Comtec Encore 4 User manual

User's Manual
Portable Printer
Part No. UMAN-EN4
Comtec Information Systems, Inc.
Rev. 1.2 July 21, 1998

WARNING
This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15 of FCC Rules. These
limits are designed to provided 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 own expense.
Changes or modifications to this unit not expressly approved by the
party responsible for compliance could void the user's authority to
operate this equipment.
Proprietary Statement
This manual contains proprietary information of Comtec Information
Systems, Inc. It is intended solely for the information and use of
parties operating and maintaining the equipment described herein.
Such proprietary information may not be used, reproduced, or
disclosed to any other parties for any other purpose without the
expressed written permission of Comtec Information Systems, Inc.
Inasmuch as every effort has been made to supply accurate informa-
tion in this manual, Comtec is not liable for any erroneous information
or omissions.
Copyrights
The copyrights in this manual and the printer described therein are
owned by Comtec Information Systems, Inc. All rights are reserved.
Unauthorized reproduction of this manual or the software in the
printer may result in imprisonment of up to one year and fines of up
to $10,000 (17 U.S.C.506). Copyright violators may be subject to
civil liability.

iii
Contents
Introduction ................................................................... 1
Printer Specifications ................................................... 3
Physical......................................................................3
Environmental............................................................3
Printing Characteristics..............................................3
Communications Interface .........................................3
Communications Protocol.......................................... 4
Pin Assignments ........................................................ 4
Media Type.................................................................5
Media Handling.......................................................... 5
Software Features...................................................... 5
Controls ......................................................................... 7
Keypad Functions ...................................................... 7
Self Test ..................................................................... 7
Batteries and Charging................................................. 8
Removing and Replacing Batteries ........................... 8
Low Battery Shutdown............................................... 9
Conditioning............................................................... 9
Installation of Media: DirectThermal Units............... 11
Peeler not in use ...................................................... 11
Peeler in use ............................................................ 11
Troubleshooting .......................................................... 13
Self Test: ..................................................................13
Troubleshooting Guide............................................. 13
Maintenence ................................................................ 15
Cleaning the print head:........................................... 15
Cleaning the platen.................................................. 16
Cleaning the peeler roller: ......................................16
Cleaning Sensors .................................................... 16
Communicating to the Printer....................................17
Cable Communications............................................17
IR Communications ................................................. 18
SRRF Communications ........................................... 18
continued next page

APPENDIX A ............................................................. A-1
APPENDIX B ............................................................. A-4
APPENDIX C ............................................................. A-5
APPENDIX D .............................................................. A-6
Patent Information..................................................... A-7

Operation Section

O-1 UMAN-EN4
Encore 4 Printer
Introduction
The Encore™4 Intelligent Portable Printer utilizes the
latest in direct thermal or thermal transfer printing tech-
nology. This product is designed for portable printing and
is ideally suited to print shelf labels, tickets, price change
stickers, receipts, linerless labels and any other mobile
applications where printing is required on-site.
Integrated battery status and hardware diagnostics
circuits, as well as its compact size, make the Encore 4
ideal for mobile printing. Some Encore 4 models offer
wireless communications via short range radio frequency
(SRRF) or infrared (IrDA) interfaces.
This manual should be read in its entirety before at-
tempting operation of this product. Further information
regarding this printer’s features and operation can be
found in the Comtec Printing Systems Programming
Manual (Comtec p/n PRO-MAN).

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Printer Specifications
Physical
Height: 5.5" (139.7 mm)
Width: 6.1" (154.9 mm)
Depth: 4.0" (101.6 mm)
Weight: 2.90 lbs.(1.32 kg) w/o stock
Environmental
Operating temperature: 14°to 104°F (-10°to
40°C)
Storage temperature: -4°to 140°F (-20°to 60°C)
Relative humidity: 95% non-condensing
The Encore 4 automatically compensates for head
temperature when printing. Protection circuitry prevents
damage due to excessive print head temperatures.
Printing Characteristics
Print Head Life: 1,964,160" (50 Km nominal)
(estimated)
Technology: Direct Thermal or Thermal
Transfer
Print Speed: 2-3 IPS (50.8-76.2 mm)
Print Head Width: 4.25" (108 mm)
Print Head Density: 203 DPI (8 dots/mm)
Number of Dots: 832
Communications Interface
• Built-in RS-232 port for one or two-way communi-
cation to terminal or other host up to 19.2K BPS.
• Encore 4 Wireless: Infrared communications via
IrDA specifications or Short Range Radio Fre-
quency (SRRF) communications at 900 MHz or 2.4
GHz. Frequencies of 418 and 433 MHz, compat-
ible with EC specifications, are also available.

