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Maintenance Manual
HP PCL-4, and HP Laser Jet II are Trademarks of Hewlett Packard Corporation
CG Triumvirate is a trademark of Agfa Corporation.
CG Times, based upon Times New Roman under license from The Monotype Corporation.
plc, is a product of Agfa Corporation.
Futura is a registered trademark of Fundición Tipográfica Neufville, S.A.
Allegro, SEAQ, and PC Batch are trademarks of Datamax Barcode Products Corporation.
As an Energy Star Partner, Datamax Corporation has determined that this product meets the Energy Star guidelines for
energy efficiency.
Firmware (Software) Agreement: The enclosed Firmware (Software) resident in the EPROM’s is owned by Licensor
or its suppliers and is licensed for used only on a single printer in the user’s Trade or Business. The User agrees not to,
and not to authorize or permit any other person or party to, duplicate or copy the EPROM’s or the information
contained in the EPROM’s. The firmware (Software) is protected by applicable copyright laws and Licensor retains all
rights not expressly granted. In no event will Licensor or its suppliers be liable for any damages or loss, including direct,
incidental, economic, special, or consequential damages, arising out of the use or inability to use the Firmware
(Software).
Information in this document is subject to change without notice and does not represent a commitment on the part of
Datamax Barcode Products Corporation. No part of this manual may be reproduced or transmitted in any form or by
any means, for any purpose other than the purchaser's personal use, without the expressed written permission of
Datamax Corporation.
7500 Flying Cloud Drive • Suite 655 • Eden Prairie, Minnesota 55344 • (612) 946-0026
Für 230 Volt (Europa): Benützen Sie ein Kabel, das mit "HAR" markiert ist, bestehend mindestens aus einem H05VV-
F Kabel, das mindestens 0,75 Quadratmillimeter Drahtdurchmesser hat; sowie eine IEC320 Steckdose und einen für
das Land geeigneten Stecker, 6A, 250 Volt.
For 230 Volt Operation (Europe): Use a cord set, marked "HAR," consisting of a min H05VV-F cord which has a
minimum 0.75 square mm diameter conductors, provided with an IEC 320 receptacle and a male plug for the country of
installation rated 6A, 250V
Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15
of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instructions in this manual, it may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.
Important Safety Instructions
This printer has been carefully designed to give you many years of safe, reliable performance. As with all electrical
equipment, however, there are a few basic precautions you should take to avoid hurting yourself or damaging the printer:
• Carefully read the installation and operating instructions provided with your printer.
• To protect your printer from overheating, make sure all openings on the printer are not blocked.
• Do not use your printer near water, or spill liquid into it.
• Be certain that your power source matches the rating listed on your printer. If you are unsure, check with your
dealer or with your local power company.
• Do not place the power cord where it will be walked on. If the power cord becomes damaged or frayed replace it
immediately.
• Do not insert anything into the ventilation slots or openings on the printer.
• Only qualified, trained service technicians should attempt to repair your printer.
♦ Contents
♦ Appendix A
ASCII Control Code Chart ...................................................................................................... A-1
♦ Appendix B
Switch Settings and Cable Interfacing...................................................................................... B-1
♦ Appendix C
Available Fonts and Barcodes.................................................................................................. C-1
♦ Appendix D
Cable Listings ......................................................................................................................... D-1
♦ Appendix E
Error Codes....................................................................................................................................E-1
♦ Appendix F
Specifications .................................................................................................................................F-1
♦ Appendix G
Warranty Information .................................................................................................................... G-1
ii
Introduction and Overview
1.0 Introduction
The Allegro Label Printer, hereafter referred to as the "Printer", incorporates high-performance/low
cost direct thermal and optional thermal-transfer label printing capabilities. The combination of
powerful capabilities, easy-to-use features, a contemporary look, and affordable pricing set a new
standard for direct-thermal and thermal-transfer label printers in retail, office and industrial
applications.
The Printer is factory installed with all standard bar codes and a variety of font styles and sizes
already stored in memory. The Printer is designed to work with any IBM compatible
personal computer, and may be modified to perform with Mainframe computers and other
work stations.
This manual is intended to provide the technician with all of the information needed to set-up,
adjust, and troubleshoot the Printer, and to perform any necessary maintenance. For additional
information on the day-to-day operation of the Printer, please refer to the Allegro Printer
Operations Manual.
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
1.1 Overview
The Printer can be divided into three main areas; the Media Path, the Printhead area, and the
Electronics and Power area. A description of each area is described below.
Media Path: Consists of the transport mechanism that moves print media through the
Printer, and includes the supply and take-up hubs, ribbon transport,
motors, drive belts, idler rollers and related mechanical parts.
The Printhead Area: Contains the printhead and printhead mounting assembly, printhead
adjustments, media edge sensor and latching mechanism.
Electronics and Power: Includes the main logic, front panel, options interfacing, sensor circuit
boards, and the power supply.
1.2 Specifications
Switches: Power, Pause, Feed, Stop/Cancel, Thermal/Thermal Transfer, Baud Rate Selection
and Function Switch Bank Variable Head Temperature Control
Communications Interfacing
IEEE RS-232C +RS-422: 300, 600, 1200, 2400, 4800, or 9600 baud.
Character Set: ANSI ASCII character set
Input Buffer: Approximately 7000 bytes. Xoff is transmitted and DTR goes low
when 750 bytes are available in the buffer. Xon is transmitted and
DTR goes high when 750 bytes are left in the buffer. Characters are
transmitted with no parity from the Printer.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
Electrical
Power Source: 115, 220/240 VAC, 50/60 Hz
Circuit Protection: 115 VAC: 1 amp time delay fuse; 230: 2 time delay fuses T 0.5 amp
Environmental
Operating
Temperature: 40°F to 90°F (4°C to 32°C)
Storage
Temperature: 32°F to 120°F (0°C to 49°C)
Electromagnetic
Radiation: Moderate RF fields can be tolerated
Physical
Dimensions: 8.8"H x 16.6"W x 14.5"D (224mmH x 421mmW x 368 mmD)
3
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
Options
Front Rewind: 6" (152mm) maximum O.D. capacity (full supply roll)
8” (203mm) maximum O.D. capacity (full supply roll)
256K and 512K RAM Used for temporary storage of fonts, formats and graphics; 512K
Memory modules: Module also extends label length to 20.25" (514mm).
4
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
5
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
6
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
7
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Introduction and Overview
8
2.0 Set-up and Configuration
• Ensure that the work area conditions are within recommended environmental range, (See
Section 1.3)
• Ensure that the supply voltage is correct for the version of the printer (115V or 230V).
Protocols: Most host devices will provide the RS-232c serial protocol. If the RS-422 protocol
is required, an optional RS-422 interface is available.
Cable Type: The following table is a list of Datamax cables available, with Part Numbers:
Note: The pin connections for all of the usable cable types, as well as installation instructions for the
Centronics Parallel Interface Converter cable, are listed in the Appendix.
Handshaking: The Printer is DTE equipment and supports both CTS/DTR and XON/XOFF
handshaking. (Note - in RS-422 protocol, only XON/XOFF handshaking is used).
Baud Rate: These settings are also determined by the host device requirements. They are
selected by setting switches on DIP Switch SW1, (see Figure 1-4 for DIP Switch
locations).
The Printer can accept either 7 or 8 bit data words, and at least one Stop Bit is
required. If ASCII characters 128-255 (foreign language characters) are to be
used, the 8 Data Bit, 1 Stop Bit option must be selected.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
If the cutter option, internal batch mode, or prodigy emulation are to be used, they must be selected
by setting the appropriate DIP switch. Section 2-2 describes in detail installing the various options.
Table 2-2 lists the correct DIP switch settings.
11
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
DIP Switch SW-1, located on the back of the Printer, is used to select the baud rate, word length,
prodigy printer emulation, and to enable the Cutter and Internal Batch options.
