Casio UP-250 User manual

EXTERNAL PRINTER
FEB. 2000
MODEL UP-250
(without price)
TECHNICAL MANUAL

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FCC CLASS A
FCC Compliance Statement
For American Users
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the
FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment
is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference, in which case the user will be required to correct the interference
at his or her own expense.
WARNING
The connection of a non-shielded printer interface cable to this printer will invalidate the FCC Verification of this device
and may cause interference levels which exceed the limits established by the FCC for this equipment.
You are cautioned that changes or modifications not expressly approved by the party responsible for compliance could void
your authority to operate the equipment.
FOR CANADIAN USERS
This Class A digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations.
Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.
GEREÄUSCHPEGEL
Gemäß der Dritten Verordrung zum Gerätesicherheitsgecsetz (Maschinenlärminformations- Verordnung-3. GSGV) ist der
arbeitsplatzbezogene Geräusch-Emissionswert kleiner als 70 dB(A) (basierend auf ISO 7779).

Introduction
PU-250 Series (Type B) printers are one-station printers for ECR and POS use that can print the results of weighing or
measuring. The main features of the PU-250 Series (Type B) printers are the following:
oHigh-speed printing through logic-seeking control
oExcellent reliability and long life resulting from the use of two stepping motors, one for moving the carriage and one
for paper feeding
oFlexible paper feed setting permits printing in accordance with any user-defined format
oCommand protocol based on ESC/POS, a widely used standard
oBuilt-in drawer kick-out interface provides capability to drive two drawers
oSelectable character fonts (7 x 9, 9 x 9)
oSemi-automatic paper loading capability
oAC adapter (included) provides compact power supply
oCompact and light in weight
oAutomatic Status Back (ASB) function to automatically send printer status changes
oAuto-cutter euipped
oTwo-color printing: black and red are selectable.
Notes and Cautions
Note:
Notes have important information and useful tips on the operation of your printer.
CAUTION:
Cautions must be observed to avoid damage to your equipment.

CONTENTS
Chapter 1 Features and General Specifications ......................................................1
Features .......................................................................................................................... 2
Printing Specifications ........................................................................................................ 2
Character Specifications..................................................................................................... 3
Paper .................................................................................................................................. 4
Auto-cutter .......................................................................................................................... 5
Paper Roll Supply Device................................................................................................... 5
Receive Buffer .................................................................................................................... 5
Electrical Specifications...................................................................................................... 5
Ribbon Cassette .................................................................................................................5
External Dimensions and Weight........................................................................................ 6
Environmental Specifications ............................................................................................. 6
Reliability ............................................................................................................................ 7
Safety Standards ................................................................................................................7
Printer Installation Position ................................................................................................. 7
Hardware Configuration ................................................................................................ 8
Main Unit Specifications ............................................................................................... 9
Paper Feed Motor............................................................................................................... 9
Carriage Motor.................................................................................................................... 9
Print Head Unit ................................................................................................................... 9
Home Position Sensor........................................................................................................ 9
Paper End Detector .......................................................................................................... 10
Paper Roll Near-end Detector (Optional) ......................................................................... 10
Connectors ................................................................................................................... 10
Interface Connector .......................................................................................................... 10
Power Supply Connector...................................................................................................11
Drawer Kick-Out Connector...............................................................................................11
Interface ........................................................................................................................ 13
RS-232 Serial Interface .................................................................................................... 13
RS-485 Serial Interface (option) ....................................................................................... 16
IEEE 1284 Parallel Interface ............................................................................................ 16
Buttons and Switches ................................................................................................. 19
Power Switch....................................................................................................................19
Panel Button ..................................................................................................................... 19
DIP Switches ....................................................................................................................20
Panel LEDs ................................................................................................................... 22
Self-test......................................................................................................................... 22
Error Processing.......................................................................................................... 23
Printer Operation When an Error Occurs........................................................................... 23
Data Receive Error ............................................................................................................ 23
Buffer Full Printing ...................................................................................................... 23
Detectors and Printing ................................................................................................ 23
Hexadecimal Dump...................................................................................................... 24
Performing a Hexadecimal Dump..................................................................................... 24
Options .........................................................................................................................24
External Power Supply PS-170 ........................................................................................ 25

