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Genicom 3600 User's Manual

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12. LA OFF s OFF o o a 3600M 024 Testing and Adjusting Format This label which can be a test of a single format or can provide a two label sample of all the formats has bar codes and human readable fields that you can use to determine whether the printer you are testing is attaining the best print quality possible using a particular format Oda ZV BBM adan AAA 2L RAUM AZARAE 2 lI III III an aan CODES 0123456789 aeaneaenaanenanaet CODE ge PHA PB 082 PAM 3600 TEST LABEL 3600 TEST LABEL 3600 TEST LABEL 3600 TEST LABEL 3 E e 3600 TEST LABEL 3600 TEST LABEL 3600 TEST iden l0 IIIII IIIIIIIIIIIIIIIIII 6X uM 3600M 026 Pitch This label is a gray scale printout of every third dot The test label should present a regular pattern with dots that line up diagonally when held at an angle Look for irregularities that may signal a problem with the pl
13. a0 11 15 3600M 091 3600M 092 lt gt 3600M 094 3600M 095 3600M 096 endix p p A Appendix A This appendix describes the theory of operation for the 3600 printer Functional Description of the 3800 Mechanics This section describes the basic mechanical functionality of the 3600 printer The 3600 printer has a sheet metal frame base plate and main deck plate to which mechanical and electrical components are attached The printer holds moves routes for contact by the printhead and stores label stock and ribbon by electronically controlled mechanical means Sheet metal covers protect media and components The printer has one electrically powered motor that is the source of simultaneous movement for all of the driven parts The motor shaft uses a pinion gear to impart drive force to the rotating parts producing ribbon and liner movement The motor pinion gear drives the platen roller by meshing with the 96 tooth gear mounted on the end of the roller The platen roller gear contacts a 96 tooth gear pulley assembly on the TTR drive roller assisting ribbon movement and providing drive to the TTR takeup hub by means of the drive belt
14. 19 3 556605 R121 RES S M FILM 12W 5 47 KOHM R239 20 7 556607 R21 RES S M FILM 12W 5 100 KOHM Ww Hr Hs O Q L CO iS uS O gt O N P OO O 00 Q uS ds ES ES 21 3 556613 R117 RES S M FILM 12W 5 10 OHM 10 R229 10 22 70 556629 R76 RES S M FILM 12W 5 47 OHM d SI 000000 O1 O1 O1 O1 O1 O1 Oy O1 I2 J C O O O0 MN IP O No 4 WW CO N CO Y CO O1 CO O1 Y O1 O1 Q O1 O1 O i Q Q O O a P2 P5 C P2 N CO A CO O N gt OI O O mp AA pP mo OI O O1 C Oy O0 O P C GO 00 1 1 VO CO OO CO 010 OO CO O OO CO CO PO CO IN ES tal taj Ex taj o bz taj ba Ex pb En Fr br Fn bel Ex o ta N N NO N N ES R92 3600 Printer Maintenance Manual PL 061591 003 TITLE PCB ASSY MAIN 3600 PAGE 4 10 PL REV D 02231995 RUN DATE Feb 23 15 19 02 E ITEM OTY UM PART NO REFDES DESCRIPTION Y F B AAA SI SI OY N Q Q CO CO 4S ONASNANSNSIONIASINAIASNNA
15. 2 Seren ATS 115 PHLATCH 51 PP184 ua 334 E Sha 2 R177 3164 ee PP133 lt cs 1521 START aaa 8 1 ri gt amp TPL 9 rs EL nu e 5 25 65 start STEPINT 48 NEWLINE gt aa PLACE 22 CLOSE TO EACH OTHER _ START Sister R178 S _ IN r 5 F OPTION CARD 50 R75 Dx EH T FIFOCLKL SUBZ ON THE RIGHT SIDE 59 IDATAEN S BA 1DATAEN FIFOCLK 47 4 Pris 2n 1 C182 1892 _ IN3 115 rs DEN esia 4 REN AAA Y AR as d ALE Bes C123 La P IN4 NEWLINE 7112 F2 57 8 17 Fl INS Xx y de ke mie R261 18 GND 18 0Ex PP194 C132 EP 4 3 MUN E E C104 1 Y PP176 aU X R198 C125 10 PLATCH E N 5 J E 158 KKK ma teed iai 126 1 P _ FIFOCLKI ls an 16 2 5 che ge 10 FIrocuxe DRAMLCS 12 Es noun eps Bl Enc Y Sx is d 232RCU MBDSACK ASICAD ABSRCU 31 5 im ET STBDURx 13 STECHOP AD lt 7 gt 18 19 0 5 STROBEx C145 u28 R184 1U Y SP 28 8 2 5907 25 X4 pw m cis
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19. _ s 10 Basis 273 Als RIAL 290051 8 PLS Basis X ONDPH 04 a e Pur canos u 5 H X v Riga 24 e lus N x 4 22154 N zi SENSE B1 GNDPH CNIPH PP255 UEF y xu MCLASD41 cda ma 458V uN PRES 5228 To tau 4 i T BS X mus p mue o AER pg gt THE ana PISS nor Tee n s Tbe exten qud 3 AG mus cour NSTALLEO RKNESS ANG usi 1 gt DARKNESS lt 5 TRIP n m KA NS ime M293 Thig LABEL MARK PD285 n az 18 TAKEN BNOPH ANN R134 3 PP216 _ 147 2 154 NT a B ji 25915 18 cse INSTALLED E K ADIN Laus AS ADCLK lt vss DE as Rege 4 H R143 R144 108 MARK Z 4 x PP174 prin TT ci ges is X MIN 8 zole Ai 12 em es mo prose 3 GNDPH CHASSIS x 12V 154 El 35A 520 f man _ LE car 58 APS _ 75 38515 BASIB x R218 Hs p uos PP254 tu 3 iue om n39 an qum _ 200 sun 7 I
20. Tear bar P d gt support To replace the platen roller and platen roller gear 1 Loosen the motor as necessary to mesh the platen roller gear with the motor pinion gear and TTR drive gear pulley upon reassembly 2 Install the washer removed in Step 6 and a new retaining E ring on the platen roller and insert it through the main deck plate and into the washer removed in Step 4 and the platen drive gear 3 Reassemble the tear bar and bar support and then install the lower outboard plate securing the tear bar assembly and the rollers Note Use the roller alignment tool during reassembly to align the outboard plate 4 Secure the platen drive gear with a new retaining ring and slide the motor forward to mesh the motor pinion gear with the platen drive gear and the liner drive gear pulley Turn the TTR roller drive gear to check for proper gear engagement and tighten the motor mounting screws 5 Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 23 3600 Printer Maintenance Manual Replacing the Liner Drive and Takeup Components 5 24 To replace any combination of the liner takeup hub liner reverse gears liner drive roller liner takeup cl
21. Print Energy Compensation The digital thermal compensation system and the global compensation system combine to provide the printer with maximum printhead energy control to optimize print quality Digital Thermal Compensation Each dot on the printhead has its own history RAM This RAM contains a dot s previous burn history what the current burn will be and what adjacent dots are doing This data along with the media sensitivity information is used to determine the proper amount of energy for that dot For example if the dot history showed that the dot had been turned on most of the time this profile would indicate that the energy built up in the dot area was sufficient enough for the task and the dot would be turned off for a period of time Using this method provides for a specific amount of energy for the task that dot is performing Global Compensation Global compensation is the energy management to the printhead that affects all of the dots on the printhead External inputs to this system are the darkness adjust control and the online darkness command Other inputs include the ambient temperature the printhead resistance and printhead temperature Appendix A Font Caching Flow Chart Request for character Character does pice ui not exist in cache exists in cache Check cache for requested character Available memory is returned No memory Allocate memory is available in cache for chara
22. Printing Regardless of your computer setup you can use several methods to download information to print labels This section describes different ways you can communicate with the printer Refer to the 3600 User s Manual for detailed information Note Remember that these factors affect print quality correct media media sensitivity setting print speed and correct bar code orientation Using Label Debut If you are using a point to point printer to PC connection to communicate with the printer the printer parameters can be easily set using the DOS based software package Label Debut The Label Debut prompting screens assist you in designing printing and editing labels Refer to the Label Debut User s Manual for more detailed information Using Third Party Software Your customer may be using third party software to create label formats and convert graphics into a UDC format that the 3600 printer can interpret You can use the same software to set the printer parameters General Information 1 Using the Printer Command Set You can also create labels by downloading formats designs and data created with the printer command set The commands in the printer command set can perform any function or activate any feature of the 3600 printer You can use the following methods to download commands e Downloading printer commands using DOS e Using ASCII control characters or hexadecimal equivalents e Using readable protocol command c
23. WD 3600 005 Connecting the Printer to a Computer To operate as intended the 3600 must be interfaced with a computer desktop or laptop PC local area network AS400 or similar mainframe with its serial port configured for the communications protocol appropriate to the computer interface It is assumed that the correct interface point to point non switched modem network etc was achieved originally at installation and should have a history of correct operation Refer to the 3600 User s Manual or contact an applications analyst for detailed information about the type of installation you are servicing 1 13 3600 Printer Maintenance Manual Serial Port Settings 1 14 Parameter Settings Description Baud Rate 1200 2400 4800 9600 The rate in bits per second bps at 19 200 which the host exchanges data with the printer Parity Even Odd None Checks each transmitted character for errors Protocol Intermec XON XOFF The type of network used to connect XON XOFF with status the printer the host and the rest of the data collection system Intermec protocol includes Standard Polling Mode D and Multi Drop protocols Device A to Z Unique address for each device Address 0 to 5 connected using Multi Drop protocol Test and Test Prints Data Line Provides printer diagnostics to the Service Print Cloning Selective host and prints test labels Transfer Memory Reset
24. gt DLP FIFOHRK 05 mu 1 Ra Pew Bear INSTALLED Pause AME S LAK Ban ABS 2 REE RE ott 1 B 23 qc PE Ra t n BERR Pr2a6 435 Ss ab y y RI ass 1 ape LITT GREEN 7 a 4 HALT 4 u 3 Locus pees MTS 5 LU R36 R 8 3 25V ES A Ss 0 LEE v E ACID Bat L 0322 10 E 4 ww 1 MIGL gs a ID IRAMLC y PL ES T 53 259 AER m ITO Senna X IRBMHCOK y AA 157 n 8 raout Tarn 12 RRMICOK Fla te E FIFOELSHE PPLAL gue ca 15 fraou TIN 24 t OPTICNABICCS ALS yy LEX RESET AM Ze conen T FIFOWRIx y RES y LX En Y n 2 RTS zu R159 2 enm ram X C135 al TCREEN L cu SARA LES so PR LEG 10 Tu Lu L RAW IDATREN mers STECHOPx EE oe L us STHDURX 051 a IDATAEN ui E EID ac18 gt e 1 gt ZIERCU ADDRESS 2 ASK Ir um Hae y 5 a 202 8 a START E I3 Hd e 015 Error RED ma oum 9 a 5 nas ms E LEX Gg vssus n siz 8 5 S 5242 B E te
25. 35 Xena mw Y 3 RAMAD U28 PP197 i348 02 pe su Y LAST NOT PP144 RACB gt USED USED ev T SCR 9 PP123 PP122 BTI y 49 C71 68 119 122 ET T 047 517 033 AK ADDSEL 16082 217 JS Jie J17 ucc 22 L3 12 13 Rue 21 r7 lig R94 108 312 23 15 x 518 513 Fa PISAK _ Bl zer mepsackn 8114 tg CAD DB REF 61591 4 ms 215 FP HIEZE IF OF 25 8144 188 190 208 lek 7 og 3 oa She Ars 6001 36TH AVENUE WEST x TPL 2 36 7 9 13 j IT gt ETT WA 98203 9288 PPi24 12 GND GL tes 2 ie Iu EVERI u32 U6 UB U T Y x P y SIZE CAGE CODE DRAWING 261591 RE R185 XU or Pi 2 1 c 47 B 3 2 ad pgs 2 33825 RB 200 2 SCALE SHEET 5 220 1 4 3 7 6 3 3600M 076 Replacement Parts Replacement Parts This chapter contains list of 3800 printer replacement parts referenced to illustrations Replacement Parts The following table is a copy of the 3600 service parts matrix with illustration references added It lists the 3600 printer parts that can be ordered for replacement by the part number indicated Each part on the list has an ID number corresponding to a callout on the illustration showing its location Multiple ID numbers occur when parts are used more than once or
26. 7 5 REVISIONS 5 D PROUED REU DESCRIPTION DATE DRAWN 8 APPRO 988 28 954 D 003 RELEASED AT REV D E 004 MFG RELEASE Sl HE ki 150 MU 7 NOT cog 1 STBCHOP PEL ET STALLED STBDURK 2 TP t au Y PP156 18 SLCSk PP73 me X cai 45d EY L6MHZ L 2 LOREX cag T d pass 45V Be u E gt DRAMHCSx X ASICAD ADDRESS p 1502 E 77 E iU PT ISICCS Y OPTION 65 615 lt 7 B gt 15 8 das p E Dare ASICAD RT XK E 1u T c an Y AD lt 7 0 gt ADDRESS te x PPB2 ASIC u23 1 3 ated IDATAL 7 ipara auod 45V a 1 s CASHx XK FR die co co c76 2 lt T S a La PAL22V1 4 i 8 9 18MHZk ANN BOK1 0x STPINT PP89 38 ans i d R173 E 3 OPTIONK ol lt 4 gt 33 g B 2175 MU SL d a I RAS X an ape 152 gt 158 lt 15 gt 41 I Be ig Ate 975 Est 93 75 n T z IN3 1g al PP131 PPS4 T 2 INS 18 Ba IE IM OPTION ASICCS 3 107 Tesle IDATAEN 3 X PP95 TESK x RE 13 AUS 109 FHCSIx 281 START lt x PP Re eiaa PPSS0 R35 a5 R175 x Hess
27. a lift lever 3600M 040 Testing and Adjusting 3 Aligning the TTR Supply Hub You should align the TTR supply hub only if you are experiencing ribbon wrinkle on full width ribbon after the rollers and printhead have been aligned To perform this procedure you need the following tools e TTR supply hub alignment tool Intermec Part No T43149 2 Phillips screwdriver To align the TTR supply hub 1 Switch off the printer power 2 Remove the media cover and the electronics cover 3 Install the TTR supply hub alignment tool as shown Ribbon supply hub alignment tool 3600M 041 4 Tighten the alignment tool thumbscrew so the bushing tab is flush against the bushing on the hub adjustment plate Loosen the two screws securing the hub adjustment plate Switch on the printer power Print a series of the same kind of labels that were having the ribbon wrinkling problem While they are printing adjust the TTR supply hub up or down with the thumbscrew on the tool until ribbon wrinkling is eliminated 3 25 3600 Printer Maintenance Manual 3 26 10 Note If this adjustment does not eliminate ribbon wrinkling try readjusting the ribbon supply hub and realigning the printhead When an alignment is achieved that eliminates the ribbon wrinkling tighten the two screws on the hub adjustment plate Remove the tool and retest for ribbon wrinkling After the printer is correctly adjusted switch off th
28. and signs on the main PCB Lithium A Main PCB 3600M 042 3 Install the covers and power cord Check the printer for proper operation Remove and Replace Procedures Replacing the Printhead To replace the printhead you will need the following parts and tools 6 6 inch 5 mil printhead Intermec Part No 0616115 001 e ESD grounding strap Medium straight slot screwdriver To replace the printhead 1 Switch off the printer power and remove the power cord 2 Remove the media cover 3 Raise the printhead Remove media and ribbon if loaded 4 Release the locks on the printhead cable by pressing in on each side of the cable connector Remove the printhead cable Note If you need slack to separate the printhead and cable unplug the cable from the main PCB and pull some of it through the cutout in the main deck plate Straight slot screwdriver Cable Printhead m connector cable Printhead retaining Screw 3600M 043 3600 Printer Maintenance Manual 5 Use a straight slot screwdriver to loosen the printhead retaining screws located in the center of the printhead heatsink The screw is easier to loosen if you place one of your fingers underneath the printhead between the printhead and the platen roller Pull the printhead away from the printer since it is a tight fit you may need to pull it out from the outboard side rather than from the front Replace the printhead and cable and tig
29. or statement that must be strictly observed to avoid death or serious injury to the persons working on the equipment Caution A caution alerts you to an operating procedure practice condition or statement that must be strictly observed to prevent equipment damage or destruction or corruption or loss of data Purpose of This Manual The purpose of this maintenance manual is to provide the information you need to clean adjust and repair the Intermec 3600 Bar Code Label Printer Who Should Read This Manual This manual is written for experienced electronic technicians trained by Intermec who will service and if necessary repair the 3600 printer Detailed operating instructions and specific related information is provided in the 3600 Bar Code Label Printer User s Manual This document is not intended to support user operations or persons untrained in troubleshooting and repair You should have a working knowledge of electronics with an advanced understanding of PCs DOS data communications and bar code applications It is assumed that you are familiar with the installation programming and operation of the Intermec 3600 Bar Code Label Printer and all of its options including a working knowledge of the Label Debut or Label software tool How This Manual Is Organized Before You Begin You will find the following information in the referenced section For information about A basic description of the 3600 Schedule
30. CARB 211 5 750 0 OHM 12 11 551800 R160 RES S M O OHM JUMPER R250 t R251 R252 R253 R254 R255 R256 1 R257 R258 y R259 555450 R125 555901 R6 555909 001 R191 556600 R214 R224 17 16 556603 R1 RES S M FILM 12W 5 4 7 KOHM R11 O POP BWW WOO OY ES POT SIDE ADJ W KNOB 10KOHM ES S M POT TOP ADJ 100 KOHM ES S M POT TOP ADJ 20 KOHM ES S M FILM 12W 5 100 OHM Np R36 R74 R75 v R107 R108 R113 R142 t R157 N R164 R185 R212 R240 n R241 18 81 556604 R2 RES S M FILM 12W 5 10 KOHM R3 R5 1 gt Q O J OY Q N O1 4S N N O gt A dS QO OY C O QO O O Q OY O O O 1 gt Jl EQ FA O 4 OO gt i gt O O Q O gt 00 O OY O1 PF F N C O N O gt IS OY IS OO N C0 4S tz tz rz Hz fr z ofr P z Gr Pr z Pr GI U z ofr P z Gr o Pr Pr fI fi Uz Gi z z P gt QI O0 Q N o O Q Q ds ds 0000 O rS ES PAORrNWAORWOROKRKBUDOODOWWUEFR 3600 Printer Maintenance Manual PAGE 2 10 PCB ASSY MAIN 3600 De TITLE PL 061591 003 m TW TS z Oo A gt N N o x O H O
31. Small straight slot screwdriver To adjust the label taken sensor 1 Remove the media cover and the electronics cover 2 Connect the positive lead of a multimeter to TP19 TAKEN and the negative lead to TP14 GND on the main PCB 0000004 Hp 0000004 eier Ba Ae 00000 Do 0000000005 We 6 0000000000000 000000000 m Jh 3600M 037 Switch on the printer power gt Feed label out of the printer so that it rests under the label taken sensor in a correct orientation Adjust R190 on the main PCB until the voltage at TP19 is 1 2V 0 2V Remove the label from under the label taken sensor The multimeter reading at TP19 should now read above 4 5V Install the printer electronics cover and the media cover SO Check the printer for proper operation Testing and Adjusting 3 Aligning the Printer WARNING CAUTION CAUTION The following procedures provide instructions for aligning the rollers aligning the printhead and aligning the ribbon supply hub on the 3600 printer Note These alignments should be made in the sequence given Performing them out of order can introduce and not solve printing problems Warning Always disconnect the power cord before removing the
32. or include the data Check the format transmission syntax The correct syntax is lt ESC gt x n with n ranging from 0 to 19 Check the page transmission syntax The correct syntax is lt ESC gt y n with n ranging from 0 to 9 Check the font transmission syntax The correct syntax is lt ESC gt v n with n ranging from 0 to 24 Check the UDC transmission syntax The correct syntax is lt ESC gt u n with n ranging from 0 to 99 4 7 3600 Printer Maintenance Manual Printer Errors continued Error Code Problem 32 Non immediate command or data received after buffer full 33 Invalid field delimiters 34 Invalid escape command 35 Invalid data shift command 36 Invalid or undefined format number 37 Insufficient room in RAM to print format 38 Invalid or undefined field number 41 Syntax error for program commands 42 Insufficient room in RAM to store format 43 Too many fields in label format 46 Undefined statement 52 Invalid UDC UDF bitmap cell height width or intercharacter space 53 Insufficient room in RAM to store UDC or UDF 54 Invalid UDC command syntax Solution Allow the printer to empty the buffer contents before sending commands or data Check for all pairs of field delimiters and make sure both are numeric or both are alphanumeric Correct the escape command syntax Correct the shift command syntax Verify that the format numbers are between 0 and 19 Reduce the number of d
33. u r m N E lt nia N Q Q I gt S Qd El E gt 06 Zi m H Boa r ir r r r Er Er r r r Er r r r r Er r r r r Er r r r r Er r r r r Er r r r r Er Er r r r Er Ei r r r Fu Eu COSMO HO SO ENTE O MN EEE EUREN DIT TE FEED E q S AD O Kw St sh AD 10 LO P C 10 10 LO LO cO cO cO CO P P P P P P LO 00 9 cO 00 P sn sh HID Soupe 201 HOS ES Q OSO Ds rs SEEN NO HOD SEL DUOC Qs ERROR SO in n qudmoooooooooooooo000O0nQqdq ACTIONS SES HONO Tz OA R70 st LO XO 00 CN 00 CN st LO XO 00 CN SP LO XO 00 CN AWM 00 1 INN NN NAN O Y Y SP SP XP h h si lt H LO LO LO LO LO LO LO LO LO LO LO uus x v 1 RW Eu nau xq EXXX mu A Bu D xum auam PCB Drawings and Schematics PL 061591 003 TITLE PCB ASSY MAIN 3600 PAGE 3 10 PL REV D 02231995 RUN DATE Feb 23 15 19 02 E ITEM OTY UM PART NO REFDES c ESCRIPTION Y F B O1
34. 3600 printer to IBM coax systems The 3600 emulates an IBM 3287 printer by connecting the printer to IBM 3270 Type A coax cable computer systems operating in the VTAM CICS IMS TSO or 8100 DPPX environments Connection can be made to an IBM 3174 76 99 system controller multiplexer Parallel Interface This option lets the user connect the 3600 to a PC through any Centronics parallel interface in addition to the standard serial interface Network Connectivity Using the Parallel Interface option and an Ethernet or other network adapter the 3600 can be connected to a network Kanji Katakana Character Support The 3600 has two Kanji Katakana options bitmap fonts only or outline and bitmap fonts Users shipping finished materials or work in process materials to Japan can meet Japanese label requirements for Kanji Katakana JIS Interleaved 2 of 5 Batch Takeup A larger diameter liner takeup hub permits printed labels to be spooled for later use without causing as much label curl as the smaller diameter hub The maximum takeup outside diameter is 5 inches General Information 1 Principal Functional Parts The following illustrations identify the common name and location of the major functional elements of the 3600 printer Media window Front Panel cover gu Media access door Darkness adjust control DIP switches a Optional _ board port _ Serial communicat