Baud Rate
Baud 9600 4800 2400 1200 600 300 Test
SW-1 OFF OFF OFF OFF ON ON ON
SW-2 OFF OFF ON ON OFF OFF ON
SW-3 OFF ON OFF ON OFF ON ON
Word Length
SW-4 Data Bits Parity Stop Bits
ON 7 NONE 2
OFF 8 NONE 1
Printer Options
SW-5 SW-6 SW-7 SW-8
FUNCTIO Compatibili Not used Batch Cutter
N ty
ON Prodigy N/A Enabled Enable
d
OFF Allegro N/A Disabled Disabl
ed
12
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
Table 2-3 lists the available modules and their Part Numbers.
13
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
RAM Modules are available in both 256K and 512K capacity. Both size modules will add 256K of memory
space for storing soft font, graphics, and label format data storage. The 512K RAM module also provides an
additional 256K for the label format buffer, which increases the maximum label length from 8.25 in. to 20 in.
RAM memory is volatile, that is, it requires power in order to retain data. When the Printer is turned off, all
data stored in RAM will be lost.
The 256K FLASH module provides the same storage function as the 256K RAM module, with the added
advantage that the FLASH module is non-volatile, that is, data will be held until erased or overwritten, even
without power.
NOTE - When using the Internal Batch program, a 256K FLASH module is required.
Six 512K FONT modules are available. They are listed, along with other module types, in Table 2-3.
14
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
The following is a list of the connector sockets on the Printer Main PC Board.
Fig. 2-2 shows the location of these connectors (J1 - J9) and of Test Points TP1 - TP3
J1 - Options Board Connector - Connects the Options P.C. Board to the Main Logic Board
J2 - Front Panel Connector - Connects the Front Panel P.C. Board to the Main Logic Board.
J3 - Power Connector - Supplies power from the Power Supply to the Main Logic Board.
J5 - Label Sensor - Provides connection for the Label (Media Edge) Sensor.
J7 - Printhead - Provides connection for power and control signals for the Printhead.
J8 - Memory Module I/O - Provides connection for data signals to and from the external memory
modules.
J9 - Motor - Provides connection for power and control signals to the Printer's Line Feed Stepper Motor.
Test Points TP1-TP3 may be monitored for specific voltages during test procedures.
15
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
16
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
17
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Setup and Configuration
18
3. Basic Operations
♦ The Control Panel
♦ Loading Media
♦ Changing Ribbons
♦ Maintenance
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
20
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
This section briefly reviews the basic operation of the Printer, including the use of the Control Panel
and buttons, loading label stock, installing ribbons and using the Printer’s self test function.
• Pause The Pause button allows a print job to be interrupted and then re-started. Pushing the
switch causes the Printer to (1) stop printing upon completion of the current label, (2) turn
on the Pause indicator, and (3) stop the label counter while holding the count balance. All
data is retained in memory.
Pressing Pause a second time will (1) turn off the Pause indicator, and (2) re-start the
Printer and cause it to continue with the current print job.
21
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
• Feed The Feed button allows the operator to control the feeding of labels through the
Printer. The button works in different ways, depending on whether the Printer is
currently On Line or on Pause.
When On Line, the Printer will first finish printing the current job, and then feed one
label.
• Stop/Cancel Pushing the Stop/Cancel button cancels the current print job. If another print job has
been sent to the Printer, it will begin to print the next job. If there is no other job, the
Printer stops.
Located above the Control Buttons are LEDs that provide information on machine status. The LED’s
are labeled On Line/Pause, Ribbon/Media, and Power.
• On Line/Pause The LED is on when the Printer is Paused, and off when the Printer is On Line.
• Paper/Ribbon This LED is normally off. It comes on only to indicate a fault in the Media or Ribbon
path.
• Power This LED comes on when the Printer is powered up, and stays on as long as the
Printer is receiving power.
• Transfer Switch Sets the Printer for either Thermal Transfer or Direct Thermal media.
Must be in the ON position when printing with a ribbon installed.
22
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
The Printer can use either of two printing methods, called Direct Thermal and Thermal Transfer.
Both methods use heat to produce the printed image - they differ in the way in which the heat is
applied.
In Thermal Transfer printing, the individual dot elements of the Printhead apply heat to a ribbon. The
“ink” on the ribbon is a specially formulated material that is literally melted into the print media,
bonding with it to produce the black dots that form an image.
Direct Thermal printing dispenses with a ribbon and instead applies heat directly to the print media.
This media is formulated to react to the heat by turning black. Direct Thermal printing requires the use
of a special Direct Thermal print media. It also requires that if a ribbon is already installed it must be
removed.
NOTE - When Printing with the Thermal Transfer method, the Transfer Switch must be set to ON (See
Figure 3-1 for Transfer Switch Location). For Direct Thermal, the switch must be set to OFF.
NOTE - Using Direct Thermal print media while a ribbon is installed will produce unacceptably poor
print quality.
23
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
3.2.2 Media
The Printer is designed to make loading media and ribbons a simple task. The following section
describes in detail how to load stock and ribbons.
· Slide the Media Retainer to the outer edge of the Supply Roll Bracket and swing the Media Guide
out and to the DOWN position.
¹ Swing the Media Retainer back to the UP position and slide it in until just touching the supply
roll.
º Route the media between the Guide Plates and Sensor, and over the Platen Roller.
» Turn the Head Lift Lever counter-clockwise to the DOWN position. Flip the Media Guide UP and
slide it in until it just touches the media edge.
¼ Press the FEED button. Note - It may be necessary to feed a few labels before they align
themselves correctly.
RIBBON RIBBON MEDIA
TAKE-UP SUPPLY SUPPLY MEDIA
HUB HUB ROLL RETAINER
DARKER
ON
RIBBON
OFF
HEAD
LIFT
UP
LEVER
DOWN
MEDIA
OUT
PATH
24
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
When the stock is correctly loaded, the Media Sensor will detect the leading edge of each label as it
passes through the Printer. If the Printer advances stock more than 12 in. (305 mm.) without detecting
a label edge, an error condition will be triggered - the Printer will stop and the PAPER OUT light
will go ON. If this happens, first, be sure that the stock is routed as shown in Fig. 3-2. If the stock is
routed correct, adjust the Media Sensor by turning the Edge Sensor Adjust Knob (See Fig. 1-6)
clockwise one half-turn at a time until the error condition clears. If the adjustment fails to correct the
problem, refer to Section 4, "Troubleshooting".
If the stock feeds only a short distance and does not seem to stop on a label edge when the FEED
button is pressed, the THERMAL TRANSFER switch may be set to the ON position without a
ribbon installed. For Direct Thermal printing (no ribbon), the Transfer switch must in the OFF
position.
The Printer accepts a wide range of media sizes. It can be loaded with Roll Fed media of either
Thermal Transfer or Direct Thermal type. The table below lists the range of acceptable sizes
Minimum Maximum
Width .75 in. (19mm) 4.65 in. (118mm)
Maximum Recommended Width 4.25 in. (108mm)
Thickness .0025in (.0535mm) .01 in. (254mm)
25
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
When using thermal transfer stock, a ribbon must be installed and the Thermal Transfer switch (Fig.
3-1) must be turned ON.
¹ Place the ribbon over the hub and slide the Ribbon Clasp onto the hub and ribbon.
Note: It may be necessary to feed a few labels before the ribbon aligns itself correctly.
To Remove Ribbon
Ribbon may be removed completely from the Printer, if desired. However, the procedure in Sec.
3.2.2.5 is also acceptable, and is generally more convenient.
· Remove the Ribbon Clasp, and unwind the end of the ribbon from the Supply Hub.
¸ Carefully pull the free end of the Ribbon back through the media path.
26
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
When switching between Thermal Transfer and Direct Thermal media for different printing jobs, it is
not necessary to remove the ribbon completely. The ribbon may be removed from the Media Path,
without removing it from the Printer completely, in the following manner:
¶ Cut or tear the ribbon at a point near the Ribbon Take-up Hub.
· Turn the Head Lift Lever clockwise, to the UP position. It is not necessary to remove the
unused portion of the ribbon. Turn the Ribbon Shaft Supply Hub clockwise to draw the
unused portion of the ribbon back until it is clear of the Printhead.