Chapter 2 Mechanism Configuration and Operating Principles...........................26
Printer Mechanism Operating Principles................................................................... 26
Print mechanism unit ........................................................................................................ 27
Print head unit movement................................................................................................. 28
Wire movement when a single dot is printed.................................................................... 28
Printing a character (9x9 font) ......................................................................................... 29
Paper Feed Mechanism Unit ............................................................................................ 30
Paper loading (semi-automatic loading) ........................................................................... 31
Paper feeding ...................................................................................................................31
Ribbon Feed Mechanism Unit .......................................................................................... 32
Ribbon feeding ................................................................................................................. 33
Detection Mechanism Unit................................................................................................ 34
Home position detection mechanism................................................................................ 34
Paper detection mechanism ............................................................................................. 35
Paper roll near-end detection mechanism (optional)........................................................ 35
Auto-cutter mechanism..................................................................................................... 35
Ribbon Switch Mechanism Unit ................................................................................. 36
Switching from Black to Red............................................................................................. 36
Releasing from Red to Black ............................................................................................ 36
Electrical Circuitry Operating Principles ................................................................... 37
Hardware Configuration.................................................................................................... 37
Principles of Operation ............................................................................................... 41
Power Supply Circuitry ..................................................................................................... 41
Control Circuitry................................................................................................................ 42
CPU .................................................................................................................................. 43
Various detector circuits.................................................................................................... 46
Host interface circuit ......................................................................................................... 47
Drawer kick-out drive circuit ............................................................................................. 47
DIP switch read circuit ...................................................................................................... 48
Printer Mechanism Driver Circuits ............................................................................. 50
Print head driver circuit..................................................................................................... 50
Paper feed motor driver circuit ......................................................................................... 51
Carriage motor driver circuit ............................................................................................. 51
Auto-cutter driver circuit.................................................................................................... 52
Chapter 3 Handling and Maintenance .....................................................................53
Handling Precautions .................................................................................................. 53
Storage Precautions ......................................................................................................... 53
Use Precautions ............................................................................................................... 53
Paper Handling Precautions ............................................................................................. 53
Ribbon Cassette Handling Precautions ............................................................................ 54
Replacing the Paper Roll............................................................................................. 54
Replacing the Ribbon Cassette .................................................................................. 57
Removing Jammed Paper ........................................................................................... 60
Using the Power Switch Cover ................................................................................... 64
Inspection and Maintenance....................................................................................... 65
Cleaning........................................................................................................................66

Lubricants..................................................................................................................... 66
Standard Lubrication ........................................................................................................ 66
Lubricants ......................................................................................................................... 66
Lubrication Points ............................................................................................................. 67
Tool List ........................................................................................................................ 67
Chapter 4 Troubleshooting ......................................................................................68
Self-test......................................................................................................................... 68
Initiating the Self-test ........................................................................................................68
Self-test Standby .............................................................................................................. 68
Ending the Self-test .......................................................................................................... 68
Troubleshooting Flowchart ......................................................................................... 69
Troubleshooting Tables ............................................................................................... 76
Error Types and Countermeasures ............................................................................ 82
Chapter 5 Disassembly, Assembly, and Adjustment .............................................87
Small Part Specifications ............................................................................................ 87
Disassembly ................................................................................................................. 88
Removing the fuse............................................................................................................ 88
Removing the print head unit............................................................................................ 89
Removing the auto-cutter ................................................................................................. 91
Removing the main circuit board assembly ...................................................................... 92
Sub-assembly A ........................................................................................................... 94
Paper feed frame unit assembly ....................................................................................... 94
Main Assembly 1 .......................................................................................................... 98
Ribbon switch lever, ribbon release spring, ribbon release lever,
ribbon intermediate gear, ribbon transmission gear, ribbon take-up assembly,
and ribbon drive plate assembly ....................................................................................... 98
Main Assembly 2 ........................................................................................................ 100
Tension plate assembly .................................................................................................. 100
Main Assembly 3 ........................................................................................................ 100
Paper feed frame assembly ............................................................................................ 100
Main Assembly 4 ........................................................................................................ 101
Carriage motor assembly................................................................................................ 101
Main Assembly 5 ........................................................................................................ 102
Carriage sub assembly................................................................................................... 102
Main Assembly 6 ........................................................................................................ 103
Carriage shaft assembly................................................................................................. 103
Main Assembly 7 ........................................................................................................ 104
Adjustment roller shaft holder assembly......................................................................... 104
Main Assembly 8 ........................................................................................................ 105
Carriage guide shaft assembly ....................................................................................... 105
Main Assembly 9 ........................................................................................................ 105
Belt tension spring assembly.......................................................................................... 105