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UMAN-EN4
Communications Protocol
The Encore 4 supports RTS/CTS (hardware) and XON/
XOFF handshaking protocols to synchronize with the
host terminal. The handshaking protocol and the baud
rate are programmable. The default communications
parameters are:
Handshaking = RTS/CTS Baud Rate = 19,200
Parity = None Data Bits = 8
Stop Bits = 1
Pin Assignments
The following are the pin assignments for the 8-pin DIN
RS232C serial connector.
Pin Pin Signal Signal
Number Name Type Description
1 RXD input Receive Data
2 TXD output Transmit Data
3 CTS input Clear To Send from host
4 RTS output Request To Send
set high when printer
is ready to accept command/
data
5 GND Ground
6 NC No Connect
7 DSR input Data Set Ready
Low to high transition turns
printer on, High to low
transition turns printer off
(if enabled)
8 DTR output Data Terminal Ready
set high when printer is on
(set to battery voltage for
“S” versions)

O-5 UMAN-EN4
MediaType
• Paper Labels
• Synthetic Labels
• Tags
• Two-part thermal receipts
• Linerless labels (on linerless models only)
• Plain paper (Thermal transfer units only)
Media Handling
Media Width: 4.25" (108 mm) max. width
1.5" (38 mm) min. width
Maximum Print Width: 4.09" (104 mm) max. width
.005" (.13 mm) min. width
Media Core Size: .75" (19 mm)
• Self-centering stock width adjustment (patent
pending)
• Easy stock loading system
• Optional automatic label peeler
• Optional label present sensor
Software Features
• Vertical or horizontal printing
• Left, right, or center justification
• Scale to fit
• Concatenation
• Line print mode- ideal for reciept printing
• Optional PCL5 emulation
• Programmable label odometer with on-demand
terminal reporting
• Serial number reporting to terminal on demand
• Automatic print head temperature compensation
• Programmable inactivity shut-off
• Out of paper/head-up error LED indicator
• Power On/Off from terminal or built-in keypad
• Black bar/gap sensing

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UMAN-EN4
Formats
• 25 Resident fonts
• Optional international character fonts
• Flash memory for down-loadable programs, label
formats, fonts and graphics
• Fully scalable fonts
• Built-in graphics support
Accessories and Options
• Single-bay battery pack fast charger/conditioner
• Four bay battery pack fast charger/conditioner
• Trickle charger
• Vehicle Charger
• Extra NiMH battery pack
• Variety of interface cables
• IrDA Option
• All commonly used frequency short range radio
frequency (SRRF) interface options
• Soft carrying case
• Protective rubber boots for severe use
• Mobile mount for use on heavy equipment
Power
The Encore 4 utilizes a removable NiMH battery pack.
If not connected to a terminal with DTR present, the
Encore 4 will automatically power off to conserve battery
life. The time-out value can be programmed from the
host terminal; the factory default time-out is two minutes.
Additional power features include:
• Charge duration of 600 to 800 labels
• Low battery indicated by flashing LED and reported
to terminal on demand
• Power on/off controlled from terminal or keypad

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Controls
Keypad Functions
Advances media to
next label or sense
mark without printing.
Momentary on action
turns printer on Turns printer off.
Power Light:
Indicates
Printer is
turned on
Status Light: Steady
light indicates printer is
either out of media, or
head release latch is
open.
Flashing during data
transmission between
host and printer
indicates normal
wireless operation.
Low Battery Light:
Flashes when battery is
near its shut off voltage.
Steady light indicates
battery must be
recharged or replaced.
SelfTest
The Encore 4 can perform a self test which will print a
solid black line to insure all elements of the print head are
working, and then print out the version of software loaded
in the printer. Refer to the Troubleshooting section for
more details on interpreting the self-test.
The self test is activated by the following key sequence:
1.Press the "FEED" key
2.While still holding down the "FEED" key, turn on
the printer by pressing and releasing the "ON" key.
3.Release the "FEED" key
The Encore 4 will perform the self test and remain on.

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UMAN-EN4
Lift Release Latch to
remove battery pack.
Battery Contacts.
Encore 4 Battery Installation/Removal
Batteries and Charging
Removing and Replacing Batteries
Batteries are removed from the Encore 4 by the follow-
ing procedure:
1.Face the front of the printer. Push the battery
release button on the right side of the printer to-
wards the top of the printer.
2.Firmly slide the battery pack out the left side of the
printer until it is clear while still keeping the battery
release button raised.
Batteries are replaced by the following procedure:
1.Align the battery pack to the printer so that the
battery contacts (the metal plates on the top of the
battery) are oriented towards the top and inside of
the printer.
2.Slide the pack into the printer until it locks in place.
3.The battery will engage with a distinct “click” .

