Citizen iDP3240 User manual

LINETHERMAL PRINTER
MODEL iDP3240
Rev. 1.0 First created Feb 10th, 2000
Service Manual

i
REVISION
Rev.No. Date Content
Rev. 1.0 Feb 10th, 2000 First created

ii
TABLE OF CONTENTS
1. MECHANISMSAND OPERATING PRINCIPLES...................1
1.1 Power transmission and mechanism for feeding recording paper................ 1
1.2 Mechanism for attaching and detaching the platen roller ............................ 2
1.3 Sensor mechanism........................................................................................ 2
1.3.1 Paper sensor......................................................................................... 2
1.3.2 Paper-near-end sensor.......................................................................... 3
1.4 Print head mechanism .................................................................................. 3
1.4.1 Outline of drive control ....................................................................... 3
1.4.2 Print data and print position ................................................................ 4
2. DISASSEMBLING AND ASSEMBLING METHODS..............5
2.1 Required tools .............................................................................................. 5
2.2 Disassembling procedure ............................................................................. 5
2.2.1 Before starting disassembling: ............................................................ 5
2.2.2 Remove the printer cover: ................................................................... 5
2.2.3 Remove the top cover:......................................................................... 6
2.2.4 Remove rollers from the top cover:..................................................... 6
2.2.5 Disassemble the platen roller SA: ....................................................... 6
2.2.6 Remove the pressure roller:................................................................. 7
2.2.7 Remove the bottom cover:................................................................... 7
2.2.8 Remove the Auto Cutter ACS-241 from the chassis: .......................... 7
2.2.9 Remove the control board from the chassis: ....................................... 7
2.2.10 Remove the thermal head from the chassis: ..................................... 8
2.2.11 Remove the motor assembly from the chassis: ................................ 8
2.2.12 Remove the paper-end sensor SA: ................................................... 8
2.2.13 Remove the wire springs from the chassis: ...................................... 9
3. MECHANICAL SERVICE PARTS LIST.................................10
3.1 Parts List..................................................................................................... 10
3.2 Exploded View 1 ........................................................................................ 12
3.2 Exploded View 2 ........................................................................................ 13
4 iDP3240 CIRCUIT DIAGRAMS ................................................14
4.1 Parts List for Control PCBAssy................................................................. 14
4.2 Block diagram ............................................................................................ 18
4.3 Parts Layout Drawing................................................................................. 19
4.3.1 Control PCB Assy –Top side of the board
(Serial Interface D-sub 25) ................................................................ 19
4.3.2 Control PCB Assy–Reverse side of the board ................................... 20
4.3.3 Control PCB Assy –Top side of the board (Parallel Interface) ......... 21
4.3.4 Control PCB Assy–Reverse side of the board ................................... 22
4.4 Circuit Diagram.......................................................................................... 23
4.4.1 Control PCB Assy (Serial Interface D-sub 25) ................................. 23
4.4.2 Control PCB Assy (Parallel Interface) .............................................. 24
5. TROUBLESHOOTING ..............................................................25
5.1 Troubleshooting Procedure ........................................................................ 25
5.2 Repair guide ............................................................................................... 26
5.2.1 Faulty power supply .......................................................................... 26
5.2.2 Faulty printing ................................................................................... 27
5.2.3 Faulty feeding of recording paper ..................................................... 28
5.2.4 Faulty sensor...................................................................................... 29
5.2.5 Faulty auto cutter............................................................................... 29
6. OUTLINE DRAWING .................................................................30

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1. MECHANISMS AND OPERATING PRINCIPLES
The basic mechanism of the printer and their operating principles are explained for each block as
follows:
• Power transmission and mechanism for feeding recording paper
• Sensor mechanism
• Print head mechanism
1.1 Power transmission and mechanism for feeding
recording paper
The driving force of the motor is transmitted from the motor gear attached to the motor shaft via
the platen gear to the platen roller, and this driving force rotates the platen roller. The platen
roller is pressed against the surface of the heating unit of the thermal head by wire springs
located at both sides of the roller.
When the recording paper is inserted between the platen roller and the thermal head, the recording
paper is pulled in between the platen roller and the thermal head by the rotation of the platen roller
and transported to the output port in conjunction with the rotation of the platen roller.
Platen roller
Platen gear
Thermal head
Motor
Heating unit
Motor gear
Platen roller
Heating unit
Thermal head