35. Adjusting the Label Taken Sensor 3 20 Aligning the Printer 3 21 Aligning the Rollers 3 22 Aligning the Printhead 3 23 Aligning the TTR Supply Hub 3 25 Troubleshooting About Troubleshooting and Repair 4 3 Troubleshooting Tips 4 3 Where to Start 4 3 Repair 4 3 Troubleshooting Checklist 4 4 Error Handling 4 5 Syntax Errors 4 5 Parameter Errors 4 5 Image Overrun Errors 4 5 Invalid Numeric Character Errors 4 6 Insufficient Storage RAM Errors 4 6 Error Codes 4 6 Printer Operation Problems 4 9 Print Quality Problems 4 10 Communications Problems 4 12 Environmental Problems 4 13 Electrostatic Discharge ESD 4 13 Electromagnetic and Radio Frequency Interference 4 14 Ground Loops Between Equipment 4 14 Inadequate Earth Ground 4 14 AC Power Problems Surges Sags Spikes Noise and Outages 4 15 Miscellaneous Problems 4 16 vii 3600 Printer Maintenance Manual viii Remove and Replace Procedures Replacing Printer Components 5 3 Replacing the Lithium Battery 5 4 Replacing the Printhead 5 5 Replacing the Bezel PCB 5 6 Replacing the Main PCB 5 8 Replacing the Kanji Katakana Option PCB 5 9 Replacing the Label Mark Sensor 5 10 Replacing the Label Taken Sensor 5 12 Replacing the Label Gap Sensor 5 13 Replacing the TTR Drive Roller and Gear Pulley 5 15 Replacing the TTR Takeup Hub Clutch Pulley and Belt 5 18 Replacing the TTR Supply Hub and Adjusting Plate 5 20 Replacing the Platen Roller and Gear 5 22 Re
36. Battery The battery is used to back up the static RAM for font format and UDC storage R34 limits the reverse current into the battery a safety requirement for lithium batteries The battery itself is a 3 6V lithium battery with 1 75 Ah Diode D4 is a low leakage schottky diode used to isolate the battery voltage from VCC of the circuit card when the power is off but it has minimal voltage drop to RAMVCC when power is on Transistor Q2 and IC U5 cause the RAM chip select to be held in a high inactive state when RESET is low to prevent inadvertent writes to RAM during power up or power down Battery Life Calculations Battery capacity 1 75 Ah RAM Data Retention current 20 HA maximum 1 uA typical With printer off all the time and worse case scenario Battery life 1 75 Ah 20 uA 87 500 hours 10 years With printer off all the time and typical case Battery life 1 75 Ah 1 uA 1 750 000 hours 200 years Reset RESET is generated by MKC34064 under voltage sensing circuit U29 The output of U29 is low for any supply voltage less than 4 6V 3600 Printer Maintenance Manual A 6 Motor Driver The motor driver circuit of the 3600 consists of ICs U2 U21 U17 and U19 discreet parts Q16 O1 O4 O6 O11 O12 O13 O14 and associated diodes resistors and capacitors The eight D MOS FETs make up a dual full bridge motor driver There are four FETs to drive each motor phase There are two FETs at each end
37. Expansion 1 7 Twinax Interface 1 7 Coax Interface 1 8 Parallel Interface 1 8 Network Connectivity 1 8 Kanji Katakana Character Support 1 8 Batch Takeup 1 8 3600 Printer Maintenance Manual Principal Functional Parts 1 9 Basic Printer Setup and Operation 1 11 Front Panel Operation 1 11 Over Temperature 1 11 Media or System Faults 1 12 Feed Pause Pushbutton 1 12 Checking the Printer Configuration 1 12 DIP Switch Settings 1 13 Connecting the Printer to a Computer 1 13 Printing 1 14 Using Label Debut 1 14 Using Third Party Software 1 14 Using the Printer Command Set 1 15 Preventive Maintenance Preventive Maintenance Actions and Intervals 2 3 Inspecting the Printer 2 4 Cleaning the Printer 2 4 Removing the Media Cover 2 5 Cleaning the Printhead 2 6 Cleaning the Rollers and Tear Bar 2 8 Cleaning the Media Guides and Media Path 2 9 Cleaning the Label and Ribbon Sensors 2 11 Cleaning the Printer Covers 2 12 Testing and Adjusting Testing the Printer 3 3 Running Test and Service Mode at the Printer 3 4 Setting DIP Switches 3 4 Printing Test Labels 3 7 Running Test and Service Mode From a Host Computer 3 11 Testing Printer and Host Communications 3 12 vi Contents Adjusting the Printer 3 13 Adjusting the Print Bias for Print Quality 3 14 Adjusting the Print Intensity 3 15 Adjusting the Printhead Adjustment Lever for Print Quality 3 16 Adjusting the Label Mark Sensor 3 17 Adjusting the Label Gap Sensor 3 19
38. O ring between the TTR drive gear pulley and TTR takeup clutch pulley The motor pinion gear also meshes with a 96 tooth gear pulley on the liner drive roller assisting liner movement and providing drive to the liner takeup hub by means of another drive belt between the liner drive gear pulley and the liner takeup clutch pulley The liner takeup clutch pulley rotates an idler shaft and gear that meshes with an identical gear on the liner takeup hub shaft to produce reverse rotation of the liner takeup hub The TTR drive function and the liner drive function each use one way clutches to facilitate label retract A one way clutch is part of each roller drive gear The TTR drive roller gear is white while the liner drive roller gear is black This makes it easy to distinguish between the two gears which is necessary because the clutches are one way in opposite directions and would not work if interchanged The clutch pulley assemblies on the TTR takeup hub and liner reverse shaft are similarly color coded because they have different torque values The springs inside are color coded as well TTR white gear white pulley clutch white spring inside liner black gear black pulley clutch black spring The belt driven TTR takeup 16 in oz hub and liner reverse 34 in oz idler shaft use one way clutches that manage takeup force and prevent slackening during retract Reversed liner takeup rotation produces less slippage The TTR
39. SPECIFICATION 047233 T B v o gon CHANGES REQUIRE SAC APPROVAL o S A HU o gue HES TET O 4 PLACE ITEM 90 CONNECTOR PINS AT THE FOLLOWING LOCATIONS ni RR OO J5 J8J7 J8 TP 14 TP 15 TP 18 H VALE 0000077 m t EO E im gt Mz o s 6 mc p P e ao AMALI 14 DIII d 2S me E D o Ln qum LU a TH q m 512 EIG mg HL E E O 2194 WO dre HH eo vo au TEMO gv lio gt R LT O E B E TTT Hom TAKEN E JETER E Ana 12130 Te nme mas Xu mesi h q 7 a m o LES 4 1 RIZ n 1 is Miam IN o Lo a odk 1 16 hi i H RUE ho RI eo Q E Quo 9 I sus we PH s gt mao iie O qum EN Mies 29 m 19090990 m TT Us 4 1 Ru lc TPB as m ow che zn B El 3 Ey i n 0 oo gt B ets ora i wor no 1 cos GU 50 a0 Beh m ollo x oo BA sl 5 T a o 314 o N E 059 o e em gt ooo PIER e 20 i E SO S s EE SEPARATE PARTS LIST FOR 061591 006 CAD DB RE
40. adjustable from the inboard edge of the extrusion to one half of the paper path width toward the outboard edge To adjust the label mark sensor potentiometer sensitivity 1 2 3 4 un Remove the electronics cover Switch on the printer power Enable the printer for mark sensing using the lt SI gt T 2 command Connect the positive lead of a digital voltmeter to TP18 MARK and the negative end to TP14 GND on the main PCB 0000000 Sant 000107 O 884200000 000000000 EP ES 464400008480 00000000000000000 0000000007 m Til 3600M 035 Place the white portion of a label under the mark sensor Adjust R191 on the main PCB so the voltage at TP18 15 1V 0 2V Place the black mark portion of the label under the mark sensor The voltage at TP18 should now be greater than 2 5V Install the printer electronics cover and the media cover Check the printer for proper operation Testing and Adjusting 3 Adjusting the Label Gap Sensor The label gap sensor output enables the software to determine the leading edge of a label by detecting the label gap The label gap is the space between labels on the backing material This reading enables the printer to properly position the start of print point To perform this procedure you need the following
41. bit first 3600M 02 Dot Increment Switch Settings Bottom Bank OFF 1 or ON ZI IZ IZII I 12 3 4 5 of dot increments 1 1 O O O 0 2 O 1 O O O 3 1 1 O O O 4 O O 1 O O 5 1 O 1 O O 6 O 1 1 O O 7 1 1 1 8 O O O 1 9 1 O O 1 O 10 O 1 O 1 O 11 1 1 9 1 12 1 1 13 1 1 1 14 1 1 1 15 1 1 1 1 16 O O O O 1 17 1 O O O 1 18 O 1 O O 1 19 1 1 1 20 O O 1 O 1 21 1 1 1 22 1 1 1 23 1 1 1 1 24 O O O 1 3 25 1 o O 1 1 26 1 1 1 27 1 1 1 1 28 1 1 1 29 1 1 1 1 30 1 1 1 1 3600 022 Testing and Adjusting 3 Printing Test Labels The test labels can be used for checking printhead alignment printhead bias dots out of specification label tracking and ribbon wrinkling The examples show the DIP switch settings that select the illustrated label Hardware Configuration The hardware configuration label is the first label printed when you enter Test and Service mode This label serves as a configuration reference as well as an alphanumeric and alignment print test This label contains the following information and uses Printer memory including both storage and image RAM e Printer mileage including inches processed and inches burned e Printhead settings including width dot size and burn pot setting Firmware checksum program and version number Vertical lines for eval
42. characters not enclosed in brackets by pressing an individual keypad key For example E3 F3 is entered as E 3 F 3 with the E and F in uppercase Before You Begin Additional Information The following documents may be of interest or help to you in servicing the 3600 printer 3600 Bar Code Label Printer User s Manual P N 062732 Label Debut User s Manual P N 062982 Data Communications Reference Manual P N 044737 The Bar Code Book by Roger C Palmer XV General Information General Information 1 This chapter identifies basic features options and technical specifications of the 3600 printer It names principal functional parts and reviews basic printer setup and operation Overview of the 3600 Printer The Intermec 3600 is a microprocessor based thermal printer that prints standard bar code or 2D symbology human readable characters graphics lines and borders on 3 inch 7 62 cm to 6 6 inch 16 8 cm wide continuous feed label stock The 3600 prints directly to thermal label media or can print on regular label media with the use of a thermal transfer ribbon TTR 3600M 001 The 3600 supports applications that need a wider print capability than the Intermec 3400 Bar Code Label Printer can provide 3600 Printer Maintenance Manual 3600 Features The 3600 printer s features are summarized in the following list Print speed from 2 to 5 ips Programmable nonvolatile printer
43. describes how the 3600 printer handles certain error conditions it may encounter in printer or programming commands Error codes sent to the host the problem the code is reporting and the usual solution are listed in a table at the end of this section Syntax Errors The 3600 printer responds to syntax errors in the messages it receives from the host by attempting to execute the commands It does not ignore a command with a syntax error Instead the printer produces output even if it is erroneous which gives you an indication of what went wrong and what should be done to correct the problem Parameter Errors Certain commands require optional parameters If these parameters are not supplied default values are substituted If a parameter is above its maximum range limit the maximum value is used If it falls below the minimum range the minimum value is used The range and the default value for each command are listed in Chapter 6 of the user s manual Image verrun Errors Image overrun occurs when a label is too complex to image for a given print speed An overrun will cause the printer to abort the label being printed This error is most common on labels over 5 inches long The printer automatically attempts to correct for this error condition by resetting to the lowest print speed and to the highest number of image bands and then repeats printing the label The printer remains at this setting until you reset it If an im
44. even contact with the media Using different width media especially narrow media can result in uneven contact or a spot where there is no media between the printhead and the platen roller Extra wear and damage can occur if narrow media is used for extended periods with incorrect bias To adjust the bias adjust screw 1 If printing is light on Remove the media cover and locate the bias adjust screw Printhead bias adjust screw If printing is light on 3600M 030 2 Turn the bias adjust screw counterclockwise to compensate for light print on the right side of the label turn the bias adjust screw clockwise to compensate for light print on the left side Install the media cover 3600M 031 the right side of label the left side of label turn the bias adjust screw CHN turn the bias adjust screw UY counterclockwise clockwise T J E MM L WEN Testing and Adjusting 3 Adjusting the Print Intensity Note Before you adjust print intensity verify the sensitivity rating for the media matches the rating set in the printer Use the darkness adjust control in combination with the darkness adjust command lt SI gt d to fine tune the intensity of print on your cust
45. executed is terminated and the new function begins To exit Test and Service mode 1 Switch off the printer power 2 Return all DIP switches to their original settings 3 Switch on the printer power Setting DIP Switches Use the information provided in the following tables and examples to set the DIP switches for the Test and Service mode function that you wish to perform The 0 s indicate that the switch is in the OFF position and the 1 s indicate that the switch is in the ON position Testing and Adjusting Test and Service Switch Settings Top Bank Bottom Bank OFF OFF 225 TESTS ON 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Test Prints Configurations Hardware 00000000 Software 0000001000 Test Labels Print Quality 00010000 00010010 Single Page 00001000 BB BBBOOA All Pages 00010110 1 1 11 100 A Format Single Format 00011000 All Formats 00011010 1 1 111 UDC Single UDC O0O0000100 BB BBBBB A All UDCs 00000110 1 111111 A Font Single Font 00010100 BB BB BBOO All Fonts 000101 1 0 11 111100 Data Line Print 000000 Cloning Receiver 01000000000000
46. good working location If you take this kind of action be careful not to cause additional problems or confuse your search If you decide you need to and can carefully and logically swap known good printers subassemblies or components with failing or suspect items as a means of isolating the cause of the problem Do not do this if you think any known good item can be damaged Repair Repair is whatever action you take to eliminate the problem that you are on site to fix If repair is the removal and replacement of a key printer component refer to Chapter 5 Remove and Replace Procedures 3600 Printer Maintenance Manual Troubleshooting Checklist If the host receives an error message or a functional problem with the printer is encountered the user s manual starts with the following Check whether the printer sends an error code to the host in response to a BEL command e Ifan error code is sent find it in the Error Codes table in this chapter Try the solution given for the respective error code to attempt to correct the problem If the printer does not send an error message to the host try to match the symptom of your failure in the Printer Operation Problems or Print Quality Problems tables in this chapter Try the solution given for the respective symptom to attempt to correct the problem Clean the printer components and check all connections Troubleshooting 4 Error Handling This section
47. of each motor phase When a phase is driven or turned on one FET on each end of a phase is turned on One of the FETs will be a high side FET putting 50 volts on one end of the winding The other FET will be a low side FET putting zero volts on that end of the winding When the motor is running the windings are being excited first with 50 volts on one end and then the 50 volts on the other end At no time are both FETs on the same end of a winding on at the same time When a winding is turned on the current is first monitored and then controlled by turning the FETs on and off at a high rate This is called pulse width modulation The current in the winding is monitored measuring the voltage across the sense resistors R18 R22 R97 and R99 These voltages are called sense 1 and sense_B1 These voltages are inputs to U2 U2 is a comparator that compares a reference voltage voltage at U2 pins 2 and 6 to the voltages sense 1 and sense_B1 When these voltages become greater than the sense voltage the associated out put of U2 switches from low to high This voltage is fed into the GAL U21 and then to the appropriate driver IC U17 or U19 which turns the associate FET off The off time during this pulse width modulation cycle is constant and controlled by the C109 R127 for sense A1 or C42 R137 for sense Bl The reference voltage on pins 2 and 6 of U2 is established by the pulse width modulation input M5 This is an input from the microprocess
48. of the equipment housing Failure to comply can result in damage to components or the printhead Caution Do not remove the motor plate or subplates Changing the position of the motor plate can alter factory alignment and cause ribbon wrinkling or liner stripping problems 3600 Printer Maintenance Manual Replacing the Lithium Battery WARNING To replace the lithium battery you will need the following parts and tools 1 75AH 3 6V AA lithium battery Intermec Part No 586229 e ESD grounding strap 2 Phillips screwdriver Warning There is danger of explosion if the battery is incorrectly replaced Replace it only with the same or equivalent type battery recommended by the manufacturer Discard used batteries according to the manufacturer s instructions Il y a danger d explosion s il y a remplacement incorrect de la batterie Remplacer uniquement avec une batterie du m me type ou d un type recommand par le constructeur Mettre au r but les batteries usag es conform ment aux instructions du fabricant To replace the lithium battery Note The printer will lose data if the battery fails or is removed Before removing the battery upload and save the fonts formats pages graphics and configuration settings 1 Switch off the printer power and remove the power cord the media cover and the electronics cover 2 Remove the old battery and install the new battery matching the and ends of the battery with the
49. plastic clips and push it through the cutout in the main deck plate Slide the sensor housing away from the main deck plate Label taken Sensor gt 3600 050 Install the new sensor routing cable through cutout in main deck plate and plugging it into the main PCB Place the cable in the plastic clips with the black sleeve positioned as close as possible to the sensor end Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation Remove and Replace Procedures 5 Replacing the Label Gap Sensor To replace the label gap sensor you will need the following parts and tools Label gap cable assembly Intermec Part No 059495 001 ESD grounding strap Small straight slot screwdriver 12 inch shank 2 Phillips screwdriver To replace the label gap sensor 1 Upper and lower PLA media guide assembly Switch off the printer power and remove the power cord the media cover and the electronics cover Raise the printhead Remove media and ribbon if loaded Disconnect the label gap sensor cable from the main PCB Gap sensor cable Label gap N sensor ej 3600M 051 Remove the three screws securing the upper lower me
50. replace the platen roller gear If none of the rollers turn you may need to replace the stepper motor Remove and Replace Procedures Remove and Replace Procedures 5 This chapter contains illustrated instructions for removing and replacing key components of the 3600 printer Replacing Printer Components WARNING A CAUTION CAUTION When a printer component needs replacing use the appropriate following procedure See Chapter 7 Replacement Parts for a complete list of spare parts After replacing a component refer to Chapters 2 and 3 for the procedures to complete the repair by ensuring that you leave the printer performing at its optimum level Prior to taking any action review all warnings cautions and procedures associated with any component you intend to remove When performing any of the procedures in this chapter heed the following warnings and cautions at all times to avoid the consequence identified Warning Always disconnect the power cord before removing the electronics cover unless the procedure requires the unit be energized Failure to disconnect the power cord may result in injury or death due to electric shock Caution The printhead and integrated circuits on printer circuit boards in this equipment are sensitive to damage by electrostatic discharge ESD Prevent ESD by always wearing skin contact ground straps firmly attached to the equipment metal base assembly when working inside
51. supply hub uses an 18 in oz slip clutch The hub has a TTR encoder sense label attached to it that is used for ribbon motion sensing 3600 Printer Maintenance Manual A media supply assist roller and brake assembly are part of the media supply post function The free spinning roller reduces the drag of the media core over the stationary supply post allowing the media to turn smoothly during printing When printing stops the media slackens under the upper media guide causing the media brake pedal and brake arm to lower onto the rubber contact strip on the brake drum which inhibits media roll momentum by stopping the assist roller Functional Description of the 3500 Electronics This section describes the basic electronic functionality of the 3600 printer Components are identified by the reference designators used on the schematic diagrams provided in Chapter 6 Power Supply The power supply for the 3600 is primarily a linear supply with a switching buck converter for the 24V printhead supply The switching buck converter takes the unregulated 50V and uses a switching transistor to reduce the output voltage to 24V The base mechanism is equipped with an AC input filter and a transformer that supplies the board 12 VAC and 50 VAC The 5V supply is generated from the 12 VAC inputs on connector J10 Diode bridge D12 rectifies the AC voltage and regulator VR1 regulates the DC voltage to 5V Capacitors C53 through C56 are used fo