¸ Turn the Ribbon Shaft Take-up Hub counter-clockwise to roll up the used portion of the
ribbon
¹ Remove the Ribbon Clasp, slide the used ribbon off the Hub and dispose of it.
º Turn the Head Lift Lever counter-clockwise to the DOWN position to lock the Printhead
The unused portion of the ribbon may be left in place until the next Thermal Transfer print job, at
which time it may be re-installed following the ribbon installation procedure
Once the label stock (and ribbon, in thermal transfer mode) have been loaded, the next step is to
perform a Self Test. See Sec. 4, "Troubleshooting", for instructions on the Self Test.
NOTE - When performing the Self Test, for best results use labels 2.5 in. x 4.25 in. (64 x 108 mm.) or
larger.
27
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
Memory modules are used for storing; (1) graphic images, (2) bitmaps of smooth fonts, (3) label
formats for recall by host computers, and (4) Internal Batch program formats.
Memory modules are inserted into the slot located on the upper left side of the Printer (See Figure 3-3).
Place the module cartridge with the label facing the front of the printer, and slide the cartridge into the
slot until it seats itself.
28
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
The Printer has a built-in set of fonts. Additional font styles are available, stored on Font ROM
modules. The modules are programmed at the factory and cannot be used for any other purpose. The
documentation included with each module explains the font style, size range, and the font number for
each size.
When creating labels, label size is directly related to memory space. Creating larger or longer labels
uses more memory. SRAM modules are a simple way of plugging in more memory, making it possible
to print longer labels. Modules are available in two versions, 256K and 512K. The 256K SRAM
module provides storage space that can be used for fonts, graphic images or label formats. Like the
256K version, the 512K SRAM module sets aside 256K for data storage space. The remaining 256K
is used by the printer to extend its bit-mapped label area from 8.25 in. (210mm) to 20.25 in. (514mm).
When a module is added, the Printer recognizes the module as (external) Memory Bank B and uses it in
addition to its own 48K of built-in memory (Bank A). Data can be stored in the popular HP PCL-4
format (used by the HP LaserJet printer), as well as .PCX, .IMG, and .BMP formats.
RAM modules cannot be selectively erased. In order to remove a part of the data, the entire module
must be erased and the desired data re-loaded. In addition, RAM is "volatile", that is, it requires power
to operate. Turning the printer off, or removing the module, causes immediate loss of the data. (Note -
some popular Bar Code label programs require the use of volatile RAM).
FLASH modules provide the same features as RAM modules, with the added benefit of virtually
permanent storage. Unlike the RAM module, FLASH memory does not require power in order to
retain data. In addition, the module contains a WRITE PROTECT switch to prevent data stored on
the cartridge from being overwritten or erased.
29
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
This option consists of a Cutter mechanism and a tray. The Cutter mechanism shears off labels from
continuous rolls, under the control of the Printer. The cut labels are collected in the tray. The Printer
may be ordered with the option factory installed, or it may be ordered and installed later by the user.
When ordered separately, the option comes with complete installation instructions.
CAUTION: If attaching or removing the Cutter option, turn the printer OFF for 2 minutes or longer
before proceeding.
¸ Remove the Cover Plate (or Tear-Off Bar, if installed) in the following way:
(a.) Lift the Cover Plate or Tear-Off Bar until it releases, and
(b.) Pull it straight out and away from the printer. Store the Plate or Tear-Off
Bar for future use.
¹ Slide label stock through Cutter (from back to front) until the stock extends a few inches beyond the
mechanism.
º Line up the mounting pins on the back of the Cutter with the installation slots on the Printer (Located
just below the drive roller). Slide the pins straight into the slots and push down until the Cutter snaps
into place. Make sure that the stock is free to flow through the Cutter mechanism.
» Plug the Cutter's power cable into the Options Connection (J2) located on the right side of the
Printer, below the Label Edge Sensor Adjustment Knob (See Fig. 3-4).
30
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
½ Locate DIP Switch SW1 (See Figure 2-1 for switch location). Turn the switch in position 8 to the
ON position to enable the options port (J2).
¾ Turn the printer ON. The cutter should complete one cutting cycle when the Printer goes on. Test the
cutter by pressing the FEED button. The Printer should feed and cut one label
31
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
• Exterior The exterior surfaces may be cleaned as needed, using a general purpose cleaner and a damp (not
wet) soft cloth or sponge. Do not use abrasive cleansers or solvents.
NOTE: This condition will be encountered more often if poor quality paper has been used. To minimize the
chance of this happening, always use good quality stock. Your local printer supplier can provide a
list of approved stock types.
The Printhead must be cleaned as needed. If spots, streaks, or drop-outs appear on printed labels, the first
step in improving print quality should be to clean the Printhead.
In Thermal Transfer printing, the ribbon will help to keep the Printhead clean, so, remember that if Direct
Thermal is the main printing mode in use, the Printhead will require cleaning more often.
Two cleaning methods are outlined below. The quick cleaning method is convenient, since it does not require
that the Printhead be removed. However, this method may not remove heavy buildups of debris. In these cases,
the Thorough Cleaning method should be used.
32
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
· Raise the Printer cover and turn the Head Lift Lever to the UP position.
¹ Insert the swab into the Printhead area as shown in Fig. 3-5. Gently rub the underside of the
Printhead with the moistened swab.
33
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
¶ Remove the Printhead from the printer. (See Section 6.3.1, Printhead Replacement and
Adjustment, steps 1-7.)
· Lay the Printhead on a flat surface with the aluminum heat-sink side facing down.
¸ Dampen (do not soak) a soft clean cloth with Isopropyl (Rubbing) alcohol solution, and rub the
Printhead gently until the dirt is removed from the surface of the Printhead.
CAUTION - The edges of the Printhead are sharp. Avoid touching them. Also, do not touch the print
surface of the Printhead with any sharp object.
º Reinstall the Printhead into the printer. (See Sec. 6.3.2, Printhead Replacement and Adjustment,
steps 8-10.)
34
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
Print quality may also be adversely affected if the drive roller becomes contaminated with grit, label adhesive
or ink.
· Turn the Head Lift Lever to raise the Printhead to the UP position.
¸ Dampen a soft, clean cloth with Isopropyl (Rubbing) alcohol and wipe off any accumulated debris
from the Drive Roller.
NOTE - For very bad soiling, acetone may be used to remove severe contamination build-ups.
3.6 Lubrication
All bearings in the Printer are either permanently lubricated or made of materials that do not require
lubrication. The Slip Clutches are pre-lubricated, and therefore, under normal circumstances they need no
lubrication. However, if the Ribbon Supply Slip Clutch begins to squeak or hum, it may be lubricated as
follows:
To lubricate:
¶ Remove the Printer cover to expose the electronics compartment. (Sec. 6.1)
· Using needle-nosed pliers, or a similar tool, unhook one end of the Clutch Spring from the Shaft Support
Bracket (Fig. 3-7).
¸ Apply small amount of IBM #23 grease into groove on the Slip Clutch pulley.
35
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Basic Operations
36
4. Troubleshooting
• Self Test
• Configuration and Test Labels
• Increasing Processing Speed
• Troubleshooting Procedures
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
38
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
4.0 Overview
This chapter discusses a number of topics related to troubleshooting the Printer. It covers the
generation and use of the pre-programmed Configuration and Test Labels, the Printer's Power On Self
Test, Error Messages and their causes, and some techniques for isolating and correcting faults.
When faults are isolated to the Main Logic or Operator’s Panel P.C. boards, it is recommended that the
entire P.C. board be replaced. Only insertion and removal instructions for socketed components, (i.e;
RAM, EPROM, etc.) and jumper settings are provided in this manual. It is not generally feasible to
provide component level service in the field.
· Press the FEED button, and, while holding the button down, turn the power ON.
The printer will power up in the Self Test mode. It will feed one blank label and then print two Test
Labels. The first label is the Configuration Test Label, which contains a listing of the Printer's
current set-up and status. The second label is the Dot Pattern Test Label, which is an array of printed
dots that is very useful when testing for possible Printhead faults.