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1.3 Sensor mechanism
1.3.1 Paper sensor
The paper sensor is located immediately before
the thermal head to detect whether recording
paper is present or not. Applying electrical
power to the thermal head while recording paper
is not inserted could result in damage to the head
or reduce the service life of it. The paper sensor
is provided to help prevent this, as well as to
detect whether recording paper is inserted or not
in the case of auto loading.
Platen roller
Paper sensor
Recording paper
Thermal head
1.2 Mechanism for attaching and detaching the platen roller
The platen roller, which is a part of the mechanism for feeding recording paper, is removable
with this printer. The platen roller, which has the platen gear, platen bushings and platen holder
attached, comprises a platen roller unit. When this unit is placed in the U-formed bearings of the
chassis, the platen gear engages the motor gear. The wire springs, with one end anchored to the
chassis, press against the platen bushings to keep the roller in contact with the thermal head. The
platen roller unit can be attached or removed by hooking or unhooking the movable ends of the
wire springs to or from the hooks on the chassis.
Wire spring
Motor gear
Platen gear Platen roller (Platen roller unit)
Platen holder
Platen bushing
Platen roller
Chassis U-formed bearing
Chassis hook

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1.3.2 Paper-near-end sensor
The paper-near-end sensor detects when the remaining amount of recording paper becomes
small. When the remaining amount of recording paper decreases (about 50 cm to 2 m for
specified recording paper), the outside diameter of the paper roll becomes small with its edge
surface getting out of the range of the sensor. This permits the paper-near-end sensor to detect
that the paper supply has become low. The amount of remaining paper differs with the thickness
of the recording paper and the material of the roll core. Remaining amount cannot be adjusted.
1.4 Print head mechanism
A thermal head is employed as the print head of this printer. The thermal head consists of a heat
generating unit and a head driver to drive and control the thermal head.
1.4.1 Outline of drive control
The serial print data which is input from DATA
IN (DI) is transferred to the shift register in
synchronism with CLOCK (CLK), and then
stored in the latch register by LATCH (LAT)
signal.
When the gates are turned ON by head electric
signals (print command STR1 to 6), power is
applied to the heating elements which
correspond to the print data stored, enabling the
data to be printed on thermal paper by the heat.
Platen roller
Paper-near-end sensor
Recording paper
Thermal head
Feed roller
Heating element
Gate
Latch register
Shift register
Thermistor
Equivalent circuit of thermal head
TH
TH
GND
Vcc
DATA OUT
CLOCK
DATA IN
/LATCH
dot 832 dot 1
STR 1
STR 3
COM
(Vp)

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1.4.2 Print data and print position
The 832-bit print data numbered 1 to 832 and transferred by DATA IN (DI) are printed at the
positions indicated in the following diagram.
Recording paper
Direction of paper feed
Printed surface Printed surface
Direction of paper feed
Data
DATA IN
1234 · · · · · · · · · 831 832

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2. DISASSEMBLING AND ASSEMBLING
METHODS
The following precautions should be adhered to at the time of maintenance.
(1) Do not disassemble, assemble or adjust the printer if it is operating satisfactorily. In particular,
do not carelessly loosen the screws holding various parts in place.
(2) Following inspection, perform a check to ensure that everything is in order before turning ON
the power.
(3) Never allow the printer to print without paper placed in it.
(4) Check that recording paper and platen roller are placed correctly.
(5) When servicing, be sure not to leave used parts or screws, etc. inside the printer.
(6) When handling the thermal head, do not wear gloves, etc. likely to generate static electricity.
(7) When disassembling or assembling, inspect cords and boards for damage and be sure not to
route cords in unreasonable fashion or fasten them in unreasonable positions.
2.1 Required tools
• Philips and flat-end screwdrivers #1, #2.
• A pair of tweezers
• A pair of suitable pliers
2.2 Disassembling procedure
2.2.1 Before starting disassembling:
(1) Remove the paper roll from the printer.
(2) Disconnect theAC adapter and the cable connected on
the back of the printer from the respective connectors.
2.2.2 Remove the printer cover:
(1) Placing your finger in the small hollow on each side of
the printer cover, open it upward.
(2) Pushing the cover hinges inwards, remove the printer
cover from the upper cover. Printer cover