52. the TTR drive roller and the TTR shaft printhead pressure cam assembly and pivot block 8 Remove the TTR drive roller sliding the gear pulley off of the roller shaft Retain the washer located between the roller and the main deck plate and the washer located between the gear pulley and the main deck plate 9 You now replace either the TTR drive roller the TTR drive gear pulley or both 5 16 Remove and Replace Procedures 5 To replace the TTR drive roller and TTR drive gear pulley 1 10 Position the TTR drive gear pulley with the correct washer installed between the gear pulley and the main deck plate Insert the TTR drive roller with a new retaining E ring and the other washer through the main deck plate and into the gear pulley Install the upper outboard plate making sure that the printhead spring is in place on the pivot block and that all four shafts are securely inserted into their correct positions in the plate Note Use the roller alignment tool during reassembly for proper alignment of the outboard plate Hook the printhead spring around the upper plate Install the printhead lift lever and secure it with a new retaining snap ring Secure the TTR drive gear pulley on the roller shaft with a new retaining E ring and the washer you removed in Step 5 Fit the loose end of the TTR drive belt over the TTR drive gear pulley Reattach the front bezel cover Ensure that the media access door operat
53. the printer when the cover is closed Testing and Adjusting Testing and Adjusting 3 This chapter contains procedures for testing the printer s performance as a quality check during preventive maintenance as a functional check when troubleshooting and as part of the repair process after replacing a printer component This chapter also contains procedures for making adjustments and alignments that ensure the printer is operating normally Testing the Printer If you are on site for preventive maintenance or are following up a corrective action and the printer is working start conducting quality checks from the Test and Service mode If you are on site for corrective maintenance determine if the problem lies with setup and process or the printer itself Use the Test and Service mode to determine if the printer can print If it can perform the communications test The quality and efficiency of producing labels reveals if a printer is operating correctly In addition to analyzing labels to evaluate printer performance the 3600 printer Test and Service mode allows you to conduct printer tests that include printing test labels illustrated in this section with a fixed look so you can compare them to an expected standard The test labels can be used for checking printhead alignment printhead bias dots out of specification label tracking and ribbon wrinkling Test and Service mode functions can be run at the printer or from a host ter
54. the static RAM which is used for font format and UDC storage CS3 is used to access the ASIC and I O option port U23 then decodes these chip selects using address lines CS4 is used for interrupt acknowledge CS5 combines the chip selects for both loading the FIFO with image data and also for reading the DIP switches U20 decodes these chip selects using address lines A16 and A17 CS6 is used as A19 CS7 CS8 and CS9 are reserved to be used as A20 A21 and A22 for possible memory expansion TPU The TPU is the time processor unit of the MC68332 It has 16 programmable channels that can be used to generate output waveforms or capture input signals All of the 16 channels are used in the 3600 printer design The TPU contains built in functions but it is also possible to override these functions by downloading new functions into the MC68332 standby RAM The 3600 design uses custom TPU functions to perform the following tasks Channel 0 This input captures the STPINT signal When STPINT goes active channel 0 interrupts the CPU to indicate a step links to channels 1 through 6 and 10 and sets up a match for the half step time Channels 1404 These outputs control motor signals M1 to respectively After initialization to set up motor direction each channel outputs the next bit of a programmable bit pattern whenever a link is received from channel 0 A fixed delay is set for each channel to ensure that all four channels switch simu
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56. with sharp objects will damage the printhead Clean with only a cotton swab or a clean lint free cloth or tissue moistened with isopropyl alcohol To clean the printhead 1 Remove the media cover 2 Raise the printhead by rotating the head lift lever clockwise until the printhead releases TTR ribbon Printhead lift lever 3600M 011 Preventive Maintenance 2 3 Remove the media from the paper path and the ribbon if installed from the TTR supply and takeup hubs 4 Usea cotton swab moistened with alcohol to remove any dirt adhesive or debris from the print surface on the bottom of the printhead printhead 3600M 012 5 Wait 5 to 10 seconds for the print surface to dry Reload the media and ribbon if used 6 Engage the printhead by rotating the head lift lever counterclockwise until it locks in place 7 If you are finished cleaning install the media cover 3600 Printer Maintenance Manual Cleaning the Rollers and Tear Bar Cleaning the platen roller and the tear bar preserves print quality by ensuring close contact between the media and the printhead The TTR roller liner roller and media roller are cleaned in the same fashion to minimize general debris and to maximize their efficiency To clean the rollers and tear bar 1 2 Remove the media cover Raise the printhead by rotating the head lift lever clockwise until the printhead releases Remove the media fr
57. 00 Sender Selective Transfer Receiver 11000000 00 000000 Send Pages Single Page 110100ccicc CDDODOD All Pages 11 001 1 1 4 11111 1 Send Format Single Format 1100100000 ODDDD D All Formats 11 0010412 1 1 1 11 11 1 1 Send UDC Single UDC 114 09 1 1 All UDCs 11 01 10414 1 1 1111 100 Send Font Single Font 1 CDD DDO All Fonts 11 0001 11 1 1 11 11 1 1 Send Configuration 000000 Send Tables 11001100 00000000 Send All 1101110000 000000 Memory Reset Page Format 00100000 00000000 UDC Font 0011000000 000000 Configuration 0010100000 000000 Tables 0011000000 000000 All 0011110000 000000 A OFF Batch of 1 ON Batch of 100 B Page Format UDC Font number Least significant bit first C Source Page Format UDC Font number Least significant bit first D Destination Page Format UDC Font number Least significant bit first 3600M 020 3600 Printer Maintenance Manual Test and Service Configuration Settings Top Bank Bottom Bank O OFF OFF P 1 ON AAAA ON 2 3 4 5 6 7 8 1 2 5 6 7 8 Label Rest Point O 1 1 Adjust Forward N N N NN Adjust Backward 1 N N N NN 86XX Emulation 1 O 1 Advanced Mode 10 Mil 1 0 15 Mil 1 1 X Forms Adjust a 1 1 1 Adjust Forward NNNNN Adjust Backward 1 Y Forms Adjust 1110 NN N NN N Number Least significant
58. 20 70 75 25D Tco Tco 2 10 26D Tpd Tpd 3 15 27D Tco Tco 2 10 28D Tchav 2 39 2 39 29C Tasr 0 0 65 75 30D Tco Tco 2 10 31C Trpc 10 lt 39 50 gt 320 2 10 330 2 10 340 Tclsn 3 30 3 30 35D Tclsa 3 30 3 30 36D Tco Tco 2 10 37C Trp 60 60 57 A 12 amp l V Ons 100ns 200ns 300ns 400ns 500ns 600ns Tee tae UD op up je TD aa da pe cho dede b vp d lt o x I 6 a ck so 62 54 XS 60 SW ek N Z N RUS Zb N 1 5 D3 D4 ps N D0 refresh 35 Lin 7 34 4 cs h la 11 1 12 J 37 257 26H4 27 32L 36 ras id 10 H 24 gt 184 17 30 54 cas Lc 15 44 1654 4 WA addsel tol 20L 4 dsack 28 4 8 add row col TOW 001 0096 s 5 3600 Printer Maintenance Manual Functional Description of the 3500 Software A 14 This section describes the basic software functionality of the 3600 printer Band Buffering and Font Caching Image band buffering and font caching allow Intermec printers to image and print labels at the same time Virtually any label length can be acco
59. 23 A SE R226 Dee SI SE R230 9 9 0 6 Fr 27 1 556651 R189 RES S M FILM 12W 5 510 OHM 8 4 249 28 10 556658 RES S M FILM 12W 5 1 0 1 5 SE gt R98 73 54 UE R122 954 323 E R126 0 6 5 2 R127 4 0 LE T R137 4 0 0 6 F R148 E T R150 ue R199 10 57 243 E R200 106 2 6 29 1 556665 R136 RES S M FILM 12W 5 2 0 KOHM 10 7 3 5 30 1 556670 R186 RES S M FILM 12W 5 3 3 KOHM 10 0 3 6 F 31 2 556672 R149 RES S M FILM 12W 5 3 9 KOHM 10 4 3 2 i R228 OI uL SE 32 3 556674 R124 RES S M FILM 12W 5 5 1 KOHM 10 7 3 4 R217 4 4 0 9 F 7 R234 4 0 0 9 F 33 1 556676 R106 RES S M FILM 12W 5 6 2 KOHM JE 34 1 556687 R101 RES S M FILM 12W 5 22 KOHM 0 43 55 1 556690 R138 RES S M FILM 12W 5 30 KOHM 9 97 248 36 1 556692 R196 RES S M FILM 12W 5 36 KOHM 9 2 Sa Sy 2 556710 R30 RES S M FILM 12W 5 330 KOHM Dek usw E R104 2 8 Over 38 2 556721 R225 RES S M FILM 12W 5 1 0 MOHM 4 4 1 0 E ji R231 404 2143 SE 39 2 556742 R31 RES S M FILM 12W 5 9 1 MOHM 4 292 m 3E R73 6 2 242 00 E 40 4 556837 301 R119 RES S M FILM 1 8W 1 1 OHM 6 2 0 3 Y R135 Sa eA E R151 II Wd CE R152 2046 41 2 556837 161 R7 RES S M FILM 1 8W 1 4 99KOHMS 10 6 1 7 F R100 l0 2 5 E 42 4 556838 287 R18 RES S M FILM 1 4W 1 1 0 OHMS 759 DE R22 use clues UE T R97 deme R99 2
60. 24 25 30 31 32 33 34 35 36 37 38 39 40 41 none a N PRINT SPEED 3 0 IPS RIBBON SAVE Disabled IMAGE BANDS 3 SELF STRIP Disabled MAX LABEL LENGTH 4 inches CUTTER Disabled LABEL STOCK Inter label gap DARK ADJUST 0 MEDIA TYPE Direct Thermal X FORMS ADUST 0 MEDIA LENGTH 0 inches Y FORMS ADJUST 10 CHARACTER SET US ASCII LABEL REST POINT 0 TRANSLATION Disabled SENSITIVITY 420 EMULATION Disabled LABEL RETRACT Enabled Print Quality This label contains bar codes and human readable fields that you can use to determine whether the printer you are testing is attaining the best print quality possible If you notice problems with the print quality check and perform the adjustment and alignment procedures provided in this chapter to achieve optimum printer performance 82 85 88 50 3100 S m ad T MANN NO Ol ad m 8 E m a 3 Z amp rij mz m m B 2 SO ms lt gt ON 93W331NI BAUD RATE 9600 DATA BITS 7 MESSAGE LENGTH 255 PARITY Even STOP BITS 1 PROTOCOL Xon Xoff No Status DEVICE ADDRESS A INTERNAL OPTIONS none EXTERNAL OPTIONS Self Strip ON ON OFF FERRER E Ed tt OFF
61. 4 0 R17 kei l WIS R2130 ol llc 60 ES R1730 9 Li us H T 5 E cel S S 85 bE m 3 261 d L 4 D ES OO l bd 013 012 Ed D27 L o Em 25 M A l o os o os 35 io s so 55 75 55 ex 10 0 105 i i i i i i A A 9 2 5 gt 3600M 073
62. 97 19 E 43 4 561008 C65 CAP ALUM RDL LEAD 50VMIN 100UF 9 7 2 1 C124 Dial 3600 Printer Maintenance Manual PL 061591 003 TITLE I PL REV D RUN DATE Feb 23 15 19 02 PCB ASSY MAIN 3600 PAGI Di 6 10 02231995 ITEM OTY UM PART NO EFDES DESCRIPTION K F B 44 561018 001 45 1 561908 46 2 563602 Hi 47 7 563605 48 3 563606 49 61 563700 51 25 140 123 C53 C46 C54 C55 C56 C126 C127 C128 C129 C141 CAP AL ELCTLT R L 63V 12000UF CAP AL R L 16V 4700 UF CAP S M TANT 10V MIN 20 10UF CAP S M TANT 35V 20 1UF CAP S M TANT 6VMIN 10 68UF CAP S M CER 50VMIN 20 1 UF n O OO CO CO OY O1 gt Ys OY O1 O Q OY O1 Q N O S O RU 4S IS gt uS ds uS OI QI P2 IS Oy O N IP F PS P 0100 gt 0 Co Oy iS O gt O Oy O1 OO Q XO S gt S O N O ND gt O O1 Q N JAR N O gt O O S QI O FP BUN ds QO QO E QO gt I N ds I OI S I OI O F Oa P Nr O O O O F O O F O O N O N N i Q0 00 G Q CO CO O OY O JO PO IP OY Q CO N O O N O CO CO uS N BON OS tz tz r7 r
63. C68332 ICs U14 and U15 are used to route address or data to the AD 0 7 bus Appendix A Chip Select Generation GALs U23 and U25 are designed to take the MC68332 bus control signals and convert them into ASIC and I O option control signals A state machine governs the timing of the signals and also dictates that the OPTION ASICCS from the processor be programmed for two wait states 1 0 Option Connector The I O option connector J8 is a 40 position pin field Two chip selects OPTION and BOKI O are used to select either the board identification number or the data port XMT and RCV are outputs from the I O option cards that are inverted and go to the processor to generate communications interrupts FIFO The FIFOs U11 and U24 are the same part as used in the Intermec 3400 and 4400 printers The IDT 72105 is a 256 x 16 FIFO with parallel inputs and serial output The processor loads image data into the FIFO with word writes At the beginning of a line the MC68332 loads three lines of data into the FIFO This causes the HF flag to go high The ASIC then begins clocking data out of the FIFO The processor checks each line of the HF flag and loads the next line of data if there is still more image to load If the image has been completely loaded the FIFO empties and the EF flag goes low The low EF flag tells the ASIC to stop clocking data from the FIFO Front Panel Interface Connector J15 connects to the front panel boar
64. CKET CORE LOCKING 129 142 150 506040 005 WASHER FLAT SST 327 X 50 X 30 130 060214 001 FLAP PRINTHEAD CBL RESTR 133 061563 002 GEAR PULLEY CLUSTER L H 135 061557 003 GEAR PLATEN D SHAFT 137 061569 002 GEAR PULLEY CLUSTER RH 138 506040 004 WASHER FLAT SST 817 X 1 0 139 062927S 001 CLUTCH ASSY RIBBON TRANSPORT TAKE UP 3600 SPARE 140 506049 001 WASHER FLAT NYLON 320ID 141 160 501461 001 RETAINING RING EXTERNAL 395 143 152 501410 RETAINING RING 310 DIA GRIPPING Replacement Parts ID Part Number Description 144 061551 002 CABLE ASSY MOTOR MAIN STEPPER 147 059102 002 BRACKET MOTOR MOUNT 148 061554 004 PLATE MOTOR 149 061584 002 SUBPLATE LINER TAKEUP 151 154 505359 001 SCREW W CONE WASH 8 32X1 153 061588 002 GEAR LINER REVERSE 156 062603 001 PLATE HUB ADJUST 157 061583 002 SUBPLATE TTR 158 061574S 001 CLUTCH ASSY SELF STRIP LINER TAKE UP 3600 SPARE 159 506040 007 WASHER FLAT SST 446 X 56 161 061589 001 SHAFT LINER REVERSE 162 163 501462 003 O RING 2 800ID X 210THK 164 506040 006 WASHER FLAT SST 327 X 500 X 080 166 061565 002 CLAMP LINER HUB not shown 061605 001 CORE RIBBON 3600 CDBD 6 7 IN not shown 0621975 003 FIRMWARE 3600 VER 1 1 SPARE 3600 Manuals Part No Description 062732 001 3600 Bar Code Label Printer User s Manual 062733 001 3600 Bar Code Label Printer Getting Started Guide
65. F 06159 1 006hay1 SYSTEM VALID ALLEGRO 8 0 UNLESS OTHERWISE APPROVALS DATE 6001 3BTH AVENUE WEST SPECIFIED DRAWN T PETERSON 11 03 94 Inte mn EVERETT WA 98203 928D NOTICE DIMENSIONS ARE TITLE THIS DRAWING SHALL NOT BE DUPLICATE OR USED FUR ANY PURPOSE N INCHES CHECKED POR x MAIN OTHER THAN THAT FOR WHICH PROVIDED THE INFORMATION DISCLOSED RESP ENG HEREIN ORIGINATED BY AND IS THE PROPERTY OF INTERMEC CORPORATION EXPANSION 5400 AND EXCEPT FOR RIGHTS EXPRESSLY GRANTED BY WRITTEN CONSENT SUCH XXX SIZE CAGE CO ANNE NUNBER REV INFORMATION SHALL NOT BE DISCLOSED OR DISSEMINATED WHOLE OR N PART S 205 INTERMEC CORPORATION RESERVES ALL PATENT PRUPRIETARY DESIGN USE ANGLES MEGTENG D 3382 0 61 TS 1 H SALE MANUFACTURING AND REPRODUCTION RIGHTS THERETO SAG SHEET 1 OF 5 en 4 J SCALE 2 1 A 3600M 072
66. FF Testing Printer and Host Communications This is a simple test of host to printer communications If this test fails there may be a problem with the printer serial port receiver circuitry or the setup To test host to printer communications 1 3 12 Switch the printer power off Return the DIP switch settings to the standard configuration if they have been changed Press and hold the Feed Pause button while powering on the printer The printer presents the hardware configuration test label Release the Feed Pause button after the hardware configuration label is printed You are now in data line print mode within the Test and Service mode Send down some characters from the host At this point the printer does not attempt to interpret any printer commands but simply prints each character and its hexadecimal equivalent as it is received If you are using a PC running DOS send down the following strings of commands from the DOS prompt Note AZ is Ctrl Z NMODE COMI 96 E 7 1 N Enter to configure the serial port NCOPY CON COM1 Enter tells the PC to copy the following text to the COMI port ABCDEF Z Enter these characters are sent to the printer Testing and Adjusting 3 5 A good test will result in the following printout A BCOE F 41 4243 44 4546 3600M 029 6 enter normal print mode again switch the printer power off and then on agai
67. IAASANAASISNDDDANANASISINONIDNDWOIPWO O1 O1 N CO AG O1 O1 F2 O0 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 O1 PN O1 O1 O1 C0 O1 O PO AG O O O O Q O O O F E O F O Q Q Y i gt ds C C00 QQ RR a S OI SX S S O FF O O O O B O O Q PF Q PS gt OY 4S Q Q Oy 4S OO 1 O N 4S O N O O0 XO O Oy J O HP J J Q N N OBO Hip te tal ta tai tay ooo Yapita taj taj Fr o e 23 1 556640 R198 RES S M FILM 12W 5 150 OHM PCB Drawings and Schematics PL 061591 003 TITLE PCB ASSY MAIN 3600 PAGE 5 10 PL REV D 02231995 RUN DATE Feb 23 15 19 02 ITEM QTY UM PART NO REFDES DESCRIPTION X Y F B 25 2 556648 R34 RES S M FILM 12W 5 390 OHM 34 0 1604 E A R115 9 2 4 4 F R123 10 14 54 37 R132 222 SE R143 OA BRO SE 26 9 556650 R105 RES S M FILM 12W 5 470 OHM 5 9 1 0 E R114 39 Weds E R128 Sao dL E R129 dida 1467 R147 Suo dud E T R216 S49 QA IE R2
68. Impulses can range from 200 to 5000V and are caused by lightning switching operations firing of SCRs triacs static discharge and arc welders Use a power line monitor to verify the presence of impulse noise and use a spike suppressor to eliminate its effect Irregular sine waveforms on the AC power line can also affect printer performance They are caused by switching power supplies Use a power line monitor to verify the presence of irregular sine waveforms and use a power line conditioner to eliminate their effects High frequency noise and hash riding on the AC waveform can affect printer performance They are caused by transmitters and ignition systems Use an oscilloscope to verify the presence of noise and hash Install EMI RFI filters to eliminate their effects To troubleshoot environmental problems Correlate an environmental event with the failure Check for static discharges Check for adequate grounding Check the AC power for proper level and purity VS WAS S Check for inductive motors relays or other spike inducing equipment on the power line 6 Exercise good judgment and common sense 4 15 3600 Printer Maintenance Manual Miscellaneous Problems 4 16 The following information identifies some possible printer problems and what might be their cause Problems with printer to computer communications motor control or media advance may be caused by a faulty main PCB assembly If information downloa
69. Intermec Maintenance Manual 3600 Bar Code Label Printer P N 062905 001 Intermec Corporation 6001 36th Avenue West P O Box 4280 Everett WA 98203 9280 U S technical and service support 1 800 755 5505 U S media supplies ordering information 1 800 227 9947 Canadian technical and service support 1 800 688 7043 Canadian media supplies ordering information 1 800 268 6936 Outside U S and Canada Contact your local Intermec service supplier The information contained herein is proprietary and is provided solely for the purpose of allowing customers to operate and or service Intermec manufactured equipment and is not to be released reproduced or used for any other purpose without written permission of Intermec Information and specifications in this manual are subject to change without notice 1995 by Intermec Corporation All Rights Reserved The word Intermec the Intermec logo Label Debut and CrossBar are trademarks of Intermec Corporation The name Centronics is wholly owned by GENICOM Corporation IBM is a registered trademark of International Business Machines Corporation Throughout this manual trademarked names may be used Rather than put a trademark TV symbol in every occurrence of a trademarked name we state that we are using the names only in an editorial fashion and to the benefit of the trademark owner with no intention of infringement The software contained in the 3600 printer and the accom
70. ON PRINTHEAD 32 73 059032 002 BRACKET PRINTHEAD PIVOT 33 76 061559 003 BLOCK PIVOT 35 501272 001 FEET RUBBER ADHESIVE BACKED 36 061570 003 HEATSINK ASSY PRINTHEAD 37 505767 SCREW PHM 8 32X 375 38 061611S 001 PRINTHEAD 6 6 INCH 5 MIL 3600 39 062862 002 CAP BIAS SCREW 41 87 061556 004 PLATE LOWER MODULE OUTBD 47 059103 002 BUTTON CAP 48 058776 004 LIGHT PIPE DOCK CHARG 49 061591S 005 061591E 005 ASSY MAIN exchange part 50 55 059727 001 CABLE ASSEMBLY BEZEL 51 98 059496 004 CABLE ASSY LABEL TAKEN SENSOR 52 061578 001 CABLE ASSY LBL MARK SENSOR 53 123 059495 001 CABLE ASSY LABEL GAP 57 586142 INS SHIM 58 507846 SPACER 235 RD NY SHOULDER 59 505312 SCREW PHM PHIL 4 40X 25 60 061549 003 HEATSINK PCB DRIVERS 7 4 Replacement Parts ID Part Number Description 61 585525 001 XFMR 3600 47 63HZ 100V 120V 585525 002 XFMR 3600 47 63HZ 200V 240V 62 041776 JUMPER AY 25 TERM LUGS 4 IN 63 060246 001 FILTER ASSY LINE AC 64 506103 WASHER LOCK EXT STAR NO 65 501273 001 CIRCUIT BREAKER SWITCH 2 AMP 65 501273 002 CIRCUIT BREAKER SWITCH 1 AMP 67 506111 WASH LOCK SPLIT NO 4 68 060544 001 GASKET ESD RS232 CONNECT 69 507659 001 SCREW JACK 4 40X 312 71 586229 BATTERY LITHIUM 3 6V 1 75AH 72 145 525034 001 SCREW THD ROLL W CONE 8 74 93 106 506013 WASHER SST 255ID X 4070D 108 132 75 506827 001 SPRING COM