When the self test is complete, the printer shifts to the Character Dump mode. In its normal mode,
some of the data sent to the Printer would represent the characters to be printed, while other data would
be format commands and other control codes. In Character Dump mode, the Printer will print the
numerical data sent from the host as though they were all ASCII characters. This mode is useful
when testing serial transmissions from the host device to the printer.
39
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
To avoid this problem, a special software command was written which starts the Self-Test without
allowing the Printer to re-set the defaults. The command STX Z will print the Self Test information
and STX P will change to Character Dump Mode.
A sample program which will send these software commands is listed in the Appendix. Complete
information on sending software commands may be found in the Programmer's Manual for Allegro,
Prodigy, and Prodigy Plus (Part No. 88-2054-01).
The operation of the Serial Ports (RS-232c or RS-422) can be checked by plugging a Loopback Test
Plug into the Serial Port and performing the TXD/RXD and CTS/RTS loop check tests. The Loop
Checks will automatically be performed as a part of the Self-Test, so long as the Test Plug has been
plugged in before the tests are started.
If a Test Plug is not available, one can be made by following the connection pattern shown in Appendix
Sec. A-1.
If the Loopback Tests were successful, the test results will be printed on lines 7 and 8 of the Test
Label.
If the tests are not successful, lines 7 and 8 of the Test Label will be blank.
If the Printer passes one test and fails the other, the result of the successful test will be printed in the
appropriate line.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
Figure 4-1, below, is an example of the Self Test Label. The remainder of this section describes the
items on the label in detail.
41
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
NOTE - Lines 7 and 8 will be printed only if the Test Plug is installed and the Serial
communications are operating correctly. If the test plug is installed and this line still
does not appear on the test label, a hardware problem with the printer’s
communications system should be suspected.
42
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
Lines 11 and 12 of the Test Label indicate the positions of the switches of DIP switch SW1. These
switches should be correctly set during the Printer's initial configuration. The meanings of the switch
settings are discussed in Sec. 2.1.
LINES 14 - 16 of the Test Label are values which correspond to the voltages that were detected in the
Analog to Digital converter circuits on the Printer's Main Logic Board. The voltages will normally vary
slightly from printer to printer and from label to label. The information is usually most useful during
in-shop technical support, but may also be useful when troubleshooting in the field.
Values may range from 0 to 255, where 000 = 0.0 V, 1.00 = 19.6 mV, and 255 = 5.0 V.
PAPER: 229
EDGE: 173
The PAPER and EDGE values are voltages measured in the Media Edge and Reflective Sensors.
Potentiometer RP2 controls this value. The PAPER value represents the voltage detected when paper is
present in the sensor. The EDGE value represents the voltage detected when only media backing is
present at the sensor. The PAPER value should always be larger than the EDGE, usually about 120%
greater.
43
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
TEMP: 062
The TEMP value is the voltage detected at the Printhead Thermistor. During power up or idle at
room temperature, this value should be between 060 and 065. Normal printing will produce readings
ranging from 070 to 120. Consistent readings above 130 indicate voltages that could decrease the life
of the Printhead.
POT: 133
POT is the voltage setting of the Darkness Potentiometer on the front panel board. It will vary from
000 (darkest) to 255 (lightest). Generally, this value should be set to a midrange of 128.
VOLT: 195
VOLT is a voltage reading is meant expressly for engineering and production use at the factory. It
should be somewhere near 190.
This is a test of the data in the Font Cartridge. The test will be performed if a font module is installed
in slot B. Each module has a different checksum value. Table 2-1 lists the proper checksums for each
type of module.
Checksum Module
0CA3 CG Triumvirate Italic
41E5 CG Triumvirate Bold
8B5A CG Times
F146 CG Times Bold
62E9 Plantin
F0E9 Futura Extra Bold Condensed
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
The second label printed is the Dot Pattern Label. This is an element and electronic matrix test which
checks all of the Printhead’s electronic circuitry. If there is a hardware problem, such as a burned out
Printhead element, the defect will show up on the test label (shown below). This label will print the
entire width of the Printhead. If there are areas of missing print, including streaks or spots, refer to Sec.
4.4.3, Troubleshooting, "Problem Isolation Checklist - Print Quality".
Fig. 4-2.
Dot Test Label
Once the Dot Pattern Test Label has been printed, the Printer will set itself to Character Dump Mode.
This means that all data sent from the host device will be printed as a continuous string of data. Any
numeric value that equals an ASCII character will be printed as that character (Any ASCII values less
than 20 are interpreted as control characters).
The Printer will begin to print the data in its buffer as soon as a full line of information has been
received from the host, or whenever the data stream from the host has been paused for more than 0.25
second.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
Character Dump mode is used mainly to detect problems in the data flow from the host to the Printer.
The simplest way to check the data flow is to repeatedly send label data (such as the example shown in
Fig. 4-3) to the Printer. The test will uncover such errors as data corrupted by a defective cable, Serial
Port malfunctions, or overflow of the Printer's buffer (which is characterized by large gaps in the
printed text). A sample Test Label program is included in Appendix Section A2.1.
^Bs^M^BO0000^M^BM3000^MBL^M:0001^MC0000^MH
10^MD11^MR0000^M^01^M1Y1100000050000MAN3^M
191100700850097PACKING^M191100700450097LIS
T^M191100700050097ENCLOSED^MQ0005^ME^M
NOTE - When the self test is complete, to reset the printer, turn the power OFF, wait approximately two
seconds, and turn power back ON. This is the only method that will return the printer to normal
operation.
46
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
The label formatting process requires time to read the label field data and to move it into the Printer's
bit-mapped buffers. Before the Printer can begin to print the label it must process and map 203 Kbytes
of data. This can take from virtually no time at all to several seconds, depending on the complexity of
the label format and the size of the area that will be printed on.
When the processing and mapping process is complete, the printer will begin to print as many labels as
were requested by the software's Quantity command. Generally there is no delay between the printing
of each label. However, the following situations will tend to add time between each label.
• Printing different data on each label. A batch of different labels are being sent to the printer in
a continuous string of data. The Printer must process and map between each label.
• Placing an incrementing field in the label format. An Incrementing field is one in which the
value of the field changes by a set amount between each label. These fields are embedded in the
label format and will continue to change the label format until the end of the batch has been
reached.
• Including a time and date field in the label format. If the time and date are to be printed on the
label, the field must be updated for every label printed in the batch.
• Using external module fonts. Time is added because the Printer must refer to the external
module in addition to the normal processing time.
• Printing in rotations other than 1. Rotation adds a step to the normal processing cycle.
• Using the Cutter option. The printer must stop and wait for the cutter to execute the cutting
cycle.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
Data loss and other communication problems can have many sources. This section presents some ideas
on ways to isolate these problems and determine their cause.
The Printer is a Serial ASCII device, that is, the host system must be able to interface to other
equipment in ASCII format, using a serial communication I/O port. The Printer uses both hardware
and software handshaking and sends both forms of handshaking simultaneously whenever the printer's
input buffer is full. Handshaking is the practice of using a standard set of control signals, either
software codes or signals sent by wire, to reduce the occurrence of lost data. Loss of data will cause
printing errors.
The Printer's hardware handshaking is the logic state on pin 20 of connector J4, the RS-232/422
communications port located at the back of the printer (See Figure 1-4 for location). This signal will be
High when the printer is ready to receive data. The signal will be Low when the Printer's input buffer
is full. In this state, the printer is busy and can no longer receive data.
The Printer uses the software handshaking standard called XON/XOFF. In this system, when the
Printer's input buffer is full, an XOFF (CHR$19) character is sent, which tells the host system that
the printer is full and cannot receive any more data. When the input buffer has memory space
available, the printer will send an XON (CHR$17) character. This tells the host device that the printer
is ready to receive more data.
If the printer seems to have communication problems, check the following first:
¶ Verify that the correct interface cable is installed between the host device and the Printer.
The wrong kind of cable will make it impossible for the Printer to communicate correctly.
· Verify that the DIP Switch positions (Switch S1, located on the back of the printer) are set
correctly for the current application.