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Roller
E-ring
Platen gear
Platen bushing
Platen holder
Platen roller
Wire spring
Pan head screw M3 × 8
Bushing guide
Platen roller SA
2
1
2.2.3 Remove the top cover:
(1) Disengage the wire springs from the hooks on the top cover, and then remove the platen
roller SA.
(2) Remove screws M3×8 (three locations).
(3) Placing the printer upside down, insert a flat-end screwdrive into the gap between the case
and chassis near the locations indicated by the 2 arrows 12, to disengage the claws
holding the chassis and the case.
(4) Return the printer to its normal position. While being careful not to damage the wire
springs, slowly lift out the top cover.
2.2.4 Remove rollers from the top cover:
(1) Remove the 2 rollers, each by bending the roller
axis holding part outwards.
2.2.5 Disassemble the platen roller SA:
(1) Remove the E-rings, platen gear, and platen
bushings.
(When assembling, the notches in the platen
bushings should mesh with the protrusions
of the platen holder sides.)
(2) Remove the platen roller by first
disengaging its end with no D-cut and then
D-cut end from the platen holder.

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2.2.6 Remove the pressure roller:
(1) Remove the 2 M2.6×6 Screws from
the printer cover.
(2) Bend the roller spring to remove it
from the roller holder.
(3) Bend the roller holder’s bearing
section to remove the roller.
2.2.7 Remove the bottom cover:
(1) Remove the 2 M3×8 screws located in the
lower part of the bottom cover.
(2) Lifting the back of the bottom cover, remove it.
2.2.8 Remove the Auto Cutter ACS-241
from the chassis:
(1) Disconnect the connector for the cutter
connected to the control board.
(2) Remove the 2 M2.6×6 screws and lift the
ACS-241 upwards to remove.
2.2.9 Remove the control board from the chassis:
(1) Remove all connecting cables on the board.
(2) Remove the 3 M3×8 screws.
(3) While taking special care not to deform or
damage the paper-near-end sensor and power
switch, etc, lift the chassis straight up.
ACS-241
Screw M2.6 × 6
Bottom cover
Control board
Screw M3 × 8
Chassis
Roller
Roller holder
Pan head screw M2.6 × 6
Roller spring
Printer cover

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2.2.10 Remove the thermal head from the chassis:
(1) Remove the 2 M3×4 screws holding the
head from the underside of the chassis.
(2) Detach the cable on the underside of the
chassis from hooks.
(3) Remove the 2 connecting cables from the
head.
2.2.11 Remove the motor assembly from the chassis:
(1) Remove the 2 M3×5 screws from the chassis.
(2) While playing attention to its cable, remove
the motor.
2.2.12 Remove the paper-end sensor SA:
(1) Remove the 2 M3×5 screws from the chassis.
(1) Remove the paper-end sensor SA.
Screw M3 × 5
Motor assembly
Chassis
Connecting cable
Chassis
Screw M3 × 4
Screw M3 × 5
Motor assembly
Chassis

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2.2.13 Remove the wire springs from the chassis:
(1) Raise the wire springs until vertical, then
push them down (with care not to deform
them) to remove.
Note: Assemble all parts by following the disassembling procedure in reverse order.
Wire spring
Chassis

