should only be used for data that can easily be recreated or that are only
relevant for one power-on cycle. It is much faster than the flash memory.
Therefore, at startup the kernel is copied from the Flash memory to the
SDRAM, where the various instructions are executed.
One SDRAM SIMM (standard size 8MB) must always be installed in
socket J10 (SDRAM0-1).
The SDRAM is also used for the font cache and various buffers. The
remainder is used for the two print image buffers where the bitmap
patterns are stored prior to printing. One buffer is used for the label that
is being printed, while the other receives the bitmap for next label as the
Intermec Fingerprint instructions are processed. By switching between the
buffers, batch printing without stopping between labels can be achieved.
The size of the buffers depend on two factors:
• Number of physical dots on the printhead.
• Present label length setup value in dots.
Calculate the buffer size according to this formula:
(No. of dots / 8 + 4) × (Media length in dots) = Buffer size in bytes
(Buffer size in bytes) / 1024 = Buffer size in kbytes
Buffer size in kbytes × 2 = Memory requirement in kbytes
Example:
The number of dots on the 8 dots/mm printhead of an EasyCoder PM4i is 832.
“Media; Length” is set to 1500 dots (= 187.5 mm/7.38 inches)
[[(832 / 8) + 4) × (1500)] / 1024] × 2 = 316 kbyte total
If a longer print length or more storage space is required, the printer can
be fitted with a 16MB SDRAM instead of the standard 8MB. However,
regardless of memory size there is an absolute print length limit of 32,767
dots (4,095 mm/161.2 inches).
Electronic Key Circuit (J30), Fingerprint-only option
The optional electronic key circuit is an iButton which contains a real-time
clock. It has a built-in battery backup with a life of at least 10 years. When
the printer is on, the circuit is power supplied via the CPU board and will
not consume any power from the battery. The circuit also contains 4Kbits
(500 bytes) of battery backed-up memory for the devices "lock:" and
"storage:".
The Electronic Key Circuit (J30) contains an integrated lithium
battery. Replace only with original Electronic Key Circuits from
Intermec. Dispose of used Electronic Key Circuits in compliance with
local regulations for lithium batteries.

Der elektronische Schlüsselschaltkreis (J30) ist mit einer integrierten

Lithium-Batterie ausgerüstet. Dieser darf nur durch elektronische
Original-Schlüsselschaltkreise von Intermec ersetzt werden. Benutzte
elektronische Schlüsselschaltkreise müssen unter Einhaltung örtlicher
behördlicher Vorschriften für Lithium-Batterien entsorgt werden.
Since the communication between the RISC processor and the electronic
key circuit is comparatively slow, the content of the key circuit is copied
to SDRAM at startup and used from there. At power off, the content is
read back to the key circuit, provided there is time enough. Thus, there is
a small risk that new data may be lost, before it has been saved back to the
electronic key circuit. The original data in the electronic key circuit will not
be damaged, if the read-back process should fail.
Memory Card Adapter (J22)
The CPU board has a built-in memory card adapter which can use
standard Type I CompactFlash memory cards with a size of 8MB to 1GB
(thickness 3.3 mm/0.13 in.). It is not suited for other types of memory or
I/O cards! Cards marked “CF+” and Type II cards (thickness 5.0 mm/0.20
in.) cannot be used.
In Fingerprint, CompactFlash cards can be used to expand the printer’s
memory (device "card1:"). IPL does not support CompactFlash cards as a
means of expanding the memory.
Memory cards are only detected by the firmware at startup and must thus
be inserted in the memory card adapter before the power is switched on or
the printer is rebooted.
Switch off the power to the printer before you insert or remove any
memory cards.
Die Stromversorgung des Druckers abschalten, bevor Speicherkarten
eingesetzt oder entfernt werden.
Preprogrammed CompactFlash Memory Cards
There are four types of preprogrammed CompactFlash memory cards from
Intermec.
• Font Cards
Font stored in font cards can only be used while the card is present in the
printer’s memory card adapter.
• Font Install Cards (Fingerprint only)
Install additional fonts in the printer’s memory. These fonts can be used
without the card being present.
• Firmware Cards
Install a new firmware kernel in the printer including standard fonts. Used
for upgrading the firmware or switching between Fingerprint and IPL.
• Configuration Cards
Configures a CPU board for the type of printer in which it is installed, see
Section 13.8, or changes the printer’s EasyLAN setup.

13.3 Connections
The following connectors on the CPU board are used in the printer for
communication with various devices and sensors.
1-971630-00 PO2
CONSOLE
PCI
J50
RIBBON
J56
POWER
J84
J52
J59
P35 J62
PRINTHEAD
WAND
RS232
J61
J61
GAP J40
J55 J54
HEADLIFT BM
J60
USB
J58
EXP BOARD
J57
PAPER J53 LTS J51 FINISHER
Left side (from top down)

J59 Bar Code Wand (not supported by IPL)
J61 RS-232
J60 USB
Bottom (from left to right)
J62 Expansion board(s) (optional interface boards)
J57 Paper Sensor
J53 Label Taken Sensor (option)
J51 Finisher
Top (from left to right)
J84 PCI (EasyLAN interface, option)
J50 Console (keyboard, display, and print or feed/pause button)
Right side (from top down)
J56 Ribbon Low sensor
J52 Power from PSU
J40 Data to printhead
J55 LSS (gap)
J54 LSS (black mark)
J58 Headlift sensor

13.4 Test Points

The CPU board is provided with many test points. Only those of
immediate interest to the field service technician are shown below. If
further testing or servicing is required, replace the CPU board and return
the faulty board to a service center.
1-971630-00 PO2
DEBUG
J23
F70
WAND
P35
2.5V
DONE
R718
3.3V
GND
Test Points
If available, use an oscilloscope to measure the various voltages. When
using for example a multimeter, a fluttering value may indicate an
erroneous voltage.
GND Ground
2.5V 2.5V –> GND (max ± 0.2V)
3.3V 3.3V –> GND (max ± 0.2V)
5.0V R718 –> GND (max ± 0.2V)
24V F10 left side –> GND (allowed deviation, see Chapter 12)
(If no voltage on the left side, check the right side. If voltage
there, fuse is blown, else cable or PSU trouble.)
DONE High level = U30 programmed, see Section 13.5
DEBUG Startup check, see Section 13.5
WAND Use an oscilloscope. OK if there is a pulse train when the wand is
reading a bar code.

13.5 Startup
The prerequisite for the printer to start is that a flash memory SIMM with
a boot sector is fitted in J20. A SDRAM SIMM must also be installed in
J10.
At power up, the printer starts executing code in the boot sector and one of
the following sequences will be performed:
1. A Compact Flash card with a firmware file is recognized.
- The firmware will be copied from the memory card to the internal
SDRAM.
- The processor will start to execute code from SDRAM.
- The firmware on the memory card will be copied to the internal flash
memory.
2. A valid firmware is recognized in the internal flash memory.
- The firmware will be copied to SDRAM and the processor will start
execute code from SDRAM.
If the printer is fitted with an EasyLAN interface, there are also facilities
for updating the firmware from the printer’s home page.
After the initial boot sequence is performed, the number of steps will be
taken before the printer starts, which includes programming the support
chip (U30). The startup procedure can be followed on the printer’s display.
You can also follow the startup from the host provided a strap is
temporarily fitted at J23 (DEBUG) on the CPU board. Connection
between printer and host should use the default serial communication
setup (9600 baud, 8 bits, parity none, 1 stop bit) on the standard serial
port "uart1:". For each of the steps, either “OK” or “Fail” is returned on
"uart1:". In addition, some other useful information is also returned.
Refer to Appendix B for information on how to upgrade the firmware.

C900 J81
J50
TMS
R905
R923
R922
R847
R925
R920
R200
R921
R300
R924
R202
R892
R129
R127
R128
R126
R125
R124
R123
R904
PP32
R215 TDI
J30
R216 R926 CCLK TCK
R137 R983
J24 J23 R217
R138
J56
R218 R139
PP56
R985
R219 R140
R981
R141
U20
R220 R980
R221 R142
R978 PP55
R143
R222 R977
R144
C953 R975
R895 R145
R146 R974
U92 R147 R973
R148 R972
R231 R970
13.6 Components
R149
R894
R232 U13 R969
R150
R233 R967
J84
R893 R151
R234 R152 R966
U22
R153 R989
R235
R154 R990
R236 R992
R155
C955 R156 R993
R157 R995
R223 R996
R158
PSU_INT_N
R224 R159 R998

R225 R130 R965
R963
R226
R962
R227 R960
U21
R228 C12 R959
J52
J22
R265 R229 C11 R999
R230 R957
R110
Y10
R955
C954 D0 R954
R952
R101
C921 R951
U72
R237
1
R238 C10
R136
R239 U11 F70
J20
J21
J10
R240
R100
C712
R241
PSA_TDO
U23
J83 R242
D50 R243
C700
K R244
R102
R103
C975
C974
A NC
U81 C956
R915
R914
C963
R934
C951
R245
R621

R246
C R897 L402
T80 R247
C540
B E
U80
L52 WAND R206 R896
R913 R248
U91
L415
U31
R912 R249
R911 R898 PP52
U24
R250
R430
R500 C952 U30

R251 L400
R252
J59
L51
C961
C957 2.5V
PP51 R431
L50
1
35
R432
R932
R317 R321 R325

C976
R301
PROG
INIT
R313
U26
R318 R322 R433
U90 R302 R326 R314
R323
U42
R303 R327 R315 R434

R324 R328
J40
R253 R304 R316

C938 DONE R435
R254
L64 R255 R309 R305 PP30 R436
C66 R256 R310 R306
C64 R623 R203 R311 R437
R339
L63 R307
C966
R611 R312
C63 R308 R319
U25
R625 R257
R438
L67 R402 PP54
B
R615 R204
PP31
C65 PP40
U32
R405
U43
R320 R439
T42
R624
E
L62 U40 PP53
1-971630-25 CPU Board; Component Side

R613 C958
U61
B60 R401 R700 R701
B
R619 R440
J61
R610 C964
C
A
L66 R404
T41
E
K
PP50
R411
R410
C405
C403
R614 R717
D40
R720
NC
R400
J62
R629 R721 R716
B
L61 R620 R409

R408
C
R612
C701
R719 R722
T40
R403
E
B
C401 R705 R723

C
L65
T44
E
R406 R702 C703
R618
C
T43
C702 R706
E
L68 R407 J55
R510
C400 R708 R703
C402
U51 R414
B
R418 R421
R718
C972
R709
U70
R601
R600
C
R417 L70
T47
E
EXP1_INT_N C704
R420 R419
R422
C404
R413 R707
B
RP60
R710
R704
U50
C
R416 R423 R424

T46
E
J54
R521
C511
R520
R412 PP41
R509
U41
B
R603 USB_INT_N
C971
C406
C
C709
R522
R523
R604
T45
E
U60 R415
R602 C708 C
D72 B E
R712
R711
L60 THY70
C973
EXP2_INT_N U52 C D70
J60
D71 T71 T70
C967
C62 B E J58
C710
34
68
T1 3.3V GND K C K R715
K
A NC B E A NC C717
C965 C60 R605 C61 C507 C508 A NC
R724
R525
R526
C512
R713 R714
C706
Z70
R524
C509
C510
C705
MH71 Y60 PP58 MH70

C716
PP57 U71 L72 T72 L71

L74 J51
J57 J53
PP59
117
209R
309R
009R
C530
R533
R537
R536
R535
R534
C533 R910
R530 R901
R207
R210
R209
R208
R329
R815 R873
R982 C915 C914 C913 C912 C911
C531
C532
C504
R515
R532
R531
R984 R811 R881

R831 R874
R986 R827 R882
C983
109C
C984
C916
C982 R814 R875 C992

R514
C503
R979 R883
R810
C981
C980
R830 R876 R884 C977
R931 R976 R826
C988
C902
C990
C917
R987 R836
R890
R889
R929 R846 R855
R971 R845 R848
R930 R844 R856
C903
C918
R549 C538 R968 R832 R843 R849

R547 R933 C979
R988 R135 R842 R857
R841 R850 C978
R546
R899
C989
R548
C904
C991
C919
R991 R134 R840 R858

C539 R133 R839 R851
R994
R132 R813 R877
C905
C920
R997 R131 R809 R885

C987 R201 C986 R829 R878
R964 C985 R825 R886
1-971630-25 CPU Board; Soldering Side

R961 C910 R812 R879
C909 C908 C907 C906 R808 R887
R958 R828 R880
R111 R824 R888
R956 R838 R859
C711
R953 R837 R852

R860
R950 R835 R853
C715
R834
R861
R854
C932 C931 C930 C929
R862
R863
C933
C944 C943 R807

C942
R803
R823
R819
C948
C934
R425
R872
R871
C939
C922
C407 R806
R426 R802 R864
R427 R822 R865
C408 R866
C968
R818
C949
C935
R429 C409 R867
C940
C923
R428
C969
R868
R833 R869
R870
C936
C950
C941
C924
C947 C946 C945
C937
R805
R801
C970
C928 C927 C926 C925 R821

R333
R817
C32
R804
R336
R337
R338
C31
R800
R820
R816
R335
R334
C30
R927
R928
C33
C502
R513
C513
C501
R512
R628
R518
R519
R627
R626
R539
C707
C535 R540 R538
C718
C714
C713
R542
C537
R544 R725
C505
C506
R541
R516
R517
C534 R545 R543 C536
118
UART<5..0>
TDI
0
1
2
3
4
5
CLOCK DRIVER
3.3V
TCK
TMS
TDI
ID_N
PCST1
CPU
CS2_N
CS0_N
DMA_N
ACK_N
ADS_N
PCST2
PCST0
U11
M_WR_N
M_RD_N
TRST_N
EJ_TMS
INT1_N
INT0_N
CF_CS_N
CPU_TDO
7 VCC CLKA R101
PSA_CS_N
M_WAIT_N
BUS_EN_N
EJ_DBOOT
1 CPU_CLK 3.3V
XTALIN
EXP1_CS_N
PCI_INT_N
PCI_RES_N
3
DMA_DONE_N
PCI_GNT2_N
PCI_REQ2_N
Y10 CLKB 5 R102 SD_CLK
4 XTALOUT
CLKC 6 R103 PSA_CLK
12Mhz OE/FS
208
207
206
205
204
203
202
201
200
199
198
197
196
195
194
193
192
191
190
189
188
187
186
185
184
183
182
181
180
179
178
177
176
175
174
173
172
171
170
169
168
167
166
165
164
163
162
161
160
159
158
157
8
2 R136 CLIC_CLK
GND
R100 CY2071A
13.7 Schematics
GND20
GND19
VCCI7
VCCI6
GND18
VCCI5
GND17
GND16
VCCO16
M_OE_N
VCCO15
VCCO14
VCCO13
INT1_N
INT0_N
MODE
M_WE3_N
M_WE2_N
M_WE1_N
M_WE0_N
M_CS5_N
M_CS4_N
M_CS3_N
M_CS2_N
M_CS1_N
M_CS0_N
SPI_SCK
UART_RX0
UART_TX0
M_WAIT_N
SPI_MOSI
SPI_MISO
SPI_SS_N
JTAG_TCK
JTAG_TMS
JTAG_TDO
JTAG_TDI
EJTAG_TMS
PCI_RST_N
(INCL M_A(22..17))
M_245_OE_N
DMA_RDY0_N
EJTAG_DCLK
PCI_GNT2_N
PCI_REQ2_N
D SD_OE_N 1 SD_245_OE_N PCI_GNT1_N 156
DB_CPU_ID_N
EJTAG_DBOOT
EJTAG_PCST2
EJATG_PCST1
EJATG_PCST0
JTAG_TRST_N
DB_CPU_DMA_N
DB_CPU_ACK_N
DB_CPU_ADS_N
SD_WE_N R137 2 SD_WE_N PCI_CLK 155 PCI_CLK
SD_CAS_N R138 3 SD_CAS_N PCI_GNT0_N 154 PCI_GNT0_N 3.3V
D SD_BE0_N R139 4 SD_BE0_N PCI_REQ0_N 153 PCI_REQ0_N
SD_BE1_N R140 5 152 31 PCST0 R123
SD_BE1_N PCI_AD31
6 GND1 VCCO12 151
7 150 PCST1 R124
VCCO1 GND15
SD_CS0_N R141 8 SD_CS0_N PCI_AD30 149 30
SD_CS1_N R142 9 148 29 PCST2 R125
SD_CS1_N PCI_AD29
SD_RAS_N R143 10 SD_RAS_N PCI_AD28 147 28
1
11 146 27 ID_N R126
SD_S0_N PCI_AD27
SDRAM SIMM 12 SD_S1_N PCI_AD26 145 26
2 R144 13 144 25 ACK_N R127
M_A2 PCI_AD25
3 R145 14 M_A3 PCI_AD24 143 24
4 R146 15 142 PCI_CBE3_N ADS_N R128
3.3V 3.3V M_A4 PCI_BE3_N
SDRAM_SIMM 16 GND2 VCCO11 141
17 140 DMA_N R129
VCCO2 GND14
1 VSS1 VSS5 41 5 R147 18 M_A5 PCI_AD23 139 23
0 2 42 16 6 R148 19 138 22 22 R130
D0 D16 M_A6 PCI_AD22
8 3 D8 D24 43 24 7 R149 20 M_A7 PCI_AD21 137 21
1 4 44 17 8 R150 21 136 20 21 R131
9 5 D9 D25 45 25 9 R151 22 M_A9 PCI_AD19 135 19
6 46 10 R152 23 134 18 20 R132
VCC1 VCC5 M_A10 PCI_AD18
2 7 D2 D18 47 18 11 R153 24 M_A11 PCI_AD17 133 17
10 8 48 26 25 132 16 19 R133
D10 D26 OUT_CLK PCI_AD16
3 9 D3 D19 49 19 26 GND3 VCCI4 131
R134
11 10
11
D11 D27 50
51
27
12
27
28
VCCI1
RC32332 GND13 130
129 PCI_CBE2_N
18

VSS2 VSS6 M_A12 PCI_BE2_N
2 12 52 SD_CLK SD_A12 R154 29 128 PCI_FRAME_N 17 R135 D
SDA0 CLK0 SD_A12 PCI_FRAME_N
3 13 SDA1 CKE0 53 SD_CKE 30 SD_CKE PCI_IRDY_N 127 PCI_IRDY_N
4 14 54 15 SD_CS2_N 31 126 PCI_TRDY_N 16 R832
SDA2 SDA13 SD_CS2_N PCI_TRDY_N
5 15 SDA3 SDA14 55 SD_CS3_N 32 SD_CS3_N PCI_DS_N 125 PCI_DS_N
16 56 R155 33 124 PCI_STOP_N 15 R833
VCC2 VCC6 SD_BE2_N PCI_STOP_N
6
7
17
18
SDA4
SDA5
RAS*
CAS*
57
58
SD_RAS_N
SD_CAS_N 13
R156
R157
34
35
SD_BE3_N
M_A13
U13 PCI_LOCK_N
PCI_PERR_N
123
122
PCI_LOCK_N
PCI_PERR_N 14 R834
8 19 SDA6 J10 DQM2 59 SD_BE2_N 36 GND4 VCCO10 121
9 20 60 SD_BE3_N 37 120 13 R835
SDA7 DQM3 VCCO3 GND12
21 VSS3 VSS7 61 14 R158 38 M_A14 PCI_SERR_N 119 PCI_SERR_N
4 22 62 20 15 R159 39 118 PCI_PAR 12 R836
D4 D20 M_A15 PCI_PAR
12 23 D12 D28 63 28 16 40 M_A16 PCI_BE1_N 117 PCI_CBE1_N
5 24 64 21 17 41 116 15 11 R837
13 25 D13 D29 65 29 18 42 M_A18 PCI_AD14 115 14
26 66 19 43 114 13 10 R838
VCC3 VCC7 M_A19 PCI_AD13
6 27 D6 D22 67 22 20 44 M_A20 PCI_AD12 113 12
14 28 68 30 21 45 112 11 9 R839
7 29 D7 D23 69 23 46 GND5 VCCO9 111
15 30 70 31 47 110 8 R840
D15 D31 VCCO4 GND11
31 VSS4 VSS8 71 22 48 M_A22 PCI_AD10 109 10
10 32 72 SD_WE_N 10 49 108 9 7 R841
SDA8 WE* M_D10 PCI_AD9
11 33 SDA9 CS0* 73 SD_CS0_N 11 50 M_D11 PCI_AD8 107 8
1-971630-25 CPU Board; Core (Schematics #1)

SD_A12 34 74 SD_CS1_N 20 51 106 PCI_CBE0_N 6 R842
SDA10 CS1* M_D20 PCI_BE0_N
13 35 SDA11 NC2 75 RESET_N 52 COLD_RES_N PCI_AD7 105 7
36 76 5 R843
VCC4 VSS9
14 37 SDA12 NC3 77
38 78 4 R844
NC1 NC4
SD_BE0_N 39 DQM0 PD1 79 SD_PD1
M_D12
M_D19
M_D13
M_D18
M_D14
GND6
VCCO5
M_D17
M_D16
VCCI2
M_D15
MAST_CLK
M_D31
M_D0
M_D30
GND7
VCCO6
M_D1
M_D29
M_D2
M_D28
M_D3
M_D27
M_D4
VCCP
GNDP
M_D26
M_D5
GND8
VCCI3
245_DT_R_N
M_D25
M_D6
M_D24
M_D7
GND9
VCCO7
M_D23
M_D8
M_D22
M_D9
M_D21
NMI_N
PCI_AD0
PCI_AD1
GND10
VCCO8
PCI_AD2
PCI_AD3
PCI_AD4
PCI_AD5
PCI_AD6
SD_BE1_N 40 80 SD_PD0 3 R845

DQM1 PD0
2 R846
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
D D 1 R847
12
19
13
18
14
17
16
15
31
0
30
1
29
2
28
3
27
4
26
5
25
6
24
7
23
8
22
9
21
M_D<31..0>
M_A<22..1>
0
1
2
3
4
5
6
CPU_CLK D PCI_AD(31..0)
R110
R111
C10 + C11 C12
BUS_DIR_N
119
120
BUS/ADDRESS D<15..0>
ISOLATOR/DRIVER
U20 A<25..1>
19 G3 R215 0
3EN1[BA]
1 3EN2[AB] R216 8
M_D<31..0> AHC245
1 R217 BOOT FLASH EXP FLASH COMPACT FLASH
0 9 2
11 1
8 8 12
1 7 13 R218 9 3.3V 3.3V 3.3V 3.3V 3.3V 3.3V
3.3V 9 6 14
2 5 15 R219 2
4 16 1 37 1 37 COMPACTFLASH
10 VSS1 A14 14 VSS1 A14 14
3 17 R220 2 38 2 38 1 GND1 CD1* 26 CF_CD1_N

3 10 0 D0 A7 7 0 D0 A7 7 2 27
2 18 3 39 3 39 3 D3 D11 11
11 8 D8 A15 15 8 D8 A15 15 3 28
R221 4 40 4 40 4 D4 D12 12
VCC=3.3V;GND=DGND 3 1 D1 A16 16 1 D1 A16 16 4 29
5 D5 D13 13
R200
R201
9 5 D9 VSS5 41 9 5 D9 VSS5 41 5 30
R222 6 42 6 42 6 D6 D14 14
11 VCC1 NC1 VCC1 NC1 6 31
U21 7 43 7 43 7 D7 D15 15
BUS_EN_N 19 2 D2 NC2 2 D2 NC2 CF_CS0_N 7 32 CF_CS1_N
G3
R223 4 10 8 44 10 8 44 CS0* CS1*
D10 NC3 D10 NC3 8 33
3EN1[BA] 9 45 9 45 A10 VS1*
BUS_DIR_N 1 3 D3 NC4 3 D3 NC4 9 34 CF_RD_N
3EN2[AB]
R224 12 11 10 46 11 10 46 ATASEL* IORD*
D11 VCC5 D11 VCC5
AHC245 10 A9 IOWR* 35 CF_WR_N
1
11 VSS2 A24 47 24 11 VSS2 A24 47 24 11 36
4 9 11 R225 5 8 12 48 17 8 12 48 17 A8 WE*
2 A8 A17 A8 A17 12 37 CF_INTRQ
8 12 13 49 13 49 A7 INTRQ
12 1 A1 A18 18 1 A1 A18 18 13 38
5 7 13 R226 13 9 14 50 19 9 14 50 19 VCC1 J22 VCC2
A9 A19 A9 A19 14 39
6 14 15 51 15 51 A6 CSEL*
13 2 A2 VSS6 2 A2 VSS6 15 40
6 5 15 R227 6 16 52 20 16 52 20 A5 VS2*
VCC2 A20 VCC2 A20 16 41 RESET_N
4 16 17 53 17 53 A4 RESET*
14 10 A10 A21 21 10 A10 A21 21 17 42 CF_IORDY
7 3 17 R228 14 3 18 J20 54 22 3 18 J21 54 22 A3 IORDY
A3 A22 A3 A22 18 43
2 18 19 55 19 55 3 A2 INPACK*
15 11 A11 A23 23 11 A11 A23 23 19 44
R229 20 56 20 56 2 A1 REG*
VCC=3.3V;GND=DGND 7 4 A4 VCC6 4 A4 VCC6 20 45
21 57 21 57 1 A0 DASP*
VSS3 NC5 VSS3 NC5 21 46
R230 0 D0 PDIAG*
15 4 22 D4 NC6 58 4 22 D4 NC6 58 1 22 47 8
23 59 23 59 D1 D8 R265
12 D12 NC7 12 D12 NC7 23 48
24 60 24 60 2 D2 D9 9
U22 5 D5 NC8 5 D5 NC8 24 49
1 25 61 25 61 IIOCS16* D10 10
EN
13 D13 VSS7 13 D13 VSS7 CF_CD2_N 25 50
11 26 62 FL_CS0_N 26 62 FL_CS2_N CD2* GND2
C1 VCC3 FCS0* VCC3 FCS0*
MTG1
MTG2
AHC574 6 27 D6 FCS1* 63 FL_CS1_N 6 27 D6 FCS1* 63 FL_CS3_N

9 12 R231 8 14 28 64 BUS_WR_N 14 28 64 BUS_WR_N
1D D14 SYSWR* D14 SYSWR* MASTER MODE
8 13 7 29 D7 SYSRD* 65 BUS_RD_N 7 29 D7 SYSRD* 65 BUS_RD_N WHEN CSEL*=GND
8 7 14 R232 9 15 30 66 15 30 66
D15 VCC7 D15 VCC7 D D
9 6 15 31 VSS4 RESET* 67 RESET_N 31 VSS4 RESET* 67 RESET_N
10 5 16 R233 10 12 32 68 VPP_EN 12 32 68 VPP_EN
D A12 VPP A12 VPP
11 4 17 5 33 A5 PD0 69 FL_B_PD0 5 33 A5 PD0 69 3.3V C_2
4 3 18 R234 11 13 34 70 FL_B_PD1 13 34 70
A13 PD1 A13 PD1
12 2 19 6 35 A6 VSS8 71 6 35 A6 VSS8 71
R235 4 36 72 36 72 R206
VCC=3.3V;GND=DGND VCC4 NC9 VCC4 NC9
R236 12 U91
R237 D D D D 5 9
U23 5 1
1 3.3V 10 8 CF_CS1_N
EN R238 3.3V AHC32
11 C1
13 CLIC VCC=3.3V;GND=DGND
AHC574 R239
5 9 1D 12 6 1 U91
13 8 13
CLIC_CLK
R240 4 4
6 7 14 14 1
14 6 15 5 6 CF_CS0_N
R889
R890
R892
R893
R894
R895
R207
R241 AHC32
7 5 16 7 VCC=3.3V;GND=DGND
44
43
42
41
40 BUS_WR_N
39 BUS_RD_N
38 CF_CS_N
37 ID_CS_N
36 RESET_N
35
34
15 4 17
16 3 18 R242 15 SD_PD1 CF_CS_N
24 2 19 SD_PD0
R243
IO28
IO27
IO26
IO25
IO24
IO23
VCC=3.3V;GND=DGND 16 PCI_RES_N
JTAG
IO_GCK2
IO_GCK1
IO_GTS1
VCCINT2
IO_GTS2
R244 3.3V PROGRAMMING