Printing the Configuration Test Labels, using the Character Dump Mode, and performing the
Loopback Tests will help identify the type of printer set-up errors that can generate
problems.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
When the printer receives data from any host system, it will not function properly with an incorrectly
wired cable. Proper wiring diagrams can be found in the Appendix. Table 4-2, below, lists the signal
lines that must be correctly wired for the printer to operate properly.
Signal Pin
TX 2
RX 3
BU 20
SY
Gro 7
und
Jum 4 to
per 5
Shie 1
ld
Each time the Printer is powered up, it will reset itself to default (pre-determined) interfacing
parameters. The default values are in listed in Table 4-3.
Changing the positions on DIP Switch SW1 (on the back of the Printer) sets the unit for applications
needing settings other than the defaults. Table 2-2 lists all of the switch positions and their meanings.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
4.4 Troubleshooting
Should the Printer malfunction and require service, the following procedures should be used to isolate
and correct the malfunction.
WARNING - ALWAYS UNPLUG the unit before attempting to replace any parts. ALWAYS be
sure that the Printer has been placed on a level, stable surface.
¶ Be sure the Printer's power cord has been plugged into a known good outlet of the correct
voltage.
· Be sure the unit has been installed in an area which is within acceptable environmental
conditions Sec. 1.3).
¸ Perform a visual inspection of the Printer. Excessive accumulation of dirt or dust should
be removed (Sec. 3.4.1).
¹ Confirm that the Printer has been correctly loaded with media of an acceptable type (Sec.
3.2).
After performing the initial checks and confirming that conditions are correct, follow the Problem
Isolation Checklist (Sec. 4.4.3). The Checklist is designed to direct the Technician to the appropriate
repair routine.
Always begin with Step 1, follow the instruction listed under Check Item, and answer the question,
either Yes or No, listed under Result. The Corrective Action will direct the Technician either to
another step or to one of the Troubleshooting Procedures.
When using the Troubleshooting Procedures, again, always begin with Step 1 and proceed in the
same way as with the Problem Isolation Checklist. The Corrective Action will direct the Technician
either to another step or to a suggested repair.
50
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
51
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
52
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
53
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
4.4.3.2 Procedure 2 - Printer Powers Up, But Will Not Print Test Labels.
54
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
55
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
56
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
57
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Troubleshooting
58
5. Adjustments
• Printhead Alignment
• Non-Standard Stock
• Sensors
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
60
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
5.1 Introduction
This chapter discusses the adjustments that might sometimes be necessary to keep the Printer at
maximum performance. Most often, adjustments are needed when the label stock being used varies
significantly from the standard size of 4 in. width and 4 mil thickness. There are also adjustments that
should be made when major components, such as the Printhead, have been replaced.
The two most important factors that determine print quality are the amount of heat applied to the
Printhead, and the position of the Printhead relative to the label media.
Applied Heat
The heat that must be generated by the Printhead depends on the Reaction Temperature of the Print
Media or Thermal Transfer Ribbon. The reaction temperature is the amount of heat needed to turn the
media black, or to transfer an image from the ribbon. Many low cost types of direct thermal stock have
very high reaction temperatures - it takes a great deal of heat to make clear images on this type of
paper. On the other hand, Thermal Transfer Ribbons have a relatively low Reaction Temperature. The
Printer has limits placed in the range of possible heat adjustments, in order to prevent settings that
could damage the Printhead. The applied heat may be controlled either by adjusting the Darkness
potentiometer, or by increasing the burn time through software. (For more information on adjusting
burn time with software, see the Programmer's Manual for Allegro, Prodigy and Prodigy Plus,
"Label Format Commands".)
Printhead Position
The Printer has been factory set to produce good print quality with most media. However, when using
stock other than the recommended 4 mil thickness, the Printhead position, ribbon, and media
tracking may all require slight adjustments in order to maintain highest quality.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
• Narrow Stock
When using stock narrower than the standard 4 in. width, an adjustment may be needed to prevent the
Printhead from rubbing on the Drive Roller.
• Electrical Adjustments
It is normal for the Printer's Edge Sensors to occasionally need small electrical adjustment to keep the
sensor's sensitivity in the correct range. It may also sometimes be necessary to confirm the Power
Supply voltage levels or ground.
NOTE - Unless otherwise stated, all adjustments should be performed with label stock that is at least 4 in.
(102mm) wide. If the media that will normally be used is of a different size, make the standard
adjustments first (using 4 in. media), and then fine tune the adjustments using the stock size that
will be actually used.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
The Head Support Plate, shown in the figure above, is designed to support the outer end of the
Printhead when narrow stock is in use. Engaging the Support Plate ensures that the Printhead does not
contact the Drive Roller, which would potentially damage the Printhead and prematurely wear out the
Drive Roller.
63
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
¶ Loosen the two screws that attach the Head Support Plate and Ribbon Shield to
the Printhead Mount frame. Leave the left side screw slightly snugged.
· Load a supply of 4 in. wide label stock. (See Sec. 3.2.2.1 for stock loading
instructions). Turn the Head Lift Lever to the DOWN position to engage the Printhead.
¸ Push down the right side of the Head Support Plate until the Plate just contacts the Bearing Block
Mounting Bracket
¹ Turn the Head Support Adjustment Screw until it just contacts the Bearing Block Mounting
Bracket.
º Tighten the two screws to secure the Head Support Plate and Ribbon Shield.
NOTE - The same screws secure both the Head Support Plate and Ribbon Shield, so that moving one
could cause the other to move. Be aware, and avoid this if possible.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
CAUTION: Do not turn the head adjusting screws more than 2 complete turns in either direction.
Damage to the head mount assembly will result if the adjustment screws are turned too far.
When direct thermal stock is used, the Printhead burn point should be moved slightly back, to a point
where there is greater contact with the roller, causing heat to transfer to the media more efficiently.
For best results when using direct thermal label stock, turn both of the two Head Adjust screws 1/4
turn clockwise. Figure 5-2 is a partial cut-away view from the right side of the Printer, showing the
Adjustment Screw Location. This adjustment will move the Printhead 0.006 in. (0.15mm) back on the
roller. Remember to adjust back to the original position when returning to Thermal Transfer media.
65
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
Figures 5-1 and 5-2 illustrate the portions of the Printhead mounting assembly that are involved in the
adjustment procedures.
There are four adjustments required to align the Printhead. They are:
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
For proper performance, it is critical that the stock move evenly through the media path. Any skewing
will affect the print quality, and in some cases can cause jamming. The Stock Tracking Adjustment
must be done with the printer power ON and a full roll of 4" (102mm) stock installed.
¶ Load the stock in the normal way, but keep the Media Retainer in the DOWN position.
· Use the FEED button to feed a few labels. At first the edge of the stock may move in and out as
the media advances. After a few labels the stock should begin to track at a stable position.
¸ At this point, slightly bend the Media Guide Plate up or down to adjust the tracking position to
within approximately 0.3 in. (8 mm.) of the center plate. Bending the Plate down will move the
tracking position closer to the Center Plate, while bending up will move the tracking position
farther from the Center Plate.
(NOTE - It is suggested that a small object, such as a pen or pencil, should be placed between the
Guide Plates. This will prevent bending the Plates so close together that the media will no longer
feed smoothly.)
¹ Rotate the Media Edge Guide to the UP position, and stop feeding labels.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
This adjustment must be performed with the printer power ON, a full roll of 4" (102mm) stock, and a
ribbon installed. (See Chapter 3, Fig 3-2 for Ribbon Loading instructions). Complete the steps for
installing the ribbon, except, do not secure the ribbon to the Ribbon Take-Up Hub.
¶ Press the FEED button several times and check to see if any wrinkling or bagging of the ribbon
occurs as it moves from the supply hub and goes under the Printhead assembly. If rippling or
bagging does occur, go to step 2. If no wrinkling is observed, go on to the Printhead Fine
Adjustment procedure, Section 5.7.3.
· The next step is to adjust the tension and position of the Ribbon Supply Hub. Maintaining an
even tension will help eliminate ribbon wrinkling. On the Shaft Support Bracket, slightly loosen
(but do not remove) the four screws securing the bracket to the Center Plate (Fig. 5-3).