71. P 360 OD 44F 77 059122 001 LEVER PRINTHEAD ADJUSTMENT 78 507717 FASTENER COTTER PIN 25 79 061561 001 SPRING TORSION PRINTHEAD RETURN 80 061560 001 SHAFT TTR RIBBON 81 100 136 501409 RETAINING RING 250 DIA BASIC 82 059039 011 HANDLE PRINTHEAD PRESSURE 84 063225 001 PLATE UPPER MODULE OUTBD 85 061576S 002 CAM ASSEMBLY HEAD PRESSURE 88 061568 002 ROLLER LINER DRIVE 89 061542 003 ROLLER PLATEN 90 061543 002 ROLLER DRIVE 91 061558 002 BAR STRIP SUPPORT 92 109 134 501401 RTN RING 250 DIA 8610 2 94 061541 001 BAR TEAR 96 131 501394 001 MOUNT WIRE ROUTING ADH B 97 059423 002 MOUNT MARK SENSOR 7 5 3600 Printer Maintenance Manual ID No Part Number Description 101 061902 001 ARM MEDIA BRAKE 102 062352 002 BELT FLAT POLYURETHANE 1 75 ID 103 061900 003 DRUM MEDIA BRAKE 104 062746 002 BUSHING MEDIA ARM 105 506022 WASHER NYLON 2570 X 5 107 061587 005 PLATE INBOARD MEDIA SUPPLY 110 061903 001 POST MEDIA SUPPLY 111 061586 003 ROLLER MEDIA SUPPLY 112 059718 002 RING LABEL SUPPLY 113 061904 002 CAP MEDIA SUPPLY 114 061552 003 BRACKET MEDIA PATH UPPER 115 059030 005 EDGEGUIDE OUTER 117 059781 001 THUMBSCREW ASSEMBLY 118 061553 003 BRACKET MEDIA PATH LOWER 120 061567 002 SPRING TORSION PAPER PATH 121 059509 002 SHAFT PAPER PATH 122 062396 001 MOUNT LBL GAP SENSOR 124 061901 001 PEDAL MEDIA BRAKE 125 127 165 061562 005 ASSY 128 061566 003 BRA
72. Procedures for detailed instructions Raise the printhead with the printhead lift lever Remove media and ribbon if loaded Loosen the Phillips screws on the outboard plate that you are aligning Note Align only one outboard plate at a time either the upper or the lower to put the rollers back into factory alignment If both plates are loosened it may not be possible to align the rollers outside of the factory Align the three holes in the roller alignment tool with the platen roller the liner roller and the TTR roller The fourth hole in the roller alignment tool fits over the black plastic cap closest to the front of the printer 3600M 038 10 11 Testing and Adjusting 3 When the tool fits properly on all of the rollers and the bushing tighten the screws on the outboard plate that you are aligning Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Install the electronics cover Reload media and ribbon if used Install the media cover and the power cord Switch on printer power and check for proper operation Aligning the Printhead Align the printhead only if necessary To perform this procedure you need the following tools Printhead alignment tool Intermec Part No T43099 9 64 inch Allen screwdriver To align the printhead 1 Switch off the print
73. RT o 1 i rod 120 ig e ques paid m ix SH LABEL_GAR i c 5 0 uel 1 5 gt GNIPH 9 4 1 4 x ONAN L SWITCH TOEA pausmvez FR lI aei es CBS i 8 100 BASLE at 1 vor ka sies 1 ne 2 13 SENSI a 2 6 3 E R246 2 11 150 BFSIB Y 4 Prag 91 13 bd 5U Mot 312 1 IRrRLEG 4 14 2113 4 m PP2ED gt n 2e ns RESETK R243 Lua 2 14 47 X L e 15 Sra ee 7115 NN RUG sn H m E Se 1 e EA OH gy 48 25 y Rees 20220 m 1454 Pozas K gt 3ENSE_ZA1 E x4 B 18 197056 01 loss 23 m INSTALLED P297 ug RLAG READ Xmas L A pos ET 9121 Lheos IB AK is 025 IRFRIZD 4x PP173 Ri Te AN BHI JM dat 11 E I 2 ka 1 i as lac AW AMY 5 x lt TAHI AHO LL r Y 1 5 Ts PP1S3 707 124 J 58 7 4 3 AHS 12 AS 392 gt Presl BASLE BASLE 3 1 usu RAN SRuas ENTER aa Sen mal PX ABA BOK 2401 5 tad o n 2 BHO 20 BASLE 1 Ms 4 7K x n GE 042 JL a x N
74. S S M NPN TYPE 4401 3 4 E Q9 10 43 3 8 010 10525242050 F 4 016 1 2 67 1 565102 017 TRANS S M TYPE 4403 PNP 10 6 2 7 F 68 1 565110 Q7 XSTR S M TYPE 6427 DARLINGTON 10 5 1 3 F 69 565127 001 Q15 XSTR S M T5551 NPN 160V LOST 2 22 70 8 565130 001 01 XSTR S M HEXFET 60V 7 7A 6 29 09 T Q3 673 0 9 Q4 6 9 1 62 E Q6 6 3 146 A oll 9 3 LaS T 012 6 19 Q13 6 2 UPS i Q14 S220 SE 71 1 567024 VOLTAGE REGULATOR 5V 1A 106277 SE 74 1 5778020 U28 5 TYPE 74 04 58 dude aE 75 1 578023 U5 5 74HC32 duo 76 4 578081 07 5 74HCT245 0 92 1322 U10 02 9 440 T 014 Sade Ape VE 015 348 24 E 77 1 578087 04 IC S M TYPE 14C89 CMOS RCVR 140 250 E 78 2 578131 011 IDT72105 FIFO Doodles ru rt E U24 243 79 1 578132 U30 IC S M TYPE MC145041 80 dS 80 1 578134 01 5 75ALS180 L 0 X5 81 1 578135 U29 IC S M TYPE MC34064 1 8 E 82 1 578137 D11 IC S M TYPE LM385 1 2 2A SE 83 1 578145 Y2 CRYSTAL S M 24MHZ dad SE 84 2 578209 001 U16 IC S M TYPE 74ALS257 30 Su CE 6 11 3600 Printer Maintenance Manual PL 061591 003 TITLE PCB ASSY MAIN 3600 PAGE 10 10 PL REV D 02231995 RUN DATE Fe
75. S AP Q Q ds us OY Q PO O CO RANAN O 1 O C Q OY Q Os OO N N ds M CO ds N BOO tz Hj z rz tz z z r7 fj z z z zJ fj z z z z z z z z zJ z z z z z z z z z zJ f z z z z f z z z z fj z z z z 5 rm 5 f PCB Drawings and Schematics PL 061591 003 TITLE PCB ASSY MAIN 3600 PAGE 9 10 PL REV D 02231995 RUN DATE Feb 23 15 19 02 ITEM OTY UM PART NO REFDES DESCRIPTION X Y F B D42 4 8 0 8 F A D43 9 85 1 0 H D44 Su AQ Es E D45 4 6 ibd SE D46 4 6 0 9 F 047 4 6 0 8 59 4 564206 D1 DIODE S M TYPE MMBD301 1 9 0 6 D2 1 8 056 E 4 Su 620 OF D14 I T 229 60 1 564217 D28 DIODE S M TYPE 5231 ZENER 5V 10 97 S950 61 3 564219 D15 DIODE S M TYPE 5245 ZENER 15V 10 7 1 2 F 016 20 E 20 LOM gt dT E 62 1 564235 D9 DIODE S M TYPE 5226 ZENER 3 3V 2 5 0 4 63 2 564238 D26 DIODE S M TYPE BAS21 200VBR 9 01 Que 27 9 0 04 E 64 4 564239 002 D6 DIODE S M DUAL 6A 100V hg Os TE D10 Qu 3s E D12 Sn 20267 D13 8 3 036 65 1 565091 001 05 XSTR FET 60V 30A 98 042 66 4 565101 02 TRAN
76. Summary Your safety is extremely important Read and follow all of warnings and cautions in this book before handling and operating Intermec equipment You can be seriously injured and equipment and data can be damaged if you do not follow the safety warnings and cautions Do Not Repair or Adjust Alone Do not repair or adjust energized equipment alone under any circumstances Someone capable of providing first aid must always be present for your safety First Aid Always obtain first aid or medical attention immediately after an injury Never neglect an injury no matter how slight it seems Resuscitation Begin resuscitation immediately if someone is injured and stops breathing Any delay could result in death or permanent injury To work on or near high voltage you should be familiar with approved industrial first aid methods Energized Equipment Never work on energized equipment unless you are authorized by a responsible authority Energized electrical equipment is dangerous Electrical shock from energized equipment can cause death If you must perform authorized emergency work on energized equipment be sure that you comply strictly with approved safety regulations Xi 3600 Printer Maintenance Manual Xii WARNING CAUTION Warnings and Cautions The warnings and cautions in this manual use the following format and address the issues described Warning A warning alerts you of an operating procedure practice condition
77. acter This character alerts the host to the fact that the printer buffer is full and cannot receive any more data When the printer is ready to receive more data it sends the XON character Troubleshooting 4 To check for communications problems 1 Check cabling from the printer to the host system 2 Check the interfacing of the devices that are communicating with the printer 3 Check the printer for proper electrical operation of the serial communications port 4 Test to see that the host system is not overrunning the printer s input buffers 5 Check to see that the data string being sent to the printer contains the correct information Environmental Problems Symptoms associated with environmental problems are printing garbage resetting or total lockup One way to discover if the problem is environmental is to see if the problem goes away when the printer is moved to a new location If it shows up in a printer recently moved from another area the problem is probably environmental The following is a discussion of different types of environmental problems Electrostatic Discharge ESD ESD can cause failure or weakening of affected components Typically ESD occurs when a person with a large electrical potential unintentionally discharges that potential by touching the conductive surfaces of the equipment Static charge is created through friction from people walking conveyor belts paper moving through a
78. ad lift lever clockwise until the printhead releases 3 Remove the media from the paper path and the ribbon if installed from the TTR hubs 4 Clean the label taken sensor and the label mark sensor with a cotton swab moistened with isopropyl alcohol N decal Main PCB roller Upper media guide underside Cleaning brush Lower media guide v Label gap Sensor 3600M 016 2 11 3600 Printer Maintenance Manual 2 12 9 10 11 12 Pull down on the lower media guide to expose the label gap sensor Using a soft bristle brush remove all debris and dust from the label gap sensor Clean the label gap sensor with a cotton swab and alcohol Remove the electronics cover Very carefully clean the small ribbon motion optical sensor on the main PCB and the black and white encoder decal on the TTR supply clutch encoder assembly with a cotton swab moistened with alcohol Install the electronics cover Reload the media and ribbon if used Engage the printhead by rotating the head lift lever counterclockwise until it locks in place If you are finished cleaning install the media cover Cleaning the Printer Covers Clean the 3600 printer covers with a general purpose cleaner soapy water mild detergent Do not use abrasive cleansers or solvents Be sure to clean the transparent panel on the media cover so that you can see the media supply inside
79. age overrun still occurs printing for that batch of labels stops and any following commands are executed Installing the optional 512K memory expansion prevents image overrun errors 3600 Printer Maintenance Manual 4 6 Invalid Numeric Character Errors If non numeric characters are included within a numeric data string in a command the printer disregards them and continues to process the rest of the valid numeric characters However if a non numeric character begins the numeric data string the printer uses a default value for the affected command Here are two examples of valid numeric character strings and one example of an invalid string 12a valid 1a2 valid a12 invalid Insufficient Storage RAM Errors Before storing new formats graphics or user defined fonts in the static RAM the printer checks to see if it has sufficient memory to store them If there is insufficient memory the last editing session is disregarded The printer is designed to preserve the integrity of the existing data in the static RAM Error Codes Most of the problems you may encounter cause the 3600 printer to send an error code to the host When this happens find the error code in the following table and try the solution given to attempt to correct the problem Troubleshooting 4 Printer Errors Error Code Problem 00 No error 01 Invalid bar code check character 02 Invalid number of bar code characters Code UPC EAN 04 B
80. and port 0SM The QSM consists of two modules a serial peripheral interface SPI and serial communications interface SCI The SPI is used to communicate with the A D converter It takes continuous readings and stores the values in RAM for immediate access by the CPU The SCI is used for RS 232 RS 485 communications Other pins are used as general purpose I O Interrupt Priority Levels The SIM module has seven IRQ pins to help facilitate external interrupts in the 3600 I ORCV I OXMT PFAIL and HF are available as interrupts I ORCV and I OXMT are used for communications with the I O option interface e is used to indicate that the FIFO needs service PFAIL indicates a loss of power e The IRQ pins are used for general purpose I O Crystal The clock synthesizer of the MC68332 can operate from an on chip phase locked loop using an external crystal A 32 768KHz crystal provides a reference allowing the processor to run at frequencies from 131KHz to 16 777MHz The clock synthesizer is programmed to run at 16MHz in the 3600 Appendix A Memory The MC68332 has separate address busses and data busses All I O is memory mapped and the SIM chip selects are used to select program space data space and I O Static RAM The 3600 comes with 128K of battery backed static RAM The RAM is configured as 128Kx8 The chip select for accessing SRAM should be configured to at least one wait state The RAM can a
81. and Adjusting Plate 5 20 To replace the supply hub the supply hub adjusting plate or both parts you will need some or all of the following parts and tools TTR supply hub Intermec Part No 061562 004 TTR supply hub adjusting plate Intermec Part No 062603 001 Retaining snap rings Intermec Part No 501410 Ribbon supply hub alignment tool Intermec Part No 743149 ESD grounding strap Snap ring pliers 1 and 2 Phillips screwdriver To remove the TTR supply hub and TTR supply hub adjusting plate Switch off the printer power and remove the power cord Remove the media cover the electronics cover and the front bezel cover refer to Replacing the Bezel PCB earlier in this chapter Raise the printhead Remove media and ribbon if loaded Remove the two retaining snap rings and thin washer from the electronics side of the TTR supply hub shaft as shown on the next page Retain the washer Discard the old snap rings Pull the TTR supply hub away from the printer and remove the TTR supply clutch encoder assembly Retain the TTR supply clutch encoder assembly this assembly is not a spare part the nylon washer and the thick steel washer You can replace the TTR supply hub and TTR supply hub adjusting plate now Remove and Replace Procedures 5 To replace the TTR supply hub and TTR supply hub adjusting plate 1 Remove the two Phillips screws securing the TTR supply hub adjusting plate to the TTR subp
82. and Service mode and causes the hardware configuration label to print Checking the Printer Configuration The factory default settings for the 3600 printer are listed with the 3600 specifications in this chapter These parameters are set using a combination of DIP switch settings and downloadable printer commands which are described in the user s manual Remember you can print out hardware and software configuration labels for statistics of the printer you are servicing General Information 1 DIP Switch Settings The DIP switches on the rear panel of the printer control communications parameters media type configuration and test and service functions To change settings carefully position the plastic breakable switches to ON or OFF with a small straight slot screwdriver The printer is shipped from the factory in the standard configuration with the 16 DIP switches set as shown in the following illustration When changing switch settings you must cycle the printer power from off to on for the changes to take affect Factory Default Settings a e M 11 DIP gt i j switches ON gt OFF RCM e Serial o QU b communications Nom port o QU SL ON OFF a switch M M m lt EG lt iG on LA ore AC power cord MP receptacle I TV
83. anish Swiss Memory Base 512K of DRAM for imaging 128K of SRAM for storage Optional 512K of SRAM for storage Factory Default Settings General Information 1 The following is a list of the factory default settings for the 3600 printer Configuration Preamble Character Postamble Character Auto Transmit 1 Auto Transmit 2 Auto Transmit 3 Message Delay Power Up Mode End of Print Skip Distance Top of Form Media Sensitivity Number of Image Bands Maximum Label Length Printer Character Set Label Retract Print Speed Label Stock Type Intercharacter Delay Default Setting Disabled Disabled Disabled Disabled Disabled 0 ms Advanced mode 100 dots 20 dots 420 3 1000 dots US ASCII Enabled 3 ips Die cut 0 ms 3600 Printer Options The 3600 you are servicing can be equipped with one or more of the following options Memory Expansion Storage memory for formats pages graphics and fonts can be increased to 512K of battery backed static RAM This option provides an additional 512K of nonvolatile bulk storage to hold more formats fonts or bitmap graphics It also increases the printer s image buffering capabilities Twinax Interface Allows connection of the 3600 printer to IBM Twinax systems The printer emulates an IBM 5256 Model 1 printer and can operate with an IBM System 34 36 38 or AS 400 host computer 1 7 3600 Printer Maintenance Manual Coax Interface Allows connection of the
84. ar code check character within numeric field marks 05 Supplemental delimiter within numeric field marks Code UPC EAN 06 Invalid supplemental character count UPC EAN 07 More than one supplemental delimiter Code UPC EAN 08 Invalid start stop characters Codabar 11 Invalid bar code data 12 Data count exceeded 13 Entering data in non data entry field 21 Quantity or batch count out of range 22 Field increment decrement out of range 23 Intercharacter message delay out of range 24 Missing preamble postamble data 25 Invalid format transmission syntax 26 Invalid page transmission syntax 27 Invalid font transmission syntax 28 Invalid UDC transmission syntax Solution Verify the bar code check character modifier used in the bar code program command Verify the number of bar code characters used in the bar code program command Check the bar code program command for accuracy Check the bar code program command for accuracy Check the bar code program command for accuracy Check the bar code program command for accuracy Verify start and stop characters in the label format Verify data in the label format Data count should not exceed what is specified for the field Check the field for accuracy Quantity of labels or number of batches should be between 1 and 9999 Quantity should be between 1 and 9999 Delay should be between 0 and 9999 Delete the setup for preamble or postamble data
85. ata fields in the format Verify the field number in the label format Check the program command for proper syntax Empty the buffer contents If the format still does not fit delete some fields or other data from the format You may have to remove or reduce the UDCs formats or fonts if necessary Note Entering ESC m tells the host how much memory is installed and how much is available You can use up to 200 fields in a format and each field can use up to 250 characters Reduce field size or delete some fields Check the statement syntax Verify that cell heights and widths are between 1 and 599 and that the intercharacter space is between 0 and 199 Remove or reduce formats fonts or UDCs Correct the UDC command syntax Troubleshooting 4 Printer Operation Problems If a printer is not operating correctly try locating the problem and implementing the solution from the following table Symptom No power or loss of power Labels stop feeding through the printer Printer slows down Labels stick to door or fail to strip The stepper motor stalls while printing media that is less than 6 6 inches wide Configuration label does not print Possible Causes AC power cable is damaged or disconnected Printer circuit breaker tripped Power supply function is failing Printer is out of media Label stock is loaded incorrectly Media is sticking to the paper path Printer is set for
86. aten roller or the media path If the printhead is uneven or the print path is skewed it will be reflected in this label Use this label to determine whether the printhead is printing evenly but use the actual customer format to pass fail the printhead OFF OFF 3600M 027 3600 Printer Maintenance Manual Font This is a multiple label test of the available fonts You can test a single font Font 20 shown or all of the fonts An all font test will use a lot of media It is better that you test one font at a time to make your determinations E D E q0 48 12 16 424 192 196 200 204 E i gt z 1 5 9 13 17 125 193 197 201 205 gr gt i E 2 6 10 14 18 6 194 198 202 206 SE f _ 3 7 11 15 19 23 5 199 203 207 d N ON or J 3600M 028 Page These labels test the ability to download and correctly print single or multiple pages a group of labels always printed together of label data from a host The data can be yours or the customer s but you should include a test of the customer s labels to determine whether the printer you are testing is attaining the best print quality possible with the customer s data UDC This label tests the ability to download and correctly print single or multiple user defined characters bitmap graphic from a host The data can be yours or the customer s but you sh
87. b 23 15 19 02 ITEM OTY UM PART NO REFDES DESCRIPTION X Y F B x U18 ALO 3 2 E 85 578211 001 U3 IC S M TYPE MC68332 MICPRCS 0 4490 86 3 578245 001 U2 S M LM293 DUAL VOLT COMPTR 4 0 1 1 F i U27 10 4 3 6 F 031 248 Ou 87 1 578294 001 U26 IC S M DRAM 256KX16 SOJ Pele 242 88 1 578300 001 U22 S M 234 RS 232 DRVR l 5 0595 89 2 578301 001 U17 S M HIP4081 HF DRVR 80V 5 4 1 2 E 019 5 4 038 90 2 610 580231 CONN 26 POSN HDR SNGL ROW 100 91 1 580285 J10 CONN 8 POSN HDR 156 FRICTION Tus E 93 3 580359 11 CONN HDR 4 POSN STRAIGHT THRO 10 6 4 2 F 912 43 J13 Il Suo 94 1 580434 1 CONN 25 POSN D SUB W SNAP O OF 95 581976 714 CONN 40 POSN HDR 1 DBL ROW 102 1 02 E 96 2 581978 J9 CONN 6 POSN HDR 100 FRIC LOCK 7 3 0 6 F T J15 S97 33 97 2 582065 SW1 SW 8 POSN DIP SIDE ACTUATED 23 9 YE 5112 0 1 4 8 98 1 582282 012 92 CONN S M PIN 8MMX6MM 80 POSN 5 97 Xl 99 1 585636 001 11 INDUCTOR 10 UH IL 100 1 586298 1 HLDR BATTERY AA SIZE 1 9 528 E 101 1 586548 001 Q8 SENSOR S M REFLECTIVE 9 4 4 6 F 102 1 588000 XL CRYSTAL S M 32 768 KHZ 5 0 6 0 E 103 2 580213 CONN 2 POSN SHORTING 10 CTRS 6 12 HIHIH H H REVISION REVISIONS 20 lt 55 A lt DESCRIPTION DRAWN amp APPR VED
88. ble It is possible to use a power line monitor such as the BMI 4800 to test for noise on the interface cable Ground Loops Between Equipment Ground loops pick up RFI as well as generate their own noise in interface cables The recommended wiring of the interface cable calls for connecting chassis ground pin 1 between the host computer and the printer to ensure that the chassis of both devices remains at the same electrical potential in the event of a faulty ground in either device This safety precaution will save people from electric shock in the situation where they touch both the host computer and the printer at the same time while there is a faulty ground in either device With this wiring you would normally expect problems with ground loops but the printer chassis ground and signal ground are connected to each other through a 10kQ resistor thus providing some ground loop immunity If connections in the interface cable described above are discovered to cause ground loop problems disconnect the shield from the backshell at only the printer and sever the chassis ground pin 1 connection between the host computer and the printer To ensure safety double your efforts to guarantee that both the host computer and the printer make a solid electrical and physical connection to earth ground Inadequate Earth Ground Poor grounds can cause fuses on equipment to blow and damage components The ground in the AC power receptacle must be a goo