Main Assembly 10 ...................................................................................................... 106
Sensor assembly ............................................................................................................ 106
Main Assembly 11 ...................................................................................................... 108
Carriage motor heat sink assembly ................................................................................ 108
Main Assembly 12 ...................................................................................................... 108
Print head FPC assembly ............................................................................................... 108
Main Assembly 13 ...................................................................................................... 110
Print head unit ................................................................................................................ 110
Main assembly 14....................................................................................................... 111
Left cover fixing plate and right cover fixing plate........................................................... 111
Main Assembly 15 ...................................................................................................... 112
Ribbon frame earth plate ................................................................................................ 112
Main Assembly 16 ...................................................................................................... 113
Ribbon frame assembly, ribbon frame spring, and ribbon frame fixing plate .................. 113
Main Assembly 17 ...................................................................................................... 114
Thumb-screw and head cover ........................................................................................ 114
Main Assembly 1 (Case Unit) .................................................................................... 115
Lower cutter plate assembly ........................................................................................... 115
Main Assembly 2 (Case Unit) .................................................................................... 116
Upper plate assembly ..................................................................................................... 116
Main Assembly 3 (Case Unit) .................................................................................... 118
Main circuit board assembly ........................................................................................... 118
Main Assembly 4 (Case Unit) .................................................................................... 119
Inserting the cables ........................................................................................................ 119
Main Assembly 5 (Case Unit) .................................................................................... 120
Lower case assembly ..................................................................................................... 120
Main Assembly 6 (Case Unit) .................................................................................... 121
Manual cutter assembly and auto-cutter fixing plate ...................................................... 121
Main Assembly 7 (Case Unit) .................................................................................... 123
Auto-cutter assembly ...................................................................................................... 123
Main Assembly 8 (Case Unit) .................................................................................... 126
Paper roll receive rollers, upper case, guide roller, and switch panel assemblies .......... 126
Main Assembly 9 (Case Unit) .................................................................................... 128
Interface circuit board assembly and connector plate .................................................... 128
Main Assembly 10 (Case Unit) .................................................................................. 130
Lower plate, ROM cover, and rubber foot assembly ....................................................... 130
Main Assembly 11 (Case Unit) .................................................................................. 131
Main cover assembly ...................................................................................................... 131
Main Assembly 12 (Case Unit) .................................................................................. 132
Near-end detector assembly (optional)........................................................................... 132
Adjustment ................................................................................................................. 134
Platen gap adjustment.................................................................................................... 134

Appendix....................................................................................................................135
RS-485 Serial Interface .............................................................................................. 135
Main Circuit Board Parts Layout .............................................................................. 140
RS-232 Serial Interface Circuit Board Parts Layout ............................................... 141
IEEE 1284 Parallel Interface Circuit Board Parts Layout ....................................... 142
RS-485 Serial Interface Circuit Board Parts Layout ............................................... 143
Main Circuit Board Diagram...................................................................................... 144
RS-232 Serial Interface Circuit Board Diagram....................................................... 145
IEEE 1284 Parallel Interface Circuit Board Diagram............................................... 146
RS-485 Serial Interface Circuit Board Diagram....................................................... 147
Printer Mechanism Unit Overall Exploded Diagram ............................................... 148
Case Unit Overall Exploded Diagram....................................................................... 149
Printer Mechanism Unit Lubrication Points Diagram............................................. 150
Case Unit Lubrication Points Diagram .................................................................... 151
Parts List....................................................................................................................152
EXPLODED DIAGRAM FOR TM-U200B/U210B NO.1 .............................................154
EXPLODED DIAGRAM FOR TM-U200B/U200PB/U210B/U210PB NO.2 ................155