¸ Apply moderate pressure up or down on the Ribbon Supply Hub or the Shaft Support Bracket
while pressing FEED to advance labels. The object is to reposition the Supply Hub so that
ribbon tension is even across entire width of the media path. An even tension should eliminate
any ribbon wrinkling.
68
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
¹ Once the bracket is positioned properly, re-tighten the four screws that attach the bracket to the
Center Plate. Feed three or four more labels to re-check the ribbon. Make certain that the ribbon
does not ripple or bag.
º Feed ribbon and labels together from the front of the printer. Check the ribbon to be sure that the
ribbon and label edges stay aligned. If the ribbon overlaps one edge of the paper stock, the ribbon
and paper are not following the same path. Should this happen, the Ribbon Shield position may
need to be adjusted. If the ribbon shows no overlap, proceed to the Printhead Fine Adjustment
procedure, Section 5.7.3.
» To adjust the Ribbon Shield, gently push the ribbon out of the way and loosen (but do not
remove) the screw securing the left side of the Head Support Plate and Ribbon Shield (Fig. 5-4).
¼ Press the FEED button to advance labels, while moving the left side of the Ribbon Shield up or
down until the edges of labels and ribbon track together.
69
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
¶ Print a few labels with Bar Codes rotated at either 90° or 270°, and inspect the print quality.
Imperfections in the print will be more evident in the rotated Bar Code images. If the print
quality is less than satisfactory, go to step 2.
Rotated Bar Codes are available on the Ribbon Test Label. To produce this label:
• Simultaneously press the PAUSE and FEED buttons. The Printer will generate a label
with a Bar Code in normal rotation.
• Press the PAUSE button. The Printer will generate a label with Bar Codes in 90°
rotation.
· With a 1/16" (1.59mm) hex key, turn the left and right Head Adjustment Screws (Fig. 5-2)
either clockwise or counter-clockwise 1/4 to 1/2 turn at a time, until the desired print quality is
achieved.
Never turn these screws more than 1/2 turn at a time or more than 2 full turns in total.
¸ Adjusting the head position often moves the Bearing Block out of contact with the Head Support
Plate. Loosen the two screws that secure the Bearing Block Mounting Bracket. Push the Bearing
Block back until it just contacts the Head Support Plate.
¹ Tighten the two mounting screws to secure the Bearing Block and Mounting Plate.
º Sometimes performing the Printhead Fine Adjustment can slightly change the stock and ribbon
tracking settings. Feed a few labels and look for any return of ribbon wrinkling. If there is any
sign of ribbon tracking problems, return to Section 5.7.2 Ribbon Feed and Tracking
Adjustment, and repeat the adjustment.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
The function of the Head Support Plate is to support the outer end of the Printhead when narrower
media is being used. Without this support, the Printhead would press on the drive roller, causing poor
print quality, premature wear and possible Printhead damage. The head support plate is needed only
when the media width is less than 3.5".
Pressure for the Printhead is provided by two springs in the head mount assembly. These springs apply
a constant force on the Printhead. If media that is less than 3.5 in. (89 mm.) wide is to be used, the
Printhead Support Plate should be adjusted. Figure 5-4 shows the assembled Printhead Mount. Figure
5-1 illustrates the relevant parts of the Printhead Mount in an exploded view.
To adjust:
¶ Loosen the two screws securing the Head Support Plate to the Printhead Mount. Leave the screw on
the left side slightly snug (Fig. 5-4)
· Load a supply of the media to be used. Turn the Head Lift Lever to the DOWN position to engage
the Printhead.
¸ Turning the Head Support Adjustment Screw will raise and lower the right side of the Printhead.
Turn the Adjustment Screw clockwise until the print on the right side of the label begins to degrade.
¹ Turn the Adjustment Screw back 1/4 turn counter-clockwise to set the correct adjustment.
º Finally, tighten the two mounting screws to secure the Head Support Plate.
71
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
The Printer contains a pair of sensors in the media path which merit discussion. Both the Label Edge
Sensor and the Reflective Edge Sensor are designed to operate without adjustment. However, if
components in either sensor's circuit have been replaced, the sensor may need a set-up adjustment.
Procedures for adjusting both sensors are given below.
¶ Remove the Printer's outer cover to expose the Main Logic Board (Sec. 6.1).
· Remove a few labels from their backing, and locate the Media Sensor (Fig. 5-5).
¸ Place the label backing material between the "fingers" of the sensor.
¹ Connect a Multi-meter to the Main Logic Board - the black lead connects to the
heat sink, and red lead to Test Point TP1
º Adjust potentiometer RP2 until the meter shows a reading of between 0.15 and 0.35 volts DC.
» Press the FEED button. The Printer may feed a few labels while it aligns itself.
Afterwards, it will feed one label each time the Feed button is pressed. When a
label is in place in the sensor, the voltage at TP1 should be greater than 2.0 volts DC.
Fig. 5-5 Insert the Label Backing between the Sensor "fingers".
72
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
73
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
The Reflective Edge Sensor detects the motion and position of label stock by sensing the presence of a
"carbon black" line on the back side of the label. Since the sensor operates by detecting interruptions in
a beam of infra-red light, this line must be a non-reflecting flat black that will absorb the infra-red
beam.
This adjustment should be performed with power on, 4 in. width label stock loaded, and the Printer
connected to a host terminal. The labels used in the procedure must be reflective type, with a black
line on the back.
¶ Remove the Printer's cover to expose the Main Logic Board (Sec. 6.1).
· Remove a few labels from their backing, and locate the sensor.
¸ Place some of the label backing material between the "fingers" of the sensor so that
black line on the label back is not within the sensor.
¹ Connect a Multimeter to the Main Logic Board. Connect the black lead
(Common) to the heat sink, and red lead (Positive) to Test Point TP1 (Fig. 5-6).
º Set the Printer to Reflective Sensor mode. (Note - Changing the sensing mode requires that the
Printer be connected to a host unit. Sending the command string "<CTL> B r" from the host unit
switches the Printer to Reflective sensing mode. (A sample program to send this command string
may be found in Appendix Sec. A2.0). See the Programmer's Manual for Allegro, Prodigy, and
Prodigy Plus (Part No. 88-2054-01) for further information on using command strings.
» Adjust potentiometer RP1 until the meter reads 0.75 Volts DC.
¼ Press the FEED button. The Printer may feed a few labels while it self-aligns. It will then feed
one label each time the button is pressed. When the reflective black mark is in place within the
sensor, the voltage at TP1 should be greater than 2.0 volts DC.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
¶ Connect a Voltmeter to the Printer in the following way: Connect the Common lead (black) to
the heat sink located at the base of the Main Logic Board. Set the meter to measure the range
around 10mV. Connect the Positive lead (red) to the left side lead of capacitor C45, located
near the top of the Main Logic Board.
· The voltage measured should be less than 10mV. If the voltage reading is above 10mV, or if
it shows large fluctuations, re-connect the Common lead to the heat sink and then re-measure.
If the voltage is still wrong, check the components connected to the heat sink - one of them
may be defective.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Adjustments
¶ Connect a Voltmeter to the Printer in the following way: Connect the Common lead (black) to
the heat sink located at the base of the Main Logic Board (Fig. 5-7).
· Connect the Positive lead (red) to test point TP2 on the Main Logic Board.
¶ Connect a Voltmeter to the Printer in the following way: Connect the Common lead (black) to
the heat sink at the base of the Main Logic Board.
· Connect the Positive (red) lead to test point TP3 on the Main Logic Board (Fig. 5-7).
CAUTION - Shorting the voltage probes with this relatively large voltage could cause damage to the meter
or the Printer.
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6. Removal and Replacement
• Printhead
• Circuit Boards
• Sensors
• Electro-mechanical Parts
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
P/N: 510391 78
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
6.0 Introduction
Even with the best design, manufacture and owner maintenance, occasionally parts will need replacement.
This section provides detailed removal and replacement procedures for the parts that most often need service.
The manual also contains complete assembly drawings and part numbers, so that any missing or defective part
may be replaced.
P/N: 510391 79
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
Removal
¶ Turn the Power Switch OFF, and unplug the Printer's power cord.