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3. MECHANICAL SERVICE PARTS LIST
3.1 Parts List
Ref. No. Parts No. Description Q’ty Remarks
3240
1 E4002-620 CHASSIS 1
2 E8510-050 MOTOR Assy 1
3 E8010-380 MOTOR BK (1)
4 E8017-110 MOTOR (SMB40-4850-D) (1)
5 23G 75069 SCREW,PH,M3 ×5 (2)
6 E6601-430 WIRE SP 2
8 E620 20430 BOTTOM COVER (R) 1 SERIAL
E620 20440 BOTTOM COVER (P) PARALLEL
10 E6302-370 RUBBER FOOT (ZUREN ZFK) 4
11 E6601-330 FINGER GARD 1
13 E66201-110 TOP COVER Assy 1
14 E66201-100 TOP COVER (1)
15 E6612-050 ROLLER (2)
16 E5200-250 OP SHEET (1)
17 E5049-030 CAP (1)
18 E6101-150 INSERT ROLLER (1)
19 23G75514 INSERT ROLLER SP (1)
20 E6101-170 INSERTER (2)
22 E40000360 PE PCB Assy 1
23 E40000370 PE PCB (1)
24 E4900-670 CODE Assy-CA3 (3240) (1)
25 E391-150 PHOTOINTERRUPTER (GP2S40) (1)
26 E4000390 PE PCB HOLDER 1
27 E62040605 PRINTER COVER Assy 1
28 E62040600 PRINTER COVER 1
29 E8031-100 ROLLER HOLDER 1
30 E8031-110 ROLLER 1
31 E8031-120 ROLLER SPRING 1
33 ACS-241-FM ACS-241 1
34 E8010-390 MOUTH PLATE R 1
35 E8010-400 MOUTH PLATE F 1
36 E6220-680 TEAR BAR 1
38 THERMAL HEAD (KF2004-GC10C) 1
39 E4900-660 HEAD CABLE Assy 1
41 E77001-510 MAIN PCB Assy R-JPN (1) SERIAL
E77001-511 MAIN PCB Assy R-USA (1) SERIAL
E77001-520 MAIN PCB Assy R-EUR (1) SERIAL
E77001-525 MAIN PCB Assy P-JPN (1) PARALLEL
E77001-530 MAIN PCB Assy P-USA/EUR (1) PARALLEL
43 E5071-140 LED KEY TOP (1)
44 E5110-530 PE SENSOR COVER (1)
45 E40000380 PE Assy (1)
47 E8040-640 PLATEN ROLLER Assy 1

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Ref. No. Parts No. Description Q’ty Remarks
3240
48 PLATEN (1)
49 PLATEN BUSHING (2)
50 PLATEN GEAR (1)
51 PLATEN HOLDER (1)
52 E-RING No.4 (2)
54 AC ADAPTER 31AD 1
55 E6100-735 AC CORD SET-1 (JPN) (1)
E6100-730 AC CORD SET-2 (USA) (1)
E6100-765 AC CORD SET-3 (EUR) (1)
E5103-560 Switching plug KPR-25-B
59 Rating plate JPN (1)
Rating plate USA (1)
Rating plate EUR (1)
63 PAPER SET LABEL 1
64 CAUTION DON’T TOUCH 3 (1)
65 CAUTION DRAWER (1)
70 SCREW, No.0, PHT (ST) (#1), M2 ×66
71 SCREW, PHT (ST), M2.6 ×62
72 SCREW, PHT (BT), M2.6 ×62
73 SCREW, PHT (ST), M3 ×52
74 SCREW, PHT (BT), M3 ×61
75 SCREW, PHT (ST), M3 ×87
76 SCREW, PHT (ST, EXT, TW), M3 ×61

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3.2 Exploded View 1
74
59
75
75
73
76
71
70
70
47
65
75
63
39
38
36
35
34
33 26
2322
20
19
18
17
16
15
1413
11
10
8
6
2
1
64

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3.2 Exploded View 2
5
4
3
7131
30
29
28
45
44
43
41
52
51
50 49
48

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Ref. No. Parts No. Description Q’ty Remarks
RP RP
IC1 IC1 CPU 1 1
IC2 IC2 GATE ARRAY 1 1
IC3 IC3 FLASH-ROM 1 1 4M product
IC4 IC4 RAM 1 1
IC5 IC5 DC/DC CONVERTER 1 1
IC6 IC6 RESET IC 1 1
IC7,8 INTERFACE 2
IC7,8 H-CMOS 2
IC9 H-CMOS 1
IC101 IC101 KANJI ROM 1 1 Only mounted for JPN
TA1 TA1 TRANSISTOR ARRAY 1 1 L-angle product
TA2 TA2 TRANSISTOR ARRAY 1 1
Tr1,9,10 Tr1,9,10 TRANSISTOR 3 3
Tr2 Tr2 TRANSISTOR 1 1
Tr3,4,8 Tr3,4,8 TRANSISTOR 3 3
Tr5 Tr5 TRANSISTOR 1 1
Tr6,7 Tr6,7 TRANSISTOR 2 2
Tr11,12 Tr11,12 TRANSISTOR 2 2
ZD1 ZD1 ZENER DIODE 1 1
D1 D1 DIODE 1 1
LED1 LED1 LIGHT EMITTING DIODE 1 1
LED2 LED2 LIGHT EMITTING DIODE 1 1
4 iDP3240 CIRCUIT DIAGRAMS
4.1 Parts List for Control PCB Assy