24 PCI_DET_N 1 33 ARESET_N
IO_GCK3 IO_GSR PORT
U90 R245 17
FL_B_PD1 2 IO1 IO22 32 CF_WR_N
U24 U26 FL_B_PD0 3 IO2 XC9536XL IO21 31 CF_RD_N
SD_CLK 2 1
1 EN 25 13 9 FL_CS0_N 4 30
ADS_N 3 1 11 R246 1 3 GND1 IO20 0
C1
25 14 0
G- 10 FL_CS1_N PSA_DONE 5 29
LVC02
24 0 3 2 IO3 IO19 1
VCC=3.3V;GND=DGND AHC574 R247 1 11 FL_CS2_N PSA_INIT_N 6 IO4 IO18 28 2 J24
DMUX
17 9 1D 12 18 CS0_N 15 0 12 FL_CS3_N PSA_PROG_N 7 IO5
U92 IO17 27 3 1 VCC
R208
R209
R210
25 8 13 AHC139 8 26
1-971630-25 CPU Board; Flash Interfaces (Schematics #2)

18 7 14 R248 19 IO6 VCCIO 2 GND
VCC=3.3V;GND=DGND CLIC_TDI 9 25 CLIC_TCK
6 15 TDI GND3 3 CLIC_TCK
19 U26 CLIC_TMS 10 24 CLIC_TDO
20 5 16 R249 20 TMS TDO 4 CLIC_TDO
21 4 17 22 3 1 3 7 EXP2_CS_N DEBUG CLIC_TCK 11 TCK IO16 23 4 CLIC_TDI 5 CLIC_TDI
0
R250 21 2 0 G- 2 6 USB_CS_N CLIC_TMS 6 CLIC_TMS
22 3 18 21 3
1 5 J23
23 2 19 DMUX
R251 CS2_N 1 0 4 ID_CS_N
M_A<15..1> VCC=3.3V;GND=DGND 22 AHC139 1
IO7
IO8
IO9
VCCINT1
IO10
GND2
IO11
IO12
IO13
IO14
IO15
VCC=3.3V;GND=DGND 3.3V
R252 23 2
3.3V U25 3.3V D
1
19 & EN
R253 1
12
13
14
15
16
17
18
19
D
AHC541
7 20
6 21
5 22
R202 1 9 11 R254 2 D
2 8 12 D(15..0)
R255
R203
R204
3 7 13 3
M_RD_N 6 14 D
M_WR_N 5 15 R256 BUS_RD_N
4 16
3 17 R257 BUS_WR_N
PSA_RES_N
P24EN
VPP_EN
USB_RES_N
EXP1_RES_N
EXP2_RES_N
2 18
VCC=3.3V;GND=DGND
D

D0
TCK
PSA_TDO IBUTTON
M_RD_N
ADS_N
0
TCK
PSA_CS_N
PSA_CLK
CPU_TDO
PSA_TDO
M_D<31..0> 5V
3.3V 2.5V
10
11
20
12
19
13
18
14
17
16
15
31
30
1
29
2
28
3
27
4
26
5
25
6
24
7
23
8
22
9
21
R329
3.3V J30
208
207
206
205
204
203
202
201
200
199
198
197
196
195
194
193
192
191
190
189
188
187
186
185
184
183
182
181
180
179
178
177
176
175
174
173
172
171
170
169
168
167
166
165
164
163
162
161
160
159
158
157
DATA
2 IBUTTON
R300
GND
TCK
TDI
TDO
TMS
GCK3
GCK2
IO140
IO139
IO138
IO137
IO135
IO134
IO133
GND24
IO132
IO131
IO130
IO129
IO128
GND23
IO127
IO126
IO125
GND22
IO124
IO123
IO122
IO121
GND21
IO120
IO119
IO118
IO117
IO116
GND20
IO115
IO114
IO113
IO111
IO110
IO109
IO108
IO107
GND19
VCCO16
VCCO15
VCCO14
VCCO13
CCLK 1
IO136_NC
VCCINT12
VCCINT11
VCCINT10
IO112_NC
1 GND1 VCCO12 156 PP32
TMS 2 TMS CCLK 155 PSA_CS_N
M_WR_N 3 IO1 DOUT_IO106 154 D
SENSOR ADJUST DMA_N 4 IO2 DIN_IO105 153 0
DMA_DONE_N 5 IO3 IO104 152 CON_IO1
ACK_N 6 IO4 IO103 151 CON_IO2
7 IO5_NC IO102 150 CON_IO0
PL_PRE R309 M_WAIT_N 8 IO6 IO101_NC 149 CON_NOT_N
0 CF_INTRQ 9 148 RL_INST
IO7 IO100 A/D-CONVERTER
R310 CF_IORDY 10 IO8 IO99 147 PSU_INT_N
1 11 146 PSU_NOT_N
GND2 IO98
R311 12 VCCO1 GND18 145 5V
2 13 144
VCCINT1 VCCO11 U31
R312 3
PSA_RES_N 14 IO9 VCCINT9 143 GAP_SEN 1 20
PL_GAIN(3..0) INT0_N 15 IO10 IO97 142 P24EN BM_SEN 2 CH0 5V 19
INT1_N 16 IO11 IO96 141 9 TPH_RES 3 CH1 NC 18 AD_CS_N
EXP2_INT_N 17 IO12 IO95 140 8 RL_SEN 4 CH2 CS* 17 AD_DI
RL_PRE R313 0 EXP1_INT_N 18 139 7
IO13 IO94 PL_SEN 5 CH3 DI 16 AD_CLK
19 GND3 IO93 138 6 THERM 6 CH4 CLK 15
R314 1 IBUTTON 20 137
IO14 GND17 LTS_INST 7 CH5 SARS 14 AD_DO
21 IO15 IO92 136 5 8 CH6 DO 13
R315 2 WAND 22 135 4
IO16 IO91 9 CH7 SE* 12
BEEP 23 IO17 IO90 134 3 3.3V COM REF
R316 3 USB_INT_N 24 133 2
10 11
IO18 IO89 GND AGND
RL_GAIN(3..0) 25 GND4 IO88 132 1
26 VCCO2 GND16 131 TLC0838
BM_DIODE R317 0
SCL 27
28
IO19
VCCINT2
XC2S30, XC2S50, XC2S100, XC2S150 &XC2S200
PINS WITH _NC NOT USED IN XC2S30
PSA VCCO10
IO87
130
129 0
D D

R318 1
SDA 29 IO20 VCCINT8 128
TPH_GAIN2 30 IO21 IO86 127 13
R319 2
TPH_GAIN1 31 IO22 IO85 126 12
32 GND5 IO84 125 11
R320 3
TPH_GAIN0 33 IO23
U30 GND15 124 C30
BM_DRIVE(3..0) TPH_MEAS_EN 34 IO24 IO83 123 10
TPH_CAL2 35 IO25 IO82 122 TT_PWM STEPPER(13..0)
BM_PRE R321 0
TPH_CAL1 36 IO26 IO81 121 AD_DO
TPH_CAL0 37 120 AD_CLK R334
IO27 IO80 3.3V
R322 1
38 VCCINT3 IO79 119 AD_DI
39 VCCO3 VCCINT7 118
R323 2
40 GND6 VCCO9 117 5V R335
FIN_IO2 41 IO28 GND14 116
U32
8
R324 3
FIN_IO1 42 IO29 IO78 115 AD_CS_N
FIN_NOT_N 43 114 TPH_STRB_N RL_SEN R333 3
BM_GAIN(3..0) IO30 IO77
44 IO31_NC IO76 113 TPH_LATCH_N 1 RL_DIG
FIN_IO0 45 112 TPH_CLK C32 2
GAP_PRE R325 0 IO32 IO75_NC
3 46 IO33 IO74 111 1
4
R326 1
2 47 IO34 IO73 110 2
1 48 IO35 IO72 109 3
R327 2
0 49 IO36 IO71 108 4 D PP30
50 M1 INIT_N_IO70 107 LM393M D
1-971630-25 CPU Board; PSA (Schematics #3)

R328 3
51 GND7 PROGRAM_N 106
GAP_GAIN(3..0) 52 M0 VCCO8 105
DONE 2.5V C31
LTS_SEN R301 7 PROG R339
R302 INIT 3.3V
VCCO4
M2
NC1
NC2
IO37
IO38
IO39
IO40_NC
IO41
IO42
IO43
GND8
VCCO5
VCCINT4
IO44
IO45
IO46
IO47
IO48
GND9
IO49
IO50
IO51
VCCINT5
GCK1
VCCO6
GND10
GCK0
IO52
IO53
IO54
IO55
GND11
IO56
IO57
IO58
IO59
IO60
VCCINT6
VCCO7
GND12
IO61
IO62
IO63
IO64_NC
IO65
IO66
IO67
IO68
IO69
GND13
DONE
6 R337
R303 5 PSA_INIT_N R338
PSA_PROG_N
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
R304
100
101
102
103
104
4 PSA_DONE U32
PL_SEN R336 5
R305 3 7 PL_DIG
8
7
6
5
C33 6
R306 2
TPH_DATA(8..1)
LM393M
R307 1 D
PL_INST
D PP31
7
6
5
4
3
2
1
0
R308
LTS_DIG
HEADLIFT
0
PL_DIG
RL_DIG
LTS_GAIN(7..0) 3
2
1
0
BM_DRIVE(3..0)
3
2
1
0
BM_GAIN(3..0)
3
2
1
0
GAP_GAIN(3..0)
3
2
1
0
RL_GAIN(3..0)
121
122
DOT RESISTANCE TEST CIRCUIT THERMAL PRINT HEAD (TPH)
5V
TPHV R425 L400

TPH_CAL0 5V_TPH
TPH_CAL1 D40
TPH_CAL2 SDA R426 R427
PP40
R403 R404 R405 R428 R429
THE CORRESPONDING SCL
DIODE ON PSU L402
BOARD MUST BY OF THERM
C
C
C
SAME TYPE C408 C409
R400 B R401 B R402 B C407
T40 T41 T42 J40
U42 R430 1 I2CDATA
E
E
E
2 THERM1
D 1 3 I2CCLK
19 & EN D 4 THERM2
D D D R431
AHCT541 5 STROBE1
TPH_STRB_N 2 18 6 STROBE2
24V_S TPH_LATCH_N 3 17 7 LATCH
TPH_CLK 4 16 R432
8 VCC
R408 U40 1 5 15 9 CLOCK
2 6 14 10 VCC
E
R409 3 3 7 13 R433
IN OUT 2 11 DATA1
R407 B 4 8 12 12 GND
T44 C403 ADJ R410 5 9 11 13 DATA2
R434
VCC=5V;GND=DGND 14 GND
C
15 DATA3
C
1
C401 C405
R435 16 GND
TPH_MEAS_EN R406 B
T43 17 DATA4
C400 D R411 18 GND
R436 19 DATA5
E
20 GND
C402
21 DATA6
D U43 R437 22 GND
D C404 23 DATA7
+ 1 24 GND
D 19 & EN 25 DATA8
R438
AHCT541 26 GND
R422 9 11
R418 R419 8 12
7 13 R439
TPH_GAIN0 6 14
TPH_GAIN1 PP41 5 15
TPH_GAIN2 6 2 18 R440
8
7 3 17
R415 R416 R417 3 U41 8 4 16
1 R423 TPH_RES L415 GND_TPH
TPH_DATA<8..1> VCC=5V;GND=DGND
2
LM358M R424 D
C
C
C
C406
4
R412 B R413 B R414 B R420 R421
T45 T46 T47 D
E
E
E
C_1
D D D D D D D
U41
5
7
6
1-971630-25 CPU Board; Thermal Printhead Interface (Schematics #4)

D LM358M

SENSORS BLACKMARK
5V
J54
BM_SEN R512
1
PP52 2
I2C INTERFACES BM_PRE BM_DIODE 3
PP53 C501 4
C513
CONSOLE FINISHER PSU/

5V 5V 24V_S MOTOR DRIVERS D PP54 D GAP
TPHV GAP_PRE 5V
CON_IO2 R530 R534 J50 24V_I J55
FIN_IO2 R538 R542 J51 5V PP50
GAP_SEN R513
R531 R535 1 1 1
CON_IO1 2 FIN_IO1 R539 R543 J52 PP51 C502 2
3 2 F70 3
CON_IO0 R532 R536 3 1
4 FIN_IO0 R540 R544 4
5 4 2
R537 5 C700 + 3
CON_NOT_N R533 6 FIN_NOT_N R541 R545
7 6 4 D RIBBBON LOW
8 7 5
9 8 6 5V
RL_PRE
C530
C531
C532
C533
9 7 J56
C534
C535
C536
C537
10 10 TT_PWM 8 PP55 R514
RL_SEN 1
9 PP56 2
10 10 C503 RL_INST
D 11 11 3
D 12 12 C504 R515 4
D D 13 13
SDA 14
0 15
SCL 1 16 D D
2 17 PAPER LOW
3 18
5V 19 5V
PL_PRE J57
5V 4 20
5V 5V U51 5 PP57 PL_SEN R516
U50 21 1
6 22 PP58 2
24C02A LTC1694 7 C505 PL_INST
R509 R510 STEPPER<13..0> 23 3

1 A0 VCC 8 1 VCC SMBUS1 5 24 C506 4
2 7 8 R517
A1 WP 25
3 A2 SCL 6 3 N/C P24EN 9 26
4 GND SDA 5 27
2 4 PSU_INT_N R546 R548
GND SMBUS2 28
29 D D HEADLIFT
PSU_NOT_N R547 R549
30 5V
D 31 J58
32
HEADLIFT
C538
C539
D PSU_INT_N 33 1
34 2
R518 R519 3
D 4
5
24IGND D
D D
5V 5V LTS
WAND BEEPER
J53
5V U80 R521
U52 1
L50
BEEP 9 =1 2
10 8 R524
J59 LM567 3
C
AHC86
1-971630-25 CPU Board; Internal Interfaces (Schematics #5)

1 OUT FILTER OUT 8 LTS_DIG 4
VCC=5V;GND=DGND R525 R526
1 L51 R500 2 5 R522 B
IN FILTER TONE
2 D B60 T1
+
+
3 C507 C508 3 4
TONE IN VCC
4 1
E
5 L52 U80 U80 2 7 LTS_INST

WAND C509 6 TIME CAP GND
6 12 =1 4 =1 R523
MTG1 D50 BUZZER R520
13 11 5 6 LTS_SEN C512
MTG2 AHC86 AHC86
VCC=5V;GND=DGND VCC=5V;GND=DGND
C510
C511
R621 C540
WAND
C_2 D D D
PP59
D
123
124
3.3V
EXP BUS
5V 24V_S
J62
3.3V USB 1
U60 Y60 35
R600
R601
2
USBN9604 24Mhz 36
R605
3
USB_CS_N 1 CS* CLKOUT 28 M_WAIT_N 37

BUS_RD_N 2 RD* XOUT 27 4
BUS_WR_N 3 WR_SK XIN 26 BUS_RD_N 38
USB_INT_N 4 INTR MODE0 25 J60 5
5 DRQ MODE1 24 BUS_WR_N 39
1
C60
C61
6 23 R603 NC
+
DACK* GND C62 VDD 6
7 A0_ALE_SI VCC 22 R602 2 D- 40
0 8 D0_SO GND 21 3 D+ 0 7
USB_INT_N 1 9 D1 D- 20 4 GND 1 41
2 10 19 R604
D2 D+ MTG1 8
3 11 D3 V3.3 18 MTG2 2 42
4 12 D4 AGND 17 3 9
5 13 D5 RESET* 16 43
6 14 D6 D7 15 USB_RES_N L60 4 10
5 44
7 11
6 45
D 7 12
D C_2 C_2 46
8 13
9 47
14
10 48
11 15
D<15..0> 49
12 16
13
4
50
A<24..1> 17
14 51
15 18
UART<5..0> 52
1 19
2
0
1
2
3
4
5
53
3 20
3.3V 5V 4 54
21
U61 5 55
RP60 6 22
R610
R611
R612
R613
R614
R615
2 26 7 56
C64 GND VCC 8
C65 C66 RS232 23
28 27 3.3V 57
BUS NO. CPU PINS RS232 25 C1+ V+ 9 24
C63 C1- 10 58
1 4 L68
0 - UART_RX0 - RXD 11 25
1 - UART_TX0 - TXD 3 C2+ V- R626 R627 R628 12 59
2 - SPI_MOSI - CTS C2- D 26
24 5 L61
3 - SPI_MISO - RTS T1IN T1OUT 60 SPARE
4 - SPI_SCK - DSR 23 6 27 SPARE
5 - PCI_GNT1_N - DTR 22 T2IN T2OUT 7 SDA 61 SDA
19 T3IN T3OUT 10 L62
T4IN T4OUT J61 28
17 12 SCL 62 SCL
T5IN T5OUT 1 29 SA1
L63
2 TXD EXP1_RES_N 63 RESET
16 3 RXD EXP1_CS_N 30 CS
21 R1OUTB 8 4 DSR EXP1_INT_N 64 INT SLOT 1
20 R1OUT R1IN 9 L64
3.3V R2OUT R2IN 5 GND NC 31 DREQ
18 11 6 DTR 65 DACK
R3OUT R3IN 3.3V 7 CTS EXP1_INT_N 32 DACK
15 L65
R623 MBAUD 8 RTS NC 66 DREQ
13 14 9 EXP2_INT_N 33 INT
EN* SHDN* R620 MTG1 EXP2_CS_N 67 CS SLOT 2
R624 L66 EXP2_RES_N
1-971630-25 CPU Board; External Interfaces (Schematics #6)

MAX3237E MTG2 34 RESET
R625 R629 R618 R619
68 SA1
L67
EXP2_INT_N
D D
REFERENCE - IBM STANDARD DB9
D C_2 1 DCD - DATA CARRIER DETECT
D 2 RD - RECEIVE DATA
3 SD - TRANSMIT DATA
4 DTR - DATA TERMINAL READY
5 SG - SIGNAL GROUND
6 DSR - DATA SET READY
7 RTS - REQUEST TO SEND
8 CTS - CLEAR TO SEND
9 RI - RING INDICATOR

24V TO 5V CONVERTER
24V_I
L72 24V_S
D71
R711
R712
C
R708 R710 B
U70 T71
D
4 DTC VCC 12 D70
E
R709 3 R713 G T72
FB 5V
C
6 C1 8 L70
C702 C703 RT E1 9
5 CT C705
S
C2 11 B R718
C701 1 10 T70
+ R702 1IN+ E2
2 1IN- R716 R720 R722
E
2
16 2IN+
C
15 2IN- REF 14 C716 + C717 C706 THY70

13 OC GND 7 L74 Z70
A
R701 R703 R706 3 + C708

TL594
1
R724
R700 R704 R705 R707 C704
D72
R714 R715 R717 C718 R719 R721 R723 C707 R725

L71 D
24IGND
1-971630-25 CPU Board; Power (Schematics #7)

5V TO 3.3V 5V TO 2.5V
5V 3.3V 5V 2.5V MH71 MOUNTHOLE AT MH70 MOUNTHOLE CLOSEST TO 24V SOURCE
U71 U72 LOWER LEFT ON PCB
3 2 3 2 SHORT CIRCUIT DIGITAL GROUND (D)
VIN VOUT 3.3V VIN VOUT 2.5V WITH MH70 IN THIS POINT AND IN
C709 + C713 GND/ADJ C714 GND/ADJ TAB C715 THIS POINT ONLY!
+ C710 + C712
C711
1
1
4
GND
D D D C_2 D C_1
D D
125
126
3.3V BUS PULL-UPS 3.3V MISC PULL-UPS
3.3V 3.3V
31 R816
R800 30
29 R817
EXP1_INT_N R896
R801 28
27 R818
R897
R848
R849
R850
R851
R852
R853
R854
R855
R856
R857
R858
R859
R860
R861
R862
R863
R864
R865
R866
R867
R868
R869
R870
R871
R872
R873
R874
R875
R876
R877
R878
R879
R880
R881
R882
R883
R884
R885
R886
R887
R888
R802 EXP2_INT_N
26
25 R819
USB_INT_N R898
R803 24
1
2
3
4
5
6
7
8
9
R820
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
23 PSU_INT_N R899
A(25..1) R804 22
0
1
2
3
4
5
6
7
8
9
R821
10
11
12
13
14
15
21 TMS R910
D(15..0) R805 20
R822
19 CON_NOT_N R931
R806 18
17 R823
FIN_NOT_N R932
R807 16
3.3V R824
15 PSU_NOT_N R933
R808 14
13 R825
M_WAIT_N R920
R809 12
11 R826
DMA_DONE_N R921
R810 10
9 R827
INT0_N R922
R811
R950
R951
R952
R953
R954
R955
R956
R957
R958
R959
R960
R961
R962
R963
R964
R965
R966
R967
R968
R969
R970
R971
R972
R973
R974
R975
R976
R977
R978
R979
R980
R981
8
7 R828
INT1_N R923
R812 6
R829
0
1
2
3
4
5
6
7
8
9
5 CS0_N R924
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
R813 4
PCI_AD(31..0) R830
3 CS2_N R925
R814 2
1 R831
SD_OE_N R926
R815 0
M_D(31..0) SD_CS0_N R927
SD_CS1_N R928
3.3V SD_CS2_N R929
SD_CS3_N R930
PCI_GNT2_N R982
J81 5V
R903
R900
R901
PCI_REQ2_N R983
1 TRST_N PCI
2 PCI_INT_N R984
3 TDI 0 1 PCI_AD0 SCA80 PCI_AD1 41 1
4 2 VSS1 PCI_AD2 42 2 PCI_GNT0_N R985
R905 CPU_TDO 3 3 43
5 PCI_AD3 VCC1
6 4 4 PCI_AD4 PCI_AD5 44 5 PCI_REQ0_N R986
EJTAG 7 EJ_TMS 6 5 PCI_AD6 PCI_AD7 45 7
8 6 VSS2 PCI_CBE_N0 46 PCI_CBE0_N PCI_CBE3_N R987
9 TCK 8 7 PCI_AD8 VCC2 47
10 9 8 PCI_AD9 PCI_AD10 48 10 PCI_CBE2_N R988
11 E_RESET_N 11 9 PCI_AD11 PCI_AD12 49 12
12 10 VSS3 PCI_AD13 50 13
PCI_FRAME_N R989
13 14 11 PCI_AD14 VCC3 51
14 15 12 PCI_AD15 PCI_CBE_N1 52 PCI_CBE1_N PCI_IRDY_N R990
PCI_PAR 13 PCI_PAR PCI_SERR_N 53 PCI_SERR_N
14 VSS4 PCI_PERR_N 54 PCI_PERR_N PCI_TRDY_N R991
R902 PCI_LOCK_N 15 PCI_LOCK_N VCC4 55
PCI_STOP_N 16 PCI_STOP_N PCI_DEVSEL_N 56 PCI_DS_N PCI_DS_N R992
PCI_TRDY_N 17 PCI_TRDY_N PCI_IRDY_N 57 PCI_IRDY_N
18 VSS5 PCI_FRAME_N 58 PCI_FRAME_N PCI_STOP_N R993
PCI_CBE2_N 19 PCI_CBE_N2 VCC5 59
16 20 PCI_AD16
J84 PCI_AD17 60 17 PCI_LOCK_N R994
18 21 PCI_AD18 PCI_AD19 61 19
D 22 VSS6 PCI_AD20 62 20 R995
21 23 63 PCI_PERR_N
PCI_AD21 VCC6
22 24 PCI_AD22 PCI_AD23 64 23 R996
1-971630-25 CPU Board; Pull-ups (Schematics #8)

PCI_CBE3_N 25 65 24
PCI_SERR_N
PCI_CBE_N3 PCI_AD24
RESET GENERATOR 26 VSS7 PCI_AD25 66 25 PCI_PAR R997
26 27 PCI_AD26 VCC7 67
3.3V 27 28 PCI_AD27 PCI_AD28 68 28 PCI_CBE1_N R998
29 29 PCI_AD29 PCI_AD30 69 30
3.3V 30 VSS8 PCI_AD31 70 31 R999
PCI_REQ0_N 31 71 PCI_CBE0_N
R914 3.3V PCI_REQ_N0 VCC8
PCI_GNT0_N 32 PCI_GNT_N0 PCI_CLK 72 PCI_CLK
U81 PCI_INT_N 33 PCI_INT_N PCI_REQ_N2 73 PCI_REQ2_N
5 34 74 PCI_RES_N CF_INTRQ R934
E_RESET_N 4 VSS9 PCI_RST_N
MR* VDD 35 TCK VCC9 75
36 76 EJ_DBOOT R904
TMS NC1
R911
R912
RESET 3 37 77 SCL
U80 TDO SCL
C
2 RESET* 1 ARESET_N 38 78 SDA
CF_CD1_N 1 VSS10 SDA
=1 R915 GND
CF_CD2_N 2 3 R913 B 39 TDI PCI_DET_N 79 PCI_DET_N
T80 TPS3825 40 TRST_N 24V 80 D
AHC86
VCC=5V;GND=DGND
D
E
J83
1 EXT.RESET
2 D
D

DECOUPLING/BYPASS CAPACITORS
3.3V 3.3V
C900 + 3.3V
C921 + 2.5V
C911 C913 C915 3.3V
C912 C914
C982 C983 C984
D C929 C930 C931 C932
C938 +
D
3.3V 3.3V D D 3.3V
2.5V
203
193
183
173
163
C942 C943 C944
C901 7 151 C916
208
197
184
170
3.3V D
C933
156 D 2.5V
2.5V
12
C902 C988 17 141 C922
197
181
171
C990 C917
C934
144 C948
C939 13 143
C923
C903 27 131 C918
26 PSA 3.3V
CPU C935
130
C949
U13 U30 C940
28 PSA 2.5V 128
37 C924 C936 U30

C904 C989 121 C991 C919 117
39
C950
C941
38 118
C905 C937
C920 D
47 111 105

66
76
91
59
69
82
89
99
53
65
78
92
3.3V D 2.5V D
D D
3.3V D C945 C946 C947
C906 C908 C910
C907 C909 C925 C926 C927 C928
C985 C986 C987
D
D D
3.3V 5V
U90
11 1
C951 C967 3.3V 12 13
U81 RESET GENERATOR U52 LM567 LVC02
VCC=3.3V;GND=DGND
C961 3.3V C968 C992 C977 U90

U26 AHC139 U31 A/D 8 1
9 10
U92 LVC02
C953 C974 C969 C978 C979 VCC=3.3V;GND=DGND
U20 AHC245 U11 CLOCK DRIVER U42 AHCT541 U90
1-971630-25 CPU Board; Bypass/Decoupling (Schematics #9)

CLIC 5
C954 C975 C970 C980 C981 1
6 4
U21 AHC245 U11 CLOCK DRIVER U43 AHCT541 LVC02
VCC=3.3V;GND=DGND
C955 C963 C971

U22 AHC574 U91 AHC32 U50 EEPROM D
D
C956 C976 C972
U23 AHC574 U90 LVC02 U51 PULL-UP IC
24V_S
C957 C965 C964
U24 AHC574 U60 USB DRIVER U32 LM393
C973
C958 C966 C952 U41 LM358
U25 AHC541 U61 RS232 DRIVER U80 AHC86
D D D D
127
13.8 Replacing the CPU board

To replace the CPU board
3 Remove any optional interface boards.
4 Disconnect all cables from the CPU board.
5 Remove the four #T20 Torx screws and the hexagonal spacer that hold
the CPU board to the plate that covers the power supply unit.
6 Lift out the CPU board and remove all SIMMs and any real time clock.
Take precautions against electrostatic discharges!
7 Fit the SIMMs and possibly the real-time clock on the new board and
install it in reverse order.
The same CPU-board can be used for a range of EasyCoder printers.
However, the firmware can not detect in which type of printer the CPU
board is installed. All replacement CPU boards are preprogrammed for
the EasyCoder PF2/4i-series printers, which means that replacement CPU
boards always must be reconfigured after being installed in an EasyCoder
PM4i printer.
If the printer feeds out labels in a peculiar way, the CPU board may
be configured for the wrong type of printer (there is a difference in the
distance between the dot line and the LSS position). You can easily check if
the CPU board is correctly configured by printing the “Hardware Info” or
“HW” test label in the Setup Mode or sending the Fingerprint instruction
PRINT VERSION$(1).
To reconfigure the CPU board

2 Insert a configuration card in the memory card slot.
3 Switch on the power.
4 Using the same method as in the Setup Mode, select the correct printer
type from the menus shown in the display window.
6 Remove the card.
7 Switch on the power again and check.