Figure 1-1 PU-250 appearance
POWER LED
Power switch
PAPER OUT LED
ERROR LED
FEED button
(PAPER OUT/PRESS FEED)
PROM
DIP switches
Power supply connector
Drawer kick-out connector
Frame ground screw
Interface connector
Frame ground screw
— 1 —
Chapter 1 Features and General Specifications

Features
Printing Specifications
NOTE: If the print duty ratio is too high, the operation of the print head is stopped by the duty limit. In
such circumstances, the print speeds shown above cannot be guaranteed.
cpi = characters per inch.
Printing method: Serial impact dot-matrix
Head wire configuration: 9-pin serial type
Figure 1-2 Dot configuration
Dot pitch: 0.353 mm (1/72")
Dot wire diameter 0.29 mm (0.01")
Printing direction: Bidirectional with logic seeking
Printing width: 63.34 mm (2.49")
Line feed: 4.233 mm (1/6"): default setting
Programmable in units of 1/144 inch by using commands.
Paper feed method Friction feed
Paper feed speed: Approximately 4.17 inches/second (25 lines/second) during
continuous paper feeding
Characters per line: See the table on the next page.
Characters per inch: See the table on the next page.
Total dot count (horizontal
direction) 7 x 9 font: 400 half-dot positions per line 9 x 9 font: 400 half-dot positions per line
Print speed Approximately 3.5 lines/second (40 columns, 16 cpi)
Approximately 6.4 lines/second (16 columns, 16 cpi)
0.29 mm (0.01")
(wire diameter)
0.317 mm (0.012")
0.353 mm
(0.014")
— 2 —

Character dimensions, characters per inch, characters per line
NOTE: The default font is 7 x 9; the dot spacing between characters is either 3 half dots or 2 half dots,
depending on the setting of DIP switch 2-1.
Character Specifications
Character Structure
Horizontal x Vertical
Character
Structure
Character Set
Character
Dimensions
WxH
Dot Spacing
Between
Characters
Characters Per
Line (cpl) Characters Per Inch (cpi)
7 x 9 ANK 1.2 x 3.1 mm
(.047 x .122")  3 half dots 40 16
Graphics 1.7 x 3.1 mm
(.070 x .122")  0 40 16
9 x 9 ANK 1.6 x 3.1 mm
(.063 x .122")  3 half dots 33 13.3
Graphics 2.0 x 3.1 mm
(.079 x .122")  0 33 13.3
7 x 9 ANK 1.2 x 3.1 mm
(.047 x .122")  2 half dots 42 17.8
Graphics 1.6 x 3.1 mm
(.063 x .122")  0 42 17.8
9 x 9 ANK 1.6 x 3.1 mm
(.063 x .122")  2 half dots 35 14.5
Graphics 1.9 x 3.1 mm
(.075 x .122")  0 35 14.5
Character sets: Alphanumeric: 95
International: 32
Graphics: 128 x 8 pages
Character structure: 7 x 9 with 400 half-dot positions per line
9 x 9 with 400 half-dot positions per line
Figure 1-3 Character size (7 x 9 font example)
3.1 mm
(0.122")
2.4 mm
(0.094")
1. 24 m m (0 .049" )
1.59 m m ( 0.0 63")
0.159 mm (0.006")
0.353 mm
(0.014")
— 3 —