89. ches an over temperature condition the Alert LED on the printer flashes and the printer halts printing Usually you will not need to intervene If you allow the printer enough time to cool down it normally resumes operation on its own 1 11 3600 Printer Maintenance Manual 1 12 Media or System Faults If you are servicing a printer indicating a media or system fault refer to Chapter 4 Troubleshooting for information about the problem Feed Pause Pushbutton Operating the Feed Pause button produces the following actions depending on what condition the printer is in Printer Condition Operation Function If the printer is idle Pressing and releasing the Feed Pause button causes the printer to feed out one label or a minimum specified amount of media Pressing and holding the button down causes media to feed continuously until the button is released Pressing the Feed Pause button twice takes the printer offline Press the button once more to bring the printer online If the printer is printing Pressing and releasing the Feed Pause button causes the printer to pause Subsequent pressing and releasing of the button allows the printer to resume printing Pressing and holding the Feed Pause button down until the printer stops printing cancels the current print job When the printer is first Pressing and holding the Feed Pause button powered on down when turning printer power on places the printer in the Test
90. complex the influence that print speed and the number of buffers has on throughput is limited by imaging speed New considerations come in to play such as delay between printing and perceived printer performance Unfortunately there is no formula to use to calculate an ideal configuration Instead it will have to be found through trial and error by the user 3600 Printer Maintenance Manual 4 18 Font Caching Most of the imaging time during text creation is spent converting character description data into character images The remainder of the time is used to copy the character images into image RAM Font caching helps to eliminate the reimaging of characters that have already been used With font caching a character is imaged into the cache the first time it is requested It is then copied from the cache into the appropriate area of image RAM The next time that same character is needed it only has to be copied from the font cache The illustration on the following page shows the process of generating and caching a specified character When used with band buffering even if there are no repeated characters in a label font caching may still enhance imaging If a character is large or is positioned near a band boundary portions of its image may fall into multiple bands The character s image will be referenced repeatedly as each of the bands is imaged As before if the character is cached it will only need to be imaged a single time
91. configuration e Bitmap font capabilities Outline vector font support e User selectable gap feature for fonts e 2Dsymbology support Code One PDF 417 and Maxicode e 128k standard 512k optional storage memory Autoselection of Intermec protocols e Printable control characters mage banding and memory management Dot by dot digital thermal compensation e Self strip or continuous print with internal rewind e Media sensitivity numbering system e Wide range of label media Label Debut label design software 3600 Printer Specifications The specifications and performance parameters for the 3600 printer are itemized in this section Dimensions no options installed Height 11 inches 27 9 cm Width 12 inches 30 5 cm Length 17 inches 43 2 cm Weight 45 pounds 20 3 kg Electrical Requirements Input Voltage 100 115 or 230 VAC 10 Frequency 47 to 63 Hz Printing Methods Direct Thermal Thermal Transfer thermal transfer ribbon TTR required General Information 1 Printing Speed Maximum 5 ips 50 8 mm per second Minimum 2 ips 127 mm per second The print speed can be changed in 1 ips increments only 2 3 4 or 5 Printhead Specifications Element size 0 00492 inch square 0 13 mm Width 6 6 inches maximum print 168 mm Resolution 203 dots per inch 8 dots per mm of Elements 1344 per printhead Xdimensions 10 mil to 50 mil or 0 25 mm to 1 27 mm 5 mil 0 13 mm in drag m
92. continuous label stock Label sensor s dirty out of adjustment or failing Image bands or print speed are incorrectly set Printer has aborted and print speed and image bands were reset The self strip roller is dirty or the pinch roller is not contacting the strip roller The bias is not adjusted properly The media is loaded incorrectly Solution Make sure the power cable is plugged into both the printer and an outlet or power strip Replace the cable if it is damaged Turn the printer off and then back on again determine why it tripped Replace circuit breaker if defective Check the transformer and the main PCB Replace whichever is defective Load new media Check the media path Clean any extraneous material from the paper path and clean it thoroughly Use the Transmit Configuration Parameters ESC p command to check the configuration setting Select the correct setting with the Select Label Stock Type command lt SI gt T Clean and adjust or replace the sensor s as required Change the image bands or print speed settings Change the image bands or print speed settings Clean the self strip roller Adjust the bias adjust screw to the optimum printing position Try reloading the media 4 9 3600 Printer Maintenance Manual Print Quality Problems Symptom Blotches on labels Printing is too light or too dark Printing not aligned on label Labels are not stoppi
93. cter Image character Image character in allocated cache in reserve cache Return requested character 3600M 101 A 19
94. d Inputs consist of one button Feed Pause and three LEDs Power Alert and Empty Pause The Alert LED indicates system errors or printhead over temperature The Empty Pause LED indicates a paused state or a media fault Debug Interface J5 provides a debug interface to the processor which allows for troubleshooting of the main PCB This interface can be used to put the processor into background mode and then send commands to read or write memory or register locations This interface is used for in house functional testing and is used for engineering development 3600 Printer Maintenance Manual Timing Row Name Formula Min Max Margin Comment 1D 13 301 3 30 332 Clk low to sel asserted 2V Tco 2 10 2 10 GAL Clk to output delay 3D Tchav 2 39 2 39 332 Clk hi to add valid 4D Tsy Tsy 4 12 5C Trah 15 15 lt 13 25 gt DRAM row add hold time 6C Taist 5 5 lt 38 50 gt 332 DSACK setup time 7D Tclsn 3 30 3 30 332 Clk low to sel negated 8D Tsy Tsy 4 12 9V Tpd 3 15 3 15 GAL Tpd 10C Tasc 0 0 lt 6 25 gt DRAM col add setup 11C Tasr 0 0 lt 65 75 gt DRAM row add setup 12C Tras 80 80 lt 38 gt DRAM ras low time 13C Tds 25 25 lt 18 50 gt DRAM 14V Tsy 4 12 4 12 Sel to output HC257 15D Tpd Tpd 3 15 16D Tpd Tpd 3 15 17D Tco Tco 2 10 18D Tpd Tpd 3 15 19D Tco Tco 2 10 20D Tpd Tpd 3 15 21C Tcas 20 20 35 50 22D 13 301 3 30 Same as 1 23C Trp 60 60 52 24C Tcah 20
95. d solid earth ground Do not rely on conduit for ground The ground rod should penetrate the earth at least 8 feet below the frost line The soil should contain clay minerals dry sandy soil does not provide a good ground Ensure that all ground connections from the service panel to the AC receptacle are solid and secure Troubleshooting 4 AC Power Problems Surges Sags Spikes Noise and Outages Most environmental problems involve the AC power line In the 3600 printer 115V supply voltages can range from 90 to 132 VAC Outside the U S 230V supply voltages can range from 180 to 264 VAC Voltage overages or underages can result from poor utility regulation to in plant loading of the power service Use a power line monitor such as the BMI 4800 to look for power service problems To eliminate the effects of voltage overages and underages install an uninterruptible power supply UPS or install a dedicated circuit for the printer and the host computer Intermittent power outages can be caused by a combination of vibration and loose connections between the service panel and the AC receptacle Check the wiring to ensure that all connections are solid and secure Use a power line monitor to test for outages To eliminate the effects of power outages install a UPS Impulse noise on the power line can also cause the printer to lockup or reset All Intermec products including the 3600 printer meet IEC 801 Surge and Burst specifications
96. d cleanings and checks Making sure the printer is operating correctly and providing quality results Problem solving Removing and replacing components Main PCB drawings and diagrams Spare parts Theory of operation Refer to Chapter 1 An illustrated overview of the 3600 printer listing printer features specifications and options identifying primary parts and summarizing some setup and operating information Chapter 2 Actions intervals and illustrated preventive maintenance procedures Chapter 3 Procedures for running printer tests printing test labels printing out the configuration settings and for making printer adjustments and alignments Chapter 4 Information for identifying duplicating isolating and eliminating conditions or failures in the printer environment or the printer components Chapter 5 Instructions for the removal and replacement of key components Chapter 6 Engineering drawing and schematic diagram of the main PCB Chapter 7 Two lists of the spare parts one in ascending part number sequence and one alphabetically by description keyed to exploded illustrations of the printer Part numbers for tools and documentation are also provided Appendix functional descriptions of the 3600 mechanics electronics and firmware xiii 3600 Printer Maintenance Manual Terms and Conventions The following terms and conventions occur throughout this manual A complete
97. ded to the printer memory is lost after the printer is powered off lost data includes configuration setting changes reverting to their factory defaults when power is cycled the lithium battery may be bad The appearance of long white streaks in printed labels indicates a dirty printhead or possible printhead failure If you have problems with the bezel LEDs or the Feed Pause button you may need to replace the bezel PCB assembly If the printer no longer registers the use of marked label stock you may need to replace the label mark sensor Light print on one side of a label can occur if the printhead is not making even contact with the media This condition can happen with any size media but is most common when using narrow labels where there is no media between the printhead and the platen roller Uneven lateral print darkness may be eliminated by adjusting the bias screw If the printer is no longer sensing when labels have been removed you may need to adjust or replace the label taken sensor If the TTR takeup hub fails to roll up ribbon you may need to replace the upper drive belt and or the TTR takeup clutch If a ribbon fault occurs when the printer is in the TTR mode you may need to replace the TTR encoder sensor If the liner takeup hub discontinues rolling up liner you may need to replace the liner takeup lower drive belt or clutch If the platen roller does not turn but the liner drive roller does you may need to
98. dia guide assembly to the main deck plate Slide the upper media guide outward to separate it from the rest of the assembly 5 13 3600 Printer Maintenance Manual Label gap sensor Label gap sensor Tar housing Locking tabs 3600M 052 6 Use a small straight slot screwdriver to lift up on each of the two molded tabs that secure the label gap sensor Slide the label gap sensor from its housing and replace it with the new label gap sensor The label gap sensor should snap into place 7 Slide upper media guide plate back together with the lower media guide plate 8 Route the label gap sensor cable through the cutout in the main deck plate and reattach the media guide assembly to the frame Be sure that the media brake arm does not rub on the upper media guide and that the sensor cable is not contacting any moving parts 9 Attach the label gap sensor cable to the main PCB 10 Reload media and ribbon if used and lower the printhead 11 Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 14 Remove and Replace Procedures 5 Replacing the TTR Drive Roller and Gear Pulley To replace the TTR drive roller or the TTR drive gear pulley or both you will need some or all of the following parts and tools e TTR drive roller Intermec Part No 061543 002 e TTR drive gear pulley Intermec Part No 061563 002 white e Retaining E rings Int
99. e power and reattach the electronics and media covers Troubleshooting Troubleshooting 4 This chapter provides you with information that will help you determine why a printer may not be working and how to get it working again About Troubleshooting and Repair Use the information in this chapter to identify the cause of a failing printer It is assumed that a printer is not working and that the troubleshooting actions referenced in the user s manual were not used failed to clear the problem or pointed to a printer malfunction Troubleshooting Tips One of your first concerns is to duplicate and isolate the problem to confirm if the problem is the printer or not Usually the printer was already working at some point before you were called so start with the last time it worked and move forward logically considering what might have changed since then Do not neglect to check simple things like Is the printer plugged in Is there power at the outlet Are all of the connections good Spend a minute visually examining the unit and considering the situation to see if anything obvious stands out Where to Start If you have not already done so review the user s troubleshooting information in this chapter and use tests from Chapter 3 Testing and Adjusting to determine if and how the printer performs offline If you have a working installation at hand consider the value and difficulties of trying the printer in a known
100. e the media and ribbon if loaded Remove the five screws that secure the lower outboard plate to the main deck plate and pull the plate away from the rollers The tear bar and tear bar support come loose when the outboard plate is removed Retain them for reassembly Snap ring Lower outboard N 4 gt plate i gt B 4 E ay 2 3600M 059 9 3 9 Liner drive roller lt 2 10 11 12 13 Remove and Replace Procedures 5 Remove the liner drive gear pulley retaining E ring Retain the washer located between the E ring and the liner drive gear pulley Discard the old E ring Loosen the motor as necessary to disengage the pinion gear from the liner drive gear pulley to facilitate disassembly Remove the liner drive roller sliding the liner drive gear pulley off of the roller shaft Retain the washer between the roller and main deck plate The gear pulley will remain trapped by the drive belt until the belt is removed as described in the following procedure Be sure to retain the washer between the gear pulley and the main deck plate when it comes loose Note Now is a convenient time to replace other liner drive and takeup components according to the following procedures You can replace the liner drive roller now Install the first washer you removed in Step 5 and a new retaining E ring on the liner drive roller shaft Position
101. ectors attached to the power switch Power switch Rear ircuit breaker panel gt gt y I Transformer lead AC power plug lead Tabs lt 3600M 063 Remove and Replace Procedures 5 Compress the tabs that hold the power switch secured to the back plate and push it out of the main deck plate Install the power switch by pushing the new receptacle into the cutout in the main deck plate Reattach the two push on connectors removed in Step 3 Install the electronics cover the media cover and the power cord and check the printer for proper operation Replacing the Transformer To replace the transformer you will need the following parts and tools Note The printer uses a different transformer for 220 volt and 115 volt printers XFMR 3600 47 63HZ 100V 120V Intermec Part No 585525 001 or XFMR 3600 47 63HZ 200V 240V Intermec Part No 585525 002 ESD grounding strap 2 Phillips screwdriver To replace the transformer 1 Switch off the printer power and remove the power cord the media cover and the electronics cover Disconnect the transformer cable from the main PCB and the two leads with push on connectors from the AC power plug and the power switch Power switch circut breaker did PCB AC power e Screw 2 places 3600M 064 5 33 3600 Printer Maintenance Manual 3 Remove the two screws holding the transformer to the base plate and slide
102. ed in the following section Inspect after every roll of media Clean after every roll or 6 000 inches of media or more often if necessary Inspect or test print quality every service visit Make any necessary adjustments Clean after every five rolls of media Using hi tack adhesive requires cleaning after every roll of media If the customer uses tag stock or continuous media you may want to clean after every five rolls of media or more often if necessary Harsh or dusty environments dictate the need to clean more frequently Inspect or test the operation of these printer elements at every service visit Make any necessary adjustments 2 3 3600 Printer Maintenance Manual Inspecting the Printer You should routinely inspect the printer and the rest of the data collection system Your inspection needs to address the following and similar concerns Make sure the printer is properly grounded e Make sure the printer s AC power source is within tolerance Make sure the printer is clean Make sure the printer is away from liquids Inspect the work environment for cleanliness and arrangement Large electric motors welders and switching equipment can negatively affect printer performance e Check the data collection network regularly for loose wires or poorly installed connections Be sure to replace corroded wires Cleaning the Printer WARNING Use these procedures to access the printer parts and clean them Heed
103. electronics cover unless a procedure requires the unit be energized Failure to disconnect the power cord may result in injury or death due to electric shock Caution Integrated circuits on printer circuit boards in this equipment are sensitive to damage by electrostatic discharge ESD Prevent ESD by always wearing skin contact ground straps firmly attached to the equipment metal base assembly when working inside of the equipment housing Failure to comply can result in damage to components Caution Align only one outboard plate at a time either upper or lower to put the rollers back into factory alignment If both plates are loosened it may not be possible to align the rollers outside of the factory 3 21 3600 Printer Maintenance Manual Aligning the Rollers You should perform this procedure every time an outboard plate is removed or replaced To perform this procedure you need the following tools Note If the printer you are servicing has upper outboard plate Intermec Part No 062476 002 installed you need to replace it with a new upper outboard plate Intermec Part No 063225 001 before you can perform the following roller alignment Roller alignment tool Intermec Part No T43150 2 Phillips screwdriver To align the rollers 1 2 3 22 Switch off the printer power and remove the power cord Remove the media cover the electronics cover and the front bezel cover refer to Chapter 5 Remove and Replace
104. eplacing the Stepper Motor 5 30 To replace the stepper motor you will need the following parts and tools Main stepper motor and cable assembly Intermec Part No 061551 002 ESD grounding strap 2 Phillips screwdriver To replace the stepper motor 1 Switch off the printer power and remove the power cord the media cover and the electronics cover Unplug the motor cable from the main PCB and remove the motor from the motor plate and motor mount bracket Screw Do not install 8 places ps a screw in this Stepper Motor mounting hole molor plate 3600M 061 3 Mount the new motor loosely to the motor plate with the cable positioned at the bottom rear corner Properly mesh the pinion gear with the platen drive gear and the liner drive gear before tightening the screws completely Plug the motor cable into the main PCB Check that the motor cable to main PCB connection is correctly aligned before applying power to avoid damaging the main PCB Install the electronics cover the media cover and the power cord and check the printer for proper operation Remove and Replace Procedures 5 Replacing the AC Plug Input Filter To replace the AC plug and input filter assembly you will need the following parts and tools 3600 line AC plug and filter assembly Intermec Part No 060246 001 ESD grounding strap 1 and 2 Phillips screwdriver Needlenose pliers To replace the AC plug and input fi