14 Interfaces
This chapter describes the various communication interfaces for the

EasyCoder PM4i printers. However, some interfaces are not supported by
the Intermec Programming Language (IPL) even though the connectors
are present.
The chapter describes three categories:
• Standard built-in interfaces
RS-232 interface
USB interface
Bar code wand interface (not supported by IPL)
• Optional interface boards
Serial/Industrial interface board (not supported by IPL)
Double Serial interface board (not supported by IPL)
RFID Serial interface board
IEEE 1284 Parallel interface board
• EasyLAN interface boards
EasyLAN Ethernet interface
EasyLAN Wireless interface
The EasyCoder PM4i printer can—in addition to the standard built-in
interfaces—also be fitted with one or two optional interface boards and
one EasyLAN interface board.
Note: Device designations, such as "uart1:", "usb1:", or "net1:", apply
only to Fingerprint, not to IPL.

Chapter 14—Interfaces
14.1 Introduction
In Fingerprint, "auto" is by default the standard IN and OUT
communication port, that is, the printer will scan all communication
channels for incoming data. To select a specific communication port as
standard IN and/or standard OUT port, use an Intermec Fingerprint
SETSTDIO statement (see Intermec Fingerprint v8.xx, Programmer’s
Reference Manual). This gives better performance. Note that many
application programs, for example Intermec Shell, contain instructions
that select the correct standard I/O for the application in question. The
settings for the selected communication channel will appear in the display
window when pressing the <info> key on the printer’s keyboard.
In IPL, all communication channels are always scanned for incoming data
and the firmware automatically switches to the same channel for output
too. The settings for the active communication channel will appear in the
display window when pressing the <info> key on the printer’s keyboard.
The standard interfaces (RS-232, USB, and Wand) are fitted directly on
the rear of the CPU board with connectors protruding through slots in the
printer’s rear plate. USB and Wand are not supported by IPL.
All optional interface boards, except the EasyLAN boards, are fitted in a
slot on the printer’s standard rear plate and connected to the CPU board
via a flat cable. If no interface board is fitted, the slot is closed by a cover
plate.
The EasyLAN boards are fitted directly to the front of the CPU board and
connected by wire to a connector or antenna. There are provisions for both
the wired EasyLAN connector and the EasyLAN wireless antenna on the
standard rear plate. All rear plates have slots for two interface boards as well
as for the standard interface connectors.

14.2 RS-232 Serial Communication Port ("uart1:")

The EasyCoder PM4i printers are always fitted with one RS-232
communication port. In Intermec Fingerprint, this port is designated
"uart1:" (uart = Universal Asynchronous Receiver and Transmitter.) The
circuitry is fitted on the CPU board (see Chapter 13) and has a fixed set of
signals in a DB-9pin female connector which protrudes through a slot in
the printer’s rear plate.
Protocol
Default setup
Baud rate: 9600
Char length: 8 bits
Parity: None
Stop bits: 1
RTS/CTS: Disabled
ENQ/ACK: Disabled
XON/XOFF: Disabled in both directions
New line: CR/LF
Signals on serial port ("uart1:")
MTG DB-9 socket Signal Meaning

1 External +5VDC max 500 mA (automatic switch-off at
5
overload, short-circuit protected)
9
GND
4 DSR in 2 TXD Transmit data
RTS out 8
3 RXD in 3 RXD Receive data
CTS in 7
2 TXD out 4 DSR Data set ready
DTR out 6
1 +5V DC 5 GND Ground
6 DTR Data terminal ready
MTG 7 CTS Clear to send
8 RTS Request to send
9 – Not used
RS-232 socket
("uart1:")

14.3 USB Interface ("usb1:")

The EasyCoder PM4i printers are, as standard, fitted with a USB
(Universal Serial Bus) interface connector on the CPU board.
USB
("usb1:")
The supported USB version is USB 1.1 (also called “USB 2.0 full speed”).
To use the USB interface for printing from a PC, you need a USB-
compatible Intermec InterDriver installed in your PC. The printer
works only as a “slave”, that is, the USB interface is not suitable for
programming. Unlike for example RS-232, there is no communication
setup in regard of baud rate, parity, handshaking, etc. Select the USB
interface as standard IN/OUT channel in Intermec Fingerprint,
the Intermec Direct Protocol, or Intermec Shell as device "usb1:"
(communication channel 6).
The EasyCoder PM4i printers are so called “self-powered devices.” We
recommend that you only connect one printer to each USB port on the
host, either directly or via a hub. Other devices, like a keyboard and a
mouse, can be connected to the same hub. If you need to connect more
than one Intermec USB printer to a host, you should use different USB
ports.
Using a USB Class A/B cable, connect the Class A plug to the PC or hub
and the Class B plug to the printer.
USB Class A connector. USB Class B connector.

Connect to PC or hub. Connect to USB port on printer’s rear plate.

14.4 Bar Code Wand Interface (wand:)

The printer has a socket (J59) on the CPU board for connecting a bar code
wand or scanner. The socket is accessible through a slot in the printer’s rear
plate. The bar code wand interface is not supported by IPL.
If the Code 128 bar code that contains the character FNC3 is read via this
port, the data will be treated as a setup string and will change the printer’s
setup accordingly. A setup bar code may contain a single parameter or a
combination of up to 3 or 4 setup parameters. Refer to the EasySet Bar
Code Wand Setup manual for more information on how to produce setup
bar codes.
The printer will acknowledge that a bar code has been successfully read by
emitting a short beep signal.
If no FNC3 character is found in the bar code, the data will be stored in a
buffer which could be read by specifying the "wand:" device. The buffer is
small, so it is recommended to use short bar code data (max. 36 characters)
and read the buffer regularly to avoid overflow.
For more demanding applications or for reading bar codes other than
Code 128, choose a regular bar code scanner from Intermec’s wide product
range and connect it to a serial port.
Wand interface
("wand:")

14.5 Installing an Optional Interface Board

To install an optional interface board
Note: This chapter does not apply to installation of any type of EasyLAN
interface board, which instead is described in Section 14.9. The general
description DOES however apply to the installation of RFID interface
boards, and RFID-specific information has been marked in the text.
1 Open the electronics compartment, see Section 11.2.

The electronics compartment contains wires and components
with dangerous voltage (up to 380V). Always switch off the power
and unplug the power cord before you remove the cover over the
electronics compartment!
Before you install driver circuits and straps on the interface board,
make sure that the circuit is not installed upside down (see front end
markings in the illustrations). Also make sure that the circuit pins
fit into the slots in the socket and are not bent. Take precautions to
protect the board and circuits from electrostatic discharge.
Vor der Installation von Treiberschaltkreisen und Kabelbändern
auf der Schnittstellenkarte muss sichergestellt werden,
dass der Schaltkreis nicht verkehrt eingebaut ist (die
Vorderkantenmarkierungen in den Abbildungen beachten).
Außerdem muss sichergestellt werden, dass die Schaltkreisstifte
in die Schlitze in der Buchse passen und nicht verbogen werden.
Vorsichtsmaßnahmen treffen, um die Karte und die Schaltkreise vor
elektrostatischer Entladung zu schützen.
2 Remove the two #T10 Torx screws that hold the inner interface cover
plate. Remove the cover plate.
#T10 Torx screw
Cover plate
#T10 Torx screw

3 Save the cover plate for possible later use. Keep the screws.
4 Remove the #T20 Torx screw fitted on the hexagonal spacer at the
center of the CPU board. Keep the screw.
5 If necessary, fit or remove circuits and straps on the interface board
according to the descriptions of each board later in this chapter.
6 RFID only: If the interface board has been designed to hold an RFID
radio module, slide the module into its designated slot. Note: Jumpers
J5-J9 must be set to comply with the type of radio module installed. See
Section 14.8.
RFID Card
7 Attach the flat cable included in the kit to connector J62 (marked “EXP
BOARD”) on the CPU board (see illustration on the next page).
8 Insert the interface board with the component side facing right, as seen
from behind.
Component side
#T10 Torx screw
Interface board
#T10 Torx screw
9 Attach the interface board to the printer’s rear plate using the two screws
left over when you removed the original cover plate.

10 Using the #T20 Torx screw you previously removed, attach the interface
board to the hexagonal spacer at the center of the CPU board.
11 The kit contains two flat cables, one with two connectors for use with a
single interface board and one with three connectors for use with double
interface boards. Connect the appropriate flat cable to connector P1 on
the interface board, also see the next page.
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
R54
C24
C23
C22
C21
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3
IC28
IC2
IC22
C36 C34
REL2
IC3 C66
P1
RS232: IC11, J2A
REL1 P35 P1 J62
C33
RS422: IC12, J3, J4
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
R14
C2 C1 C50
UARTA
C32
B A IC13
J2
R5
R13
R15
IC11 IC12
R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
J61
J3 R10
C56
R16
IC4
IC6
R9
C57
J4
C53
C31
R17
R6
R1
R7
IC9
IC5
IC1
C52
C54
C30
R2
R3
C55
P2 J1
R11
R4
EXP BOARD
Hexagonal
Flat cable spacer
(two types)
12 The flat cable should run as illustrated below.

CPU Board
Cable
Inner Interface Board
(Outer Interface Board)
13 Put back the cover over the electronics compartment.

14 Connect the communication cables to the connectors on the printer’s
rear plate.
15 RFID only: Apply the RFID label to the rear plate of the interface
board. Make sure the specifications printed on the label correspond to
those of the board and radio module.
16 Connect the power cord and switch on the power.

17 In case the interface board provides additional serial communication

ports, enter the Setup Mode to set the proper communication
parameters for these ports.
If you need to install two interface boards, first install the inner board,
then the outer one using the same flat cable from one of the kits. Put
the hexagonal spacer included in the kit between the inner and the outer
interface board. The list below shows which combinations are allowed in
Fingerprint and IPL respectively and how the ports will be designated in
Fingerprint.
Allowed interface combinations (Fingerprint)
Left-hand slot Ports Right-hand slot Ports
Double Serial uart2: + uart3: – –
Double Serial uart2: + uart3: IEEE 1284 centronics:
Double Serial uart2: + uart3: Double Serial uart4: + uart5:
Double Serial uart2: + uart3: RFID uart4:
Serial/Industrial uart2: – –
Serial/Industrial uart2: Serial/Industrial uart3:
Serial/Industrial uart2: IEEE 1284 centronics:
Serial/Industrial uart2: RFID uart3:
IEEE 1284 centronics – –
IEEE 1284 centronics Double Serial uart2: + uart3:
IEEE 1284 centronics Serial/Industrial uart2:
IEEE 1284 centronics RFID uart2:
RFID uart2: Double Serial uart4: + uart5:
RFID uart2: IEEE 1284 centronics
RFID uart2: Serial/Industrial uart4:
Allowed interface combinations (IPL)

Left-hand slot Ports Right-hand slot Ports
IEEE 1284 parallel RFID serial*
RFID serial* IEEE 1284 parallel
Remarks:
• The left-hand slot is the slot closest to the center section.
• Always start by fitting an interface board in the left-hand slot.
• RS-485 is only supported by "uart2:"
• The serial port (*) refers to the RFID interface. The 9-pin contact on the
back plate of the interface board is not functional on IPL printers.

14.6 Serial/Industrial Interface Board (not IPL)

Description
The Serial/Industrial Interface Board is a Fingerprint-only optional device
for EasyCoder PM4i. It provides these printers with two extra interfaces.
The Serial/Industrial Interface kit contains:
• One Industrial Interface Board fitted with straps and circuits for RS-232
• One hexagonal spacer
• Two flat cables
• One Installation Instruction booklet
Serial Interface ("uart2:" or "uart3:")
This interface contains one serial communication port ("uart2:" or
"uart3:") which can be configured for one of the following alternatives:
• RS-232 non-isolated
• RS-422 isolated, full duplex (reconfiguration required)
• RS-485 isolated, half duplex (reconfiguration required)
Selection of type of serial interface is decided by fitting various types of
socket-mounted driver circuits and straps.
Industrial Interface
This interface contains eight digital IN and eight digital OUT ports with
optocouplers, plus four OUT ports with relays.
The status of all ports can be read by means of PORTIN functions and
the OUT ports can be set using PORTOUT ON/OFF statements (see
Intermec Fingerprint v8.xx, Programmer's Reference Manual).Thus, it is
possible to design Intermec Fingerprint application programs which
control not only the printer but also various external devices, for example
in a production line. The digital IN ports can read the status of various
sensors and the program can, for example, switch control lamps on or off,
open or close gates, and start or stop conveyor belts accordingly using the
relays and the digital OUT ports.
Industrial Interface
(DB-44pin socket)
Serial Interface
"uart2:"
(DB-9pin socket)

Serial Port Configuration

The serial communication port "uart2:" or "uart3:" is as standard
configured for RS-232 but can be reconfigured for two other types of serial
communication by fitting certain driver circuits and straps. The circuits
can be ordered separately from Intermec:
• RS-422 isolated, full duplex
• RS-485 isolated, half duplex
RS-232 Non-Isolated (standard)
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
C24
C23
C22
C21
R54
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3 IC28
IC2
IC22
C36 C34
REL2
IC3 C66
REL1 P1
RS232: IC11, J2A
C33
RS422: IC12, J3, J4
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
R14
C2 C1 C50
UARTA
C32
B A IC13
J2
R5
R13
R15
IC11 IC12
R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
J3 R10
C56
R16
IC4
IC6
R9
C57
J4
C53
C31
Strap fitted on J2 A
R17
R6
R1
R7
IC9
IC5
IC1
RS-232 circuit fitted on

C52
C54
C30
R2
IC11
R3
C55
P2 J1
R11
R4
Connector Configuration (RS-232 on "uart2:" or "uart3:")

DB-9 socket Signal Meaning
MTG
5 GND
9 2 TXD Transmit data
4 DSR in
RTS out 8
3 RXD Receive data
3 RXD in
CTS in 7
DTR out 6
9 – Not used

RS-422 Isolated, Full Duplex (Reconfiguration required)
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
C24
C23
C22
C21
R54
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3
IC28
IC2
IC22
C36 C34
REL2
IC3 C66
REL1 P1
RS232: IC11, J2A
C33
RS422: IC12, J3, J4
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
R14
C2 C1 C50
UARTA
C32
B A IC13
J2
R5
R13
R15
IC11 IC12
Remove strap on J2 A R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
J3 R10
C56
R16
Fit straps on J3 and J4
IC4
IC6
R9
C57
J4
C53
C31
R17
R6
R1
R7
IC9
IC5
IC1
C54 C52
C30
Remove RS-232 circuit

R2
R3
C55
P2 J1
R11
R4
on IC11
Fit RS-422 circuit on IC12
Connector Configuration (RS-422 Isolated on "uart2:" or "uart3:")

5
overload, short-circuit protected) provided strap is fitted
9
GNDE on J2:A which spoils the galvanical isolation
4
-TXD 8 2 +TXD +Transmit data
3 +RXD
-RXD 7
3 +RXD +Receive data
2 +TXD
6
1 +5V DC 4 –
if GND strap
fitted 5 GNDE Ground
MTG 6 –
7 -RXD -Receive data
8 -TXD -Transmit data
9 –

RS-485 Isolated, Half Duplex (Reconfiguration required)
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
C24
C23
C22
C21
R54
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3
IC28
IC2
IC22
C36 C34
REL2
IC3 C66
REL1 P1
Remove strap on J2 A RS232: IC11, J2A
C33
RS422: IC12, J3, J4
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
Remove RS-232 circuit UARTA

R14
C2 C1 C50
C32
B A IC13
on IC11 J2
R5
R13
R15
IC11 IC12
Fit RS-485 driver circuit R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
on IC13 J3 R10
C56
R16
IC4
IC6
R9
Fit strap on J4 J4 C57
C53
C31
R17
if end of cable
R6
(terminator)
R1
R7
IC9
IC5
IC1
C52
C54
C30
R2
R3
C55
Fit strap on J1 P2 J1
R11
R4
Connector Configuration (RS-485 Isolated on "uart2:" or "uart3:")

5
9
4
-DATA 8 2 +DATA
3
7
2 +DATA 3 –
6
1 +5V DC 4 –
if GND
strap fitted 5 GNDE Ground
MTG 6 –
7 –
8 -DATA
9 –
Note: The increased use of LAN networks has made the RS-485 interface
somewhat obsolete, because RS-485 requires a special communication
protocol and a dedicated wiring system limited to 1,200 m (4,000 ft). We
only recommend RS-485 for existing applications and advise the customer
to consider a LAN network solution for new applications.

Industrial Interface Configuration

The Industrial Interface provides:
• 8 digital IN ports with optocouplers (Opto In)
• 8 digital OUT ports with optocouplers (Opto Out)
• 4 OUT ports with relays (Relay Out)
The Industrial Interface has no straps or circuits to be fitted or removed.
All signals are available on a DB-44pin socket and the various ports
are controlled by the Intermec Fingerprint instructions PORTIN and
PORTOUT ON/OFF (see Intermec Fingerprint v8.xx, Programmer's
Reference Manual).
Digital Opto In
The status of the digital IN ports can be read using PORTIN functions. If
a current is led through the optocoupler of the port, PORTIN returns the
value -1 (true), else it returns the value 0 (false).
Signal Description Min. Typical Max.
Vin [High] Input Voltage High 10V 24V 40V
Vin [Low] Input Voltage Low -1V 0V 1V
Connector Configuration
Pin Signal Name Description Fingerprint Ref. No.
10 IN1A Anode Opto In Channel 1 + 101 (301)
40 IN1K Cathode Opto In Channel 1 -
The Fingerprint reference numbers inside the parentheses refer to a second
Serial/Industrial interface board.
INA
INK
GND
Simplified schematics of a digital IN port.

Digital Opto Out

The current to each optocoupler of the digital OUT ports can be turned
on and off using PORTOUT ON/OFF statements.
The status of the ports can be read using PORTIN functions. If a current
is led through the optocoupler of the port, PORTIN returns the value -1
(true), else it returns the value 0 (false).
Signal Description Max.
Vceo Collector-Emitter breakdown voltage 35V
Veco Emitter-Collector breakdown voltage 6V
Collector Current 15 mA
Vog Output to ground (optocoupler) 100V
20 Out1c Collector Opto Out Channel 1 221 (421)
5 Out1e Emitter Opto Out Channel 1
Serial/Industrial interface board .
VCC
OUTc
OUTa
Simplified schematics of a digital OUT port.

Relay Out
The relays of the OUT ports can be individually activated using PORT-
OUT ON/OFF statements.
The status of the ports can be read by means of PORTIN functions. If a
relay is activated, PORTIN returns the value -1 (true), else it returns the
value 0 (false).
Max AC Load Breaking Capacity

Signal Description Max.
I Current 1A
Psw AC Switching power 100VA AC
Usw AC Switching voltage 100V AC
Max DC Load Breaking Capacity
b a
1
DC current (A)
0.5
0.1
10 20 30 40 50 100
a: resistive load DC Voltage (VDC)

b: inductive load L/R=20 ms
16 REL1nc Relay 1 Normally Closed 201 (401)
1 REL1no Relay 1 Normally Open
31 REL1com Relay 1 Common
Serial/Industrial interface board.
VCC
REL no
REL nc
REL com
Simplified schematics of a relay OUT port.

Components
C40
R31
R32
IC20
C63
C64
R33
IC24 IC23 R34
R35
R36
R37
R38
R54
C24
C23
C22
C21
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
R27
IC27
C62
R26
IC25 IC26 R25
R24
R23
R22
R21
P3
IC21
REL4
R28
C61
C51
IC28
C67
REL3
IC2
IC22
C36 C34
REL2
C66
IC3
REL1 P1
35
1
C33
RS232: IC11, J2A C35
RS422: IC12, J3, J4

C4 C3
RS485: IC13, J1, J4* C50
*: IF END OF CABLE C2 C1
R5 C32
R14
IC10
UARTA B A
J2 R13
R8
F1 F6 F2 F7 F3 F8 F4 F5
R15 R18
R12 R10
C56
R9
C53
C31
R16
C57 IC6 IC4

J3
IC11
P2
R7
R17
R6
R1
J4
C52
C30
IC9
IC13
IC12
IC5 IC1
C55
34
68
J1
C54
R11
R3
R2
R4
1-971643-26 Serial/Industrial Interface Board; Component side

146
5V SWITCH FOR
P1 EXTERNAL 5V
1 +24VI 5V
35 5V IC9
2 3.3V POWER_SWITCH
1 GND OUT 8 5V_EXT
36 2 7
3 R6 R7 IN OUT
WAIT_N 3 IN OUT 6
37 4 5
4 R5 EN_N OC_N
38 RD_N 5V_EXT_EN_N
5
39 WR_N OVERCURRENT_N
6
D<15..0> DCDA_N R18

40
7 0
1
4
3
2
1
0
41 VCC=3.3V
8 A<12..1> =1 4 DSRA_N
42 2 6 IC5 5 R8
6
5
4
3
2
1
44
43
41
40
5V
42
9 3 AHC86
43 3.3V VCC=3.3V
RS232
12 CTSA_N C1
4 1 IC11 C3
Schematics; Serial Port
10
D4
D3
D2
D1
D0
NC
11 IC4 13 +
44 5 MAX238 +
VCC
RI*
AHC32
DCD*
DSR*
CTS*
11 5 7 39 RESET 10 C1+ VCC 9 C4
45 6 D5 MR 12 11
3.3V 6 8 38 C2 C1- V+ +
12 7 D6 OUT1* VCC=5V
7 9 37 1 =1 + 13 15
46 VCC=3.3V 10 D7 DTR* 36 2 IC6 3 C2+ V- F1
13 8 1 =1 RCLK IC10 RTS* 14 C2- GND 8 P2 9PIN DSUB
RESET_N 2 3 RESET 11 35 AHCT86
47 9 IC5 SIN OUT2* 2
12 34 5 T1IN T1OUT F2
14 AHC86 NC NC VCC=5V RS232 RS422 RS485
13 33 INTA 4 =1 DTRA_N 18 T2IN T2OUT 1
48 10 SOUT INTRPT 5 6 RTSA_N 19 24
14 16C550 32 IC6 T3IN T3OUT F3 1 +5V
15 11 VCC=3.3V CS0 RXRDY*
12 1 15 31 1 AHCT86 21 T4IN T4OUT 20 2 TXD +TXD +DATA
49 1 CS1 A0
2 IC4 3 CSA_N 16 30 2 6 R1OUT R1IN 7 F4 3 RXD +RXD
16 12 CS2* A1 29 4 3
AHC32 17 3 R2OUT R2IN 4 DSR
50 13 BAUDOUT* A2 23
22 R3OUT R3IN F5 5 GND GNDE GNDE
17 VCC=3.3V 17 R4OUT R4IN 16 6 DTR
51 14 11 4
1 F6 7 CTS -RXD
18 15 5 IC4 6 CSB_N
8 RTS -TXD -DATA
XIN
XOUT
WR1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
52 AHC32 F7
19 1 3.3V 9
2 MTG1
18
19
21
22
23
25
26
27
28
53 VCC=3.3V
J1 F8 MTG2
20 3 9
1 1
54 4 WR_N 10 IC4 8 WRB_N
21 AHC32 RS485 2 GND-SHIELD
55 5
WR_N 20
RD_N 24
22 6 VCC=3.3V VCC=5V 5V RS422
7
INTA 9 =1 9 =1
1 A J2
56 10 IC5 8 INT_N 10 IC6 8 TXDA IC12 2B C
23 8 MAX1490 3
AHC86 AHCT86 1 VCC1 AC1 24
57 5V 2 VCC2 AC2 23
24 9 VCC=3.3V
=1 12 RXDA 3 D1 IVCC1 22
58 10 11 13 4 21 R16
11 IC5 D2 IRCDRV J3
25 AHC86 5 GND1 A 20 1 TERM.REC.
59 12 R1 R2 R3 3.3V R4 6 19 2
FS B R17
26 7 SD Z 18 J4
4
60 IC3 8 VCC3 Y 17 1
27 R9 9 16 2 TERM.TRA.
SDA VCC DI ICOM1
61 10 VCC4 IDIDRV 15
28 1.8432MHZ 11 RO IVCC2 14
62 SCL 1 CLK 12 13
SA1 NC/EN_N OUT 3 GND2 IRLED
29
63 RESET_N 5V GND
30 CS_N RS485
2
64 INT_N
31 IC1 IC13
MAX1480
65 1 VCC1 AC1 28
32 2 VCC2 AC2 27
66 1 A0 VCC 8 3 D1 IVCC1 26
33 2 A1 WP 7 4 D2 B 25
3 6 5 24 R15
67 A2 SCL GND1 IRCDRV
34 4 GND SDA 5 6 FS A 23
7 22 R12
68 SD IDIIN
5V 8 VCC3 IDEIN 21
9 DI ICOM1 20
3.3V VCC=5V
1-971643-26 Serial/Industrial Interface Board; Schematics 1

5V 12 =1 10 VCC4 IDIDRV 19
IC2 R10
485_DIR
13 IC6 11 11 DE IVCC2 18
3 2 AHCT86 12 17 R13
VIN VOUT GND2 IDEDRV
C50 + LD1117 13 RO_N ICOM2 16
C51 C52 C53 C54 C55 C56 C57 C30 C31 C32 C33 C34 C35 C36 14 15 R14
GND VCC5 IRLED
R11
1
INTERFACE CONFIGURATION
RS232: IC11, J2A
RS422: IC12, J3, J4
RS485: IC13, J1, J4*
*: IF END OF CABLE

VCC=5V
IC28
5 12
ULN2003A
IC28
IC22 4 13 5V
1 RESET
11 ULN2003A
CLK IC28
AHCT273 3 14
A1
A2
A1
A2
A1
A2
A1
A2
8 3 2
D
A1
A1
A1
A1
9
A2
A2
A2
A2
4 5 ULN2003A
10 7 6 IC28 REL4 REL3 REL2 REL1 DSUB44
11 8 9 2 15 NO 14 NO 14 NO 14 NO 14 P3
13 12 COM 11 COM 11 COM 11 COM 11 SIGNALS
ULN2003A
5V
14 15 IC26 NC 12 NC 12 NC 12 NC 12 16 REL1NC
17 16 OPTO_COUPLER 1 REL1NO
18 19 1 16 31 REL1COM
VCC=5V IC28 17 REL2NC
1 16 R28 2 15 2 REL2NO
3 14 32 REL2COM
ULN2003A
IC27 18 REL3NC
7 10 R27 4 13 3 REL3NO
33 REL3COM
ULN2003A
5 12 19 REL4NC
IC21 IC27 4 REL4NO
RESET_N 1 6 11 R26 6 11 34 REL4COM
RESET 20 OUT1C
WRB_N 11 CLK ULN2003A
7 10
IC27 5 OUT1E
7 3 AHCT273 2 5 12 R25 8 9 35 OUT2C
6 D 21 OUT2E
4 5
Schematics; Industrial Interface
5 7 6 ULN2003A 6 OUT3C
4 8 9 IC25 36 OUT3E
3 13 12 OPTO_COUPLER 22 OUT4C
2 14 15 VCC=5V 1 16 7 OUT4E
1 17 16 IC27 37 OUT5C
0 18 19 4 13 R24 2 15 23 OUT5E
VCC=5V 3 14 8 OUT6C
ULN2003A
IC27 38 OUT6E
3 14 R23 4 13 24 OUT7C
9 OUT7E
ULN2003A
5 12 39 OUT8C
IC27 25 OUT8E

2 15 R22 6 11 30 IN8A
7 10 15 IN8K
ULN2003A
IC27 14 IN7A
D<15..0> 1 16 R21 8 9 44 IN7K
43 IN6A
ULN2003A 29 IN6K
IC24 28 IN5A
OPTO_COUPLER R48 R58 13 IN5K
CSB_N 16 1 12 IN4A
C28 42 IN4K
RD_N 15 2 41 IN3A
IC20 R38 14 3 R47 R57 27 IN3K
1 26 IN2A
EN & 19 C27 11 IN2K
13 4
AHC541 R37 R46 R56 10 IN1A
7 11 9 12 5 40 IN1K
6 12 8 MTG1
5 13 7 11 6 C26
MTG2
4 14 6 R36 R45 R55
3 15 5 10 7
2 16 4 C25
1 17 3 9 8
0 R35 C
18 2
VCC=3.3V IC23
OPTO_COUPLER R44 R54
16 1
3.3V
15 2 C24
1-971643-26 Serial/Industrial Interface Board; Schematics 2