Paper
(*1) This dimension shows the distance from the manual cutter to the print position.
(*2)
Values fo r the p rinting are a are calcul ated (between dot centers) with the wire d iameter (0.29 m m [.011 "]).
Paper types: Paper roll: Plain paper or pressure-sensitive paper
Paper roll width: 76 ± 0.5 mm (2.99 ± .020")
Paper roll maximum
diameter:
83 mm (3.27")
Paper roll core: Unless there is an optional near-end detector, you cannot use a paper
roll with the core and paper glued together.
Normal paper: Thickness: 1 sheet: 0.06 to 0.085 mm (.0024 to .0034")
Weight: 52.3 to 64 g/m 2
(13.9 to 17 lb)
(45 to 55 kg/1000 sheets/1091 x 788)
Pressure-sensitive paper Original sheet + up to 1 copy sheet
Thickness: 1 sheet: 0.05 to 0.08 mm (.0020 to .0031")
Total thickness: 0.2 mm (.0079") or less
Recommended paper: Mitsubishi - carbonless paper (blue)
Top and middle sheets: N40Hi
paper thickness: 0.06 mm (.0024")
weight: 47.2 g/m 2
(12.6 lb)
Bottom sheet: N60
paper thickness: 0.08 mm (.0031")
weight: 68.0 g/m 2
(18.1 lb)
Figure 1-4 Printing area
Maximum of 200 dots, 400 positions
76 mm (2.99")
20.2 mm (0.79") (*1)
Cutting position (manual cutter)
(*2)
63.34 mm (2.49")
[5.9 mm (0.23")] [6.76 mm (0.27")]
Cutting position (auto-cutter)
27 mm (1.063")
— 4 —

Auto Cutter
Partial cut is executed by a command. (A partial cut leaves one point uncut.)
Paper Roll Supply Device
Receive Buffer
Either 1KB or 40 bytes, selectable by DIP switches.
Electrical Specifications
Ribbon Cassette
Ribbon cassette specifications
(*1) Ribbon life is based on the following conditions:
Character font: 7 x 9 font (with descenders)
Print pattern: ASCII 96-character rolling pattern. See the specification published by EPSON for the print
pattern example.
NOTE: Malfunctions and other problems may occur if a ribbon cassette other than the specified one is used.
Supply device: Drop-in loading
Power supply One of the following five AC adapters is included, depending on
the specifications:
AC adapter specifications
Power consumption
(except when driving
drawer kick-out):
Operating: Mean average 43 W
Standby: Average 6 W
Model number Color Ribbon life (*1)
ERC-38 (P) Purple 4 million characters (with continuous printing at 25°C [77°F])
ERC-38 (B) Black 3 million characters (with continuous printing at 25°C [77°F])
ERC-38 (B/R) Black and
Red
Black: 1.5 million characters (with continuous printing at 25°C [77°F])
Red: 750,000 characters (with continuous printing at 25°C [77°F])
Settings and
shipment Input voltage range Model
name
Japan 100 V ±10%, 50/60 Hz PA-6508
North America 120 V ±10%, 60 Hz PB-6509
Europe (Germany) 230 V ±10%, 50 Hz PB-6510
Europe (U.K.) 230 V ±10%, 50 Hz PA-6511
Australia 240 V ±10%, 50 Hz PA-6513
— 5 —

External Dimensions and Weight
Environmental Specifications
Height: 150 mm (5.91")
Width: 160 mm (6.30")
Depth: 248 mm (9.76")
Weight: Approximately 2.5 kg (5.5 lb)
Color: EPSON standard gray
Temperature: Operating: 0° to 50° C (32° to 122° F)
At 34° C (93° F) or higher, there are humidity restrictions;
see the figure below.
Storage: –10° to 50° C (14° to 122° F), except paper and ribbon
Humidity: Operating: 10% to 90% RH (non-condensing)
Storage: 10% to 90% RH (non-condensing), except paper and ribbon
Figure 1-5 Operating temperature and humidity range
Vibration resistance: When packed:
Frequency: 5 to 55 Hz
Acceleration: 2 G
Sweep: 10 minutes (half cycle)
Duration: 1 hour
Directions: x, y, and z
Operating Temperature Range
40° C (104° F), 65%
34° C (93° F), 90%
50° C (122° F), 35%
80
60
40
20
00 10 40 Environmental Temperature
Relative Humidity [% RH]
50
90
10
3020
— 6 —