· Remove the two screws on the upper, inside cover which attach the cover to the center plate.
¸ Gently pull outwards and up at a point in the center of the cover below the memory module slot. Slowly
move the cover straight up to remove it.
CAUTION - The cover must NOT be removed from the top first. Doing so can damage the cover.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
Replacement
¶ To replace, gently slide the cover straight down onto the Printer, and see that the groove at the rear of the
cover slides into place around the back panel.
· When it is almost in place, gently pull outward on opposite sides of the bottom of the cover. This will
widen it and allow it to pass over the catch that holds the cover in place.
¸ With the cover fully in place, replace and tighten the two screws on the upper inside part of the cover.
P/N: 510391 81
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
Removal
Replacement
P/N: 510391 82
ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
Removal
¶ Turn the Power Switch OFF, and unplug the Printer's power cord.
· Unload the label stock and remove the ribbon (if installed). See Sec. 3.2.4.
¹ While looking into Printhead area from the side, place a small flat-head screwdriver into the notch in the
side of the Printhead plug, and gently move the screw driver back and forth to loosen the plug.
º Using needle-nosed pliers, carefully disconnect the Printhead cable from the Printhead. Be especially
careful not to damage the ribbon cable.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
» The Printhead mounting screw is located inside a small circular opening on the top of the Printhead
assembly. Loosen the mounting screw. (Note - This is a captive screw that stays with the mounting
assembly - Do not attempt to remove it completely; loosen the screw only until it disengages from the
Printhead.)
CAUTION - To prevent damage to the Printer from static electrical discharge, the technician should always
ground himself by touching the Printer chassis before handling the Printhead.
¼ To release the Printhead, turn the Head Lift Lever fully clockwise, and slide the Printhead out from the
side of the assembly, being careful not to scratch the printing surface of the Printhead.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
Replacement
½ Carefully slide a replacement Printhead into the assembly, making sure that the dowel pins on the
Printhead bracket fit into the hole on the left side of the Printhead and the slot on the right side of the
Printhead. Make sure the Printhead is flush with the head mount bracket.
¾ Secure the Printhead to the mechanism by tightening the Printhead mounting screw. Be careful not to
over-tighten the screw.
¿ Insert the Printhead cable and press it in until it snaps into place.
Adjustment
Use the Self Test function to generate test print labels. Adjust the Darkness Pot, (See Fig. 3-1 for
location) until the new Printhead achieves the same print contrast as the original.
NOTE - The Locating pins on the mount assembly act to automatically position the Printhead. Normally there
will be no need to make any alignment adjustments after installing a new Printhead. However, should
a replacement perform poorly, there are some adjustments that may help improve performance.
These are discussed in Sec. 5.3, Adjustments.
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
¶ Remove the Printer's outer cover to expose the electronics compartment. (Sec. 6.1) Remove the tear bar
unit from the front of the printer. (See Sec. 6.3)
· Using retainer ring pliers, remove the C-clip Retaining Ring which secures the electronics side of the
Cam Shaft Assembly.
¸ Loosen the Allen Set Screw with a 1/16" Allen wrench and remove the head lift lever.
¹ Remove the three screws holding the actuator mount plate, and remove the Mount Plate.
Fig. 6-7 Printhead Spring replacement - Removing the Actuator Mount Plate.
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º With the Mount Plate removed, the Cam Shaft Assembly and the two Ribbon idler rollers are freed and
should now be removed.
Fig 6-8 Printhead Spring removal - Cam Shaft and Idler rollers.
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¼ Remove the two screws which secure the Cam Lift Bracket, and remove the bracket.
Replacement
Insert the replacement springs, making certain that they fit into the retaining pockets. Then reverse the above
procedure to re-assemble.
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· Remove the 3 screws holding the Front Cover assembly. Two screws are located on the left and one on
the right side of the cover.
¸ Carefully pull out the front plate assembly and disconnect the attached ribbon cable from the Front
Panel P.C. board.
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¹ Remove the four screws securing the Front Panel P.C. board.
º Remove the Front Panel P.C. board. The Push-buttons will remain secured in the front panel board
assembly. They may be removed by bending back the securing catches until the buttons are released.
Replacement
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Removal
· Remove the retaining ring and the two washers from the electronics bay end of the Sensor Shaft.
Pull the opposite side of the shaft outwards until the shaft end disengages from the Front Panel
Mounting Bracket.
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· Remove the six screws holding the Front Panel Mounting Bracket in place, and remove the Bracket.
Replacement
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· Remove the Front Panel assembly and front panel Mounting Bracket (Sec. 6.5 and 6.6).
¹ Remove the two screws holding the Stepper Motor, and remove the Stepper Motor. It is not necessary to
disconnect the cable to the main board - simply place the motor to the side, out of the way.
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º Remove the two screws holding the Motor Mount Bracket and remove the Bracket.
» Remove the Gear Retainer Clip and the 5 mm E-Ring, and then remove the Roller Drive gear and the
Compound Idler Gear from the Hub Shafts.
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¼ Pull the Clutch Pulley off the shaft. The assembly fits snugly, so it may be necessary to turn the
pulley back and forth to remove it.
¾ Remove the drive roller retaining ring (5 mm E-ring)). The drive side of the roller is now prepared for
removal.
¾ Turn the Printhead lever fully clockwise until the Printhead is in the UP position.
¿ Pull out the old drive roller and insert the new one.
Replacement
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· Remove the retaining ring and the two washers from the electronics bay end of the Sensor Shaft. Pull
the opposite side of the shaft outwards until the shaft end disengages from the Front Panel Mounting
Bracket.
¸ Unscrew the sensor shaft (counter-clockwise), and remove the shaft and spacer.
¹ Unplug the six wire cable connected at Socket J4 on the Front Panel P.C. board. The sensor assembly is
now free to be removed from the printer.
Replacement
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
· Disconnect the ribbon sensor cable from the Main Logic Board at Socket J6.
¸ Unhook and remove the Spring from the Slip Clutch Pulley Assembly (Fig. 6-24). Loosen
the Allen Set Screw.
¹ Remove the one screw securing the Ribbon Sensor Board assembly. Remove the Sensor
Board.
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Replacement
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
¸ Remove the five screws that secure the Main Logic Board in place (Fig. 6-20)
¹ Remove the two screws that attach the heat sink to the bottom of the printer baseplate.
º Carefully slide the Main Logic Board towards the front of the printer, until the Serial Connector
(J4) is disengaged from the back plate.
» The main board can now be removed. Be careful to keep the main board free from any wires
while removing it.
Replacement:
Note: Always apply a liberal amount of Thermal Heatsink Compound to the heatsink that mates with the
centerplate, (p/n 13-0136-01).
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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL Removal and Replacement
¸ Remove the three screws that hold the Back Panel in place. Remove the Back Panel.
º Remove the two transformer wires and the ground strap screw.
Replacement
6.12 Transformer
Removal
Replacement
· Remove the retaining ring and the two washers from the electronics bay end of the Sensor Shaft. Pull
the opposite side of the shaft outwards until the shaft end disengages from the Front Panel Mounting
Bracket. (Sec. 6.6.1)
¹. Disconnect the Options Cable from the Main Logic board at connector J1.
º Remove the three screws from the Roller Mount Plate Assembly(Fig. 6-18) and pull the assembly away
from the drive roller.
» Loosen the two screws that secure the Options Board and remove the board form the Mount
Plate. (Fig. 6-23)
Replacement
· Using needle-nosed pliers, or a similar tool, unhook one end of the Spring from the Shaft
Support Bracket. Remove the Spring.
¸ Using a 1/16th in. Allen key, loosen the two Allen Set Screws.
¹ Remove the Slip Clutch Pulley and the 5/16th in. Collar.
º Loosen and remove the four screws securing the Shaft Support Bracket to the Center Plate.
¼ Using a 1/16th in. Allen Key, loosen the Allen Set Screw securing the Ribbon Drive Assembly to
the shaft of the Ribbon Take-Up Hub.
½ Slide the Ribbon Drive Assembly off the Hub shaft. Move the Timing Belt aside, out of the way.