IC28
7 10 R34 14 3 R43 R53
C40
ULN2003A
13 4 C23
IC28
6 11 R33 12 5 R42 R52
ULN2003A
11 6 C22
5V
R32 10 7 R41 R51
C60 C61 C62 C63 C64 C65 C66 C67 9 8 C21

R31
147
14.7 Double Serial Interface Board (not IPL)

Description
The Double Serial Interface Board (DUART) is a Fingerprint-only
optional device for EasyCoder PM4i printers. It provides these printers
with two extra serial interfaces.
"uart2:"
This interface can be fitted with straps and circuits for one of the following
alternatives:
"uart3:"
alternatives:
• RS-422 non isolated, full duplex
• 20 mA Current Loop.
The Double Serial Interface Kit contains:
• One interface board fitted for RS-232 on both ports.
Circuits for modifying the board for RS-422 non-isolated, RS-422
isolated, RS-485 isolated, or 20 mA current loop can be bought separately
from Intermec.
"uart3:"
(DB-9pin socket)
"uart2:"
(DB-9pin socket)

"uart2:" Configuration
The serial communication port "uart2:" can be configured for three
different types of serial communication by fitting or removing certain
driver circuits and straps:
RS-232 Non-isolated (standard)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12
J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
*: TRANSM.=J9, RECEIV.=J10
C41
PASSIVE=B, ACTIVE=A+C
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 P1
IC2
IC3
RS485: IC13, J1, J4*
C35
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
R2
C54
C55
P2
RS-232 circuit fitted on
R11
J1
IC11
Connector Configuration (RS-232 on "uart2:")

MTG
5 GND
4 DSR in
RTS out 8
3 RXD Receive data
3 RXD in
CTS in 7
DTR out 6
9 – Not used

RS-422 Isolated, Full Duplex (reconfiguration required)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
C41
Remove RS-232 circuit on
IC11
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 P1
IC2
IC3
Remove strap on J2 A RS485: IC13, J1, J4*
C35
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9

R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
Fit RS-422 circuit on IC12

R4
R3
R2
C54
C55
P2
R11
J1
Connector Configuration (RS-422 Isolated on "uart2:")

5
9
4
3 +RXD
-RXD 7
2 +TXD 3 +RXD +Receive data
6
1 +5V (0.5 A) 4 –
if GND strap
6 -
9 –

RS-485 Isolated, Half Duplex (reconfiguration required)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
Remove RS-232 circuit on 20MACL: IC23, IC24, J5 J9*, J10*
IC11
C41
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4
Remove strap on J2 A P1
IC2
IC3
RS485: IC13, J1, J4*
C35
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
Fit RS-485 driver R15
J2 R13
R8
R18
F1 F6 F2 F7 F3 F8 F4 F5
circuit on IC13 R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
Fit strap on J4
R6
R17
if end of cable
R1
R7
IC5
IC1
(terminator)
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1
Fit strap on J1

5 GNDE overload, short-circuit protected) provided strap is fitted
9 on J2:A which spoils the galvanical isolation
4
-DATA 8
3 2 +DATA
7
2 +DATA 3 –
6
1 +5V (0.5 A)
if GND strap 4 –
6 –
7 –
8 -DATA
9 –

The serial communication port uart3: can be configured for three different
types of serial communication by fitting or removing certain driver circuits
and straps:
• RS-422 non-isolated, full duplex
• 20 mA Current Loop
RS-232 Non-Isolated (standard)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12
J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
C41
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 IC3
IC2 P1
RS485: IC13, J1, J4*
C35
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
RS-232 driver circuit UARTA B A
R5
IC11 IC12
J2
fitted on IC21
R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1

5 GND
9
4 DSR in 2 TXD Transmit data
RTS out 8
3 RXD in 3 RXD Receive data
CTS in 7
2 TXD out
DTR out 6 4 DSR Data set ready
1 +5V DC
5 GND Ground
9 – Not used

"uart3:" RS-422 Non Isolated, Full Duplex (Reconfiguration Required)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
C63
C
C61
Move strap from
Z2
B
K
NC
IC8
C13
J6 A to J6 B A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
Fit straps on F9
NC
C64
R32
J5
C40
J7 and J8
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
C41
Fit RS-422 driver

circuit on IC22 C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 P1
IC2
IC3
Remove RS-232 driver RS485: IC13, J1, J4*

*: IF END OF CABLE C35
circuit from IC21 C4 C3
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1
Connector Configuration (RS-422 Non-isolated on "uart3:")

5
overload, short-circuit protected) if strap is moved from
9
GND J6 B to J6 A.
4
3 +RXD
-RXD 7
2 +TXD
6
1 +5V (0.5 A) 4 –
5 GNDE Ground
6 -
9 –

"uart3:" 20 mA Current Loop (Reconfiguration Required)

Remove strap from J6 A
IC23 C11 IC21 1-971642-01 P01
UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
Fit strap on J10 A
R33 R34
IC22
R31
if printer is receiver:
C60
C
A + C = active C62
R22
R21
A
Z1
K
B
NC
B = passive R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
Fit strap on J9
R20
P3 IC24 C36
RS232: IC21, J6A IC20

if printer is transmitter: RS422: IC22, J6B, J7, J8
A + C = active 20MACL: IC23, IC24, J5 J9*, J10*
B = passive *: TRANSM.=J9, RECEIV.=J10
C41
Fit optocouplers
on IC23 and IC24 C34 C42
RS232: IC11, J2A

Remove RS-232 driver RS422: IC12, J3, J4 P1
IC2
IC3
circuit from IC21 RS485: IC13, J1, J4*
C35
C33
IC10 C51
Fit strap on J5
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1
Connector Configuration (20 mA Current Loop on "uart3:")

1 External +5VDC max 500 mA (automatic switch-off
5
at overload, short-circuit protected) provided a strap is
9 fitted on J6 A which spoils the galvanic isolation.
4
3 +RXD
-RXD 7
2 +TXD
6
1 +5V DC 4 –
if GND strap
MTG 6 -
9 –
Note: The maximum recommended baud rate is 9600.

Components
UARTB B A
J6 C11
C10 C12
R27
F13 R30 IC23
R35
R24
R23
C C13
F12
C61
C63
J10
J7
A
F16
Z2
B
K
NC
A
F11 R34 IC21 IC8
P3 IC22
R31
C60
F15
R33 C62
F10 C
J8
R22
A
R21
J9
Z1
B K
NC
F14
R25 R28 R29

A
F9 R19
IC24 IC7
D1
R26
R32
K
NC
C64
J5
C40
R20
C36
RS232: IC21, J6A
RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
*: TRANSM.=J9, RECEIV.=J10 IC20
C41
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 IC2
P1
RS485: IC13, J1, J4*
35
*: IF END OF CABLE C35
C33
C51
IC3
C4 C3
C50
C2 C1
IC10
C32
R14
UARTA B A
R5
J2 R13
R15 R8
R18
F5
R12 R10
F4
C56
R9
F8
R16
C57 IC6 IC4

J3
F3
P2
C31
C53
IC11
F7
R6
R17
F2
J4
R7
R1
F6
C30
F1
IC9 IC5 IC1

C52
IC13
IC12
J1
34
68
R4
R3
C55
R2
R11
C54
1-971642-26 Serial/Industrial Interface Board; Component side

156
5V SWITCH FOR
P1 EXTERNAL 5V
1 +24VI 5V
35 5V IC9
2 3.3V POWER_SWITCH
1 GND OUT 8 5V_EXT
36 2 7
3 R6 R7 IN OUT
WAIT_N 3 IN OUT 6
37 4 5
4 R5 EN_N OC_N
38 RD_N 5V_EXT_EN_N
5
39 WR_N OVERCURRENT_N
6
D<15..0> DCDA_N R18

40
7 0
1
4
3
2
1
0
41 VCC=3.3V
8 A<12..1> =1 4 DSRA_N
Schematics "uart2:"
42 2 65 IC5 R8
5V
6
5
4
3
2
1
44
43
42
41
40
9 3 AHC86
43 3.3V VCC=3.3V
RS232
12 CTSA_N C1
10 4 1 IC11 C3
D4
D3
D2
D1
D0
NC
5
11 IC4 13 +
44 MAX238 +
VCC
RI*
AHC32
DCD*
DSR*
CTS*
11 5 7 39 RESET 10 C1+ VCC 9 C4
45 6 D5 MR 11
3.3V 6 8 C2 12 C1- V+ +
12 7 D6 OUT1* 38 VCC=5V
7 9 37 1 =1 + 13 C2+ 15
46 VCC=3.3V 10 D7 DTR* 36 2 IC6 3 V- F1
RESET_N 2 3 RESET 11 AHCT86
47 9 IC5 SIN OUT2* 35 2 F2
14 AHC86
12 NC 34 VCC=5V
5 T1IN T1OUT RS232 RS422 RS485
10 13 NC 33 INTA 4 =1 DTRA_N 18 T2IN T2OUT 1
48 14 SOUT 16C550 INTRPT 32 5 IC6 6 RTSA_N 19 T3IN T3OUT 24 F3 1 +5V
15 11 VCC=3.3V CS0
12 1 15 RXRDY* 31 1 AHCT86 21 T4IN T4OUT 20 2 TXD +TXD +DATA
49 1 CS1
2 IC4 3 CSA_N 16 A0 30 2 67 R1OUT R1IN F4 3 RXD +RXD
16 12 CS2* A1 29
AHC32 17 3 43 R2OUT R2IN 4 DSR
50 13 BAUDOUT* A2 22 R3OUT R3IN 23 F5 5 GND GNDE GNDE
51 14 11 4
1 F6 7 CTS -RXD
18 15 5 IC4 6 CSB_N
8 RTS -TXD -DATA
XIN
XOUT
WR1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
52 AHC32 F7
19 1 3.3V 9
2 VCC=3.3V
MTG1
18
19
21
22
23
25
26
27
28
53 INTA 9 J1 F8 MTG2
20 3 1
4
INTB 10 IC4 8 1
54 AHC32 RS485
21 2 GND-SHIELD
55 5
WR_N 20
RD_N 24
22 6 VCC=3.3V VCC=5V 5V RS422
9 =1 9 =1
1 A J2
56 7 10 8 INT_N 10 8 TXDA IC12
23 8 IC5 IC6 MAX1490
2B
3 C
57 5V 2 VCC2 AC2 23
24 9 VCC=3.3V
=1 12 RXDA 3 D1 IVCC1 22
58 10 11 13 4 21 R16
11 IC5 D2 IRCDRV J3
25 AHC86 5 GND1 A 20 1 TERM.REC.
59 12 R1 R2 R3 3.3V R4 6 19 2
FS B R17
26 7 SD Z 18 J4
60 IC3 8 VCC3 Y 17 1
4
27 R9 9 16 2 TERM.TRA.
SDA VCC DI ICOM1
61 10 VCC4 IDIDRV 15
28 1.8432MHZ 11 RO IVCC2 14
62 SCL CLK 12 13
SA1 1 NC/EN_N OUT 3 GND2 IRLED
29
63 RESET_N 5V GND
2
30 CS_N RS485
64 INT_N
31 IC1 IC13
MAX1480
65 1 VCC1 AC1 28
32 2 VCC2 AC2 27
66 1 A0 VCC 8 3 D1 IVCC1 26
33 2 A1 WP 7 4 D2 B 25
3 6 5 24 R15
34 4 GND SDA 5 6 FS A 23
7 22 R12
68 SD IDIIN
5V 8 VCC3 IDEIN 21
1-971642-26 Double Serial Interface Board; Schematics 1

9 DI ICOM1 20
5V 3.3V VCC=5V
12 =1 10 VCC4 IDIDRV 19
IC2 R10
485_DIR
13 IC6 11 11 DE IVCC2 18
3 2 AHCT86 12 17 R13
VIN VOUT GND2 IDEDRV
C50 + 3.3V 13 RO_N ICOM2 16
C51 C52 C53 C54 C55 C56 C57 C30 C31 C32 C33 C34 C35 C36 14 15 R14
GND VCC5 IRLED
R11
1
UARTA CONFIGURATION
RS232: IC11, J2A
RS422: IC12, J3, J4
RS485: IC13, J1, J4*
*: IF END OF CABLE

5V
R21 R22
3.3V
D<15..0> DCDB_N R24
4
3
2
1
0
A<12..1> VCC=3.3V
1 DSRB_N
Schematics "uart3:"
=1
32 IC7 R23
5V
6
5
4
3
2
1
44
43
42
41
40
AHC86
3.3V VCC=3.3V
RS232
=1 4 CTSB_N C10
IC21 C12
D4
D3
D2
D1
D0
NC
65 IC7 +
MAX238 +
VCC
RI*
AHC86
DCD*
DSR*
CTS*
5 7 39 10 C1+ VCC 9 C13 5V_EXT
6 8 D5 MR C11 12 C1- V+ 11 +
D6 OUT1* 38 VCC=5V
7 9 37 1 +
D7 1 13 C2+ V- 15
10 DTR* 36 2 IC8 3 8 F9
RCLK IC20 RTS* 14 C2- GND P3 9PIN DSUB
11 AHCT32
12 SIN OUT2* 35
34 5 T1IN T1OUT 2 F10
NC VCC=5V RS232 RS422 20MACL
13 NC 33 4 DTRB_N 18 T2IN T2OUT 1
SOUT INTRPT 1
14 16C550 32 5 IC8 6 RTSB_N 19 T3IN T3OUT 24 F11 1 +5V
15 CS0 RXRDY* 31 1 AHCT32 21 T4IN T4OUT 20 2 TXD +TXD TXDIN
CSB_N 16 CS1 A0 30 2 67 R1OUT R1IN F12 3 RXD +RXD RXDIN
17 CS2* A1 29 3 43 R2OUT R2IN 4 DSR
BAUDOUT* A2 22 R3OUT R3IN 23 F13 5 GND GNDE
17 R4OUT R4IN 16 6 DTR
F14 7 CTS -RXD RXDOUT
8 RTS -TXD TXDOUT
XIN
XOUT
WR1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
F15 9
3.3V RS422 MTG1
18
19
20
21
22
23
24
25
26
27
28
CLK 20MACL 5V F16 MTG2
IC22
WR_N J5 1 DS2981
2 1 5 GND-SHIELD
VCC DO-
RD_N 2 RO DO+
6
VCC=3.3V

=1 9 RXDB 3 7 1 A J6
CL_EN_N
DI RI-
8 IC7 10 4 GND RI+
8 2B C
AHC86 3
INTB
RESET R31
5V 1 J7
2 TERM.REC.
VCC=3.3V R32
12 =1 J8
VCC=5V R27 1
13 IC7 11 9 20MACL
1 2 TERM.TRA.
AHC86 10 IC8 8
AHCT32 IC23
8
VCC=5V
12 2 J9
1 R30
13 IC8 11 TXDB 7
5V 3.3V AHCT32 1 A CURR-FEED
3 6 TRANSM.
R20
2 B
6N139
5 3 C
C60 C61 C62 C63 C64 C40 C41 C42 5V 4
IC24 J10
R25 8 CURR-FEED
2 R29 1 A
2 B RECEIVER
7
R28
3 C
6 D1 4
3
5
1-971642-26 Double Serial Interface Board; Schematics 2

R26 6N139
UARTB CONFIGURATION
+24VI R19
C
RS232: IC21, J6A

RS422: IC22, J6B, J7, J8 Z1
R33 10V
A
20MACL: IC23, IC24, J5, J9*, J10*

R34
C
Z2
PASSIVE=B, ACTIVE=A+C R35 10V
A
157
14.8 RFID Serial Interface Board

Description
The RFID Serial Interface Board is an optional device for EasyCoder PM4i
printers. It provides these printers with one serial interface port and RFID
functionality. It is supported by both Fingerpint and IPL.
The RFID Serial Interface Board is available as part of various RFID Kits
that typically contain:
• One RFID Serial Interface Board
• One Radio Module
• One Dual Slot / Single Slot I/O Bus Cable (Flat Cable)
• One RFID Antenna
• Two MRT 4x8 Screws
• One MRT 3x5 Screw
• One Spacer Screw
• One RFID label
• One Quick Start Guide or User’s Guide booklet
• One Installations Instructions booklet
"uart2:"
alternatives:
"uart3:"
Jumpers J5-J9 can be fitted with straps to provide support for two different
types of RFID modules.
"uart2:"
(DB-9pin socket)

The serial communication port "uart2:" can be configured for three
different types of serial communication by fitting or removing certain
driver circuits and straps:
RS-232 Non-Isolated (Standard)
PCB NUMBER
BR1
R1
34
68
C61
P4
C3
366
P3 C5
511
R1
199 IC20
C20
IC2
R20
20 C60
60 C40
40
C41
C42
42 C34
34
35
C8
IC8 IC
C77
1
5
J5 6
J6 J7 J8 9
J9
IM3/IM4:
M3/IM4: J5A-J9A
J5A-J9A IC3
C3 P1
MPR6000:
PR6000: J5B-J9B
J5B-J9B
C33
35
1
C3
355
S232: IC11,
RS232: IC11, J2A
J2A C4 C3
S422: IIC12,
RS422: C12, JJ3,
3, JJ4
4
RS485: IC13, JJ1,
S485: IC13, 1, JJ4*
4*
*:: IF
IF END
END OF
OF CABLE
CABLE C2 IC
C10
10
R5 C32
C1 C5
500
ARTA
UARTA B A
14
R14
IC
C13
13
2
J2 IC12
C12
R13
13 R8
F1 F6 F2 F7 F3 F8 F4 F5
R18
18
15
R15
10
R10
R12
12 C56
56
J3
R9
R16
IC4
IC6
C5
57
7
C31
C53
J4
R6
R17
R1
R7
IC1
IC5
IC9
C52
34
68
C30
C55
P2 54
C54
RS-232 circuit fitted on J1
1
R11
R3
R4
R2
IC11
C11
IC11

MTG
5 GND
4 DSR in
RTS out 8
3 RXD Receive data
3 RXD in
CTS in 7
DTR out 6
9 – Not used

RS-422 Isolated, Full Duplex (reconfiguration required)
PCB NUMBER
BR1
R1
34
68
C61
P4
C3
366
P3 C5
511
R1
199 IC20
C20
IC2
R20
20 C60
60 C40
40
C41
Remove RS-232 circuit on C42
42 C34
34
35
C8
IC8 IC
C77
1
IC11
5
J5 6
J6 J7 J8 9
J9
IM3/IM4:
M3/IM4: J5A-J9A
J5A-J9A IC3
C3 P1
Remove strap on J2 A MPR6000:
PR6000: J5B-J9B
J5B-J9B
C33
35
1
C3
355
S232: IC11,
RS232: IC11, J2A
J2A C4 C3
S422: IIC12,
RS422: C12, JJ3,
3, JJ4
4
RS485: IC13, JJ1,
S485: IC13, 1, JJ4*
4*
*:: IF
IF END
END OF
OF CABLE
CABLE C2 IC
C10
10
R5 C32
C1 C5
500
ARTA
UARTA B A
14
R14
IC
C13
13
2
J2 IC12
C12
R13
13 R8
F1 F6 F2 F7 F3 F8 F4 F5
R18
18
15
R15
10
R10
R12
12 C56
56
J3
R9
R16
IC4
IC6
C5
57
7
C31
C53
J4
R6
R17
R1
R7
IC1
IC5
IC9
C52
34
68
C30
C55
Fit RS-422 circuit on IC12 P2 54

C54
J1
1
R11
R3
R4
R2
IC11
C11

5
9
4
3 +RXD
-RXD 7
2 +TXD 3 +RXD +Receive data
6
1 +5V (0.5 A) 4 –
if GND strap
6 -
9 –

RS-485 Isolated, Half Duplex (reconfiguration required)
PCB NUMBER
BR1
R1
34
68
C61
P4
C3
366
P3 C5
511
Remove RS-232 circuit on R1

199 IC20
C20
IC2
R20
20 C60
60 C40
40
IC11
C41
C42
42 C34
34
35 C8
IC8 IC7
C7
1
5
J5 6
J6 J7 J8 9
J9
Remove strap on J2 A IM3/IM4:

M3/IM4: J5A-J9A
J5A-J9A IC3
C3 P1
MPR6000:
PR6000: J5B-J9B
J5B-J9B
C33
35
1
C3
355
S232: IC11,
RS232: IC11, J2A
J2A C4 C3
S422: IIC12,
RS422: C12, JJ3,
3, JJ4
4
RS485: IC13, JJ1,
S485: IC13, 1, JJ4*
4*
*:: IF
IF END
END OF
OF CABLE
CABLE C2 IC
C10
10
R5 C32
C1 C5
500
ARTA
UARTA 14
R14
IC
C13
13
Fit RS-485 driver B A
2
J2 IC12
C12
circuit on IC13 R13
13 R8
F1 F6 F2 F7 F3 F8 F4 F5
R18
18
15
R15
10
R10
R12
12 C56
56
J3
R9
R16
IC4
IC6
C5
57
7
Fit strap on J4
C31
C53
J4
if end of cable
R6
R17
R1
R7
(terminator)
IC1
IC5
IC9
C52
34
68
C30
C55
P2 54
C54
J1
1
R11
Fit strap on J1
R3
R4
IC11
C11 R2

5 GNDE overload, short-circuit protected) provided strap is fitted
9 on J2:A which spoils the galvanical isolation
4
-DATA 8
3 2 +DATA
7
2 +DATA 3 –
6
1 +5V (0.5 A)
if GND strap 4 –
6 –
7 –
8 -DATA
9 –

"Module Select" Configuration

Straps can be fitted to jumpers J5-J9 to provide support for two different
types of RFID radio modules:
IM3/IM4
PCB NUMBER
BR
R11
34
68
C61
P4
C3
366
P3 C5
511
R1
199 C20
IC20
IC2
R2
200 C60
60 C4
400
C41
Fit straps on J5-J9, in C42
42 C34
34
35
IC8
C8 IC
C77
1
"upper" position J5 J6 J7 J8 J9
IM3/IM4:
M3/IM4: J5A-J9A
J5A-J9A IC3
C3 P1
MPR6000:
PR6000: J5B-J9B
J5B-J9B
C33
35
1
C35
35
RS 232: IIC11,
S232: C11, J2A
J2A C4 C3
S422: IC12,
RS422: IC12, JJ3,
3, JJ4
4
RS485: IC13, J1,
S485: IC13, J1, J4*
J4*
*:: IIFF E
END
ND OF
OF CABLE
CABLE C2 IC
C10
10
R5 C32
C1 C5
500
UARTA
ARTA B A
14
R14
IC
C13
13
2
J2 IC12
C12
R13
13 R8
F1 F6 F2 F7 F3 F8 F4 F5
R18
18
15
R15
10
R10
R12
12 C56
56
J3
R9
R16
IC4
IC6
C5
577
C31
C53
J4
R6
R17
R1
R7
IC1
IC5
IC9
C52
34
68
C30
C55
P2 54
C54
J1
1
R11
R3
R4
R2
IC
C11
11
MPR6100
PCB NUMBER
BR
R11
34
68
C61
P4
C3
366
P3 C5
511
R1
199 C20
IC20
IC2
R2
200 C60
60 C4
400
C41
Fit straps on J5-J9, in C42

42 C34
34
35
IC8
C8 IC
C77
1
"lower" position J5 J6 J7 J8 J9
IM3/IM4:
M3/IM4: J5A-J9A
J5A-J9A IC3
C3 P1
PR6000: J5B-J9B
MPR6000: J5B-J9B
C33
35
1
C35
35
S232: IC11,
RS232: IC11, J2A
J2A C4 C3
S422: IC12,
RS422: IC12, JJ3,
3, JJ4
4
RS485: IC13, J1,
S485: IC13, J1, J4*
J4*
*:: IIFF E
END
ND OF
OF CABLE
CABLE C2 IC
C10
10
R5 C32
C1 C5
500
UARTA
ARTA B A
14
R14
IC
C13
13
2
J2 IC12
C12
R13
13 R8
F1 F6 F2 F7 F3 F8 F4 F5
R18
18
15
R15
10
R10
R12
12 C56
56
J3
R9
R16
IC4
IC6
C5
577
C31
C53
J4
R6
R17
R1
R7
IC1
IC5
IC9
C52
34
68
C30
C55
P2 54
C54
J1
1
R11
R3
R4
R2
IC
C11
11

Components
34
68
BR1
C61
P4
C36
P3 C51
IC20
IC2
R19
R20 C60 C40

IC8
C41
IC7
35
1
C42 C34
J5 J6 J7 J8 J9
IM3/IM4: J5A-J9A P1
IC3
35
MPR6000: J5B-J9B
1
C33
RS232: IC11, J2A C4 C3 C35 IC10

RS422: IC12, J3, J4
RS485: IC13, J1, J4*
*: IF END OF CABLE
C32
C2 C1 C50
UARTA R14 IC13
R5
B A
J2 IC11 IC12
R13 R8
F1 F6 F2 F7 F3 F8 F4 F5
R15 R18
R10
R12 C56
J3
IC6
IC4
R16
R9
C57
C53
C31
J4
R17
R6
R7
R1
IC 1
IC5
IC 9
34
68
C52
C30
C55
R3
R2
P2 C54
R11
J1
R4
1-971644-53 RFID Serial Interface Board; Component side

164
5V SWITCH FOR
P1 EXTERNAL 5V
1 +24VI 5V
35 5V IC9
2 3.3V POWER_SWITCH
1 GND OUT 8 5V_EXT
36 2 7
3 R6 R7 IN OUT
3 IN OUT 6
37 WAIT_N
4 EN_N OC_N 5
4
38 RD_N R5 5V_EXT_EN_N
5
39 WR_N
OVERCURRENT_N
6 R18
40 D<15..0> DCDA_N
7 0
3
41
4
2
0
VCC=3.3V
8 A<12..1> =1 4 DSRA_N
42 2 6 IC5 5 R8
5V
3
1
6
5
4
2
44
43
42
41
40
9 3 AHC86
Schematics "uart2:"
43 3.3V VCC=3.3V
RS232
12 CTSA_N C1
10 4 1 IC11 C3
D4
D3
D2
D1
D0
NC
11 IC4 13 +
44 5 MAX238
VCC
RI*
AHC32 +
DCD*
DSR*
CTS*
11 5 7 39 RESET 10 C1+ VCC 9 C4
45 6 D5 MR
3.3V 6 8 38 C2 12 C1- V+ 11 +
12 7 D6 OUT1* VCC=5V
7 9 37 1 =1 +
46 D7 DTR* 13 C2+ V- 15 2N2
VCC=3.3V 10 36 2 IC6 3 F1
11 35 AHCT86
47 9 RESET_N 2 IC5 3 RESET SIN OUT2* 2N2
12 34 5 T1IN T1OUT 2 F2
14 AHC86 NC NC VCC=5V RS232 RS422 RS485
13 33 INTA 4 =1 DTRA_N 18 T2IN T2OUT 1
48 10 SOUT INTRPT 2N2
14 16C550 32 5 IC6 6 RTSA_N 19 T3IN T3OUT 24 F3 1 +5V
15 11 VCC=3.3V CS0 RXRDY*
12 1 15 31 1 AHCT86 21 T4IN T4OUT 20 2 TXD +TXD +DATA
49 1 CS1 A0 2N2
2 IC4 3 CSA_N 16 30 2 6 R1OUT R1IN 7 F4 3 RXD +RXD
16 12 CS2* A1
AHC32 17 29 3 4 R2OUT R2IN 3 4 DSR
50 13 BAUDOUT* A2 2N2
22 R3OUT R3IN 23 F5 5 GND GNDE GNDE
51 14 11 4 2N2
1 F6 7 CTS -RXD
18 15 5 IC4 6 CSB_N
8 RTS -TXD -DATA
XIN
XOUT
WR 1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
52 AHC32 2N2
F7 9
19 1 3.3V
2 VCC=3.3V
MTG1
18
19
53 J1
20
21
22
23
24
25
26
27
28
INTA 9 F8 2N2
20 3 1
MTG2
INTB 10 IC4 8 1
54 4
AHC32 RS485
21 2 GND-SHIELD BR1
55 5 MTG1
WR_N
RD_ N
22 6 VCC=3.3V VCC=5V 5V RS422 1 J2
9 =1 9 =1
56 7 IC12
10 IC5 8 INT_N 10 IC6 8 TXDA MAX1490
2 AB
23 8 3
57 5V 2 VCC2 AC2 23 C
24 9 VCC=3.3V
=1 12 RXDA 3 D1 IVCC1 22
58 10 R16
11 IC5 13 4 D2 IRCDRV 21 J3
25 11 1
AHC86 5 GND1 A 20 TERM.REC.
59 12 R1 R2 R3 3.3V R4 2
6 FS B 19
26 7 18 R17
SD Z J4
60 8 VCC3 Y 17 1 TERM.TRA.
4
27 IC3 R9 2
VCC 9 DI ICOM1 16
61 SDA
10 VCC4 IDIDRV 15
28 1.8432MHZ 11 RO IVCC2 14
62 SCL
1 EN/NC OUT 3 CLK 12 GND2 IRLED 13
29 SA1
63 RESET_N 5V GND
2
30 CS_N RS485
64 INT_N
IC13
31 IC1 MAX1480
65 1 VCC1 AC1 28
32 2 VCC2 AC2 27
66 1 A0 VCC 8 3 D1 IVCC1 26
33 2 A1 WP 7 4 D2 B 25
3 6 5 24 R15
34 4 GND SDA 5 6 FS A 23
7 22 R12
68 SD IDIIN
1-971644-53 RFID Serial Interface Board; Schematics 1