105. er Maintenance Manual Communications Problems Symptom Printer does not communicate with the host 4 12 If a printer is not receiving downloaded data consider the causes and solutions in this section Possible Causes Solution Serial port is incorrectly Make sure the printer s serial port settings configured match those of the host Print a software test configuration label to check the serial port settings Disconnected damaged or Check the connections at both ends Replace the incorrect I O cable cable if necessary Any loss of data can cause printing errors or missing data The 3600 printer is a serial ASCII device that communicates with the host through an ASCII serial communications port The two devices communicate through the use of hardware and software protocols handshaking The printer utilizes both forms of handshaking simultaneously when the printer s input buffer is full Consider this process when troubleshooting Hardware handshaking uses pins 11 or 20 of the RS 232 interface to control data flow When the printer is using Intermec Standard protocol pin 11 and 20 are held high when the printer is ready to receive data The pins are held low when the printer is in one of the following conditions Buffer full Ribbon fault No label stock e Label at strip The 3600 printer uses XON XOFF protocol for software handshaking When the input buffer is full the printer transmits an XOFF char
106. er power Remove the power cord and the media cover Raise the printhead with the printhead lift lever Remove media and ribbon Position the printhead adjustment lever clockwise left two clicks during the printhead alignment Loosen the two Allen screws located on the printhead yoke at the back of the printhead heatsink Printhead adjustment 25 lever wa 4 pm yes fo mo gt gt 0 039 3 23 3600 Printer Maintenance Manual SRA NECI n 3 24 Note This is a change in procedure from previous printhead alignment instructions that directed the printhead adjustment lever to be in the neutral center position during alignment Install the printhead alignment tool and press the printhead assembly down on the platen roller Align the tool with the notches in the heat sink and the printhead Alternately tighten the two 9 64 inch printhead yoke screws until secure Remove the printhead alignment tool Return the printhead adjustment lever to the neutral center position Reload media and ribbon if used Install the media cover and the power cord Switch on printer power and test for proper printhead alignment by printing out the print quality and pitch labels Guide pin Align with the notches on the heatsink and printhead Heatsink Printhead alignment tool Place the cutouts of the printhead alignment tool onto the shaft of the platen roller Printhead alignment tool
107. er7 L HH 5 y 1 1 IN RIBBONSENSE 5001 351TH AVENUE WES oua Lis tern CC EVERETT WA 8203 6200 581975 MARA ran SIZE CAGE CODE ORANING NUMBER REV D 33825 061591 SCALE NONE SHEET 3 3600M 074 CJ UJ
108. ermec Part No 501401 Retaining snap ring Intermec Part No 501409 Roller alignment tool Intermec Part T43150 e ESD grounding strap Snap ring pliers e Needlenose pliers e 1 and 2 Phillips screwdriver To remove the TTR drive roller and TTR drive gear pulley 1 Switch off the printer power and remove the power cord 2 Remove the media cover the electronics cover and the front bezel cover refer to Replacing the Bezel PCB earlier in this chapter Raise the printhead Remove media and ribbon if loaded Unloop the drive belt O ring from the TTR drive gear pulley TTR takeup 22 TTR takeup drive belt 33 TTR roller lt J shaft 3 PY 2 gear pulley Motor FAS TTR drive Motor plate 9 15 3600 Printer Maintenance Manual 5 Remove the TTR drive gear pulley retaining E ring Retain the washer located between the E ring and the TTR drive gear pulley Discard the old E ring 6 Remove the retaining snap ring that secures the printhead lift lever to the cam assembly shaft Pull the printhead lift lever off of the printhead lift shaft Discard the old snap ring TTR drive roller Cam assembly shaft Printhead 7 Upper outboard Printhead plate itt Jever Snap ring 3600M 054 7 Unhook the printhead spring from the upper outboard plate and remove the screws securing the plate to the printer Pull the plate away freeing up
109. es properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 17 3600 Printer Maintenance Manual Replacing the TTR Takeup Hub Clutch Pulley and Belt To replace the TTR takeup hub TTR takeup clutch pulley and TTR takeup drive you will need some or all of the following parts and tools TTR takeup hub Intermec Part No 061562 005 TTR takeup clutch assembly Intermec Part No 0629275 001 white 2 800ID x 210 drive belt O ring Intermec Part No 501462 003 Retaining snap rings Intermec Part No 501410 ESD grounding strap Snap ring pliers 1 and 2 Phillips screwdriver To remove the TTR takeup hub TTR takeup clutch pulley and TTR drive belt 5 18 Switch off the printer power and remove the power cord Remove the media supply cover the electronics cover and the front bezel cover refer to Replacing the Bezel PCB earlier in this chapter Raise the printhead Remove media and ribbon if loaded Remove the two TTR takeup clutch pulley retaining snap rings and the thick washer from the end of the TTR takeup hub shaft Retain the washer Discard the old snap rings TTR clutch TTR takeup ulle drive belt Thin washer A washer SH y SO Snap ring 2 Y TTR drive gear pulley 3600M 055 Remove a
110. g that holds the liner reverse shaft takeup clutch pulley and reverse gear 2 in place Retain the washer located between the snap ring and subplate Discard the old snap ring roller Y A Liner driv er drive Liner gear pulley reverse reverse M des Liner takeup Snap ring clutch pulley assembly Liner reverse gear Thin washer a Snap ring N BAAN 23 3600M 060 5 28 3 4 Remove and Replace Procedures 5 Remove the liner takeup hub and reverse gear 1 as described in Steps 4 and 5 of that procedure page 5 24 Push the liner reverse shaft through the main deck plate sliding off the takeup clutch and reverse gear Separate the drive belt from the drive gear pulley and clutch pulley You can replace the liner drive gear pulley liner drive belt takeup clutch pulley liner reverse shaft or reverse gear 2 now To reassemble the liner drive and takeup components 1 10 Install the first washer you removed in Step 5 of the previous liner roller replacement procedure and a new retaining E ring on the liner drive roller shaft Loop the drive belt around the liner drive gear pulley and position the gear pulley and the second washer you removed in Step 5 between the motor plate and the main deck plate Insert the liner drive roller through the main deck plate into the washer and gear pulley Secure the liner drive gear
111. glossary of terms is provided in the 3600 Bar Code Label Printer User s Manual Terms e Backing or liner refers to the silicon release portion of the media that carries the label Host refers to any computer that the printer is connected to refers to the thermal transfer ribbon used when the printer is in thermal transfer rather than direct transfer mode e Media is the stock on which the printer prints labels Media can be made of plain paper polyester thermally reactive paper or other materials with adhesive backing Conventions The following conventions are used throughout this manual for operating procedures and descriptions of the printer Downloaded commands appear in the order that you enter them into printer with the following conventions Convention lt gt E3 F3 xiv Description Angle brackets enclose mnemonic representations of ASCII control characters For example lt ETX gt represents the ASCII End of Text control character Braces enclose variable data For example n signifies a variable for which you can designate a constant value Brackets around a word or letter represent a key on your keypad For example Tab represents the Tab key and M represents the letter M key When two keys are joined with a dash press them simultaneously For example if you see the command Ctrl C press the two keys at the same time Enter all
112. haracters Downloading printer commands with a PC communications program or host terminal e Using a Novell network 1 15 Preventive Maintenance Preventive Maintenance 2 This chapter identifies scheduled maintenance actions and provides illustrated procedures for cleaning the 3600 printer Preventive Maintenance Actions and Intervals Preventive maintenance consists primarily of scheduled cleanings but also occassional performance checks and possibly adjustments based on those checks When you perform preventive maintenance you should also conduct the tests and adjustments described in Chapter 3 Testing and Adjusting that will ensure the printer continues to deliver the highest quality output You need to perform preventive maintenance procedures at the intervals identified to ensure a printer remains in proper working condition The following table is a schedule of recommended printer cleaning and checking Detailed cleaning procedures follow Chapter 4 Troubleshooting contains instructions for performing various tests and adjustments Printer Component Printer Printhead Drive roller and tear bar Media path edge and guides TTR drive roller Liner drive roller Media supply post Label and ribbon sensors Pinch roller Maintenance Action and Interval Inspect the printer and the rest of the data collection system at every service visit Your inspection should include the types of items list
113. hten the printhead retaining screws Reload media and ribbon if used and lower the printhead Install the media cover and the power cord and check the printer for proper operation Replacing the Bezel PCB To replace the bezel PCB you will need the following parts and tools Bezel PCB assembly Intermec Part No 0590525 001 ESD grounding strap 1 and 2 Phillips screwdrivers To replace the bezel PCB assembly 1 2 Switch off the printer power and remove the power cord Remove the media cover and the electronics cover Unplug the bezel PCB assembly from the main PCB and remove the five screws that hold the front bezel cover to the printer Front bezel cover 3600M 044 Remove and Replace Procedures 5 4 Liftthe front bezel cover away from the printer and lay it on a flat surface Use the 2 Phillips screwdriver to remove the two screws that hold the bezel PCB cover plate assembly to the front bezel cover 6 Being careful not to break the switch stem or the button cap pull the Feed Pause button cap off of the switch on the bezel PCB Retain the yellow button cap for installation onto the replacement bezel PCB 7 Use the 1 Phillips screwdriver to remove the two screws securing the bezel PCB to the front cover plate Front cover BezelPCB S plate VEA l Z v 4 Bo qg button cap 4 Front bezel cover 3600M 045 8 Use the 1 Phillips screwd
114. ions port Power on off power cord switch receptacle Fanfold media access slot 3600M 002 1 9 3600 Printer Maintenance Manual Media post TTR supply 2 Upper media guide Lower media Edge guide Self strip Thermal liner roller printhead TTR ribbon Media roll E Media p 6 post lt lt lt guide p Lower media Media Printhead lift lever access Liner takeup hub Self strip liner roller Tear bar 3600M 003 1 10 General Information 1 Basic Printer Setup and 0peration Detailed operating instructions for the 3600 printer are contained in the user s manual This section summarizes the following basic setup and operating information for you as a quick reference Front panel operations Checking printer configuration Connecting the printer to a computer e Printing Front Panel Operation The three light emitting diodes LEDs on the printer s front panel Power Alert and Empty Pause indicate the conditions identified in the following illustration LED State Indication Off Power off I Power Green LED On steady Power on Off Printing or idle LED Alert On flashing Over temperature Orange Onsteady System fault Off Printing or idle Yellow LED Empty Pause On flashing paused On steady Media fault Feed Pause 3600M 004 Over Temperature If the printhead rea
115. justment lever as shown in the illustration from the rear adjust clockwise left to move the printhead forward or adjust counterclockwise right to move the printhead backward Printhead adjustment lever 3600M 033 Testing and Adjusting 3 Adjusting the Label Mark Sensor The mark sensor detects the mark on the back of continuous media stock The output is then used to determine the start of print point This sensor is located under the label pathway across from the platen roller Two adjustments affect the performance of this sensor its physical position and sensitivity To perform this procedure you need the following tools Digital multimeter 2 Phillips screwdriver Small straight slot screwdriver To position the label mark sensor 1 Remove the media cover 2 Use your finger to reach underneath the lower guide roller AN Locate the label mark sensor JJ behind the platen roller near S the inboard edge of the printer Use your index finger to adjust the label mark sensor 1 N I Platen 552 O Inboard edge of printer The platen roller is not shown for clarity only P Label mark sensor 3600M 034 3 17 3600 Printer Maintenance Manual 3 18 3 Slide the mark sensor into a position that centers it over the label mark as the media passes by It is
116. late and install the new adjusting plate in its place 2 Install the thick steel washer removed in Step 5 above Align the TTR clutch encoder with the opening in the main deck plate and slide the TTR supply hub back through TTR clutch encoder the nylon washer the motor plate and the TTR subplate Note Do not remove the motor plate or subplates Changing the position of these plates can alter factory alignment and cause ribbon wrinkling or self strip problems Thick Nylon washer TTR washer a ei supply hub Thin washer 9 59 9 Snap ring TTR supply hub adjusting plate 3600M 056 Install the thin washer removed in Step 4 and the new retaining snap rings Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed 5 Align the ribbon supply hub as described in Aligning the TTR Supply Hub in Chapter 3 Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 21 3600 Printer Maintenance Manual Replacing the Platen Roller and Gear 5 22 The platen roller and platen roller gear can be replaced separately or at the same time To replace the platen roller the platen roller gear or both parts you will need some or all of the following parts and tools Platen roller Inte
117. lso be upgraded to 512K x 8 by swapping the component at location U6 The jumper between pins 1 and 2 of J3 must be removed and placed across pins 2 and 3 RAM Access Time Processor access time RAM access time 3x CLK gt Tcslow Tramaccess Tsetup Thc32 3x1 16 MHz gt 30 ns 120 ns 5 ns 18 ns 187 5 ns gt 173 ns EPROM The EPROM for the 3600 consists of two 512K x 8 EPROMs configured as 512K x 16 giving a total of 1M of EPROM space The EPROMs have an access time of 150 ns and do not require wait states EPROM Access Time Processor access time gt EPROM access time 2 x CLK gt Teslow Tepromaccess Tsetup 2x 1 16 MHz gt 30 ns 70 ns 5 ns 125 ns gt 105 ns DRAM The main memory consists of 256K of dynamic RAM The DRAM is configured as 256K x 16 IC U26 To support the DRAM interface GAL U13 is used to handle refresh and control lines between the DRAM and the processor See Part II Appendix A for GAL listings of the current configuration Multiplexors U16 U18 and U20 are used to generate the row and column addresses for the DRAM 3600 Printer Maintenance Manual A 10 Communications Interface The communications interface for the 3600 follows the Intermec Standard Data Connector standard J1 is a 25 pin D sub connector that supports both RS 232 and RS 485 interfaces U1 is the RS 485 driver receiver and U22 and U4 are the RS 232 driver and receivers To further enhance the interface to suppor
118. ltaneously Channel 5 This output generates the duration portion of the strobe waveform A pulse is generated after a link from channel 0 You can program the pulse delay and width Channel 6 This output generates the chopped portion of the strobe waveform A continuous square wave is generated and synchronized with each link from channel 0 The square wave frequency and duty cycle are programmable 3600 Printer Maintenance Manual Channels 7 and8 These outputs control the front panel LEDs They can be set to high low or square wave outputs The square wave output frequency is programmable Channel 9 This output is reserved It has RXD as an input for autodetection of the serial communications parameters Channel 10 This is an input for the ribbon sensor The channel detects transitions on the input If it does not receive a transition before it receives a programmable number of links from channel 0 it interrupts the CPU to indicate a ribbon failure Channel 11 This output generates the refresh requests for the DRAM It generates a low pulse at a programmable frequency and duration Channel 12 This is an input for the front panel switch It detects transitions the input debounces the switch and interrupts the CPU Channel 13 This output generates a square wave of a programmable frequency It is used to set the current level for the motor driver circuit Channel 14 and 15 These channels are reserved to support a cutter or a w
119. lter 1 Switch off the printer power and remove the power cord the media cover and the electronics cover Disconnect the three push on connectors attached to the back of the AC plug input filter assembly Push on connectors AC power EJ 7 2 places 3600M 062 Remove the two screws securing the AC plug input filter assembly to the main deck plate and remove the assembly Install the new AC power plug and input filter assembly and secure it with the two screws removed in Step 3 Reconnect the three push on connectors removed in Step 2 Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 31 3600 Printer Maintenance Manual Replacing the Power Switch Circuit Breaker 5 32 To replace the power switch and circuit breaker assembly you will need the following parts and tools Note The 220 volt printer uses a 1 amp power switch circuit breaker and the 115 volt printer uses a 2 amp power switch circuit breaker AC power switch circuit breaker Intermec Part No 501273 001 2A or AC power switch circuit breaker Intermec Part No 501273 002 1A e ESD grounding strap Needlenose pliers e 2 Phillips screwdriver To replace the power switch circuit breaker 1 Switch off the printer power and remove the power cord 2 Remove the media cover and the electronics cover 3 Disconnect the two leads with push on conn
120. media sensitivity The darkness of label print is too light or too dark Printhead platen roller or label path are dirty Uneven print contrast density Incorrect label or ribbon stock is used to print labels Ribbon wrinkling Ribbon installed upside down Direct thermal thermal transfer switch set in the wrong position Printhead or platen roller is severely worn Media may be slipping against the platen roller causing the printing to compress Troubleshooting 4 Solution Change sensitivity setting to match the type of media you are using If sensitivity is set correctly try changing the dark adjust Properly set the darkness adjust control Clean printhead platen roller and label path Adjust the bias adjust screw Use only Intermec label and ribbon stock to ensure superior print quality and product performance Check to make sure that the ribbon is installed correctly Check the following alignments in the sequence given testing for elimination of the problem before performing the next alignment Note Making these adjustments out of order can introduce and not solve printing problems 1 Roller alignment 2 Printhead alignment 3 Ribbon supply hub alignment Install ribbon with shiny side facing the printhead Set the switch for the type of media being used Replace the platen roller or printhead Switch to approved media or clean the printhead and platen 4 11 3600 Print
121. minal through the use of commands If you find a printer lacking in performance after running your tests check and make the adjustments and alignments necessary to return the printer to normal service If you cannot get a printer working properly with an adjustment or alignment troubleshoot for a component failure Note Making the alignments out of order can introduce not solve printing problems Review the section about printer alignments before making any changes 3600 Printer Maintenance Manual Running Test and Service Mode at the Printer Note When the printer is placed in Test and Service mode it prints out a hardware configuration label regardless of its initial DIP switch settings and remains in Test and Service mode until the power is switched off and the DIP switches are reset Momentarily pressing the Feed Pause button during a test will cause the test to halt Holding the Feed Pause button down will start a new run of whichever test you select To enter Test and Service mode and select test functions at the printer 1 Switch off the printer power 2 Setthe DIP switches to select the function that you want to run Press down and hold the Feed Pause button while powering on the printer The printer prints out a hardware configuration label 4 Hold the Feed Pause button down for 1 second The test begins immediately 5 If you wish to perform another function repeat Steps 1 through 4 The function currently being
122. mmodated due to the circular system of using image memory After an image band has printed it is reused to image the next part of the label which means the printer can print labels using less memory Image Band Buffering Printer throughput is affected by the number of image bands and the print speed If imaging is fast enough throughput will be maximized by using the least number of image bands with the fastest speed assuming the fastest speed delivers the desired print quality Some printers use a fixed size contiguous portion of RAM for imaging In these cases a label is imaged in its entirety before printing commences During printing there is no contention with imaging so the print speed can remain constant However if the label is fairly complex the delay before printing becomes very noticeable In addition printing of the label must finish before a second label is imaged The combination of these delays impede total printer throughput Another drawback is that the maximum length of a label is limited by the size of the RAM With the use of image band buffers 1 band 1 inch labels are divided up and imaged band by band Printing begins after the selected number of image bands is imaged minimizing the delay before printing Imaging of a second label can begin while a first is still printing In addition the length of a label is virtually unlimited With image band buffering time becomes a critical resource since printing a