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Ref. No. Parts No. Description Q’ty Remarks
RP RP
R34,39, RESISTOR 4
44,3 R34,39, RESISTOR 5
44,53,3
R31,36,41 R31,36,41 RESISTOR 3 3
R23 RESISTOR 1
R23,24 RESISTOR 2
R24 RESISTOR 1
R18~20, RESISTOR 5
26,30 R18~20, RESISTOR 5
26,30
R11,12 R11,12 RESISTOR 2 2
R1,2,16, RESISTOR 5
21,29 R1,2,16, RESISTOR 5
21,29
R5~7,17,
22,25,27, RESISTOR 16
28,35,40,
45~50 R5~7,17
22,25,27, RESISTOR 16
28,35,40,
45~50
R33,43 R33,43 RESISTOR 2 2
R8,9 R8,9 RESISTOR 2 2
R32,38,42 RESISTOR 3
R32,38,42 RESISTOR 3
R15 R15 RESISTOR 1 1
R14 R14 RESISTOR 1 1
R52 R52 RESISTOR 1 1
R51 R51 RESISTOR 1 1
R4 R4 RESISTOR 1 1
R10,13 R10,13 RESISTOR 2 2
RA1,2 RESISTOR ARRAY 2

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Ref. No. Parts No. Description Q’ty Remarks
RP RP
C1,2,37 CERAMIC CAPACITOR 3
C1,2,31 CERAMIC CAPACITOR 3
C3 C3,30 CERAMIC CAPACITOR 1 2
C4,5,8~11,
18,26~36, CERAMIC CAPACITOR 31
CP1,CP5~
16 C4,5,8~11,
18,26, CERAMIC CAPACITOR 24
CP1~16
C12,13, CERAMIC CAPACITOR 4
16,106 C12,13,
16,28, CERAMIC CAPACITOR 5
106
C14,15 C14,15 CERAMIC CAPACITOR 2 2
C17,19~25 CERAMIC CAPACITOR 8
C17,19~25, CERAMIC CAPACITOR 10
27,29
C101~105, CERAMIC CAPACITOR 7
107,108 C101~105, CERAMIC CAPACITOR 7
107,108
C110,111 CERAMIC CAPACITOR 3
114 C110,111 CERAMIC CAPACITOR 3
114
C6 C6 ELECTROLYTIC CAPACITOR 1 1
C7 C7 ELECTROLYTIC CAPACITOR 1 1
DS1,2 DS1,2 DIP SWITCH 2 2
DS3,4 DIP SWITCH 2
S1 S1 SWITCH 1 1
S2 S2 SWITCH 1 1
S3 S3 SWITCH 1 1
F1 F1 FUSE 1 1
F2 F2 FUSE 1 1
F3 F3 FUSE 1 1
X1 X1 OSCILLATOR 1 1

iDP3240 SERVICE MANUAL
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Ref. No. Parts No. Description Q’ty Remarks
RP RP
CN1 CN1 CONNECTOR 11
CN2 CN2 CONNECTOR 11
CN3 CN3 CONNECTOR 11
CN4 CN4 CONNECTOR 11
CN5 CN5 CONNECTOR 11
CN6 CN6 CONNECTOR 11
CN7 CN7 CONNECTOR 11
CN8 CN8 CONNECTOR 11
(CN9-2) (CN9-2) CONNECTOR (1) 1
CN10 CONNECTOR 1
JPN/EUR
specifications only
CN10 CONNECTOR 1 USA
specifications only
CN10 CONNECTOR 1
L1,2,4~7,
18~32,37 FERRITE BEADS 24
38,40 L1,2,4~7,
18~32,37 FERRITE BEADS 24
38,40
L3,8~17,
33~36,39 FERRITE BEADS 36
41~60 L3,8~17,
33~36,39 FERRITE BEADS 49
41~73
LED KEY TOP 1 1
PCB 1
PCB 1
(IC3) (IC3) ROM LABEL 1 1