5V 8 VCC3 IDEIN 21
9 DI ICOM1 20
5V 3.3V VCC=5V
12 =1 10 VCC4 IDIDRV 19
R10
485_DIR
IC2 13 IC6 11 11 DE IVCC2 18
2 12 17 R13
3 VIN VOUT AHCT86 GND2 IDEDRV
LD1117
13 RO_N ICOM2 16
C50 + C51 C52 C53 C54 C55 C56 C57 C30 C31 C32 C33 C34 C35 C36 14 15 R14
GND VCC5 IRLED
1
R11
FT1 FT2 FT3 INTERFACE CONFIGURATION

RS232: IC11, J2A
RS422: IC12, J3, J4
RS485: IC13, J1, J4*
*: IF END OF CABLE

RFID PC-CARD MODULE
IM3/IM4: J5A-J9A
MPR6000: J5B-J9B P4 P4
1 G ND 35 GND
2 36
J5 3 37
RXD_IM R20 T XD
1 4 TX D 38 RXD
BRXD 5 39
3.3V 2 RXD_WJ BOOT
3 6 40 WAKE
D<15..0> 7 41
SIL3 8 42 RESET
3
1
4
2
0
A<12..1> J6 9 43
TXD_IM 10 44 IOWR_N
1 BTXD 11 45
3
1
6
5
4
2
44
43
42
41
40
2 12 46 IORD_N
TXD_WJ
3.3V 3 13 47
14 RXD 48
R19
D4
D3
D2
D1
D0
NC
SIL3 5V 5V
15 49
VCC
RI*
J7
DCD*
DSR*
CTS*
5 7 39 16 50
6 8 D5 MR 38 1 17 5V 51 5V
D6 OUT1* BBOOT 18 52
7 9 37 2
D7 DTR* BOOT_WJ 19 53
10 36 3
11 RCLK IC20 RTS* 35 20 54
Schematics "Module Select"
SI N OUT2* SIL3 21 55
12 34
13 NC NC 33 22 56
SOUT INTRPT J8 23 57
14 16C550 32 RESET_IM
15 CS0 RXRDY* 31 1 1 24 58
CS1 A0 BRESET 25 59
CSB_N 16 30 2 2
CS2* A1 RESET_WJ 26 60
17 29 3 3
BAUDOUT* A2 27 61
SIL3 28 62
29 63
J9 30 64
XIN
XOUT
WR1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
COM_EN_IM 31 65
1
2 32 66
18
19
COM_EN_WJ
20
21
22
23
24
25
26
27
28
CLK 3 33 COM_ENABLE 67
34 GND 68 GND
SIL3
WR_N MTG MTG

RD_N MTG1 MTG2
INTB
VCC=5V
5V MEDIO S002 MODULE
RESET 1
1
2 IC8 3 BRESET
AHCT32 P3
VCC=5V
9 1
1
TXD 10 IC8 8 BTXD 2
AHCT32 3
VCC=3.3V 4
1 BRXD
1 5
RXD 3 IC7 2
AHC32 6 TX_TTL
VCC=5V
7 RX_TTL
4 8 SHDW_N
1
5 IC8 6 BBOOT 9 +5V
AHCT32 10 GND
VCC=5V 11
12
5V 3.3V 1 12
13 IC8 11
AHCT32 13
1-971644-53 RFID Serial Interface Board; Schematics 2

VCC=3.3V
14
C60 C61 C40 C41 C42 4 15
1
5 IC7 6 16
AHC32 17
VCC=3.3V 18
9
1 19
10 IC7 8
AHC32
VCC=3.3V
12
1
13 IC7 11
AHC32
165
14.9 IEEE 1284 Parallel Interface Board

Description
The IEEE 1284 Parallel Interface Board is an optional device for
EasyCoder PM4i printers. It provides these printers with one parallel
interface port and is supported by both Fingerpint and IPL.
The parallel communication port is addressed in Intermec Fingerprint as
device centronics: (communication channel 4). The board is IEEE1284-I
compatible. Nibble, byte, ECP, and EPP modes from printer to host are
not presently supported.
The IEEE 1284 Parallel Interface kit contains:
• One Parallel Interface Board
• One Installations Instructions booklet.
There are neither any straps nor any other types of physical configuration
on this interface board, nor any options in the Setup Mode.
IEEE 1284 interface

("centronics:")

The IEEE 1284 board has a standard 36pin IEEE 1284 B socket with the
following configuration:
Pin Signal Remark

1 DSTROBE
2 DATA 0
3 DATA 1
4 DATA 2
5 DATA 3
6 DATA 4
7 DATA 5
8 DATA 6
9 DATA 7
10 ACK
11 BUSY
12 PE
13 SELECT
14 AF
15 N/C
16 GND
17 SCREEN
18 External +5VDC max 500 mA (automatic switch-
off at overload, short-circuit protected)
19 GND
20 GND
20 GND
21 GND
22 GND
23 GND
24 GND
25 GND
26 GND
27 GND
28 GND
29 GND
30 GND
31 INIT
32 ERROR
33 N/C
34 N/C
35 N/C
36 SELECTIN

Components
1-971641-02 P01
F18
F17
R17
F16
R16
F15
R11
F14
R10
F13
R15
F12
R14
F11
R13
F10
R12
F8
R8
F7
R7
F6
R6
R18
F5
R5
F4
IC5
R4
C1 C2
F3
R3
F2
R19
R2
C13
F1 P1
IC3
R1
P3 F9
R9 D1
C9 C3
F19 C11
IC1
C8
IC4
C14
C10
C5
IC6
C6 C7
C4
R20
IC2
C12
R22
R21
1-971641-27 IEEE 1284 Parallel Interface Board; Component side

Schematics
CABLE ASSEMBLY
D1 40-PIN RIBBON CABLE
3.3V CONNECTOR -> 36-PIN
5V CENTRONICS CONN.
P1 R9 R1 R2 R3 R4 R5 R6 R7 R8 R12 R13 R14 R15 R10 R11 R16 R17 40-PIN - 36-PIN
1 IC4 3.3V
35 VCC P3
2 OSC. F9 1 STROBE 1
36 1 2 GND 19
3 NC/EN_N OUT 3
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
F1 3 DATA0 2
37 WAIT_N GND
4 4 GND 20
F2 5 DATA1 3
24
38 RD_N
5 6 GND 21
F3 7 DATA2 4
DONE
GND6
IO47
IO46
IO45
IO44
IO43
IO42
IO41
IO40
IO39
GND5
VCC5
IO37
IO36
IO35
IO34
IO33
IO32
IO31
IO30
39 WR_N
6 8 GND 22
D<15..0> F4 9 DATA3 5
40 51 25
PWRDWN_N
0 VCC6 VCC4 10 GND 23
GCK4/IO48
GCK3/IO29
7 RESET_N 52 PROG_N M0 24 F5 11 DATA4 6
41 1 53 23
INIT_N/IO38
8 IO49 GND4 12 GND 24
54 IO50/GCK5 M1 22 F6 13 DATA5 7
42 2 55 21 STROBE
3 INT_N IO51 GCK2/IO28 14 GND 25
9 CS_N 56 IO52 IO27 20 CD0 F7 15 DATA6 8
43 A<12..1> 57 IO53 IO26 19 CD1 16 GND 26
10 4 58 18 CD2
12 IO54 IO25 F8 17 DATA7 9
44 5 59 17 CD3
11 IO55 IO24 18 GND 27
11 10 60 IO56 IO23 16 CD4 F10 19 ACK 10
45 6 61 15 CD5
9 IO57 IO22 20 GND 28
12 7
8 62 IO58 IO21 14 CD6 F11 21 BUSY 11
46 63 VCC7 XCS05XL-4 IO20 13 CD7 22 GND 29
13 8 64 GND7 VCC3 12 F12 23 PERROR 12
47 9 65 11
7 IO59 IC1 GND3 24 GND 30
14 6 66 IO60 IO19 10 ACK F13 25 SELECT 13
48 10 67 9 BUSY
5 IO61 IO18 26 INIT 31
15 11
4 68 IO62 IO17 8 PERROR F14 27 AFEED 14
49 3 69 IO63 IO16 7 SELECT 28 ERROR 32
16 12 70 6 AFEED
2 IO64 TMS/IO15 F15 29 15
50 13 71 5 INIT
1 IO65 TCK/IO14 30 33
17 0 72 4 ERROR F16

51 14 VCC=3.3V
IO66/DIN TDI/IO13 31 GND 16
CS_N 2 73 IO67/DOUT IO12 3 SELIN 32 34
18 15 1
WR_N 14 74 CCLK GCK1/IO11 2 F17 33 SCREEN 17
52 IC6 75 VCC8 GND2 1 5V 34 35
19 1 IC5
AHC1G32 F18 35 EXT-5V 18
53 2 POWER_SWITCH
20 3 1 8 36 SELIN 36
GND OUT 3.3V F19 37
54 4 2 IN OUT 7
21 3 6 38
R19 IN OUT R18 39
O/TDO
GND8
IO68
IO69/GCK7
IO70/CS1
IO71
IO72
IO73
IO74
IO75
IO76
IO77
GND1
VCC1
IO1
IO2
IO3
IO4
IO5
IO6
IO7
IO8
IO9
IO10/GCK8
VCC2
55 5 4 EN_N OC_N 5
22 6 40
56 7 MAX1607
8 5V_EXT_EN_N C
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
23
100
57 5V BR1
MTG1
24 9
MTG2
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
58 10
25 11
59 12 R20 R21 R22 BR2
WR_N
26 MTG1
RD_N OVERCURRENT_N
60 MTG2
27 WAIT_N
61 SDA
28 BR3
SCL MTG1
62 MTG2
29 SA1
63 RESET_N 5V
30 CS_N
64 INT_N
1-971641-27 IEEE 1284 Parallel Interface Board; Schematics

31 IC2
65
32 5V IC3 3.3V
66 1 A0 VCC 8
33 2 A1 WP 7 32 VIN
67 3 A2 SCL 6 + C14 3.3V
4 5 C11 C12 C13 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10
34 GND SDA GND
68
169
14.10 EasyLAN Ethernet Interface Board

Description
This section describes how to install an EasyLAN Ethernet network
interface in an EasyCoder PM4i printer and how to connect it to a
100base TX Fast LAN, WAN, Intranet, or Internet network via a wired
connection.
The installation instructions describes how to physically install the
interface board in a printer. Configuration and setup are described in
the EasyLAN Interface Kit, Installation Instructions and the Intermec
EasyLAN, User’s Guide on the attached CD-ROM.
Printer Firmware
The printer must be running either Intermec Fingerprint v8.00 (or later)
or IPL v2.00 (or later). In Intermec Fingerprint, the network port is
addressed as device "net1:" (communication channel #5).
Installation Kit
The EasyLAN Interface Kit contains:
• One EasyLAN interface board
• One light guide
• One hexagonal threaded spacer
• One network extension cable
• One cable tie
• One serial number label
• One CD-ROM with software and manuals
The only tool required for the installation is a #T20 Torx screwdriver.

Installation Instructions
Also see illustration on the next page.
1 Switch off the printer and disconnect the power cord.
2 Disconnect all communication cables.
4 Remove the LAN connector plug, which is snap-locked at the top of the
rear plate.
5 Remove the #T20 Torx screw that holds the upper/front part of the
CPU board to the power supply unit and replace it with the hexagonal
LAN connector plug spacer included in the kit. Keep the screw.
6 Connect the EasyLAN board to the PCI connector (J84) on the CPU
board so the hole in the interface board becomes aligned with the spacer.
7 Secure the EasyLAN board with the #T20 Torx screw you previously
removed.
8 From the inside of the electronics compartment, press the metal socket
of the network extension cable into the square hole in the rear plate
(where you removed the LAN plug) until it is held by its snaplock.
9 Route the extension cable over the SIMMs on the CPU board and
connect it to the RJ-45 socket on the EasyLAN interface board (J2).
10 From the outside, insert the thin end of the light guide through the
small hole next to the RJ-45 socket on the rear plate. Press the clear
plastic “lamp” in place. Connect the other end to the black plastic
socket (D1) on the EasyLAN interface board.
11 Pull the cable tie through the hole in the upper edge of the CPU board
between the SIMMs and the RTC socket. Secure both the extension
cable and the light guide with the cable tie.
12 Fit the serial number label on the rear plate below the RJ-45 socket and
to the right of the memory card slot.
13 Put back the front/left-hand cover. Route the cable from the display
unit above the ribbon motor. Connect the cable to connector J50 at the
upper front corner of the CPU board.
15 Enter the Setup Mode and print the test label “Hardware Info” in
Fingerprint or “HW” in IPL to see if the printer detects the EasyLAN
Ethernet interface board. For information on how to enter the Setup
Mode and print test labels, refer to the User’s Guide for the printer in
question.
16 After startup, enter the Setup Mode to set up the network parameters.
See Appendix A. Setting the network parameters in IPL, when the server
does not support DHCP or BOOTP, is described in EasyLAN Interface
kit, Installation Instructions.

Network extension cable

Screw and spacer
Light guide
Cable tie
Optional interface board CPU board EasyLAN Ethernet interface

(Serial/Industrial, board
Double serial, or
IEEE 1284 Parallel)
RJ-45 Ethernet connector

("net1:")
Serial number label

Components
J2
C33
C39
Y2
C25
L2
L3
R12 C7 C4
D1
C27
R13 C28
C34
M1
R1
C26
C17 C6 C15 C5 C14 R9
C23
R4
IC2
R11
C29 R7
C22
C31
R6 R8
R5 C30
C24
C20
L1
IC1
C21
C10
C11
C3
C18
IC3
Y1
C13
C1
C32
C2
C38
C37
C36
R3
R2
C19 C35 C16
C12
1-971645-26 EasyLAN Interface Board; Component side
J1
1-971645-26 EasyLAN Interface Board; Soldering side

174
L2+C17 ONLY POPULATED Y2
3.3V C27 C28
FOR DP83815
PCI_AD(31..0) L2 L3 25MHZ 3.3V
C17
5V
PIN19
1
2
D1
Schematics
0 1 PCI_AD0 SCA80 PCI_AD1 41 1
36
35
34
33
32
27
26
21
20
19
18
17
16
9
8
7
6
5
4
3
2
1
31
30
29
28
25
24
23
22
15
14
13
12
11
10
2 VSS1 PCI_AD2 42 2 R4=9K31 FOR
3
4
3 3 PCI_AD3 VCC1 43 DP83815 AND
4 4 PCI_AD4 PCI_AD5 44 5 R4=10K FOR
C1
X2
X1
6 5 PCI_AD6 7 PCI_AD7 45 DP83816
CRS
MDC
MA5
6 46 PCI_CBE0_N 37 144 R9
VSS2 PCI_CBE_N0 SUBGND1/NC83816 MA2/LED100_N
TXEN
RXOE
MDIO
NC_34
TXCLK
VSS_8
RXCLK
8 7 PCI_AD8 VCC2 47 38 VSS_38 MA1/LED10_N 143
VSS_35
VSS_32
VSS_26
VSS_20
VSS_16
9 8 48 10 RXAVDD 39 142 R11
PCI_AD9 PCI_AD10 AUXVDD_39 MA0/LEDACT_N
COL/MA16
RXD3/MA9
RXD2/MA8
RXD1/MA7
AUXVDD_9
RXD0/MA6
MA3/EEDI
11 9 PCI_AD11 PCI_AD12 49 12 40 VREF MD7 141
AUXVDD_33
AUXVDD_27
TXD3/MA15
TXD2/MA14
TXD1/MA13
TXD0/MA12
AUXVDD_21
RXDV/MA11
RXER/MA10
MA4/EECLK
10 VSS3 PCI_AD13 50 13 41 RESERVED_41 MD6 140
14 11 PCI_AD14 VCC3 51 42 NC_42 MD5 139
15 12 52 PCI_CBE1_N R4 43 138
PCI_AD15 PCI_CBE_N1 NC_43 MD4/EEDO
FXVDD/NC83816
PCI_PAR 13 PCI_PAR PCI_SERR_N 53 PCI_SERR_N 44 VSS_44 AUXVDD_137 137
14 VSS4 PCI_PERR_N 54 PCI_PERR_N TPRDM 45 TPRDM VSS_136 136
15 PCI_LOCK_N VCC4 55 TPRDP 46 TPRDP MD3 135
PCI_STOP_N 16 PCI_STOP_N PCI_DEVSEL_N 56 PCI_DEVS_N RXAVDD 47 AUXVDD_47 MD2 134
PCI_TRDY_N 17 PCI_TRDY_N PCI_IRDY_N 57 PCI_IRDY_N REGEN 48 REGEN DP83815/6 MD1/CFGDIS_N 133
18 VSS5 PCI_FRAME_N 58 PCI_FRAME_N 49 VSS_49 MD0 132 3.3V
PCI_CBE2_N 19 PCI_CBE_N2 VCC5 59 50 RESERVED_50 TQFP144 MWR_N 131
16 20 PCI_AD16
J1 PCI_AD17 60 17 51 VSS_51 MRD_N 130 IC2
18 21 PCI_AD18 PCI_AD19 61 19 52 VSS_52 MCS_N 129 VCC 8
22 VSS6 PCI_AD20 62 20 TPTDM 53 TPTDM EESEL 128 1 CS EEPROM
21 23 PCI_AD21 VCC6 63 TPTDP 54 TPTDP RESERVED_127 127 2 SK
22 24 PCI_AD22 PCI_AD23 64 23 55 VSS_55 IC1 SUBGND3/NC83816 126 3 DI DO 4
PCI_CBE3_N 25 PCI_CBE_N3 PCI_AD24 65 24 56 AUXVDD_56 MACVDD2/NC83816 125 6 ORG/NC
26 VSS7 PCI_AD25 66 25 57 VSS_57 MACVSS2/NC83816 124 7 NC
26 27 PCI_AD26 VCC7 67 58 AUXVDD_58 PWRGOOD 123 GND 5
27 28 PCI_AD27 PCI_AD28 68 28 59 PMEN/CLKRUN_N 3VAUX 122
29 29 PCI_AD29 PCI_AD30 69 30 PCI_CLK2 60 PCICLK AD0 121 0
30 VSS8 PCI_AD31 70 31 PCI_INT_N 61 INTA_N AD1 120 1
PCI_REQ_N 31 PCI_REQ_N0 VCC8 71 PCI_RST_N 62 RST_N AD2 119 2
PCI_GNT_N 32 PCI_GNT_N0 PCI_CLK 72 PCI_CLK1 PCI_GNT_N 63 GNT_N AD3 118 3
PCI_INT_N 33 PCI_INT_N PCI_REQ_N2 73 PCI_REQ_N 64 REQ_N PCIVDD_117 117
34 VSS9 PCI_RST_N 74 PCI_RST_N 65 VSS_65 AD4 116 4
35 TCK VCC9 75 31 66 AD31 AD5 115 5
36 TMS NC1 76 + C12 30 67 AD30 VSS_114 114
37 TDO SCL 77 29 68 AD29 AD6 113 6
38 VSS10 SDA 78 69 PCIVDD_69 AD7 112 7 C39 ONLY POPULATED
39 TDI PCI_DET_N 79 28 70 AD28 CBEN0 111 PCI_CBE0_N FOR DP83816
40 TRST_N 24V 80 27 71 AD27 AD8 110 8
26 72 AD26 AD9 109 9 3.3V
C39
REGEN +
AD12
AD11
AD25
AD24
CBEN3
IDSEL
VSS_77
AD23
AD22
PCIVDD_80
AD21
AD20
AD19
VSSIO4/NC83816
VDDIO4/NC83816
AD18
AD17
AD16
CBEN2
VSS_90
FRAME_N
IRDY_N
TRDY_N
PCIVDD_94
DEVSEL_N
STOP_N
PERR_N
SERR_N
PAR
CBEN1
AD15
AD14
VSS_103
AD13
PCIVDD_107
AD10
84
90
91
73
74
75
76
77
78
79
80
81
82
83
85
86
87
88
89
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
3.3V
NORMALLY UNPOPULATED
C34
4
Y1
VCC R2 PCI_CLK1
32.768MHZ
1 EN/NC OUT 3 C
GND R3
PCI_CBE3_N
PCI_CBE2_N
PCI_FRAME_N
PCI_IRDY_N
PCI_TRDY_N
PCI_DEVS_N
PCI_STOP_N
PCI_PERR_N
PCI_SERR_N
PCI_PAR
PCI_CLK2 PCI_CBE1_N
25
24
11
23
22
21
20
19
18
17
16
15
14
13
12
11
10
2
M1
1 TD- TX- 16 TX-
5V 3.3V R5 J2
TPTDM 2 TDCT TXCT 15 R12
C35 1 TX+
RXAVDD 2 TX-
C36 AC RETURN PATHS 3 TD+ TX+ 14 TX+ 3 RX+
1-971645-26 EasyLAN Interface Board; Schematics

FOR PCI SIGNALS 4 NC1 NC4 13 4
CROSSING 5V TO 3.3V TPTDP R6 5 12
C37 NC2 NC3 5
BOUNDARY 6 RD- 1CT:1CT RX- 11 RX- 6 RX-
C38
BYPASS CAPACITORS 7
IC1 R7 8
TPRDM 7 RDCT RXCT 10 R13 MTG1
RX+ MTG2
3.3V PINS
C33 MTG3
8 RD+ RX+ 9 MTG4
3.3V 69/80 94/107 117 IC2 Y1
IC1 3.3V 3.3V TPRDP R8 C29 C30 C31 RJ45
PINS C13 C16 C18 C20 C32 NORMALLY
5V 3.3V UNPOPULATED
C4 C5
21 R1
IC3 L1 R1=0OHM C
3 2 ONLY POPULATED
VIN VOUT IC1 FOR DP83815
C1 C2 + C3
GND C6 C7 RXAVDD PIN19
33 3.3V PINS
C23 C24 C25 + C26
1
9 27 85 125 137
C10 C11 C14 C15 C19 C21 C22

56/58

14.11 EasyLAN Wireless Interface Board

Description
This section describes how to install an EasyLAN Wireless network
interface in an EasyCoder PM4i printer and how to connect it to a LAN,
WAN, Intranet, or Internet network via a wireless connection.
The installation instructions describes how to physically install the
interface board in a printer. Configuration and setup are described in the
EasyLAN Wireless Kit, Installation Instructions and the Intermec EasyLAN,
User’s Guide on the attached CD-ROM.
This device is country/region specific and must be ordered for the
correct country/region. Use of this device in other regions than shown
on the device home page/test label may violate applicable law.
Dieses Gerät ist für ein bestimmtes Land bzw. eine bestimmte Region
vorgesehen und muss daher für das korrekte Land bzw. die korrekte
Region bestellt werden. Wenn dieses Gerät in anderen Regionen
benutzt wird (nicht in den Regionen, die auf der Startseite bzw. dem
Prüfetikett des Geräts angeführt sind), können die geltenden Gesetze
gebrochen werden.
Printer Firmware
The printer must either be fitted with Intermec Fingerprint v8.10 (or
later) or IPL v2.10 (or later). In Intermec Fingerprint, the network port is
addressed as device "net1:" (communication channel #5).
Installation Kit
The EasyLAN Interface Kit contains:
• One EasyLAN adapter board complete with radio module fitted
• Rear plate (for EasyCoder PF2/4i-series printers only)
• RJ-45 plug (for EasyCoder PM4i only)
• One light guide
• One hexagonal threaded spacer
• One antenna extension cable
• One antenna
• One cable clip
• One cable tie
• One CD-ROM with software and manuals
The only tools required for the installation are #T10 and #T20 Torx
screwdrivers and a small wrench.

Installation Instructions
1 Switch off the printer and disconnect the power cord.
2 Disconnect all communication cables.
4 Remove any present EasyLAN Ethernet interface including cables etc.
Fit the RJ-45 plug included in the kit into the square hole left by the
RJ-45 Ethernet connector.
5 Remove the antenna plug, which is snap-locked into the rear plate.
6 Connect the antenna cable to the radio module, which is factory-fitted

on the EasyLAN adapter board, as illustrated below. Support the upper
edge of the radio module with a finger while connecting the cable.
Adapter board
Connect antenna
cable here
Radio module
7 Remove the #T20 Torx screw that holds the upper/front part of the
CPU board to the power supply unit and replace it with the hexagonal
spacer included in the kit. Keep the screw.
8 Connect the EasyLAN adapter board to the PCI connector (J84) on the
CPU board so the hole in the board becomes aligned with the spacer
and secure the board with the #T20 Torx screw.
9 Route the antenna cable over the SIMMs on the CPU board towards
the rear plate and secure it using the cable clips included in the kit.
One clip is factory-fitted on the EasyLAN adapter board and the
other should be fitted in the small hole at the top of the CPU board
immediately to the rear of the memory SIMM sockets.
10 From the inside of the electronics compartment, insert the antenna
connector through the round hole in the rear plate and lock it with the
washer and nut on the outside.

11 Fit the antenna to the connector of the antenna cable and bend the
hinge so the antenna points straight up.
12 From the outside, insert the thin end of the light guide through the
small hole next to the antenna on the rear plate. Press the clear plastic
“lamp” in place. Connect the other end to the black plastic socket (D1)
at the top of the EasyLAN adapter board. Secure it with the cable tie
through the hole at the upper edge of the CPU board.
13 Put back the front/left-hand cover. Route the cable from the display
unit above the ribbon motor. Connect the cable to connector J50 at the
upper front corner of the CPU board.
15 Enter the Setup Mode and print the test label “Hardware Info” in
Fingerprint or “HW” in IPL to see if the printer detects the EasyLAN
Wireless interface board. For information on how to enter the Setup
Mode and print test labels, refer to the User’s Guide for the printer in
question.
16 Set up the network parameters. There are several methods:
- Connect the printer and a PC and run the EasyLAN Network Setup
wizard, which can be found on the attched CD-ROM. Requires a PC
running Windows 98 or later.
- Insert a CompactFlash Card containing a configuration file in the
printer and start it up. Configuration Compact Flash cards can be
created using the EasyLAN Network Setup wizard on the attached
CD-ROM.
- Fingerprint:
Establish an RS-232 communication with the printer and set it up
using Fingerprint setup strings or setup files. IP address, netmask,
default router, and name server can also be set using the printer’s
built-in keyboard. Only requirement on the PC side is a terminal
program that can transmit and receive ASCII characters on an RS-
232 line. See EasyLAN Wireless Kit, Installation Instructions.
- IPL:
Establish an RS-232 communication with the printer and set it up
using IPL commands. Only requirement on the PC side is a terminal
program that can transmit and receive ASCII characters on an RS-
232 line. Select the method of obtaining IP address, netmask, default
router, and name server automatically from the server using the
printer’s built-in keyboard. This requires a server that supports DHCP
and/or BOOTP. See EasyLAN Wireless Kit, Installation Instructions.