123. n If this test does not work recheck after you make sure that the DIP switches are set to the default configuration and that the printer cable is securely plugged into COMI of your PC Note If you are using a different platform to communicate with your printer refer to your host computer user s manual and the 3600 Bar Code Printer User s Manual for more detailed information about downloading commands Adjusting the Printer WARNING CAUTION The following procedures provide instructions for adjusting the print bias the print intensity darkness the label mark sensor the label gap sensor the label taken sensor and the printhead fine adjustment lever on the 3600 printer Warning Always disconnect the power cord before removing the electronics cover unless a procedure requires the unit to be energized Failure to disconnect the power cord may result in injury or death due to electric shock Caution The printhead and integrated circuits on printer circuit boards in this equipment are sensitive to damage by electrostatic discharge ESD Prevent ESD by always wearing skin contact ground straps firmly attached to the equipment metal base assembly when working inside of the equipment housing Failure to comply can result in damage to components or the printhead 3600 Printer Maintenance Manual 3 14 Adjusting the Print Bias for Print Quality Adjust the bias with a straight slot screwdriver if the printhead is not making
124. nch of the label imaged into the first image band The other two image bands are still empty Printing has not begun The second 1 inch of label is imaged into the second image band Printing has still not begun 4 15 3600 Printer Maintenance Manual The third 1 inch of the label is imaged into the third image band Printing begins from the first image band as indicated by the arrow At this point all three available image bands have been filled The first band will be reused after it has been completely printed When the first image band is emptied printed the fourth band is imaged into it Printing continues from the second image band As before this band must be emptied before the final band can be imaged into it 4 16 Appendix A The final 1 inch of the label is imaged into the second image band Printing continues from the third band At this point the label has been completely imaged but printing has not finished After the third image band is emptied printing continues from the first image band Imaging of a second label could begin in the third image band while the first label is still printing The second label could begin printing immediately after the first with no delay which suggests that the only print delay encountered would be during the time when the first bands of the first label were imaged As labels become more
125. nd imaging take place simultaneously Sometimes a label cannot be imaged fast enough to keep up with the print speed The 3600 printer maintains a constant print speed regardless of label complexity Label throughput can be fine tuned by selecting the number of image bands and print speed for a specific label format Selecting image bands determines how much of a label is preimaged before printing starts Selecting too many image bands can lead to print delay If too few image bands are selected imaging falls behind the print speed If imaging falls behind printing the printer stops printing the label sets the speed to 2 ips sets the number of image bands to the maximum and then reprints the label This condition is known as an image rate error or an image overrun error Appendix A The ideal setting keeps imaging just ahead of printing This ideal setting can be found by the proper selection of image bands and print speed for the label format being printed Image Band Example The following example shows a format print using image bands The label is 5 inches long and is divided into five image bands The printer is configured for three image bands which means that three bands will be imaged before printing begins The dashed lines represent the divisions between the five image bands and the arrow T represents the portion of the image band that is being printed at that time The first diagram shows the first 1 i
126. nd Replace Procedures 5 5 Pullouton the TTR takeup hub to release the clutch pulley assembly Retain the thin washer located between the TTR takeup hub and main deck plate 6 Remove the TTR takeup clutch pulley assembly and TTR drive belt Note Do not remove the motor plate or subplates Changing the position of these plates can alter factory alignment and cause ribbon wrinkling or self strip problems 7 Replace the TTR takeup hub the TTR takeup clutch pulley assembly the TTR drive belt or any combination of them now To replace the TTR takeup hub TTR takeup clutch pulley and TTR drive belt 1 Wrap the TTR drive belt around the TTR takeup clutch pulley positioning the assembly so that the TTR takeup hub shaft can be inserted into the clutch pulley 2 Install the TTR takeup hub with the thin washer removed in Step 5 above 3 Install the thick washer removed in Step 4 and the two new retaining snap rings to secure the TTR takeup components in place 4 Loop the loose end of the TTR drive belt around the TTR drive gear pulley Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover and the media cover Install the power cord and check the printer for proper operation 5 19 3600 Printer Maintenance Manual Replacing the TTR Supply Hub
127. ng at the right point to be removed Possible Causes Dirty printhead Dirty media path or rollers Poor quality label or ribbon stock Darkness adjust control is set incorrectly Poor quality label or ribbon stock Sensitivity number is set incorrectly Dirty printhead The printhead adjustment lever is not positioned as needed Printer is misfeeding media Platen roller and or printhead out of alignment Label rest point command is incorrectly set Printer is set for continuous label stock If labels are not printing properly try locating the problem and implementing the solution in the following table Solution Clean the printhead Clean the media path Use only Intermec label and ribbon stock to ensure superior print quality and product performance Adjust the knob to achieve the best print quality Use only Intermec label and ribbon stock to ensure superior print quality and product performance Change sensitivity setting to match the type of media being used If sensitivity is set correctly try changing the dark adjust command Clean the printhead Reposition the printhead adjustment lever Make sure that media is installed properly along the entire media path Perform roller alignment first and then printhead alignment Adjust the label rest point Set the printer for proper label stock either gaps or marks Symptom Print quality is poor Possible Causes Incorrect
128. ng the Label Mark Sensor To replace the label mark sensor you will need the following parts and tools e Label mark sensor cable assembly Intermec Part 061578 001 e Roller alignment tool Intermec Part No T43150 e ESD grounding strap e land 2 Phillips screwdriver To replace the label mark sensor 1 Switch off the printer power and remove the power cord 2 Remove the media cover the electronics cover and the front bezel cover refer to Replacing the Bezel PCB earlier in this chapter Raise the printhead Remove media and ribbon if loaded Remove the screws securing the lower outboard plate to the printer and pull it away from the printer Retain the tear bar and tear bar support Tear bar lt Es Tear bar support 3600M 048 5 10 5 10 Remove and Replace Procedures 5 Disconnect the label mark sensor cable from the main PCB remove the cable from the two plastic clips and push it through the cutout in the main deck plate Slide the sensor out from the extrusion Remove the cable from the plastic cable clip on the extrusion 2 RU Label mark N aw sensor 3600M 049 AN Insert the new label mark sensor into the extrusion Route the cable through the plastic cable clip on the extrusion and through the cutout in the main deck plate and then plug it into the main PCB Secure the cable in place by inserting it into the two cable clips An
129. ode with specified media Media Specifications Roll 6 000 linear inches 152 m Length 0 5 inch 13 mm to 17 inches 432 mm stripped media Width 3 0 inch 76 mm to 6 7 inches 170 mm Thickness 0 012 inches 0 3 mm maximum Diameter 8 38 inch maximum diameter 213 mm Ribbon Specifications Roll 6 000 linear inches 152 m Widths 3 0 inches 76 mm 4 inches 104 mm 5 4 inches 137 mm 6 7 inches 170 mm Diameter 2 25 inches maximum 57 mm Environment Operating 50 F to 104 F 10 C to 40 C Humidity 10 to 90 noncondensing Self Strip Specifications The liner takeup hub can spool the backing of an entire 6 000 inch roll of media Peel Release 10 to 50 grams 3600 Printer Maintenance Manual Communications Asynchronous RS 232C RS 422 RS 485 interfaces Serial ASCII code Hardware Ready Busy flow control XON XOFF protocol Intermec Standard Block protocol Polling Mode D protocol Multi Drop protocol Baud Rates 1200 2400 4800 9600 19200 Fonts and Graphics 5 7 7x9 7x11 and 10x14 86XX compatible fonts 2 bitmap OCR fonts 3 bitmap fonts measured in point sizes 8 12 and 20 1 outline font 12 monospaced bitmap fonts Kanji Katakana bitmap font card option Kanji Katakana bitmap and outline font card option UDF size of 4 inches 101 6 mm maximum UDC size of 4 inches 101 6 mm maximum Character Sets US ASCII Norwegian Danish UK ASCII Swedish Finnish German Italian French Sp
130. om the paper path and the ribbon if installed from the TTR hubs Clean the rollers with a lint free cloth moistened in isopropyl alcohol Wipe the cloth over the rollers rotating each roller so that you clean all of it Media roll TTR roller roller 3600M 013 Clean both sides of the tear bar with a lint free cloth moistened in isopropyl alcohol Remove all traces of dust paper and adhesive Reload the media and ribbon if used and then engage the printhead by turning the head lift lever counterclockwise until the printhead locks If you are finished cleaning install the media cover Preventive Maintenance 2 Cleaning the Media Guides and Media Path Clean the media guides and media path regularly to keep debris off the media surface and printhead where irregularities can spoil print quality or damage the printhead Cleaning the guides also helps prevent media skewing or improper tracking as it travels through the paper path which can result in print problems Always clean the media guides immediately after any label jam in the printer Media debris may accumulate around the printer mechanism and along the media path during normal operation of the printer Clean debris away using a soft bristle brush or vacuum cleaner Remove all traces of dust paper and adhesive Clean the flat surfaces of the media path including the edge guide with a lint free cloth and isopropyl alcohol Also remove all traces of d
131. omer s labels The fine adjustments compensate for variations in the media lot to lot the printhead or the printer Set the darkness adjust control with a small straight slot screwdriver after entering the proper sensitivity number To adjust the print darkness control 1 Locate the darkness adjust control on the back of the printer Make adjustments with a small straight slot screwdriver 6 Turn the darkness adjust control clockwise for darker density Darkness DA a adjust control ZN the darkness adjust control counterclockwise px for lighter density Screwdriver 3600M 032 NS 5 5 5 0 N 2 Increase the darkness by turning the darkness adjust control clockwise or decrease the darkness by turning the control counterclockwise Run a test print to evaluate the print quality 3 15 3600 Printer Maintenance Manual Adjusting the Printhead Adjustment Lever for Print Quality The printhead adjustment lever is located at the end of the printhead pivot bracket It allows fine tuning of the printhead fore aft position The printhead adjustment lever provides three stops forward movement of the printhead and three stops backward movement from center position in 0 006 inch increments To achieve the best print quality raise the printhead with the printhead lift lever and position the printhead ad
132. or to Q15 through R108 The duty cycle of this signal controls the reference voltage input to U2 The magnitude of this voltage establishes the magnitude of the current in motor windings Other inputs from the microprocessor to the GAL U21 circuit are M1 M2 M3 and M4 These inputs control the stepping of the motor They go into the GAL where they are decoded and fed into the driver ICs U17 U19 which turn the FETs on and off Reset is the last input to the motor driver circuit U19 pin 3 is high when reset is applied to the DISABLE input of U17 This action ensures that all the FETs are held in the off condition to control start up and shut down transients Appendix A Processor The processor used in the 3600 is a MMC68332 32 bit integrated microcontroller Based on the MC68020 the MC68332 contains four peripheral modules CPU32 a 32 bit central processing unit a complex programmable time processor unit QSM a queued serial module and SIM a system integration module The MC68332 was chosen for its 32 bit processing power along with its high level of integration Chip Selects The SIM of the MC68332 allows up to 12 chip selects to be programmed by the software for use in the system We use seven of these chip selects CSBOOT is used to access the EPROM of the system It can handle up to 1M of EPROM organized as 512K x 16 CS0 and CS1 are used for accessing DRAM which is configured as 512K x 16 CS2 is used to access
133. ould include a test of the customer s labels to determine whether the printer you are testing is attaining the best print quality possible with the customer s data 3 10 Testing and Adjusting 3 Running Test and Service Mode From a Host Computer When conducting Test and Service mode functions from a computer hardware diagnostic information is uploaded to the host from the printer The following table describes the commands you would issue from a host terminal to run the Test and Service mode To select Test and Service mode from Print mode send lt ESC gt T from the host terminal Note All commands in Test and Service mode end with the command terminator except the last command in a message Test and Service Mode Command Descriptions Command Code A Q R Test Transmit Ambient Temperature Printhead Resistance Test Print Pitch Label Reset Printer Configuration Transmit Transmissive Sensor Value Dark Adjust Transmit Paper Path Open Sensor Value Transmit Reflective Sensor Value Transmit Printhead Temperature Sensor Value Print Quality Label Exit Test and Service The printer ignores this command Description Transmits the ambient temperature sensor output back to the host The value ranges from 00 to FF Causes the printer to begin the printhead resistance test The printer will respond with the ASCII character string pass or fail Causes the printer to p
134. panying materials are copyrighted Unathorized copying of the software including software that has been modified merged or included with other software or the written materials is expressly forbidden without the prior written consent of Intermec All right title and interest in all copies of this software are and shall at all time remain the sole and exclusive property of Intermec Customer may be held legally responsible for any copyright infringement that is caused or encouraged by its failure to abide by these terms Contributors Technical Writer Editor Technical Illustrator Technical Reviewers Robert Shaw Craig Thompson George Wilson Cathy Aragon Pixie Austin Daniel Clark John Cramer Allen Crowe Stephen Eckert Pat Helton Laura McCluer Ed Millet Art Millican Matt Roberts Joe Wade iii Contents Contents Before You Begin xi Safety Summary xi Warnings and Cautions xii Purpose of This Manual xii Additional Information xv General Information 1 Overview of the 3600 Printer 1 3 3600 Features 1 4 3600 Printer Specifications 1 4 Dimensions no options installed 1 4 Electrical Requirements 1 4 Printing Methods 1 4 Printing Speed 1 5 Printhead Specifications 1 5 Media Specifications 1 5 Ribbon Specifications 1 5 Environment 1 5 Self Strip Specifications 1 5 Communications 1 6 Fonts and Graphics 1 6 Character Sets 1 6 Memory 1 6 Factory Default Settings 1 7 3600 Printer Options 1 7 Memory
135. placing the Liner Drive and Takeup Components 5 24 Replacing the Stepper Motor 5 30 Replacing the AC Plug Input Filter 5 31 Replacing the Power Switch Circuit Breaker 5 32 Replacing the Transformer 5 33 PCB Drawings and Schematics Replacement Parts A Contents Appendix Functional Description of the 3600 Mechanics A 3 Functional Description of the 3600 Electronics A 4 Power Supply A 4 45V 4 40V A 4 24V A 4 Power Fail Detection A 5 Battery A 5 Battery Life Calculations A 5 Reset A 5 Motor Driver A 6 Processor A 7 Chip Selects A 7 TPU A 7 QSM A 8 Interrupt Priority Levels A 8 Crystal A 8 Memory A 9 Static RAM A 9 EPROM A 9 DRAM A 9 Communications Interface A 10 A D Converter A 10 DIP Switches A 10 ASIC and 1 0 Option Interface A 10 Address Data Multiplexor A 10 Chip Select Generation A 11 1 0 Option Connector A 11 FIFO A 11 Front Panel Interface A 11 Debug Interface A 11 Functional Description of the 3600 Software A 14 Band Buffering and Font Caching A 14 Image Band Buffering A 14 Image Band Example A 15 Font Caching A 18 Print Energy Compensation A 18 Digital Thermal Compensation A 18 Global Compensation A 18 ix Before You Begin Before You Begin This section describes the purpose and arrangement of this manual to you It is intended to bring to your attention important general safety concerns specific warnings and cautions and sources of additional information Safety
136. printer and wheelchairs The solution is to reduce the charge by grounding and by employing prevention measures such as antistatic bags for ICs and PCBs grounded antistatic mats antistatic spray for carpeting antistatic clothing no wool antistatic wax for tile floors conductive floor materials air ionizers and antistatic cleaners for plastics To further protect against ESD use shielded cable for interface cables and tie the shield to metal backshells at both ends of the cable Do not connect the shield of the cable to the chassis ground or signal ground of the interface metal backshells will be tied to the chassis 4 13 3600 Printer Maintenance Manual 4 14 Electromagnetic and Radio Frequency Interference Noise induced in interface cables can result in the printer receiving false data This condition may cause the printer to skip printing a label or lockup Sources of electromagnetic interference EMI and radio frequency interference RFI are radio transmitters ignition systems and relays To eliminate the effects of EMI and RFI use low capacitance twisted pair shielded cables Route cables away from sources of EMI and RFI such as large inductive motors or fluorescent lighting ballasts Do not run cables near AC power lines If communication cables must run near AC power lines cross them at 90 degree angles Eliminate ground loops they act as receiving antennas for RFI Limit the number of breaks connectors in the ca
137. pulley with a new retaining E ring Reassemble the tear bar and bar support and install the lower outboard plate capturing the tear bar assembly and the rollers Note Use the roller alignment tool during reassembly for proper alignment of the outboard plate Fit the drive belt around the liner takeup clutch pulley Position the clutch pulley and reverse gear 2 between the subplate and motor plate with the clutch pulley located at the cutout in the motor plate Note The clutch pulley will be under some tension from the drive belt Insert the D shaped end of the liner reverse shaft through outboard side of the main deck plate the takeup clutch pulley reverse gear 2 and the liner takeup subplate Install the washer removed in Step 2 and a new snap ring Install the liner takeup hub and liner reverse gear 1 as described in Steps 7 and 8 of that procedure Slide the motor forward and mesh the motor pinion gear with the liner drive gear pulley and the platen roller gear Turn the TTR roller drive gear to check for proper gear engagement and tighten the motor mounting Screws Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 29 3600 Printer Maintenance Manual R
138. qed jupitery 2 14 Y exi e BF s 5001 AVENUE WEST mermec EVERETT WA 8203 9280 y SIZE CAGE CODE DRAWING NUMBER REU 23 CO FF RAT vy 189 NOT INSTALLED 33825 061581 e LLE en SCALE NONE SHEET 4 N gl h 2 L 3600M 075 E 4 3
139. r filtering and storing energy for hold time at power down or blackout VR1 is rated at 1 5A and is sufficiently heatsinked to handle this amount of current The typical 5V load is approximately 1A 40V The 40V supply is generated from the 40 VAC inputs on connector J10 Diode bridge D13 rectifies the AC voltage capacitors C95 and C58 that are used as filters 40 VAC is unregulated and used for the stepper motor voltage The 40V supply is also zenered down to 5 1V to supply the motor logic This prevents excessive motor currents on power up Another zener diode is used to supply 15V that is used by the 24V buck converter 24V The 24V supply is generated by a switching buck converter Appendix A Power Fail Detection The power fail detection circuitry consists of IC U31 diodes D7 D8 D9 and D11 and various resistors and capacitors Diodes D7 and D8 rectity the incoming 12 VAC and R101 and R107 act as a divider D9 is a zener diode used to prevent the input on U31 from exceeding 5V D11 is a 1 235V reference When the voltage at pin 3 of U31 exceeds 1 235V the output is pulled up by a 10K resistor R183 R104 adds some hysterisis to help filter out noise or brownouts C44 and C49 are also for filtering C46 and R107 set up a time constant of 1 5 60 Hz cycles to filter out brownouts The hold time of the 5V varies with line voltage and the state of the printer The printer exceeds 20 ms at low line and when not printing