Reliability
Safety Standards
The following standards are applied only to the printers that are so labeled.
Printer Installation Position
Install the printer horizontally. Make sure it does not tilt more than 15°. The printer must also be installed
so that it does not move or vibrate during paper cutting or the drawer kick-out operation. Fastening tape
is available as an option.
Impact resistance: When packed:
Package: EPSON standard package
Height: 60 cm (23.62")
Directions: 1 corner, 3 edges, and 6 surfaces
When unpacked:
Height: 5 cm (1.97")
Directions: Lift one edge and release it (for all 4 edges)
Life
Mechanism: 7,500,000 lines (See the UP-250) Specification for the print color
switching number.
Print head: 150 million characters (using an average of 2 dots/wire per character.)
(The print pattern is shown in the UP-250 Specification in Figure A-1.)
Auto cutter: 800,000 cuts
End of life is defined as the point at which the printer reaches the
beginning of the wear out period.
MTBF 180,000 hours
Failure is defined as a random failure occurring within the time of the
random failure period.
MCBF 18,000,000 lines
This is an average failure interval based on failures relating to wear out
and random failures up to the life of 7,500,000 lines.
For Europe: CE Marking:  EN55022, EN50082-1, EN45501
Safety standards:  TÜV
EMI:  FCC class A
For USA:
Safety standards:  UL1950-2TH-D3
c-UL
— 7 —

Hardware Configuration
Figure 1-6 UP-250 main unit configuration
Carriage motor
Paper feed motor
Paper end detector
Print head unit
Home position sensor
Paper roll near-end detector (optional)
Main circuit board
Interface circuit board
— 8 —

Type: 4-phase, 48-polarity, PM-type stepping motor
Drive voltage: 24 VDC ±10%
Winding resistance: 58 Ω±2.9 Ω at 25°C (77°F), per phase
Current consumption: Peak: 1.1 A in worst case
Average: 200 mA at 24 VDC, 25°C (77°F), 600 pps
350 mA maximum
Type: 4-phase, 48-polarity, PM-type stepping motor
Drive voltage: 24 VDC ±10%
Winding resistance: 39.5 Ω±1.9 Ω at 25°C (77°F), per phase
Current consumption: Peak: 1.5 A maximum
Average: 400 mA at 24 VDC, 25°C (77°F), 952 pps
600 mA maximum
Number of solenoids: 9
Winding resistance: 19.2 Ω±5% at 25°C (77°F), per phase
Drive voltage: 24 VDC ±10%
Type: Photo sensor
Voltage: 5 VDC ±5%
Output level: LOW when the carriage home position is detected
— 9 —
Main Unit Specifications
Paper Feed Motor
Carriage Motor
Print Head Unit
Home Position Sensor

Paper End Detector
Paper Roll Near-end Detector (Optional)
Connectors
Figure 1-7 Connector panel (serial interface)
Figure 1-8 Connector panel (parallel interface)
Interface Connector
See the interface section.
Type: Microswitch
Voltage: 5 VDC ± 5%
Output level: High when paper end is detected
Type: Microswitch
Voltage: 5 VDC ± 5%
Output level: Low when a paper near-end is detected
Frame ground
screw connector
Power supplyDrawer kick-out
connector
Interface
connector
Frame ground
screw
Power supply
connector
Drawer kick-out
connector
Frame ground
screw
Interface
connector
Frame ground
screw
— 10 —

— 11 —
This connector is used to connect the printer to an external power source.
NOTE: Be sure to ground the frame ground (FG) screw on the board at the bottom of the unit. Ground
wire terminal hole diameter: 3.2 mm (.13"). Ground wire thickness: AWG 18 or equivalent.
A pulse specified by the ESC p command is output to the drawer kick-out connector. The host
can confirm the status of the input signal by using the GS a,GS r, or DLE EOT
commands.
The host computer can check the drawer open/closed status with the DLE EOT, GS a, and GS r
commands.
Pin assignments: See the table below.
Pin Number
1 + power supply
2 GND
3NC
Shell Frame GND
Pin Number Signal name Direction
1 Frame GND
2Drawer kick-out drive signal 1
(See "Drawer kick-out drive signal," below.) Output
3Drawer open/close signal
(See "Drawer open/closed signal," below.) Input
4 +24
—
—VDC
5Drawer kick-out drive signal 2
(See "Drawer kick-out drive signal," below.) Output
6 Signal GND —
Input signal level: LOW = 0 V
HIGH = 2 to 5 V (at connector pin 3)
2
3 1
Signal Name
Power Supply Connector
Drawer Kick-Out Connector
Power supply connector pin assignments
Drawer kick-out connector pin assignments
Drawer open/closed signal