Cable tie Cable clips Light guide #T20 Torx screw

Antenna and spacer
cable
EasyLAN
adapter board
Antenna
Antenna
(packed separately when the EasyLAN Wireless
interface is factory-installed)

Components
D1 C11
C11
R28
R28
C12
C12
R7
R6
R5
R9
R4
R8
R7
R6
R5
R9
R4
R8
R29
R29
IC2
IC2
R30
R30
R27
R27 R26
R26 C5
C5
C1
C1
R19
R18
R20
R21
R22
R23
R25
R24
R19
R18
R20
R21
R22
R23
R25
R24
C2
C2
C9
C9 C6
C6
J1
C10
C10
IC1
IC1
Y1
Y1
R1
R1
R2
R2
C7
C7
C3
C3
C4
C4
C8
C8
R12
R12 R17
R17
R15
R15 R11
R11
1
R13
R13 R14
R14 R16
R16
2 4 124
J2
J2
1 3 123
L1
Primary Side Secondary Side
1-971646-26 Adapter Board

Schematics
PRINTER PCI INTERFACE MINI-PCI INTERFACE
PCI_AD(31..0)
5V
0 1 PCI_AD0 PCI_AD1 41 1 3.3V 3.3V

2 VSS1 PCI_AD2 42 2
3 3 PCI_AD3 VCC1 43
4
6
4
5
6
PCI_AD4
PCI_AD6
PCI_AD5
PCI_AD7
44
45
46
5
7
CBE0_N
J2
VSS2 PCI_CBE_N0 1 2
8 7 PCI_AD8 VCC2 47 3 4
9 8 PCI_AD9 PCI_AD10 48 10 5 6
11 9 PCI_AD11 PCI_AD12 49 12 7 8
10 VSS3 PCI_AD13 50 13 9 10
14 11 PCI_AD14 VCC3 51 LED1_GRNP 11 12 LED2_YELP 5V
15 12 PCI_AD15 PCI_CBE_N1 52 CBE1_N LED1_GRNN 13 14 LED2_YELN
PAR 13 PCI_PAR PCI_SERR_N 53 SERR_N 15 16
14 VSS4 PCI_PERR_N 54 PERR_N 17 18
15 PCI_LOCK_N VCC4 55 19 20 INT_N
STOP_N 16 PCI_STOP_N PCI_DEVSEL_N 56 DEVSEL_N 21 22
TRDY_N 17 PCI_TRDY_N PCI_IRDY_N 57 IRDY_N C 23 24
18 VSS5 PCI_FRAME_N 58 FRAME_N CLK2 25 26 RST_N
CBE2_N
16
19
20
PCI_CBE_N2
PCI_AD16
J1 VCC5
PCI_AD17
59
60 17 REQ_N
27
29
28
30 GNT_N
18 21 PCI_AD18 PCI_AD19 61 19 31 32
22 VSS6 PCI_AD20 62 20 31 33 34
21 23 PCI_AD21 VCC6 63 29 35 36
22 24 PCI_AD22 PCI_AD23 64 23 37 38 30
CBE3_N 25 PCI_CBE_N3 PCI_AD24 65 24 27 39 40
26 VSS7 PCI_AD25 66 25 25 41 42 28
26 27 PCI_AD26 VCC7 67 43 44 26
27 28 PCI_AD27 PCI_AD28 68 28 CBE3_N 45 46 24
29 29 PCI_AD29 PCI_AD30 69 30 23 47 48 11
30 VSS8 PCI_AD31 70 31 49 50
REQ_N 31 PCI_REQ_N0 VCC8 71 21 51 52 22
GNT_N 32 PCI_GNT_N0 PCI_CLK 72 CLK1 19 53 54 20
INT_N 33 PCI_INT_N PCI_REQ_N2 73 55 56 PAR
34 VSS9 PCI_RST_N 74 RST_N 17 57 58 18
35 TCK VCC9 75 CBE2_N 59 60 16
36 TMS NC1 76 IRDY_N 61 62
37 TDO SCL 77 63 64 FRAME_N
38 VSS10 SDA 78 CLKRUN_N 65 66 TRDY_N
39 TDI PCI_DET_N 79 SERR_N 67 68 STOP_N
40 TRST_N 24V 80 69 70
PERR_N 71 72 DEVSEL_N
CBE1_N 73 74
14 75 76 15
77 78 13
12 79 80 11
10 81 82
83 84 9
8 85 86 CBE0_N
5V 3.3V 7 87 88
89 90 6
IC1 5V 5 4
91 92
3 2 93 94 2
VIN VOUT
+ C1 C2 C3 + C4 3 95 96 0
GND 97 98
1 99 100
101 102
1
AC_SYNC 103 104

AC RETURN PATHS 105 106 AC_SDATA_OUT
FOR PCI SIGNALS AC_BIT_CLK 107 108 AC_CODEC_ID0_N
CROSSING 5V TO 3.3V AC_CODEC_ID1_N 109 110 AC_RESET_N
BOUNDARY 111 112
113 114
115 116
5V 3.3V 117 118
3.3V
C5 119 120
121 122
123 124
C6
4
Y1 MTG1
VCC R1 MTG2
CLK1
C9 C10 C7
32.768MHZ
1 EN/NC OUT 3
GND R2 CLK2 C8 C
2
LED BLINK ONE-SHOT CIRCUIT
LED_LINKP
3.3V
COLOR SWITCH
RESISTORS R29 LED_ACTP LED_LINKP R7
SOURCE SIDE
LED_ACTP R4 R8
5V
R18
IC2
LED2_YELP
2
1
C11 AHCT123
R19 + 14 D1
R26 GREEN/YELLOW
CEXT
R20 R28 15
REXT/CEXT
3
4
LED1_GRNP R21 1 13
A Q R9 R5
LED_ACTN
2
B 4 LED_LINKN R6
Q
3
CLR
LED1_GRNN R22
VCC=5V;GND=GND
R23 R27
R24 R26 OR R27

ONLY
R25 POPULATED ONLY IC2 OR
LED2_YELN IF IC2 R29 OR R30
POPULATED POPULATED
R30 LED_ACTN
COLOR SWITCH
RESISTORS
SINK SIDE
LED_LINKN
TERMINATION OF UNUSED
MINI-PCI SIGNALS
DECOUPLING IC2
3.3V
R11 UNUSED PART
AC_CODEC_ID0_N 5V
R12 C12
AC_CODEC_ID1_N IC2
CLKRUN_N R13 AHCT123
6
AC_SYNC R14 CEXT
7
AC_BIT_CLK R15 REXT/CEXT
9 5
R16 A Q
AC_SDATA_OUT DO NOT POPULATE
10
AC_RESET_N R17 L1 B 12
Q
11
CLR
VCC=5V;GND=GND
C
1-971646-26 Adapter Board

15 RFID
This chapter describes the various components included in Intermec RFID

kits for the EasyCoder PM4i printer.

Chapter 15—RFID
15.1 Key Components of Intermec RFID Kits

The various RFID kits available for the PM4i printer all contain the
following basic components:
• An antenna used to transmit RF signals between the RFID tag and
the reader module. The antenna is mounted in close vicinity to the
printhead, and is connected to the reader with a cable that runs from
the media compartment to the electronics compartment via a cavity in
the center deck.
• A reader module with RF transceiver that generates radio frequency
signals and receives RF transmissions from the RFID tag. Depending
on which reader type is used in the kit, the reader is mounted either
directly on the I/O board or on a separate bracket assembly in the
electronics compartment.
• An RFID I/O board which handles communication between the RFID
reader module and the main board. The RFID interface board occupies
one of the slots for optional interfaces at the back of the printer and
features an extra RS-232 serial interface.
Note: The RS-232 interface on the RFID I/O board can only be utilized
in printers running Fingerprint firmware. The interface is referred to as
“uart2:”, “uart3:”, etc. depending on which slot is used and what other
optional interfaces are installed.
RFID Reader Module
RFID I/O
Board Antenna
Antenna Cable
Main Components of an RFID Kit
The following sections describe how to replace and service the individual
parts of the RFID kits. For more detailed information and illustrations of
the different steps involved, refer to the documents listed in the next table.

Chapter 15—RFID
RFID related documentation

Document Title Part Number
RFID Kit for the EasyCoder PM4i Installation Instructions 931-041-xxx
RFID Kit for the EasyCoder PM4i User’s Guide 934-008-xxx
RFID Kit (Class 1, 915 MHz) Installation Instructions 1-960650-xx
RFID Kit (Gen 2, 869&915 MHz) Installation Instructions 1-960654-xx
Replacing the Antenna

To prevent damage, handle the radio module delicately and be careful
when attaching or detaching the antenna cable.
Zur Vermeidung von Schäden das Funkmodul sorgsam behandeln und
das Antennenkabel nur vorsichtig anbringen bzw. abtrennen.
There are currently two types of RFID antenna installations:
• Type 1: Antenna is fitted underneath the lower media guide.
Antenna installed under lower media guide.

• Type 2: Antenna is installed as part of a replacement upper media guide.
RFID Antenna

Chapter 15—RFID
To replace the antenna (Type 1)

1 Disconnect the power cord and open the electronics compartment, see
Section 3.2.
2 Detach the antenna cable from the radio module.
The antenna is fitted underneath the lower media guide in the media
compartment.
3 Remove the screw which holds the antenna to the center deck.
4 Pry the antenna loose, and proceed by carefully pulling the antenna
cable out of the electronics compartment through the hole in the center
deck.
5 Take the cable end of your replacement antenna, and feed it through
the opening in the center deck. This operation can be facilitated by
laying the printer down on its left side (to prevent damage to electrical
components, be sure to put back the metal chassis prior to this).
6 In the electronics compartment, connect the antenna to the upper
contact on the radio module.
7 Put back the cover over the electronics compartment. Follow the
procedure as described in Section 3.2.
To replace the antenna (Type 2)

Section 3.2.
2 Detach the antenna cable from the radio module.
The antenna is fitted in a slot in the upper media guide.
3 Carefully slide the upper media guide out along the support shaft.
Loosen the edge guide and remove both items from the shaft.
4 Carefully pull the antenna cable out of the electronics compartment
through the hole in the center deck.
Take out your replacement upper media guide (with antenna).
5 Route the antenna connection cable through the opening in the center
deck. Slide the antenna assembly and the edge guide onto the shaft.
6 In the electronics compartment, connect the antenna to the upper
contact on the radio module.
7 Put back the cover over the electronics compartment. Follow the
procedure as described in Section 3.2.
Replacing the Dual Slot I/O Bus Cable (“Flat Cable”)
This procedure is described in section 14.5 (“Installing an Optional
Interface Board”).

Chapter 15—RFID
Replacing the Radio Module

There are currently two types of radio module installations:
• Type 1: Radio module is the “PC-Card” type installed directly on the
RFID I/O board.
Radio module installed directly on I/O board.

• Type 2: Radio module is installed on a bracket assembly in the middle
of the electronics compartment.
Radio module installed on brackets.
To replace the radio module (type 1)

Section 3.2.

Chapter 15—RFID
RFID Card
Jumpers J5-J9 in
“upper” or “lower”
position
2 Remove the old radio module, and slide the new one in place. The label
should be facing outward.
3 Make sure jumpers J5-J9 are set to their correct position (modifying
jumper positions is not necessary if, for example, a faulty unit is
replaced with a unit of the same model). Refer to section 14.8 for more
information on this issue.
To replace the radio module (type 2)

Section 3.2.
2 Disconnect all cables (adapter, data and power) from the radio module.
3 Remove the three screws that hold the module to the horizontal and
vertical brackets. Lift the module off the brackets.
4 Put the new module in place, connect the cables and attach the screws.
Upgrading the Radio Module’s Firmware
Note: This procedure applies only to PC Card RFID modules (described
as Type 1 in preceding section).
To upgrade the firmware

1 Remove the radio module from the RFID serial interface board as
described above.
2 Download the latest firmware version from the Intermec Global Services
& Support web site to a computer equipped with a PCMCIA slot.
Insert the Radio Module in the slot and install the new firmware.

Chapter 15—RFID
Replacing the RFID Serial Interface Board

Please refer to section 14.5 (“Installing an Optional Interface Board”) for
information on how to replace this part.
15.2 Verifying RFID functionality

Once a part (or parts) have been replaced, it is important to verify that the
RFID-equipped printer works properly before put into active use.
Recommendations for Printers Running Fingerprint
Turn on the printer and set RFID > ENABLE either via the
Setup menu, the web page or by using the command SETUP
“RFID,MODE,ENABLE”. Print an RFID test label to make sure the
printer can communicate with the RFID tag.
To print an RFID test label

1 Load the printer with RFID media.
2 Press Setup.
3 Navigate to PRINT DEFS > TESTPRINT > RFID TEST LABEL.
4 Press Enter. The test label prints.
Recommendations for Printers Running IPL
Turn on the printer and set RFID > ENABLE either via the Setup menu,
the web page or by using the command <STX><SI>J1<ETX>. Raise and
lower the printhead, and then perform a Tagread operation. If successful,
the printer will return the contents of the current RFID tag.
To perform a Tagread
1 Load the printer with RFID media.
2 Press Setup.
3 Navigate to RFID > TAGREAD.
4 Press Enter. The printer reads and returns the content of the current
RFID tag.

Chapter 15—RFID

16 Troubleshooting
This chapter explains how to diagnose and fix problems that may occur in
an EasyCoder PM4i printer, even if great effort has been made to ensure
problem-free printing. Some parts are, however, subject to wear and may
need periodical replacement, such as the printhead.
Please note that replacement parts are generally only available as complete
modules (see the Spare Parts Catalog or Spare Parts List).
This chapter is supplemented by the Technical Bulletins that are
distributed as soon as any new problem has been reported and a remedy
has been found.

Chapter 16—Troubleshooting
16.1 Diagnosing
To diagnose the printer for faults, take steps in the following order:
1 In case the printer is running the Intermec Fingerprint firmware, use
Intermec Shell to check printer’s setup and functions. Intermec Shell
can be accessed regardless of any running autoexec.bat files as described
below.
2 Browse through the remainder of this chapter to find symptoms that
apply to the faulty printer.
3 Refer to the Printer Technical Bulletins for updated information.
Fingerprint only
The keyboard, display messages, sounds, and other functions will be
custom-configured, if a custom-made program is running in the printer.
Normally, such a program is started at power-on using an autoexec.bat file.
The procedure of starting up Intermec Shell, bypassing any other autoexec.
bat files the printer’s memory, is called the Test Mode. In fact, the Test
Mode is just a convenient way of accessing Intermec Shell and, via
Intermec Shell, also the Setup Mode.
Note: Any changes done in the Test Mode will remain after leaving the
Test Mode.
To enter Intermec Shell in Test mode

3 Press any key on the printer’s built-in keyboard, with the exception of
<Shift>, and keep on pressing it.
4 Switch on the power.
5 The printer will start the initialization procedure.
6 Release the key.
7 The printer will start up Intermec Shell.
8 Press <Enter> before the 5 sec. countdown is completed.
Inside Intermec Shell you have a variety of options, for example:
• Enter the Setup Mode to check or change the setup. Before changing
the setup, you should print out or write down the settings so you can
restore them before returning the printer.
• Make a printout of the present setup values.
• Perform testfeed operations.
• Print test labels to check the printout quality.
• Reset all setup values to default. Before resetting the setup, you should
print out or write down the settings so you can restore them before
returning the printer.
• Enter Intermec Fingerprint, for example to check what files the printer’s
memory contains or to list files.

• Restart the printer and exit Test Mode.

Refer to the Intermec Shell Overview in Appendix 1 or in the User’s
Guide.
If the printer works normally in the Test Mode, it is likely that the
malfunction is either due to communication problems, abnormal
conditions at the site of operation, or a custom-made program.
Fingerprint and IPL
Use this list to find the symptom that applies to the printer:
Symptom See Section
• No reaction at power up 16.2
• Printer stops working after startup 16.3
• CPU board failures 16.4
• Power supply unit failures 16.5
• Console errors 16.6
• Error messages 16.7
• No communication (general) 16.8
• No serial communication 16.9
• Network communication troubles 16.10
• Sensor malfunctions 16.11
- Label stop sensor
- Headlift sensor
- Label taken sensor
- Ribbon end sensor
• Printing troubles 16.12
- No printout at all
- Overall weak printout
- Weaker printout on either inner or other part of label
- Overall dark printout (bleeding)
- Weak or missing printout of some dots
- Unexpected black printout (completely or partially)
- Only first part of label printed
- Media feed does not work properly
- Printing is slow and halted inbetween labels
• Ribbon troubles 16.13
- Transfer ribbon breaks
- Transfer ribbon wrinkles
- No transfer printout
• Liner takeup troubles 16.14
• Memory card troubles 16.15
• Paper cutter troubles 16.16
• RFID troubles 16.17

16.2 No Reaction at Power Up

Description:
There is no visible reaction when the power to the printer is switched on.
• The Power LED does not light up.
• There is no text in the display window.
Possible Causes and Suggested Remedies:
• No power in AC wall socket.
- Check with some other electrical device or a voltage meter.
• Power cord connectors not completely inserted in printer’s power cord
receptacle or in wall socket.
- Disconnect and firmly connect both ends of power cord. Try again.
• Faulty power cord.
- Replace and try again.
• Cable between CPU board and power supply not properly connected.
- Test as described in Section 16.5 using test points on CPU board (see
Section 13.5).
• Power Supply overload.
- Too high a temperature in the power supply unit. Leave the power
on and wait for the power supply to cool off (may take up to half
an hour). When the temperature returns to normal, the printer will
automatically restart. If the error persists, examine the power supply
as described in Section 16.5.
• Faulty power supply unit.
- Refer to Section 16.5.
• Faulty console unit.
• Wrong type of printhead fitted (designed for EasyCoder F-series)
causing a short-circuits because of different cablings.
- Check part number and label on printhead. If wrong type, replace
with a correct one.
- If the printer still refuses to start up, check if fuse F70 on the CPU
board has blown. Normally, this condition is very unlikely to
happen and no harm should be done to either the electronics or the
printhead.

16.3 Printer Stops Working After Startup

Description:
The printer stops working after a successful startup.
• The Power LED is lit.
• The <Feed>, <Setup>, and <Print> keys, work properly.
• Communication problems?
- Refer to Sections 16.8-16.10.
• Printer malfunction?
- Check if the printer can print test labels in the Test Mode.
Description:
• The Power LED is lit.
• There is no reaction on software commands.
• There is no reaction on any keys on the printer’s keyboard.
• The printer’s main program has halted due to high external disturbances
from other electrical sources.
- Restart the printer and find out if there are disturbances coming via
the 115/230 VAC supply, via a communication channel, or from
other electrical appliances.
• CPU board failures.
• Power Supply Unit failures.
• Console errors.
Description:
• The Power LED is not lit.
• Error in the supply of AC power to the printer.
• Faulty console, faulty power LED, or faulty cabling between CPU
board and console.

16.4 CPU Board Failures

Description:
The power LED is lit, but the printer has one of the following faults:
• The printer refuses to start.
• The program execution is halted.
• The stepper motor does not work.
• At startup, the message “Starting” is displayed followed by the message
“Timed Out.”
• Flash or SDRAM SIMMs not properly fitted.
- A SIMM is not fully inserted in its socket. Remove all SIMMs and fit
them back again, making sure they are being firmly held by the snap-
locks.
• No Boot Flash SIMM in socket J20.
- A Flash SIMM containing a boot sector must be fitted in socket J20,
or the printer will not start.
• Fluttering voltages.
- Check voltages on the CPU board test points, see Section 13.4. If a
voltage flutters with an interval of approximately one second, there
may be a short-circuit on the CPU board. If a voltage is missing,
there is probably an error in the power supply unit, see Section 16.5.
• Startup error.
- Execution of the initial boot sequence can be checked as described
in Section 13.5. If the execution stops prematurely, try changing to a
Flash SIMM that works in another printer. If that does not help, note
where the startup sequence is halted and contact Intermec’s Printer
Product Support dept.
- If there is no reaction neither on the display nor on the serial channel,
there is a major error on the CPU board. Check the Flash and
SDRAM SIMMs by installing them in another printer. Inspect
the CPU board visually in the area of the processor (U13) and the
support chip (U30). If no obvious fault is detected, replace the CPU
board.

16.5 Power Supply Unit Failures

Description:
The printer refuses to print.
• The message “Temperature high please wait”(FP) or “Printhead hot”
(IPL) appears in the display window.
The power supply unit contains wires and circuits with dangerous
voltages. For safety reasons, it is strictly forbidden to try to repair a
power supply unit or to replace a blown fuse. Whenever a fuse blows,
always replace the entire power supply unit.
Das Netzteilmodul enthält Kabel und Schaltkreise, die gefährliche
Spannungen führen. Aus Sicherheitsgründen ist es streng untersagt,
ein Netzteilmodul zu reparieren oder eine durchgebrannte Sicherung
auszutauschen. Falls eine Sicherung durchbrennt, muss das gesamte
Netzteilmodul ausgetauscht werden.
• Power Failure Interrupt signal activated because of a Power Supply
overload.
- The power supply unit is overheated, due to extreme ambient
temperatures (possibly in connection with large black areas in the
print image, high speed printing, and media that require a high
energy level), which triggers the automatic overheating protection
switch.
Leave the power on and wait for the power supply to cool down (may
take up to half an hour). When the temperature returns to normal,
the printer will automatically restart. If the error persists, examine the
power supply (also see Chapter 12).
Description:
The printer stops working or functions are unstable.
• The power LED is unstable, weak or not lit.
• Stepper motor does not run.
• No or very weak printout.
• Wrong or missing voltages from power supply.
- Check voltages using the test points on the CPU board (see Section
13.4).
- Check the cable between the power supply unit and the CPU board.
If the cable is OK, replace the power supply unit.
- Blown fuse in power supply. Replace the entire power supply unit (see
“Warning” notice).
- Stepper motor driver damaged because the platen roller has been
manually rotated while power was on. Replace PSU.

16.6 Console Errors

Description:
The complete console is “dead”.
• Power LED is not lit.
• Green background lighting in display window is not lit.
• The 5V on the CPU board is OK (see Section 13.4).
• Defective cable.
- The cable between the CPU board and the console pcb. may be
defective or not properly connected. Check cable and connector J50
on CPU board.
• Defective console pcb.
- Replace. Do not attempt to repair.
Description:
No keys on the keyboard seem to be working or no keybeep.
• Power LED is lit.
• Green background lighting in display window is lit.
• Bad connection between keypad and console pcb.
- Check connections on the two flat cables between the keypad and
connectors P2 and P3 on console pcb.
• Keys disabled or keyboard remapped by a custom-made program
(Fingerprint only).
- If the printer does not respond to any keys in the Test Mode, the
keyboard is defective and needs to be replaced.
• Keybeep disabled by a custom-made program (Fingerprint only).
- If no beep is heard when the keys are pressed in the Test Mode, but
the printer nevertheless responds to the keys, the beeper is out of
order.
• Keyboard damaged by moisture.
- Soaking the keyboard with, for example, water or cleaning fluids, may
cause short-circuits. Let it dry, replace if necessary.

Description:
No messages appear in the display window after power-up.
• Power LED is lit.
• Green background lighting in display window is lit.
• Display not utilized by custom-made program (Fingerprint only).
- If there is no display function in the Test Mode, the display is out of
order and the console unit needs to be replaced. Else, check out the
custom-made program.

16.7 Error Messages

Description:
An error message appears in the display window or is returned via a serial
port.
• The printer stops functioning.
• The Error LED is usually lit.
• Consult the Intermec Fingerprint v8.xx, Programmer’s Reference Manual
or IPL Programming, Reference Manual for the meaning of the different
error codes and use that information to correct the error.
Depending on the firmware, printer’s mode, or running program, there are
different ways of giving the error message.
Immediate Mode (Fingerprint only)
• The firmware can detect and return three error conditions, provided the
printhead is lowered and a media feed is executed.
- Error 1005 (“Out of paper”)
- Error 1027 (“Out of transfer ribbon”)
- Error 1031 (“Next label not found”)
Programming Mode (Fingerprint only)
• At every erroneous instruction during programming, the printer
transmits an error code on the selected standard OUT channel (serial
communication only), provided the verbosity is not disabled. The same
applies if programming errors are detected when the program is run.
• When a program is executed, the same errors as in the Immediate
Mode will be detected. The execution stops and an error message is
transmitted. It is recommended to include some kind of error handler in
any custom-made application program, for example ERRHAND.PRG.
Intermec Direct Protocol (Fingerprint only)
• Six error conditions can be detected. Note that by default verbosity is
off in the Intermec Direct Protocol.
- Error 1005 (“Out of paper”)
- Error 1006 (“No field to print”)
- Error 1022 (“Head lifted”)
- Error 1027 (“Out of transfer ribbon”)
- Error 1031 (“Next label not found”)
- Error 1606 (“Testfeed not done”)
The Intermec Direct Protocol has a programmable error-handler. Refer
to the Intermec Direct Protocol v8.xx, Programmer’s Reference Manual.

IPL only
• Six possible errors are indicated by messages in the display window:
- Printhead hot (Printhead over-temperature)
- Paused (Empty/paused)
- Paper out (Out of media)
- Ribbon out (Out of transfer ribbon
- Print head UP/Press Feed (Printhead lifted)
- Open&shut cutter (Cutter error)
Some additional errors can be returned to the host as an ASCII number by
the <BEL> command, see IPL Programming, Reference Manual.
Firmware Error
• In case the CPU is unable to access data on a given address, the internal
program will light up the red error LED regardless of any error-handling
program.

16.8 No Communication (general)

Description:
The following actions are valid for all communication interfaces installed
in the printer.
• Defective cable between printer and host.
- Check that the communication cable is correctly inserted and that it
is of the correct type and is correctly configured.
- Check that any clips or ground screws are properly engaged.
- Inspect cable for physical damage.
- Disconnect and connect the cable a few times to rub off possible
oxide from the connectors.
- Try using another identical cable.
• Defective cable between interface board and CPU board. This does not
apply to the serial port ("uart1:"), the USB port, or any EasyLAN board
which all are fitted directly on the CPU board.
- Check that the cable is connected correctly.
- Inspect cable for physical damage.
- Disconnect and connect the cable a few times to rub off possible
oxide from the connectors.
- Replace the cable.
• Error in host.
- Try connecting the printer to another host computer.
• Erroneous data.
- If using Fingerprint, check if the data string contains the correct
characters using the Line Analyzer program included in Intermec
Shell (see the User’s Guide).

16.9 No Serial Communication

Description:
The following actions are valid for the standard serial interface ("uart1:")
fitted on the CPU board and to some extent also to any other serial
interfaces on optional interface boards. Also see Section 16.8.
• Communication setup mismatch.
- Press the <i/F5> key or enter the Setup Mode to check that the
printer and host are set for the same communication parameters,
such as baud rate, parity, character length, stopbits, new line and
handshaking. It is stongly recommended to use some kind of
handshaking, for example XON/XOFF or RTS/CTS.
• Damaged RS-232 driver circuit.
- With the aid of an oscilloscope, or some kind of line analyzer (“break-
out box”), verify that the interface signals to and from the CPU board are
correct. The RS-232 driver (U61) could have been damaged as a result of
voltage transients from the interface, necessitating the CPU board to be
replaced. Repeated damage is an indication of insufficient cable screening,
or the electrical environment being too noisy.
• Circuits or straps on an optional interface board missing or fitted
incorrectly.
- See configuration instructions in Chapter 14.
• No supply voltage.
- Verify that the +3.3VDC and +5VDC voltages are present (see
Section 13.4).
• No external +5VDC.
- The printer supplies max. 500 mA. The current is automatically
switched off at higher loads. Check the consumption of the
connected device.
- The switch (RP60 on the CPU board; IC9 on the Industrial Interface
Board and the Double Serial Interface Board) may be out of range
and need to be replaced.
• Too long communication cables.
- RS-232 max. 10-15 m (33-49 ft).
- RS-422 max. 1,200 m (4,000 ft).
- RS-485 max. 1,200 m (4,000 ft).
- Current Loop max. 500 m (1,500 ft).
• Input buffer on host overflow.

- The input buffer should normally be handled by the software of the

host. Increase the receive buffer in the printer to a large value, restart
the host to empty its input buffer and try again.
• No response from printer when a custom-made program is run
(Fingerprint only).
- The verbosity can be controlled using the Fingerprint instructions
VERBON/VERBOFF and SYSVAR(18). In the Intermec Direct
Protocol, verbosity is disabled by default. Check the program for
instructions that affect the verbosity.
- Verify that the correct communication port is selected as standard
IN/OUT channel.