140. r reverse gear 1 can now be removed from behind the liner takeup subplate Note Now is a good time to replace other liner drive and takeup components according to the following procedures Remove and Replace Procedures 5 Liner drive roller Liner drive gear pulley reverse gear 2 3600M 058 5 25 3600 Printer Maintenance Manual 10 11 You can replace the liner takeup hub and or liner reverse gear 1 now Install the thick washer removed in Step 5 between the liner takeup hub and the main deck plate Position liner reverse gear 1 between the motor plate and the liner takeup subplate and check for proper engagement with liner reverse gear 2 Insert the liner takeup hub through the main deck plate reverse gear 1 and the subplate Install the washer removed in Step 4 on the hub shaft extending through the subplate and secure with two new snap rings Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation To replace the liner drive roller 1 5 26 If not already done switch off the printer power and remove the power cord media cover electronics cover and the front bezel cover Raise the printhead and remov
141. rint the pitch label Sets the printer configuration to the factory defaults Transmits the label gap output back to the host Values ranges from 00 to FF This command changes the darkness of the print on your labels It is for fine tuning only Transmits the Paper Path Open switch value back to the host A value of 0 indicates the paper path is open and a value of 1 means it is closed Transmits the label mark reflective sensor output back to the host The values range from 00 to FF Transmits the Printhead Temperature Sensor output back to the host Values range from 00 to FF Causes the printer to print out the print quality program and model number label Causes the printer to exit Test and Service mode 3 11 3600 Printer Maintenan ce Manual Test and Service Mode Command Descriptions continued Command Code S Test Transmit Printhead Resistance Values Transmit Label Taken Sensor Value Transmit 40V Supply Value Transmit 24V Supply Value The printer ignores this command Description Transmits the average maximum or minimum printhead dot resistance value back to the host Each value is a numeric data string separated by a comma Transmits the label taken sensor output back to the host Values can range from 00 to FF Transmits the 12V supply output back to the host The values range from 00 to FF Transmits the 24V supply output back to the host Values can range from 00 to
142. river to attach the replacement bezel PCB to the front cover plate 9 Carefully press the yellow button cap removed in Step 6 onto the switch on the replacement bezel PCB 10 Attach the bezel PCB front cover plate assembly to the front bezel cover 11 Reattach the front bezel cover to the printer Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Connect the cable 12 Install the electronics cover the media cover and the power cord and check the printer for proper operation 3600 Printer Maintenance Manual Replacing the Main PCB To replace the main PCB you will need the following parts and tools 3600 main PCB assembly Intermec Part No 0615915 005 or 06159E 005 ESD grounding strap 2 Phillips screwdriver To replace the main PCB assembly 1 Switch off the printer power and remove the power cord the media cover and the electronics cover Unplug all of the cables from the main PCB and remove the seven screws securing the main PCB to the printer to remove the main PCB Do not place the printer on its side as this may disturb alignments Main PCB assembly 3600M 046 If the main PCB you are replacing has the 512K SRAM memory expansion chip verify that the new main PCB is similarly equipped If it is not carefully unplug the existing 512K chip and plug it into the new main PCB before installing it If the main PCB you are replacing ha
143. rmec Part No 061542 003 Retaining E ring Intermec Part No 501401 Platen roller gear Intermec Part No 061557 003 Retaining snap ring Intermec Part No 501409 Roller alignment tool Intermec Part No T43150 ESD grounding strap 2 Phillips screwdriver Needlenose pliers Snap ring pliers To remove the platen roller and platen roller gear Switch off the printer power and remove the power cord Remove the media cover the electronics cover and the front bezel cover refer to Replacing the Bezel PCB earlier in this chapter Raise the printhead Remove media and ribbon if loaded Remove the retaining snap ring that holds the platen roller gear in place as shown on the next page Retain the washer between the gear and the main deck plate Discard the old snap ring Remove the five screws that secure the lower outboard plate to the main deck plate and pull the plate away from the rollers The tear bar and tear bar support come loose when the outboard plate is removed Retain them for reassembly Note Now is a convenient time to replace the liner drive roller and liner drive gear pulley as instructed in the next procedure Remove the platen roller and washer Retain the washer The platen roller the drive gear or both parts can be replaced now Remove and Replace Procedures 5 Washer lt x NN Platen SS roller NL Lower Dee NL plate D RE 7 N 7 3600 057 E ring
144. s C59 10 4 4 0 F C66 9 09 32 0 SE E C74 9 4 4 1 F 53 2 563715 C44 CAP S M CER 50VMIN 20 22 UF 2 42 053 Y C49 2 0 06 E 54 23 563720 CTT CAP S M CER 50VMIN 5 150 4 8 OF 3600 Printer Maintenance Manual PL 061591 003 TITLE I PL REV D RUN DATE Feb 23 15 19 02 PCB ASSY MAIN 3600 PAGI h 8 10 02231995 PART NO EFDES DESCRIPTION K F B 55 4 563729 56 2 5637731 57 4 563736 001 58 27 564202 6 10 C78 C79 C80 C83 C84 C85 C86 C87 C88 C89 C90 C91 C92 C93 C94 C114 C116 C130 C135 C139 C143 C144 C47 C95 C97 C98 C63 C142 CTIS C118 C120 C121 D3 D5 D7 D8 D18 D19 D21 D22 D23 D24 D25 D29 D30 D31 D32 D34 D35 D36 D37 D38 D40 S M C S M C S M C ER 50VMIN 10 1 UF ERM 001UF 200V X7R 1 ER 0603 25V O1UF DIODE S M BAS16 O1 O1 O1 iS gt O iS gt O gt O O O 0 O Q Q O xO O O s POCO IP OY OY CO gt OY UN CO PO A Q gt OO OO OO OO OO 41 OO OO O O Q 4S OY CO Q UUN O PO Q Q i gt O OO Q OO PO gt QI Q ES O O QI O O O F O O Q QI F O O Q N Q N N G
145. s a Kanji Katakana option PCB installed use the next procedure to relocate the Kanji Katakana option PCB to the new main PCB before installing it Install the new main PCB securing it with the seven screws removed in Step 3 and connect all of the cables Install the electronics cover the media cover and the power cord and check the printer for proper operation Remove and Replace Procedures 5 Replacing the Kanji Katakana Option PCB To replace a Kanji Katakana PCB you will need the following parts and tools 3600 Kanji Katakana PCB bitmap font Intermec Part No 060689 001 or 3600 Kanji Katakana PCB outline font Intermec Part No 060690 001 e ESD grounding strap e 2 Phillips screwdriver To replace the Kanji Katakana PCB 1 Switch off the printer power and remove the power cord the media cover and the electronics cover 2 Remove the screws that secure the Kanji Katakana PCB to the main PCB Main PCB assembly PCB stacking spacer 3600M 047 3600 Printer Maintenance Manual 3 Unplug the Kanji Katakana PCB from the main PCB using a gentle rocking motion while pulling it away 4 Install the new Kanji Katakana PCB onto the main PCB making sure the pins are properly aligned with the connector and that the Kanji Katakana PCB is fully seated before tightening the screws 5 Install the electronics cover the media cover and the power cord and check the printer for proper operation Replaci
146. t DTR RTS flow control the DTR pin is driven with the PIN 14 signal This arrangement allows the use of standard cables for hardware flow control which enables the user to use commands such as the DOS COPY command from any PC Zero ohm resistors have been incorporated into the RS 232 driver outputs so that the previous configuration or other configurations are possible A D Converter The Motorola MC145041 A D converter is an 11 channel 8 bit serial A D converter The reference is set to 5V Seven of the eleven channels are used Channel Function 0 Label gap sensor 1 Darkness adjust 2 Printhead thermistor 3 Label mark sensor 4 40V 5 Printhead voltage 24V 6 Label taken sensor The A D converter is continuously communicating with the MC68332 through the SPI It receives conversion commands and channel addresses while sending back results from the previous command The clock rate for the MC145041 is 1 MHz DIP Switches The 3600 has 16 DIP switches to provide configuration and test and service operation ASIC 1 0 Option Interface The 3600 uses an Intermec designed thermal compensation ASIC This ASIC handles the loading of the printhead to implement the dot by dot thermal management scheme Address Data Multiplexor Since both the ASIC and the I O option interfaces are designed to interface with a processor that has multiplexed address and data it is necessary to multiplex the address and data from the M
147. the warnings and cautions to prevent harm to yourself or damage to the printer You will need the following items to clean the printer correctly Isopropyl alcohol Cotton swabs e Clean lint free cloth Soft bristle brush e Vacuum cleaner Soapy water mild detergent Warning Energized electrical equipment is dangerous Switch off the printer power and remove the power cord before cleaning any part of the printer Failure to comply can result in injury or death Preventive Maintenance 2 Removing the Media Cover Most of the cleaning procedures require that you remove the media cover To remove the media cover 1 Place your fingers in the space at the lower center edge of the media cover and pull the bottom of the cover away from the base of the printer 2 Grasp the front of the media cover and lift the front of the cover upward Media cover NN J Media Rl release between the two 3600 010 3 Lift the media cover away from the printer 3600 Printer Maintenance Manual A CAUTION Cleaning the Printhead Since the printhead must maintain close contact with the media to provide good print quality cleaning media debris from the printhead is very important Clean the printhead after every roll or 6 000 inches of media or whenever necessary Caution Do not use sharp objects such as knives or screwdrivers to scrape the printhead clean Cleaning
148. the liner drive gear pulley and the second washer you removed in Step 5 between the motor plate and the main deck plate Then insert the liner drive roller through the main deck plate into the washer and gear pulley Note The gear pulley will be under some tension from the drive belt Reassemble the tear bar and bar support and install the lower outboard plate securing the tear bar assembly and the rollers Note Use the roller alignment tool during reassembly for proper alignment of the outboard plate Secure the liner drive gear pulley with the washer removed in Step 3 and a new retaining E ring Slide the motor forward and mesh the motor pinion gear with the liner drive gear pulley and the platen roller gear Turn the TTR roller drive gear to check for proper gear engagement and tighten the motor mounting Screws Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 27 3600 Printer Maintenance Manual To replace liner reverse gear 2 the liner takeup clutch pulley liner reverse shaft liner drive gear pulley and liner drive belt 1 Ifnot already done perform Steps 1 through 5 of the preceding liner roller replacement procedure Remove the retaining snap rin
149. the transformer toward the front of the printer to free it from the metal tabs lifting it away from the printer 4 Install the replacement transformer and push it toward the back of the printer securing it under the tabs in the printer main deck plate 5 Secure the transformer to the printer main deck plate with the two screws removed in Step 3 6 Reattach the transformer cables to the main PCB the AC power receptacle and the power switch 7 Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 34 PCB Drawings and Schematics PCB Drawings and Schematics This chapter contains the assembly drawings parts lists and schematic diagrams for the 3600 main PCB PL 061591 003 TITLE PCB ASSY MAIN 3600 PAGE 1 10 PL REV D 02231995 RUN DATE Feb 23 15 19 02 ITEM OTY UM PART NO REFDES DESCRIPTION X Y F B 1 061590 003 PCB MAIN 3600 0 001 RL 046766 LBL STK 23HX1 50L 4 HI 4MI 3 584274 XU6 SOC 32 POSN DIP LOW PROFILI u XU8 XU9 4 2 056914 U12 IC ASIC THERMAL COMPENSATION U32 5 060691 001 U25 CONFIG GAL 16V8 ASIC INTFC 6 1 060693 001 U13 CONFIG GAL 16V8 DRAM CONTROL 7 1 061869 001 023 CONFIG GAL 22V10 ASIC OPTINTFC 8 9 DN ER 061870 001 U20 CONFIG GAL 16V8 DSACK FIFOCNTL 1 061871 001 U21 CONFIG GAL 16V8 STEP MOT CNTL 10 1 550694 R192 RES CARB 1 00W 5 820 0 OHM 11 1 550893 R219 RES
150. tools Digital multimeter e 2 Phillips screwdriver Small straight slot screwdriver To adjust the label gap sensor potentiometer 1 Remove the media cover and the electronics cover 2 Connect the positive lead of a multimeter to TP15 GAP and the negative lead to TP14 GND on the main PCB 00000 0000000 000000 TP14 om az CALI sm 9 cs e LIU Ur ooo 00 0 B a Tq l R124 000000000 Benaapdacag pipi URN BBBBBEBBEBHEEB H 000000000 mu 3600 036 Switch on the printer power Insert the label backing only in the label gap sensor Adjust R124 on the main PCB so that the voltage at TP15 GAP is 1V 0 2V 5 Insert both the label and the label backing in the sensor Verify that the voltage at TP15 GAP is greater than 3V Install the printer electronics cover and the media cover Check the printer for proper operation 3600 Printer Maintenance Manual 3 20 Adjusting the Label Taken Sensor The label taken sensor output enables the software to determine that a label has been taken by detecting the label s presence To perform this procedure you need the following tools e Digital multimeter 2 Phillips screwdriver
151. uating printhead alignment To achieve the highest quality label print the hardware configuration label at a speed of 3 ips inches per second z N N 3600 Hardware Configuration UI Memory Installed o Storage RAM 128 kilobytes Image RAM 382 kilobytes Flash none ON a OFF Mileage LI Je Inches Processed 540 lt 7 Inches Burned 204 gt Labels Cut 0 Printhead Width 1344 dots lle Dot Size 5 0 mil Burn Pot Setting 213 Hardware Options S lt Option none LANA Internal Option e wil External Option Self Strip lle Firmware Checksum a ROMO 09 FAC3 ON OFF ROM U8 062198 o Version ote MIN M E Ill 3600M 023 3 7 3600 Printer Maintenance Manual Software Configuration This three label set lists current configuration parameters that are set from the host computer It also lists defined pages formats graphics fonts and installed options This label serves as a configuration reference as well as an alphanumeric and multiple label alignment and print test Program Version Pages Defined Formats Defined Fonts Defined Graphics Defined 1 0 0 19 0 1 2 7 20 21 22 23
152. ust paper and adhesive from the pinch rollers on the media access door To clean the media guides and media path 1 Remove the media cover 2 Remove the media from the paper path and the ribbon if installed from the TTR hubs 3 Pull down and hold the spring loaded lower media guide to open up the media path 4 Clean the lower media guide with a lint free cloth moistened in isopropyl alcohol S A media gt guide Lower media guide 3600M 014 3600 Printer Maintenance Manual 5 Usea lint free cloth moistened with isopropyl alcohol to clean the upper media guide Be sure to remove all traces of debris 6 Reload the media and ribbon if used 7 If you are finished cleaning install the media cover To clean the pinch rollers 1 Open the media access door 2 Usea cotton swab moistened with isopropyl alcohol to clean the pinch rollers Rotate the rollers to get any debris out of all of the grooves Pinch Roller Media access 3600M 015 3 If you are finished cleaning install the media cover 2 10 Preventive Maintenance 2 Cleaning the Label and Ribbon Sensors There are three label sensors and a ribbon sensor on the 3600 printer that require cleaning the label taken sensor the label mark sensor the label gap sensor and the ribbon motion sensor To clean the sensors 1 Remove the media cover 2 Raise the printhead by rotating the he
153. utch pulley liner reverse shaft liner drive gear pulley and liner drive belt you will need some or all of the following parts and tools Liner takeup hub Intermec Part No 061562 005 Liner drive roller Intermec Part No 061568 002 Liner reverse gears 1 and 2 Intermec Part No 061588 002 Liner takeup clutch pulley Intermec Part No 0615745 001 black Liner reverse shaft Intermec Part No 061589 001 2 800ID x 210 drive belt O ring Intermec Part No 501462 003 Liner drive gear pulley Intermec Part No 061569 002 black Retaining E rings Intermec Part No 501401 Retaining snap rings Intermec Part No 501410 Roller alignment tool Intermec Part No T43150 ESD grounding strap 1 and 2 Phillips screwdriver Needlenose pliers Snap ring pliers To replace the liner takeup hub and liner reverse gear 1 Switch off the printer power and remove the power cord Remove the media cover the electronics cover and the front bezel cover refer to Replacing the Bezel PCB earlier in this chapter Raise the printhead Remove media and ribbon if loaded Remove the retaining snap rings that hold the liner takeup hub and liner reverse gear 1 in place as shown on the next page Retain the washer between the snap rings and the liner takeup subplate Discard the old snap rings Pull the liner takeup hub away from the main deck plate to remove it Retain the thick washer between the liner takeup hub and the main deck plate Line
154. when another view of the part is called out for clarification A list of documentation part numbers you can order is also provided To order replacement parts contact Intermec Intermec Corporation 6001 36th Avenue West P O Box 4280 Everett WA 98203 9280 Note Only the listed printer parts are spares available for purchase 3600 Printer Spare Parts List ID No Part Number Description 01 07 061564 001 BEZEL TOP COVER 02 99 061550 007 PLATE MAIN DECK 03 05 06 08 522690 SCREW THD ROLL W CONE 42 43 45 70 83 86 119 146 04 059101 009 COVER ELECTRONICS 09 521528 001 TAPE TRANSFER ADH 010 T 10 059710 001 MAGNET DOOR LATCH 11 059013 002 LENS MEDIA INSPECTION 12 060622 001 LBL INTL LOADING INSTRUC 13 061547S 006 COVER REAR 14 34 061544 004 PLATE BASE 15 061545S 002 COVER MEDIA ACCESS 16 46 061546S 004 BEZEL FRONT COVER 7 3 3600 Printer Maintenance Manual ID No Part Number Description 17 27 059012 009 PLATE FRONT COVER 18 20 21 40 526036 SCREW PHP W INT STAR 6 32 X 375 66 155 19 54 059052S 001 PCB ASSY BEZEL 22 059387 003 BRACKET HINGE 23 060315 002 ROLLER PINCH 24 061581 001 SHAFT PINCH ROLLER 25 501445 RING RTN 125 DIA E RING ZINC 26 44 061579S 003 DOOR ASSY MEDIA ACCESS 28 95 061555 001 EXTRUSION PRINTED SPAN 29 116 521118 001 WASHER SPRING CONL 175 X 50 30 505613 SCREW SOC HD CAP 8 32 31 56 061548 001 CABLE ASSY RIBB
155. y slack in the cable should be arranged between the sensor and the cable clip on the extrusion There should be no slack cable on the electronics side of the printer Make sure the cable is secure and not contacting any moving parts Reassemble the tear bar and bar support and install the lower outboard plate capturing the tear bar liner drive roller and platen roller Note Use the roller alignment tool during reassembly for proper alignment of the outboard plate Reattach the front bezel cover Ensure that the media access door operates properly snaps firmly shut after the front bezel cover is installed Reload media and ribbon if used and lower the printhead Install the electronics cover the media cover and the power cord and check the printer for proper operation 5 11 3600 Printer Maintenance Manual Replacing the Label Taken Sensor 5 12 To replace the label taken sensor you will need the following parts and tools Label taken sensor cable assembly Intermec Part No 059496 002 ESD grounding strap 1 and 2 Phillips screwdriver To replace the label taken sensor 1 2 Switch off the printer power and remove the power cord Remove the media cover the electronics cover and the front bezel cover refer to Replacing the Bezel PCB earlier in this chapter Raise the printhead Remove media and ribbon if loaded Disconnect the label taken sensor cable from the main PCB remove the cable from the two
156. z fj r7 z rz fj z z z rJ z z z z zJ z z z z z z z z z z z z z z z z z z z z z z f7 z z z z z z z z n f PCB Drawings and Schematics PL 061591 003 TITLE PCB ASSY MAIN 3600 PAGE 7 10 PL REV D 02231995 RUN DATE Feb 23 15 19 02 ITEM OTY UM PART NO REFDES DESCRIPTION X Y F B C48 290 JE C50 Deo T C51 4 7 1 0 F C58 459525 E e C60 dou 4 C61 8 9 4 4 C62 Sb F C64 Q8 2 8 UE S C67 50 77 3 3 DE Y C70 1 0 7 342 y C72 10 37 2249 E C75 LOST Ga CE C76 Wl CE a c107 E T C108 US C109 4 0 0 8 F gt C110 uA VE C111 Sud E 112 Sud 3388 C113 AS SE ell 2v We CE a C136 Sy 440 7 C137 wid 138 4 9 42 50 4 563701 C9 S M CER 50WVDC 55 10 PF Dik 589 UE CTI AIR Lg C22 4 0 E C24 6 1 3 8 51 15 563702 C40 CAP S M CER 50WVDC 5 100 LO 259 CE 4 C68 E C96 1950 327 E C99 4430 SE gt C100 1 28 340 UE 4 C101 2285 3h E T C102 138 Vor VE C103 deno UE y C104 1 8 Bulk CE 4 C105 TES i322 7 C106 quo A M C131 7 8 3 8 F 132 758 33 02 133 7 8 Sud C134 228 E 52 7 563705 C14 S M 50VMIN 10 01 UF Ast 98 0 C52 942 4 3 G5 Q6 542

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