Replacement
Because of this, typical troubleshooting techniques for hardware-based systems do not apply well to this
product. For some components, such as keypad I/O, RS-232/422 I/O, motor function, and switch input,
replacing socketed components could be economical. However, in most other cases it is more efficient and
economical to replace the complete Main Board.
Several other smaller boards and devices attach to the Main Board. These boards, such as the Front Panel,
Options Interfacing and Sensor LED boards, primarily contain discrete component circuitry. A wiring
diagram is included with the Schematic Drawings at the back of this manual. It shows the Main Board and its
relationship to all of the connecting devices.
This section explains the function and operation of these boards. The information will provide assistance when
it is necessary to connect other devices to the Printer, or to repair a unit that has been damaged.
Power is applied through the Power-On switch. This is a SPST (Single Pole Single Throw) switch for the
115V model, and DPST (Double Pole Single Throw) for the 230V model.
The printer has one Line Transformer which is fuse linked both internally and externally. The external fuse for
the 115V model is a 1.0 Amp slow blow fuse. The 230V model requires two .5 Amp slow blow fuses. The
Transformer has a single primary, so, the wiring can not be changed in the field - the printer must be
ordered with the desired voltage configuration factory installed.
Quick board repairs may sometimes be made simply by swapping out socketed components. However, it is not
recommended that the board be repaired to any further degree. When problems are detected with the Main
Logic Board, the best approach is to replace the entire board!
U4 & U8 RS-232C and RS-422 line drivers. If these chips are damaged by high voltage spikes or
misuse, they may be replaced. The outputs of these two components connect to other
circuitry in such a way that they are enabled by connecting wires to the pins on connector
J4.
U3 & U9 System RAM. It is also checked when the Self-Test is run. A RAM error statement on the
Configuration Label can usually be corrected by replacing the indicated chip.
U10 74HC245 IC. Buffers the settings of the DIP switch (SW1, on the back of the Printer)
from the Main Board's data bus. If the Configuration Label, printed by the self-test,
indicates that the switch values do not change after the DIP switch has been physically
changed, this componant may be defective. The DIP switch bank may also be changed, if
necessary.
U13 System ROM. It is checked during power up and any other time the Self-Test is run. A
ROM error statement on the Configuration Label can usually be corrected by replacing
the indicated chip.
U22-U24, U27 Refresh and Bank Select. These components control the refresh cycles and bank select
of the dynamic RAM.
U2 & U6 Act as Buffers between the Main Board and the Front Panel Board and Sensors.
This I/O device can sometimes be damaged by unusually strong static electrical
discharges. Since this component acts to buffer TTL level data, if there is no LED
or push-button response from the front panel, replacing the chip may correct the
problem.
U14, U21, U25, U27 Printhead Control Circuit. These components are the IC's that most directly
affect the burning of dots by the Printhead. These components are seldom
damaged, but if replacing them is considered, replace the complete set of four.
U5, U14, U16, Memory Module Control Circuit. These are the IC's which control
U17, U24, U27 the operation of all the memory modules. U16 supplies the voltage used to
program Flash modules. U17 buffers the addressing of the Memory Modules. The
other IC's primarily control the selection of modules, or the function being
performed.
The Label Sensor can operate in either an Edge or a Reflective sensing mode. The Main Board
controls which type of sensing operation is used.
7.7 Printhead
The Printhead connects to the Main Board through connector J7. Most Printhead functions require +24
Volts DC. The Printhead itself is a thin-film type head, with both latch and forward type logic, to help
decrease the delay time between the printing of each row of dots.
The Stepper Motor is connected to the Main Board through connector J9. Component U20 (which is
not easily replaced) contains the drive transistors for the stepper motor. In most cases, replacing the
entire Main Board and/or Stepper Motor is the most efficient way to service the unit.
Flash modules may be used to store any combination of graphic images, charters fonts, or label
formats. This type of module features a write protect switch, to prevent important data from being
accidentally overwritten. The module can be programmed when the write protection is off (the write
protect switch on the module is moved towards the center of the module). The Flash module is rated to
be re-programmed 10,000 times without failure.
The 256K and 512K RAM Modules may be used for the same type of data storage as the Flash
Module. However, since RAM memory is volatile, when the Printer is turned OFF, all data will be
immediately lost. Both 256K and 512K RAM Modules provide an additional 256K of memory for
storing soft fonts, graphics, and label format data. The additional 256K of storage space in the 512K
RAM module can be used to increase the label format buffer from its normal limit of 8.25 inches to as
much as 20 inches.
The Font Modules contain pre-programmed data which is permanently stored. Font Modules cannot
be written to or erased. It is, however, sometimes possible for Font Module data to be corrupted.
¸ Press and hold the front panel FEED button, and, while holding, turn the printer ON. The Printer
should print a Test Label which will contain the Font Module checksum and will state whether the
module is GOOD or BAD.
Appendix
NOTE - This cable is typically used to connect to DCE equipment using XON/XOFF flow control. Part
Number: 556000.
NOTE: This cable is typically used to connect to other DCE equipment using XON/XOFF flow
control.
NOTE - This cable is used to connect to a P.C. with DB25P serial ports. Flow control is either
XON/XOFF or CTS/DTR. Cable Part Number: 556002.
NOTE - This cable is used to connect to a P.C. with DB9P communication ports. Flow control is either
XON/XOFF or CTS/DTR. Cable Part Number: 556001.
· Connect the cable according to the label on each plug - the side labeled PC must plug into the PC's
parallel printer port, and the side labeled PRINTER must plug the Printer's RS-232 serial port.
¸ The Printer must be set to default communication settings. These are: 9600 baud,
8 data bits, 1 stop bit, no parity. (The default settings are selected by setting DIP Switch SW1,
positions 1, 2, 3, and 4 to OFF).
CAUTION - Always TURN POWER OFF BEFORE connecting the Parallel to Serial
Interface Adapter.
NOTE - This cable is used to connect to a P.C. with a DB25M Parallel port. Flow control is
CTS/DTR only. Cable Part Number: 899516.
The following sample programs are intended to aid the technician in testing and performing
adjustments. They provide a useful test label and some software switching functions.
These programs are created in the DOS environment, using the EDIT command. Additional
information on DOS and EDIT can be found using the DOS HELP function, or the DOS manual.
• All of the sample programs require the use of the ^B character. Creating the ^B character in DOS is
done in the following way:
¶ At the DOS prompt, simultaneously press the CTRL key and the "P" key.
• When entering command sequences (e.g.; ^BZ) there should be no space between the ^B character and
any following characters (^BZ, not ^B Z).
• If the host unit's COM port has not been set, it may be necessary to run the DOS MODE command. To
do so:
· Press ENTER.
The following program will produce a useful Test Label that includes Human Readable data in
different sizes and orientations, as well as a Bar Code sample.
EDIT TEST.TST
^BO0100
^Bf120
^BM1300
^BL
PE
SE
D11
H14
131100001000050TODAY IS DAY 1
132100001500000TODAY IS DAY 2
131300002000050TODAY IS DAY 3
241100002500250TODAY IS DAY 4
1A6204000500100ABC 555
151100000000000..$......
E
¹ From the EDIT menu at the top of the screen, select SAVE and EXIT.
» Press ENTER. The Printer should now print this Test Label.
As noted in the text, testing the Printer with Continuous media installed presents a special problem,
since the Test sequence begins with a reset, which changes the Printer to its default settings. After a
reset, the Label Edge Sensor will be active, but will fail to detect label edges on the Continuous media.
The following program will avoid this problem by beginning the Self Test or the Character Dump mode
without allowing the Printer to reset.
EDIT TEST.LAB
¸ Type
^Bc0100
^BZ (for Self Test) or ^BP (for Character Dump Mode)
¹ From the EDIT menu at the top of the screen, choose SAVE and EXIT.
» Press ENTER. The Printer should now begin the chosen function.
The Printer can only be set to Reflective Sensing Mode through the use of a software command. The
following program will switch the Printer from Transmissive to Reflective Mode.
EDIT TEST.REF
¸ Type
^Br
¹ From the EDIT menu at the top of the screen, choose SAVE and EXIT.