16.10 Network Communication Troubles

This section applies both to EasyLAN Ethernet and EasyLAN Wireless
communication between a printer and a local area network. It does not
cover general network troubles in other types of equipment, such as wiring,
access points, routers, switches, servers, etc. It is assumed that the network
is in good working order, that is, other devices connected to the network
works well and the trouble can be pinpointed to the printer.
Description:
The printer cannot communicate with the network after the network
interface has been installed.
• Defect interface board or bad connection between interface board and
CPU board.
- Print a Hardware test label in the Setup Mode to see if the printer
recognizes the interface board. Also check if the Network node is
shown in the Setup Mode. If not, switch off the power, disconnect
the interface board, clean the connectors, and connect the interface
again. Switch on the power. Print a new Hardware test label. If the
troubles remains, replace the interface board.
Wireless only: Also check visually that the radio module is properly
connected to the adapter board. If the radio module is not connected
properly, the Network node will be displayed in the Setup Mode
but the wireless interface will not be recognized on the hardware test
label.
• Bad internal cabling.
- Ethernet only: Check that the network extension cable is properly
connected to the interface board. Visually check the cable for breaks
or shavings.
- Wireless only: Check that the antenna cable is properly connected to
the connection point marked “MAIN” on the radio module. Visually
check the cable for breaks or shavings.
Check that the antenna is properly connected and is pointing straight
up.
• Bad connection between printer and an Ethernet network
- Check the network LED indicator at the back of the printer. There
should be a green light flashing occasionally showing network activity
or a solid yellow background light if connected to a 100 Mbps
network. Note that there is no background light indication provided
for 10 Mbps wired networks.
- Check that the network cable is connected correctly to the network
wall socket, hub, or similar and to the RJ-45 socket on the printer’s
rear plate.

- Check that the cable connecting to the network is not of "crossover"

type. Use a straight "pin to pin" cable to connect to a LAN, but use a
crossover cable to connect directly to a PC.
If you are trying to connect the printer directly to a PC via a crossover
network cable, you may need to disable the web browser’s proxy
settings on your computer to get in contact with the printer’s web
pages.
• Bad communication between printer and a Wireless network
- Check the network LED indicator at the back of the printer. There
should be a green light flashing occasionally showing network activity,
or a solid yellow background light if the network card is associated
with an access point, or flashing yellow light if the network card is
searching for an access point.
- Press the <i> key on the printer’s front panel and browse to the
network information. There you can see the present signal strength
and channel. If both are 0, the network card is not associated with
any access point and/or the WLAN settings are wrong.
- Check if the access point is on.
- Check if the access point lists the MAC address of the network card.
- Check if other devices associated with this access point are working.
- Inspect the location and see if there is any reason why the radio
transmission between printer and access point is prevented, such
as shielding objects like walls, shelves, fork lifts, metal grids, etc.
Sometimes, just moving the printer around a little may help.
For demanding applications, Intermec offers a series of high gain
antennas that can replace the standard antenna.
- Check SSID settings.
- Check WEP settings. Note that you must have the same WEP key
settings in both the printer and the access point in regard of both the
content of the WEP keys and the order of the WEP keys. However,
you can have one active WEP key selected in the printer and another
in the access point.
- Check the region setting, which can be found on the Network Info
test label.
Description:
The printer cannot communicate with the network.
• Bad IP Settings in printer
- Use a PC connected to the same network as the printer. First of all
verify the network configuration of the printer as described in the
Installation Instructions provided with the kit.

PC Settings
You should verify that the PC has a working connection to the
network. Do this by opening a Command Prompt and type the
command that corresponds to your operating system:
- For Windows 95, 98 and ME, use the command WINIPCFG.
- For Windows NT4, 2000 and XP, use the command IPCONFIG.
The PC will show a table with its configuration containing the
settings for IP-address, Subnet Mask and Default Gateway. Verify
these settings to be sure that the computer is correctly configured to
access your network.
Printer Settings
Check the IP address of the printer. Press the <i> key on the printer’s
keyboard and use the <W> and <X> keys to browse to the IP address.
In Fingerprint, a prerequisite is that the standard IN port is set either
to "auto" or "net1:", which can be done using Intermec Shell.
Another method is using the Setup Mode:
Press the <Setup> key, on the printer’s internal keyboard, and step
your way to “NETWORK” using the <X> key.
By pressing <Enter> on the printer, you can step through the
configuration to verify the settings.
Press <Setup> to exit the Setup Mode.
More information about configuration settings can be obtained by
printing a test label.
Also check on the printer’s home page (Configuration [TCP/IP]) that
the net1 TCP Port Number is correct (default 9100).
Verifying IP Address
In the User’s Guide of the printer, you will find information on how
to print test labels in the chapter “Setting Up the Printer”. Print the
network test label and find the IP Address field. If the IP address is set
to 0.0.0.0, the network card has not received a IP address. Verify the
IP SELECTION setting under the NETWORK menu in the Setup
Mode. See the Installation Instructions for information on various
methods for setting the IP address automatically or manually.
Verifying Subnet Mask
Check subnet mask of PC and printer and make sure they belong to
the same segment. For example:
If they have the subnet mask The numbers in the PC and Printer IP
addresses have to be
255.255.255.0 <Same>.<Same >.<Same >.<Any >
255.255.0.0 <Same>.<Same >.<Any >.<Any >
255.0.0.0 <Same>.<Any >.<Any >.<Any >
Other subnet masks Contact the network administrator

In case the addresses are not in the same network segment, the
printer may not be reachable from the LAN side. Check the configu-
ration with the administrator.
Pinging the Printer
Start the Command Prompt. In the Command Prompt, type Ping
<printer IP-Address> and then click OK.
This command sends an echo command to the EasyLAN to check
if the PC and the printer can reach each other through the network.
The following figure shows a correct response to the Ping command.
The first reply to the first Ping command often takes more time than
the following. This is a normal behavior. The first time the Ping
command is executed, the PC needs some extra time to perform
a “discovery” of the network address (ARP request). The Ping
command makes the printer’s network LED flash green.
If you have completed the test procedure and all the conditions are
met, but you do not get any answer to the Ping command, then you
probably have a hardware problem.
Description:
The performance of a Wireless network connection ceases to work or the
performance deteriorates after having worked properly for some time after
installation.
• Bad radio connection between printer and access point.
- Either the printer or the access point has been moved after
installation or some kind of obstruction has come between printer
and access point. In principle, there should be a free line-of sight
between the access point and the antenna. There is also a distance
limit.
Check the signal strength.
- Check network test label for statistics.
- Try moving either the printer or the access point (or both) or
consider fitting a higher gain antenna.
• Slow response.
- Too many devices associated with the same access point.

16.11 Sensor Malfunctions

Label Stop Sensor (LSS)
Description:
Label (ticket) gap or black mark not detected by the label stop sensor (LSS)
or wrong amount of media feed.
• Lost or obsolete media feed data, for example after a headlift, change
of media, or replacement of the sensor.
- In Fingerprint, perform a TESTFEED operation, for example by
simultaneously pressing <Shift> and <Feed> or selecting the Testfeed
option in the Setup Mode.
- In IPL, adjust the media feed by pressing the Feed/Pause button.
• Bad LSS lateral alignment.
- Check that the gaps or marks actually pass between the upper and
lower parts the label stop sensor (lateral alignment), see Section 7.5.
- Check that both parts of the LSS are adjusted to the same lateral
position, see Section 7.5.
• Light path obstructed.
- Check that both the upper and lower sensors as well as the windows
in the upper and lower guide plates are clean and free from dust,
stuck labels, or other matters that may interfere with the path of light.
• Printer set for wrong media type.
- Set up the printer for the correct media type.
• Media feed detection using PRSTAT (Fingerprint only).
- PRSTAT AND 8 only checks for out-of-media conditions once as
opposed to the normal error checking (errors 1005 and 1031) that
checks for out-of-media conditions more or less continuously. Thus.
when using PRSTAT, a dark spot or a bad media angle can give an
incorrect out-of-media indication, especially when using tickets (w.
mark).
• Bad connection
- Check the LSS cables and make sure that they are correctly connected
to J54 and J55 on the CPU board, see Section 13.3.
• Faulty sensor or diode.
- Replace LSS as described in Section 7.5.
• CPU board not configured for the right type of printer.
- Reconfigure the CPU board as described in Section 13.8.

Headlift Sensor
Description:
• The printer does not work, although the printhead is lowered.
• Error condition 1022 “Head lifted” (FP) or “Print Head UP/Press Feed”
(IPL) is indicated at any attempt of printing a label.
• Headlift sensor blocked.
- Check the sensor for dust or foreign objects.
• Bad connection.
- Check that the sensor’s cable is connected to J58 on the CPU board.
Inspect cable for damage.
• Faulty sensor.
- Replace as described in Section 7.7.
Label Taken Sensor (LTS)
Description:
The label taken sensor (LTS) is not working properly.
• Intermec Fingerprint instruction missing.
- The LTS must either be enabled using an LTS& ON statement, or
the status of the LTS must be polled using a PRSTAT function in the
current Intermec Fingerprint program.
• IPL instruction missing.
- The self-strip mode must be enabled using the commands
<STX>R<ETX> and <STX><SI>t1<ETX>.
• Bad connection.
- Check that the LTS is correctly connected to J53 on the CPU board.
- Check that the cable between CPU board and sensor is not damaged.
• Dirty sensor.
- Make sure that the active parts of the sensor are not obstructed by
dust or foreign objects.
• Wrong LTS sensitivity.
- The sensitivity of the sensor’s receiver and the light intensity of the
sensor’s emitter are adjustable, see Section 9.3.
• Interference from sunlight or lamps.
- Shield the sensor from interfering light source.
• Defective sensor.
- If still no reaction, the sensor is probably defective. Replace.

Ribbon Sensor
Description:
The ribbon sensor is not working properly.
• Bad sensor adjustment (Fingerprint only).
- Adjust the sensor in the Setup Mode as described in Section 6.4.
• Bad connection or faulty sensor.
- Cable between the ribbon sensor and J56 on the CPU board
damaged or not correctly connected?
- Sensor blocked by dust or foreign material? Clean.
- Faulty ribbon sensor? Replace.
• Bad detection pattern inside ribbon supply bobbin.
- Check the black and silvery sector pattern at the inner end of the
ribbon supply bobbin for scratches or dust.
Paper Sensor (Fingerprint Only)
Description:
The ribbon sensor is not working properly.
• Bad sensor adjustment.
- Adjust the sensor in the Setup Mode.
• Bad connection or faulty sensor.
- Cable between the paper sensor and J57 on the CPU board damaged
or not correctly connected?
- Sensor blocked by dust or foreign matters? Clean.
- Faulty paper sensor? Replace.
• Bad detection pattern inside media supply bobbin.
- Check the black and silvery sector pattern at the inner end of the
media supply bobbin for scratches or dust.

16.12 Printing Troubles

The best way to start is to get an overall check of the printout quality by
printing a series of test labels in the Test Mode.
If you suspect a defective printhead, you can check it out using the
following Intermec Fingerprint instructions (see Intermec Fingerprint v8.xx,
Programmer’s Reference Manual):
• FUNCTEST$ ("HEAD")
• HEAD
• SYSVAR(21)
• SYSVAR(22)
Description:
No printout at all.
• Bad connection.
- Is the cable between the printhead and P5 on the Power Supply Unit
fitted correctly and not broken or otherwise damaged?
- Is the cable between the printhead and J40 on the CPU board fitted
correctly and not broken or otherwise damaged?
• Dirty printhead.
- Is the printhead clean? Residue from label adhesive, thermal paper
topcoating, or preprint ink prevents the printhead from functioning
correctly. Clean the printhead as described in the User’s Guide.
• Wrong type of direct thermal media.
- In case of direct thermal printing, verify that the media is intended
for direct thermal printing (not thermal transfer!) and of an approved
quality.
• Wrong type of thermal transfer ribbon.
- In case of thermal transfer printing, verify that the stock of ribbon is
of an approved quality.
• Transfer ribbon loaded incorrectly.
- Verify if the ribbon is laoded with the ink-coated side facing the
receiving face material. If not, reload the ribbon as described in the
User’s Guide.
• Transfer ribbon mechanism failure.
- See Section 16.13
• Wrong printhead voltage.
- Check that the printhead voltage +24VDC ±2V (see Section 13.4).
If the power on the CPU board is OK, but the trouble remains,
disconnect the power cable on the inner side of the printhead and use
probes to measure the voltage during printing between two adjacent
lines in the socket (see Section 12.4, connector P5 for schematics).

• Wrong printhead pressure.

- Check that the printhead is pressing against the media with a
sufficient force, see Section 7.8.
• Headlift sensor out of order.
- Check the headlift sensor as described in Section 16.11.
Description:
Overall weak printout.
• Various reasons.
- Check as for “No printout at all”.
• Wrong Contrast/Darkness setup.
- Check setup for extremely low value.
• Wrong Paper Type/Media Sensitivity setup.
- Verify that setup matches the direct thermal media or the
combination of transfer ribbon and media.
- Measure the +24VDC on the CPU board, see Section 13.4.
• Printhead pressure too low.
- Adjust as described in Section 7.8.
Description:
Weaker printout on either inner or outer part of label.
• Bad printhead pressure alignment.
- Adjust the position of the headlift arm as described in Section 7.8.
Description:
Overall too dark printout (bleeding). Too dark a printout is particularly
troublesome when printing compact bar codes, in which case spaces
between the bars become less distinctive, and consequently less readable.
• Wrong Contrast/Darkness setup.
- Check Contrast/Darkness setup for extremely high value.
• Wrong Paper Type/Media Sensitivity setup.
- Verify that setup matches the direct thermal media or the combi-
nation of transfer ribbon and media.
- Measure the +24VDC on the CPU board, see Section 13.4.

Description:
Weak or missing printout of some dots.
• Dirty printhead or platen roller.
- Examine the printhead and the platen roller for dust, adhesive
residue, or visible damage.
- Clean or replace.
• One or two missing dots.
- May be due to mechanical damage to the printhead. Try to establish
why such damage have occurred in order to prevent future failures of
this kind. (Hard foreign particles, electrostatic discharge?)
- If the printer has been used for printing on less than full width labels
for some time, the platen roller and possibly also the printhead may
have become worn from the outer edge of the media. This will show
up when reverting to wider labels. Change the platen roller and
possibly also the printhead.
• Preprinted ink has got stuck to the dot line.
- Avoid preprinted labels with ink that has a low melting point (less
than +225°C/+437°F).
• Many dots, or a block of dots, are missing.
- The internal IC circuit of the printhead is probably damaged. Replace
the printhead.
Description:
Unexpected black printout (completely or partially).
- If the printer unexpectedly produces completely or partially black
printout, or prints a black line across the media at startup (regardless
of label layout), check that the printhead voltage +24VDC ±2V
(see Section 13.4). If the power on the CPU board is OK, but the
trouble remains, disconnect the power cable on the inner side of the
printhead and use probes to measure the voltage during printing
between two adjacent lines in the socket (see Section 12.4, connector
P5 for schematics). If too high, in the range of 40 to 50V during
printing, replace the power supply unit.
- The printhead is most certainly damaged too and will also need to be
replaced.

Description:
Media feed does not work properly.
• Faulty stepper motor.
- Connect a replacement stepper motor to P10 on the Power Supply
Unit (see Chapter 12) and perform a print or feed operation. If this
motor runs, the original stepper motor is probably damaged and
needs to be replaced (see Section 7.3).
• Dirty or worn platen roller.
- Inspect the platen roller for visible wear. Replace if necessary (see
Section 7.2).
- Clean the platen roller using a cleaning card or a soft cloth moistened
with isopropyl alcohol. Paper dust or adhesive residue can deteriorate
the media feed function or make the media slip.
• Intermec Fingerprint instruction missing.
- Verify that a print command is actually issued in the current Intermec
Fingerprint program.
• Power Supply Unit malfunction or bad connection.
- The stepper motor could be incorrectly connected to P10 on the
PSU, or its drive circuit (U13) on the PSU could be damaged.
- Check that all pins in the connector of the stepper motor’s cable are
fully inserted.
- Measure the +24VDC on the CPU board, see Section 13.4. If there is
no power, when an attempt to print is made, the power supply unit is
probably faulty.
Description:
Excessive wear of printhead.
• Various reasons.
- Refer to Section 7.6 “Printhead/Precautions” for advices on how to
reduce the wear of the printhead.
Description:
Printing is slow and halted inbetween labels.
• RFID mode is ON
- The printer is trying to access an RFID label that is not there. Turn it
off with the following commands:
SETUP “RFID,OFF” (Fingerprint)
<SI>J0 (IPL)

16.13 Transfer Ribbon Troubles

Description:
The thermal transfer ribbon breaks.
• Wrong brand of ribbon.
- Check if the transfer ribbon is of an approved brand. If not,
recommend the customer to use approved brands only.
• Bad ribbon load.
- Check that the ribbon is routed so it runs above upper guide (that is,
the one where the upper part of the LSS is fitted).
• Wrong paper type setup.
- Check that the printer is set up correctly for the type of thermal
transfer ribbon in use, see the User’s Guide.
- Check printhead voltage, see Section 13.4.
Description:
The thermal transfer ribbon wrinkles.
• Media misalignment.
- Is the edge guide positioned so as to guide the media closely along the
printer’s center section?
- Is the media supply roll as far in on the post or hub as possible?
• Ribbon misalignment.
- Are both the ribbon supply roll and the ribbon rewind core pressed as
far in on their hubs as possible?
• Ribbon path obstructed.
- Check that nothing obstructs the path of the transfer ribbon.
• Wrong or uneven printhead pressure.
- Check that the pressure arm is center-aligned in the relation to the
width of the media, see Section 7.8.
- Check the printhead pressure, see Section 7.8. Decrease the pressure
somewhat and test for both wrinkles and printout contrast. You may
need to feed out 25-50 cm of ribbon (1-2 ft.) before you can see any
effect.
• Bad ribbon break shaft adjustment.
- Check the adjustment of the front ribbon break shaft, see Section 6.6.
Do not change the adjustment before you have performed all other
checks mentioned above.

Description:
No transfer printout.
• Refer to Section 16.12 for general printout troubles.
• Bad ribbon load.
- Transfer ribbon loaded incorrectly so the ink-coated side does not face
the receiving face material. Reload ribbon.
Description:
Ribbon fed out in front of printer.
• Printer is set up for direct thermal printing, but a ribbon is loaded.
- Remove ribbon or change the paper type setup to thermal transfer.
• Ribbon rewind motor does not run.
- Cable between ribbon motor and P6 on the Power Supply Unit
broken or not correctly connected?
- Faulty ribbon sensor? See Section 16.11.
- Faulty ribbon motor? Replace.
- Faulty CPU board? Replace.
- Faulty Power Supply Unit? Replace.

16.14 Liner Takeup Troubles

Description:
The internal liner takeup unit does not work properly.
• Bad liner takeup or bad separation of labels from liner at the tear bar.
- Check that the media is routed correctly as described in the User’s
Guide.
- Check that the liner is securely locked to the takeup hub by the brace,
so it cannot slip.
- Check the setup for incorrect media type and feed adjust settings.
• Takeup unit slips.
- Spring clutch inside the takeup hub is broken.
- Either the outside of the pulley or the inside of the hub has become
worn.
• Either the liner drive roller in the print mechanism or the takeup hub
is not driven by the stepper motor.
- Check if any of the belts from the stepper motor is broken or has
come off the pulleys, see Section 8.2.
• Neither the liner drive roller in the print mechanism nor the takeup
hub is driven by the stepper motor.
- Check if the stepper motor runs. If not, check as for “Media feed does
not work” in Section 16.12.
- Check if both the belts from the stepper motor are broken or have
come off the pulleys, see Section 8.2.

16.15 Memory Card Troubles

Description:
The printer cannot read a memory card. Note that in IPL, memory cards
are not used to expand the printer’s memory.
• Memory card not inserted at startup.
- The card must be inserted before the power is switched on or the
printer is rebooted.
• Memory card incorrectly inserted.
- Check that the card is inserted as far as it goes.
• Bad contact between card and adapter.
- Switch off the printer. Pull out and insert the card a few times to rub
off any oxide on the connectors.
• Wrong type of memory card.
- The memory cards must be Type I CompactFlash cards (thickness 3.3
mm/0.13 in.) commonly used with digital cameras. PCMCIA-cards
or Type II CompactFlash cards (thickness 5 mm/0.20 in.) cannot
be used. If a CompactFlash card is marked CF+, it is probably not a
regular memory card and cannot be used.
• Error in content of the card.
- If you have access to a PC equipped with a CompactFlash card reader,
list the memory content of the PC memory card to see if it is correct.
- If you can communicate with the printer via a PC, you could see
what files are stored in the memory card and their sizes with the aid
of Intermec Fingerprint command FILES "card1:".
- Try to format the card in the printer using the Fingerprint instruction
FORMAT "card1:",A. Also see Intermec Fingerprint v8.xx,
Programmer’s Reference Manual.
• Hardware error.
- Inspect the memory card for mechanical damage.
- Examine the memory card adapter on the CPU board for damaged
card mating pins, breakage, or bad soldering.

16.16 Paper Cutter Troubles

Description:
The printer cannot detect the cutter.
• In Fingerprint, error 37, “Cutter device not found” or Error 1059, “Cutter
does not respond” occurs.
Possible Causes and Sugged Remedies:
• No reboot has been performed after installation.
- Cycle the power to the printer.
• Cable between cutter pcb and CPU board is not fitted properly.
- Check that the cable has not come loose from the cutter pcb and is
fitted so all the slack is between the cable cover and the cutter, see
Section 10.2.
• Faulty cable, cutter pcb, or CPU board.
- Replace one at the time, reboot, and check.
Description:
The cutter does not cut.
• Error 1704, “Cutter open” occurs in Fingerprint.
- Check that the cutter is positively in closed position.
- The microswitch on the cutter assembly may be defect. Replace the
cutter assembly.
- Faulty cable, cutter pcb, or CPU board. Replace one at the time,
reboot, and check.
• Errors 1701-1703 occurs in Fingerprint.
- Check the “cutter top position” sensor on the cutter pcb for dust and
similar. Clean if necessary.
- Check the cutting shears and cutter mechanism for adhesive residue,
label shavings, stuck labels, or other things that may prevent the
cutter from operating mechanically. Clean if necessary, but do not use
any solvent that can dissolve the grease.
- Replace the cutter assy or cutter pcb, one at the time.
• No error occurs but cutter does still not cut.
- If using Fingerprint, check that the application program utilizes the
Fingerprint statements CUT or CUT ON/OFF correctly. See the
Intermec Fingerprint v8.xx, Programmer’s Reference Manual.

Description:
The cutter cuts at the wrong place.
• Faulty LSS or bad Feedadjust setup.
- In Fingerprint, perform a Testfeed to adjust the LSS.
- In IPL, adjust the media feed by pressing the Feed/Pause button.
- Check Start- and Stopadjust setup values (Fingerprint only).
- Check application for FORMFEED<nnn> instructions (Fingerprint
only).

16.17 RFID Troubles

Description:
"No tag found" is displayed when a TESTFEED is attempted.
• The inlay could be broken.
- Replace the inlay or use an entirely new label.
• You are not currently using RFID media.
- Load the printer with RFID media.
• The current TAGADJUST value is incorrect.
- Align the label with the edge of the tear bar (Fingerprint) or
dot line (IPL). Leave the lid open and measure the distance between
the middle of the inlay and a point orthogonally right above the
antenna. Convert the distance to dots.
TAGADJUST = Distance * TPHresolution(mm)
Enter the TAGADJUST value in the SETUP menu with the com-
mand:
SETUP “RFID,ON,TAGADJUST,<value>” (Fingerprint)
<SI>J1,<value> (IPL)
Example:
TPH resolution 203 dpi
DISTANCE 15 mm
TAGADJUST = 15 * 203 / 25.4 = 120 dots
Description:
An application writing to Class 1 RFID tags produces a large number of
VOID labels.
• Verify that the TAGADJUST value is set correctly.
- Follow the procedure as described above
• The output power to the antenna could need adjusting.
- This can be done with a run command, setting the output power to a
value between 15 and 27 dBm, where 27 dBm is 0.5 W and every 3
dBm decrease means half the output power.
run “wjsetpower read|write <value>”
(Fingerprint)
<STX><ESC>.x,wjsetpower read|write <value><ETX>
(IPL)

The current setting can be read with the command (Answer is in

dBm):
run “wjgetpower read|write” (Fingerprint)
<STX><ESC>.x,wjgetpower read|write<ETX> (IPL)
Example:
run “wjsetpower read 24”
run “wjgetpower read”
> 24
Description:
None of the RFID commands work. The message "RFID inactive" is
displayed.
• The RFID mode has been switched OFF.
- Turn it on with the following commands:
SETUP “RFID,ON” (Fingerprint)
<SI>J1 (IPL)
Description:
Printing on non-RFID media is slow and printing is halted inbetween
labels.
• RFID mode is ON
- Turn it off with the following commands:
SETUP “RFID,OFF” (Fingerprint)
<SI>J0 (IPL)
Description:
After the printer has been loaded with a new roll of RFID media, it is
unable to write to the tags.
• The printer has not yet identified the RFID media type.
- If RFID media is changed without the printer having been turned
OFF, it resets the inlay type and waits for a TESTFEED to identify
the new RFID media. A TESTFEED should take care of this
problem.

Description:
RFID operations yield "Not supported by tag type" error messages.
• A command tries to access a tag data segment that is not available on
the current RFID media.
- Example: Performing TAGWRITE or TAGREAD operations on the
”@DATA” segment for Class 1 RFID media.
• A command is referring to a tag format that is not available on the
current RFID media.
- Example: using TAGFORMAT "NUM" for Class 1 media, or trying
to write an EPC-96 format to a 64-bit tag.
• A command is used together with a "level" that is not allowed for a
particular tag type.
- Example: using TAGPROTECT ”UNLOCKP” on Class 1 media or
TAGPROTECT ”ON” for Gen 2 tags.
Description:
Data can be written unlawfully to a write-protected ISO 18000-6B tag.
• For some ISO 18000-6B tag chips the functionality to protect the tag
memory from being rewritten has not been implemented.
- Switch to tags with a different chip that have this functionality
implemented.
Description:
TAGWRITE commands yield "Invalid parameter" error messages.
• The user is trying to store an excessive amount of data in the tag's
memory.
• An invalid value has been entered, e.g. an uneven number of characters
for one of the "HEX" formats or an incorrect number of digits for a
parameter defining an EPC-format.
Description:
TAGREAD commands yield "Wrong number of parameters" error
messages.
• The number of required parameters depend on what TAGFORMAT
has been defined for the read operation.
- See the manual for Fingerprint v8.60 or later. Additional information
can be found in the EPC Tag Data Standard (v1.1, revision 1.27)
document available via http://www.epcglobalinc.org/standards_
technology/specifications.html.

Description:
The message "Error in filename" is displayed when RFID mode is set to
ON.
• No RFID kit is installed in the printer.
Description:
ISO 18000-6B tags work fine, but reading Class 1 tags yield a "No tag
found" error message.
• ISO 18000-6B tags are addressed with the IM3 or IM5 RFID reader.
For these modules, Class 1 support has not been implemented yet.
Class 1 tags require an MPR6100 RFID Radio Module.
- An MPR6100 can be ordered from Intermec Sales as part of an
upgrade kit ("RFID Kit (Class 1, 915 MHz").
Description:
"RFID" does not show up in the SETUP tree.
• The printer does not communicate properly with the RFID hardware.
- Check that the RFID kit has been installed in accordance with
the installation instructions. Check that the jumpers on the RFID
option board are set to the correct position (see section 14.8).
- Print a hardware test label to see what hardware the printer has
recognized, confirm that the RFID option board is present on
the label (this rules out potential errors in the board or I/O cable).
- Test the RFID radio module by downloading and installing the latest
firmware. If the module proves faulty, replace it.


A Program Overviews
This appendix shows overviews of the Intermec Shell and the Intermec
Fingerprint Setup Mode followed by overviews of the IPL Setup Mode.
Refer to the printer user’s guides for information on the various parameters
and instructions for navigation.

Appendix A—Program Overviews
Intermec Shell v8.0 Overview

POWER ON ENTER=SHELL SHELL SEL. APPLICATION
5 sec. v.8.0 SEL. APPLICATION CURRENT APPL.
Last selected application is started
ENTER=SHELL
SEL. APPLICATION
4 sec. v.8.0 Note: Dotted channels are only shown if
Fingerprint 8.10 the corresponding optional interface pcb
is fitted.
ENTER=SHELL STD I/O CHANNEL
SEL. APPLICATION
3 sec. v.8.0 auto
Direct Protocol

2 sec. v.8.0 uart1:
The selected application is started

1 sec. v.8.0 uart2:
Last selected STD I/O CHANNEL

application is started
Optional application uart3:
Default:
programs
Fingerprint 8.10 w. std I/O = "auto"
STD I/O CHANNEL
centronics:
Legend:
STD I/O CHANNEL
net1:
Return to previous menu.
STD I/O CHANNEL
Proceed to next menu. usb1:
SEL.APPL rom:
LINE_AXP.PRG
Accept displayed option
and proceed, or
execute displayed option. SHELL SETUP:
SETUP SER-COM,UART1
See the chapter “Setup Mode”
Perform a Testfeed
anywhere in Intermec Shell. SHELL
PRINT SETUP
Prints a list of current setup values (test label “Setup Info”).
Enter the Setup Mode

SHELL Performs a Testfeed (feeds out a number of blank copies
from anywhere
in Intermec Shell. TESTFEED while autoadjusting the label stop sensor).
SHELL Prints test labels “Diamonds”, “Chess”, “Bar Codes #1”, and “Bar Codes #2” in a loop.
TEST LABEL Press Enter for each new label.
SHELL ARE YOU SURE? DEFAULT SETUP

DEFAULT SETUP YES=ENTER/NO=ESC PERFORMED
SHELL UPDATE: TRANSFER FILE

SOFTWARE UPDATE COMPACT FLASH? USING ZMODEM
TRANSFER
COMPLETED
SHELL UPDATE: TRANSFER FILE

REBOOT FIRMWARE? USING ZMODEM
Printer rebooted
Restarts the printer (same as power off/on) automatically.
Note: To enter Intermec Shell if a custom-made autoexec-file prevents

access, lift the printhead and press any key on the printer's keyboard
(except the <Shift> key), then turn on the power while continuing to
press the key. When the Shell countdown begins, release the key and press
<Enter> to start Shell. Do not forget to lower the printhead if you want to
print for example test labels.

Appendix A— Program Overviews
Setup Mode Overview (FP v8.70) Ser-Com, uart1:

SETUP: SETUP: SETUP: SETUP: SETUP: SETUP: next
SER-COM, UART1 SER-COM, UART2 SER-COM, UART3 NET-COM, NET1 NETWORK RFID page
See separate overview See separate overview See separate overview See separate overview See separate overview
SER-COM, UART1: SER-COM, UART1: SER-COM, UART1: SER-COM, UART1: SER-COM, UART1:
BAUDRATE CHAR LENGTH PARITY STOP BITS FLOWCONTROL
BAUDRATE; CHAR LENGTH PARITY: STOP BITS: FLOW CONTROL: FLOW CONTROL:
9600
BAUDRATE; 8 CHAR LENGTH NONE
PARITY: 1 STOP BITS: RTS/CTS ENQ/ACK
19200
BAUDRATE; 7 EVEN
PARITY: 2
38400
BAUDRATE; ODD
PARITY:
57500
BAUDRATE; Scroll forward RTS/CTS: ENQ-ACK:
MARK
PARITY: Scroll back
115200
BAUDRATE; SPACE DISABLE
ENQ/ACK: DISABLE
ENQ/ACK:
300
BAUDRATE; ENABLE ENABLE
600
BAUDRATE; Scroll forward
1200
BAUDRATE; Scroll back Scroll forward Scroll forward
2400
BAUDRATE; Scroll back Scroll back
4800
Scroll forward
Scroll back
SER-COM, UART1: SER-COM, UART1: SER-COM, UART1:

NEW LINE REC BUF TRANS BUF
FLOW CONTROL: NEW LINE: REC BUF: TRANS BUF:

XON/XOFF CR/LF
NEW LINE: [1024]: [1024]:
LFNEW LINE:
CR
XON/XOFF: XON/XOFF:
DATA TO HOST DATA FROM HOST Scroll forward
Scroll back
DATA TO HOST: DATA FROM HOST:
DISABLE
DATA TO HOST: DISABLE
DATA FROM HOST:
ENABLE ENABLE
Scroll forward Scroll forward
Scroll back Scroll back

Setup Mode Overview (FP v8.70) Feed Adjust

Continued from the SETUP: Continued on
previous page FEEDADJ the next page
FEEDADJ: FEEDADJ:
STARTADJ STOPADJ:
STARTADJ: STOPADJ:
[0]: [0]:

Setup Mode Overview (FP v8.70) Media

Continued from SETUP: Continued on
the previous page MEDIA the next page
MEDIA: MEDIA:
MEDIA SIZE MEDIA TYPE
MEDIA SIZE: MEDIA SIZE: MEDIA SIZE: MEDIA TYPE:

XSTART WIDTH LENGTH LABEL
MEDIA(wTYPE:
GAPS)
TICKET (w MARK)
MEDIA TYPE:
TICKET (w GAPS)
MEDIA TYPE:
XSTART: WIDTH: LENGTH: FIX LENGTH
MEDIA TYPE:STRIP
[24]: [832]: [1200]: VAR LENGTH STRIP
Scroll forward
Scroll back
MEDIA:
PAPER TYPE
PAPER TYPE:
TRANSFER
TRANSFER: TRANSFER: TRANSFER: TRANSFER: TRANSFER:

RIBBON CONSTANT RIBBON FACTOR LABEL OFFSET RIBBON SENSOR LOW DIAMETER
RIBBON CONSTANT: RIBBON FACTOR: LABEL OFFSET: RIBBON SENSOR: LOW DIAMETER:
[90]: [25]: [0]: [14]: [0]:
Only displayed if a paper sensor is installed.
MEDIA: MEDIA:
CONTRAST PAPER
PAPER TYPE: PAPER: PAPER:

DIRECT THERMAL PAPER SENSOR LOW DIAMETER
DIRECT THERMAL: DIRECT THERMAL: CONTRAST: PAPER SENSOR: LOW DIAMETER:

LABEL CONSTANT LABEL FACTOR +0%
CONTRAST: [10]: [0]:
+2%
CONTRAST:
+4%
CONTRAST:
LABEL CONSTANT LABEL FACTOR: +6%
CONTRAST:
[85]: [40]: +8%
CONTRAST:
+10%
CONTRAST:
-10%
CONTRAST:
-8%
CONTRAST:
-6%
CONTRAST:
-4%
CONTRAST:
-2%
Scroll forward
Scroll back
MEDIA: MEDIA: MEDIA:

TESTFEED TESTFEED MODE LEN (SLOW MODE)
TESTFEED: TESTFEED MODE: LEN (SLOW MODE):

[26 28 0 10] FAST
TESTFEED MODE: [0]:
Press <Enter> to per- SLOW
form a testfeed. Scroll forward
Values are read-only. Scroll back

Setup Mode Overview (FP v8.70) Print Defs

Continued from SETUP: Return to the start of the Setup Mode loop
the previous page PRINT DEFS (SETUP/SER-COM, UART1) or press <Setup>
to exit the Setup Mode.
PRINT DEFS: PRINT DEFS: PRINT DEFS: PRINT DEFS:
HEAD RESIST TESTPRINT PRINT SPEED LSS TEST
HEAD RESIST: TESTPRINT: PRINT SPEED: LSS TEST: LSS TEST:

[nnn]: DIAMONDS
TESTPRINT: [100]: LSS AUTO LSS MANUAL
Read-only CHESS
TESTPRINT:
BAR CODES #1
TESTPRINT: LSS AUTO: LSS [G: 2]D: 6
BAR CODES #2
TESTPRINT: � �
SETUP INFO
TESTPRINT:
HARDWARE INFO Toggle between
TESTPRINT:
RFID TEST LABEL Only displayed if an gain (G) and drive
TESTPRINT:
NETWORK INFO optional EasyLAN board (D)
is installed.
Scroll forward Decrease/increase
Scroll back value inside
<Enter> to print brackets
<?> for error info
PRINT DEFS: Only displayed if an optional LTS (Label Taken

LTS Sensor) is installed in the printer.
LTS: LTS: LTS:

LTS ADJUST LTS TEST LTS VALUE
REMOVE LABEL AND REMOVE LABEL LTS VALUE:

PRESS ENTER ENTER TO STOP [10]:
SENSITIVITY 10
OUT OF 9-10

Setup Mode Overview (FP v8.70) Ser-Com, uart2

SETUP:SETUP:
SER-COM, UART2
SER-COM, UART2:
BAUDRATE
BAUDRATE;
9600
BAUDRATE;
19200
BAUDRATE;
38400
BAUDRATE;
57500
BAUDRATE;
115200
BAUDRATE;
300
BAUDRATE;
600
BAUDRATE;
1200
BAUDRATE;
2400
BAUDRATE;
4800




Setup Mode Overview (FP v8.70) Network Communication

SETUP: SETUP:
NET-COM, NET1 NETWORK These menus will only be displayed when an optional EasyLAN interface board is installed.
NET-COM, NET1: NETWORK: NETWORK: NETWORK: NETWORK: NETWORK:

NEW LINE IP SELECTION IP ADDRESS NETMASK DEFAULT ROUTER NAME SERVER
NEW LINE IP SELECTION: IP ADDRESS: NETMASK: DEFAULT ROUTER: NAME SERVER:

CR/LF
BAUDRATE; DHCP+BOOTP
PARITY: 192.168.1.79 255.255.255.0 192.168.1.1 192.168.1.7
LFBAUDRATE; MANUAL
PARITY: Read-only if DCHP
CR DHCP
PARITY: and/or BOOTP
BOOTP is selected.
NETWORK:
MAC ADDRESS
MAC ADDRESS:
00104017b80e

Setup Mode Overview (FP v8.70) RFID

SETUP:
RFID These menus will only be displayed when an RFID module is installed.
RFID: RFID: RFID: RFID: RFID:

MODE RETRIES VOIDTEXT TAGADJUST FIELDSTRENGTH
MODE: RETRIES: VOIDTEXT: TAGADJUST: FIELDSTRENGTH:

ENABLE
MODE: [1]: [VOID]: [0]: [100]:
DISABLE Read-Only

Setup Mode Overview (IPL v2.70) Serial Communication

SETUP: Continued on
SER-COM the next page
SER-COM: SER-COM: SER-COM: SER-COM: SER-COM:

BAUDRATE DATA BITS PARITY STOP BITS PROTOCOL
BAUDRATE: DATA BITS: PARITY: STOP BITS: PROTOCOL:

9600
BAUDRATE; 8 CHAR LENGTH NONE
PARITY: 1 STOP BITS: XON_XOFF
ENQ/ACK:
19200
BAUDRATE; 7 EVEN
PARITY: 2 XON/XOFF+STATUS
38400
BAUDRATE; ODD
PARITY: STANDARD
57500
BAUDRATE; Scroll forward
SPACE Scroll back Scroll forward
115200
BAUDRATE;
1200
BAUDRATE; Scroll forward Scroll back
2400
BAUDRATE; Scroll back
4800
Scroll forward
Scroll back

Setup Mode Overview (IPL v2.70) Network (option)

SETUP:
NETWORK These menus will only be displayed when an optional EasyLAN interface board is installed.
NETWORK: NETWORK: NETWORK: NETWORK: NETWORK: NETWORK:

IP SELECTION IP ADDRESS NETMASK DEFAULT ROUTER NAMESERVER MAC ADDRESS
IP SELECTION: IP ADDRESS: NETMASK: DEFAULT ROUTER: NAMESERVER: MAC ADDRESS:

DHCP+BOOTP
PARITY: 192.168.1.79 255.255.255.0 192.168.1.1 192.168.1.7 00104017b80e
MANUAL
PARITY: Read-only
DHCP
PARITY:
BOOTP

Setup Mode Overview (IPL v2.70) RFID

SETUP:
RFID These menus will only be displayed when an RFID module is installed.
RFID: RFID: RFID: RFID: RFID:

MODE TAGADJUST RETRIES VOIDTEXT FIELDSTRENGTH
MODE: TAGADJUST: RETRIES: VOIDTEXT: FIELDSTRENGTH:

ENABLE
MODE: [0]: [1]: [VOID]: [100]:
DISABLE Read-Only

Setup Mode Overview (IPL v2.70) Test/Service

the previous page TEST/SERVICE the next page
TEST/SERVICE:
TESTPRINT
TESTPRINT: TESTPRINT: TESTPRINT: TESTPRINT: TESTPRINT:

CONFIG FORMAT PAGE UDC FONT
CONFIG: FORMAT: PAGE: UDC: FONT:

SW
CONFIG: ALL ALL ALL ALL
HW
CONFIG:
NETWORK
ALL: ALL: ALL: ALL:
Scroll forward PRINT FORMATS PRINT PAGES PRINT UDC PRINT UDFs
Scroll back
TEST/SERVICE: TEST/SERVICE: TEST/SERVICE:

DATA DUMP MEMORY RESET LSS TEST
DATA DUMP: MEMORY RESET: LSS TEST

NO
CONFIG: ALL
CONFIG: LSS AUTO
YES CONFIGURATION

Setup Mode Overview (IPL v2.70) Media

the previous page MEDIA the next page
MEDIA : MEDIA : MEDIA : MEDIA : MEDIA :

MEDIA TYPE PAPER TYPE TESTFEED MODE LBL LENGTH DOTS SENSITIVITY
MEDIA TYPE: PAPER TYPE: TESTFEED MODE: LBL LENGTH DOTS: SENSITIVITY:
GAP
CONFIG: DT
CONFIG: FAST
MEDIA : 1200 420
MARK
CONFIG: TTR SLOW 100/200/400/800/ 130/140/160/180/
CONTINUOUS Scroll forward 1200/1600/2000/ 366/420/440/450/
Scroll forward Scroll back 2500/3000/3600/ 470/480/513/527/
Scroll back 4200/4800 567/627/677/687/
864
MEDIA : MEDIA : MEDIA : MEDIA :

DARKNESS LBL REST POINT FORM ADJ DOTS X FORM ADJ DOTS Y
DARKNESS: LBL REST POINT: FORM ADJ DOTS X: FORM ADJ DOTS Y:
0 0 0 0
0/1/2/3/4/5/6/7/8/ 0/2/4/6/8/10/15/ 0/2/4/6/8/10/15/ 0/2/4/6/8/10/15/
9/10/-10/-9/-8/-7/ 20/25/30/-30/-25/ 20/25/30/-30/-25/ 20/25/30/-30/-25/
-6/-5/-4/-3/-2/-1 -20/-15/-10/-8/-6/ -20/-15/-10/-8/-6/ -20/-15/-10/-8/-6/
-4/-2 -4/-2 -4/-2
Scroll forward Scroll forward Scroll forward Scroll forward
Scroll back Scroll back Scroll back Scroll back

Setup Mode Overview (IPL v2.70) Configuration

Continued from SETUP: Return to
the previous page CONFIGURATION the start of
the loop
CONFIGURATION: CONFIGURATION: CONFIGURATION: CONFIGURATION:
PWRUP EMULATION PRINT SPEED CUTTER LTS CALIBRATION
EMULATION: PRINT SPEED: CUTTER: LTS CALIBRATION:

NONE
CONFIG: 4PRINT
IN/SECSPPED: NOT INSTALLED
CONFIG: PRESS <ENTER>
86XX-10MIL
CONFIG: 5PRINT
IN/SECSPPED: ENABLE
CONFIG: Labels are fed out
86XX-15MIL 6PRINT
IN/SECSPPED: DISABLE
7PRINT
IN/SECSPPED: REMOVE LABEL AND
Scroll forward Scroll forward PRESS ENTER
8 IN/SEC
Scroll forward <Enter>
Scroll back SENSITIVITY 9
OUT OF 8-14
Read only,
press<Enter>

B Firmware Upgrading
This appendix describes various methods for upgrading the printer’s

firmware and for switching between Intermec Fingerprint and IPL.

Appendix B—Firmware Upgrading
Introduction
All EasyCoder PM4i printers can use both Fingerprint v8.xx and IPL
v2.xx firmware. There are many ways to upgrade or exchange the printer’s
firmware. Use the most convenient way. You can either do it from host by
sending the file to the printer or by inserting a CompactFlash card in the
memory card slot at the printer’s rear plate. There are 3 different file types
containing the firmware. The file types are related to the way of upgrade
procedure. The files can be obtained from Intermec.
File Description
File name Type of file
1-972020-xx.bin (for FP) These .bin files contain the firmware kernel file only.
1-972105-xx.bin (for IPL) The .bin files can be sent to the printer with a serial con-
nection using a communication program, for example
HyperTerminal or Printset, or via FTP. They can also be
stored on a CompactFlash card, which is inserted in the
back of the printer.
1-972021-xx.bin (for FP) These .bin files contain the firmware kernel file and
1-972106-xx.bin (for IPL) the factory default setup parameter values. They can be
stored on a CompactFlash card.
Note: If you run these .bin files, they will remove all files
stored on the printer except the firmware files, so it is
recommended you backup before running such a file.
The main purpose of the factory default .bin files is to
allow the user to reset login information (user name and
password will be reset to default setting).
Another format is .uff files, which are created by, for instance, NetPrintSet.
They contain the kernel and optional instructions (if necessary), images,
fonts, etc. To be stored in CompactFlash memory cards.
General Principles
• During upgrading, do not switch off the printer. Wait and follow the
prompts in the printer’s display.
• If you change firmware from IPL to Fingerprint, it is recommended you
reset the printer memory to factory default setting [FORMAT "/c",A]
after the upgrade procedure is completed.
• Some update of Fingerprint may show the error “mcs: Error during
setup” at host terminal. This just means that there was an instruction
that erased "/c" [FORMAT "/c",A]. This is a normal condition! The
error shows that no setup file [.setup.saved] is detected on "/c". The
"/rom" setup file is copied automatically into "/c" which gives printer a
factory setup setting.
• If an EasyLAN interface board is installed, by default only admin is
allowed to upgrade. See EasyLAN User’s Guide for more information.

Upgrading From a Memory Card

This chapter describes how to upgrade the printer from a CompactFlash
card.
1 Insert the card and switch on the printer. The printer’s display will
automatically show ongoing steps. The procedure ends with a normal
startup of the printer.
2 Switch off the printer and remove the card. Printer is ready for use.
CompactFlash cards with firmware (Fingerprint or IPL) can be ordered
from Intermec. Empty CompactFlash cards can be ordered from Intermec
or procured locally.
If there are more than one firmware files on the memory card, it is not
forseeable which one will be selected. However, by renaming the desired
file to FIRMWARE.BIN, you can make sure that the file will be selected.
How to Create a Firmware Upgrade Card
There are two possible places to program a CompactFlash card. One is
your PC CompactFlash card slot, another is the printer’s card slot.
At the PC-side
1 Use a computer fitted with a PCMCIA slot and a CompactFlash adapter
and insert the CompactFlash card.
2 Copy the upgrade .bin or .uff file to the CompactFlash card.
At the Printer Side (Fingerprint only)
1 Insert the CompactFlash card in the slot at the printer’s rear plate.
2 Start up the printer and select Intermec Shell.
3 Press <Enter> to go to the “Sel. Application” menu.
4 Press <⇒> repeatedly to browse to ”SOFTWARE UPDATE”.
5 Press <Enter> to go to ”UPDATE: COMPACT FLASH?”
6 Press <Enter>.
7 Start sending the file using a communication program, for example
HyperTerminal. The communication program must use zmodem.
(There is a one-minute time-out on the printer side.) Shell will
automatically rename the file to FIRMWARE.BIN to make sure that
this file will upgrade the printer.
8 Switch off the printer and remove the card.

Note: A special case is if the CompactFlash card already has a Fingerprint

firmware. Inserting such a card will always install firmware in the printer
according to CompactFlash card. However, perhaps you like to install a
later firmware version picked from the web. If so, proceed like this:
1 Insert the CompactFlash card with a upgrade firmware on. Switch on
and wait for a completed upgrade and the normal startup of the printer
so you are in Fingerprint mode.
2 Activate the Shell program from "/rom" like this:
3 LOAD "/rom/SHELLXP.PRG"
4 MERGE "/rom/ERRHAND.PRG"
5 RUN
6 In Shell, select the option “UPDATE: COMPACT FLASH?” and press
<Enter>.
7 Send the .bin or .uff file from the host using zmodem.

Upgrading From the Host

Software Suggestions
1. Intermec PrintSet (IPL and Fingerprint)
Install Intermec PrintSet software and a serial cable. Intermec PrintSet is
included on the PrinterCompanion CD. It can also be obtained from the
Intermec web site.
2. Terminal program (Fingerprint only)
Use Terminal program included in Windows (95/98/Me or NT/2000/XP)
and a serial cable. At serial communication, the software has to be prepared
by a protocol Zmodem and have same communication settings on both
side. We recommend hardware handshaking (RTS/CTS).
3. Command prompt with FTP
Use command prompt in Windows Windows (95/98/Me or NT/2000/
XP) and an Ethernet network.
4. Intermec NetPrintSet (Fingerprint only)
Use Intermec NetPrintSet software and a serial cable. Intermec NetPrintSet
can be obtained from the Intermec Printer Support Web.
Cable Suggestions
RS-232 Serial Cable
DB-9pin female -> DB-9pin male (see Spare Parts Catalog)
Ethernet Cable
Intermec does not provide any Ethernet cable.The cables are normally
provideed locally. At a straight connection between a host and printer, a
cross RJ45 cable is needed.
Parallel Cable
(see Spare Parts Catalog)
How to Use Intermec PrintSet and Serial Cable
1 Connect a serial cable between host and printer
2 Start up the printer and select Fingerprint via Shell and to listen on
serial port "uart1:" on for example baud rate 115200.
3 Start PrintSet. The program will automatically set the communication
parameters and is ready for use.
4 Select ”DataXfer\Change firmware”. Depending on settings, PrintSet
may ask for the admin’s password.
5 Send one of the following files:
1-972020-xx.bin (Fingerprint)
1-972105-xx.bin (IPL)
After file is received in printer, it will automatically replace the firmware
and boot up with the new one. The printer’s display will automatically
show ongoing steps. The procedure ends with a normal startup of the
printer.

How to Use MS HyperTerminal and a Serial Cable (Fingerprint Only)

1 Connect a serial cable between host and printer.
2 Start the HyperTerminal or a similar terminal program. Select port
com1. Use a high communication speed (baudrate 115200).
3 Start up the printer and select Fingerprint via Intermec Shell1 to listen
on serial port "uart1:".
4 Make sure that your are in contact with printer by typing for example
FONTS and the printer will respond showing fonts.
5 Type a download command2 so printer is ready for receiving data:
RUN "dlk"
6 Select .bin upgrade file. Now printer waits for about 1 minute to get the
file sent using zmodem as protocol.
7 Go to “Send file” and send it.
After file is received in printer, it will automatically replace the firmware
and the printer will boot up with the new version. The printer’s display
will automatically show ongoing steps. The procedure ends with a
normal startup of the printer.
1
/. In Intermec Shell it is also possible to select printer to be in the receiving mode. Start
up Intermec Shell and use <⇒> to browse to “Software Update\Update:Firmware”. (You
have one minute to send the file.) Also check the printer’s baud rate in the Setup Mode.
Continue with items 6-8. If the printer is fitted with an EasyLAN board, user must be
allowed to upgrade.
2
/. dlk only works if the current user is allowed to update. RUN "su admin" could be
required.

How to Use Command Prompt FTP and Ethernet

1 Connect a printer on Ethernet LAN or by a cross cable between host
and printer
2 Open an FTP session to the printer typing this command from your
Windows command prompt: FTP <ip address of the printer>
3 You will get a prompt asking you for User: type admin or user. You
may get a prompt for a Password: type pass (default; case sensitive).
Note: The user you log in as must be allowed to upgrade.
4 After some answers on your screen you will see the prompt FTP>. At
this point type bin + <Enter>, then type hash + <Enter>.
5 Now send the firmware to the printer with the command:
put <filename.bin> FLASH
6 Some ###### will appear on your screen showing the ongoing transfer.
7 The printer’s display will automatically show ongoing steps. The
procedure ends with a normal startup of the printer.
8 Close FTP session typing bye + <Enter>.
After file is received in printer it will automatically replace the firmware
and the printer will boot up with the new version. The printer’s display
will automatically show ongoing steps and the procedure ends with a
normal startup of the printer.
How to Use Intermec NetPrintSet and Serial Cable (Fingerprint only)
What is NetPrintSet?
NetPrintSet is a printer configuration utility for Intermec printers that
allows you to upgrade or configure the printer. Makes font upgrades and
other maintenance a child’s play. Available both as Netscape plugin and
standalone executable.
• The Netprintset can merge printer’s necessary file to one file either using
a CompactFlash card or download direct to printer. Necessary files are
for example Images, Fonts, Firmware, or other custom-made files.
• User instructions are embedded in the software.
If Upgrading Directly Via NetPrintSet and Printer
1 Start up the printer and select Shell. Press <Enter> to go to the “SEL.
APPLICATION” menu. Use <⇒> to browse to “SOFTWARE
UPDATE”. Press <Enter> to go to the “UPDATE: COMPACT
FLASH?” menu. Use <⇒> to go to “UPDATE: FIRMWARE?”. Finally,
press <Enter>.
User might not be allowed to update.
2 Start to send the file from the software. (There is a one-minute timeout
before the printer exits the receive mode.)
3 After file is received in printer, it will automatically replace the firmware
and the printer will boot up with the new version.

Worldwide Headquarters
6001 36th Avenue West
Everett, Washington 98203
U.S.A.
tel 425.348.2600
fax 425.355.9551
www.intermec.com
*1-960588-04*
P/N 1-960588-04

PM4i Service Manual

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PM4i Service Manual

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Service Manual

ii EasyCoder PM4i Bar Code Label Printer Service Manual

1 Models and Options

2 Front and Keyboard

3 Covers and Doors

4 Chassis 4.1 Description........... ........................................................................................................24

6 Transfer Ribbon Mechanism

EasyCoder PM4i Bar Code Label Printer Service Manual iii

9 Label Taken Sensor

iv EasyCoder PM4i Bar Code Label Printer Service Manual

15 RFID 15.1 Key Components of Intermec RFID Kits ..................................................................182

EasyCoder PM4i Bar Code Label Printer Service Manual v

EasyCoder PM4i Bar Code Label Printer Service Manual vii

Global Services and Support

viii EasyCoder PM4i Bar Code Label Printer Service Manual

EasyCoder PM4i Bar Code Label Printer Service Manual ix

x EasyCoder PM4i Bar Code Label Printer Service Manual

This chapter describes how to identify the various conﬁgurations of the

EasyCoder PM4i Bar Code Label Printer Service Manual 1

2 EasyCoder PM4i Bar Code Label Printer Service Manual

EasyCoder PM4i Bar Code Label Printer Service Manual 3

Options for EasyCoder PM4i Printer

Side door with keylock

Cover Fan-fold guide

Cutter tray Special printheads Liner takeup unit 3-inch adapter

4 EasyCoder PM4i Bar Code Label Printer Service Manual

Provision for Ether-

Provision for Easy-

EasyCoder PM4i Bar Code Label Printer Service Manual 5

Checking Hardware and Firmware

6 EasyCoder PM4i Bar Code Label Printer Service Manual

1.2 EasyCoder PM4i Printer Specifications

EasyCoder PM4i Bar Code Label Printer Service Manual 7

8 EasyCoder PM4i Bar Code Label Printer Service Manual

1.3 EasyCoder PM4i Printer Dimensions

539 mm (21.22 in.)

101 mm (3.98 in.)

Edge of cover to dot #0: Media path

EasyCoder PM4i Bar Code Label Printer Service Manual 9

298 mm (11.73 in.)

250 mm (9.84 in.)

Hole: Ø 7.1 mm (0.28 in.)

10 EasyCoder PM4i Bar Code Label Printer Service Manual

Cutter with Tray, Side View

100 mm (3.94 in.)

154 mm (6.06 in.) 593 mm (23.35 in.)

747 mm (29.41 in.)

Cutter with Tray, Top View

EasyCoder PM4i Bar Code Label Printer Service Manual 11

Open Cutter, Side View

644 mm (25.35 in.)

12 EasyCoder PM4i Bar Code Label Printer Service Manual

EasyCoder PM4i Bar Code Label Printer Service Manual 13

#T10 Torx screws (x3)

14 EasyCoder PM4i Bar Code Label Printer Service Manual

Fingerprint overlay IPL overlay

Print Button Layer

EasyCoder PM4i Bar Code Label Printer Service Manual 15

2.3 Console PCB

16 EasyCoder PM4i Bar Code Label Printer Service Manual

1-971651-26 Console PCB; Components

EasyCoder PM4i Bar Code Label Printer Service Manual 17

EasyCoder PM4i Bar Code Label Printer Service Manual