O-9 UMAN-EN4
Low Battery Shutdown
The Encore 4 monitors battery charge level in software
and will cause the low-battery LED to flash as the batter-
ies become depleted. When the LED illuminates continu-
ously, the printer should be shut off and the battery pack
re-charged. The Encore 4 will automatically shut itself off
if the batteries become severely discharged.
Listed below are the specifications for the Encore 4
chargers:
UC7200/Encore: This NiMH charger/conditioner is
designed to charge and condition individual battery
packs used on the Encore 4 portable printer. Bat-
tery packs may be charged separately or while
plugged into the Encore 4. Typical charge time is
60 to 90 minutes. Universal 110 to 230, 50-60 Hz.
VAC input.
Do not attempt to charge batteries with the
UC7200 Charger while printing. Attempting to
print while charging batteries can result in unreli-
able charging.
Trickle Charger (Comtec p/n AT13797-1): A wall type
charger which is a cost effective means of charging
battiers in a stand-by mode. Allows simultaneous
charging and printing.
Use of any other charger not approved specifically
by Comtec for use with Encore 4 NiMH batteries
could cause damage to the battery pack or the
printer and will void the warranty.
Conditioning
Encore 4 battery packs should be conditioned once a
week for maximum battery life. The UC7200/Encore
charger/conditioner’s “Condition” cycle will fully discharge
the battery pack to a safe limit and then re-charge it to its
maximum level.

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UMAN-EN4
Media Installation: Peeler not in use
Media Installation: Peeler in use
Peeler Roller
“Open” Button
Media
Liner
Edge Guide “Open” Button
Edge Guide

O-11 UMAN-EN4
continued next page
Installation of Label Media
The Encore 4 can print and separate labels automati-
cally using its optional built in label peeler, and print on
conventional media or print continuous batches of labels
without using the peeler. The following details label
media installation for these two modes.
Peeler not in use (Journal, linerless, or batch quantities of labels)
1.Turn unit off.
2.Press and hold the “Open” button on the front of the
unit. Rotate the top back to reveal the paper com-
partment
3.Remove the edge guide and install the media roll
on the spindle. Lead the free end over the rubber
roller (platen). Media should feed from the top of
the roll.
4.Slide the edge guide back over the spindle and
against the roll of media. Roll will be automatically
centered in the paper compartment.
5.Close the top and insure it is securely latched
before beginning to print.
Peeler in use (Do not use the label peeler when printing a batch quantity of
labels)
1.Turn unit off.
2.Press and hold the “Open” button on the front of the
unit. Rotate the top back to reveal the paper com-
partment
3.Remove the edge guide and install the media roll
on the spindle. Lead the free end over the rubber
roller (platen). Media should feed from the top of
the roll..
4.Lift peeler roller by depressing “Open” button on
front of unit. Lead edge of media under the
grooved peeler roller. Stock will emerge from the
slot in the front cover.

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UMAN-EN4
5.Slide the edge guide back over the spindle and
against the roll of media. Roll will be automatically
centered inside the paper compartment.
6.Close the top and insure it is securely latched
before beginning to print.
7. As media is printed, labels will be peeled off the
backing liner and will stay on the printer until re-
moved.Labels should not be printed in batches
when the peeler is being used. This will prevent
labels from sticking to one another and prevent
potential jams.
Units equipped with label presence sensor: If the sensor is
activated, further printing will be inhibited until the most
recently printed label is removed.
Installaion of Media (continued)

O-13 UMAN-EN4
Troubleshooting
SelfTest:
Perform the self test as described in the Controls sec-
tion. Unit should print a solid black line and two reports.
The first report indicates model, ROM version, serial
number, baud rate, etc. The second report contains
application information. If no second report appears,
there is no application loaded.
continued next page
Troubleshooting Guide
No power
• Check battery, recharge or replace as necessary.
Media does not feed:
• Be sure print head is closed and latched.
• Check spindle holding media for any binding.
• If unit is equipped with label presence sensor: Insure most
recently printed label is removed. Also insure label sensor is
not blocked.
• Check media. If linerless unit, insure media does not have
liner.
Poor or faded print:
• Clean print head.
• Check/replace battery.
• Check quality of media.
Partial/missing print:
• Check media alignment
• Clean print head.
• Verify print head is closed and latched properly
Prints illegible characters:
• Check baud rate.
No print:
• Check baud rate
• Replace battery
• Check cable connection to terminal
• Wireless units: verify communication link between printer and
terminal
• Invalid label format or command structure — use Hex Dump
Mode for troubleshooting.

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UMAN-EN4
Reduced battery charge life:
• Recondition battery.
• Damaged battery-replace.
• Check battery date code: if one to two years old, short charge
life may be due to normal aging.
Error light flashing:
• No application:reload program.
• If using wireless communications: normal indication while data
is being received.
Error light always on:
• Check media is loaded and print head is closed and securely
latched.
Skips labels:
• Check for correct media with top of form sense mark or label
gap.
• Check print field length has not exceeded length of label.
• Insure bar/gap sensor is not blocked or malfunctioning.
Communication Error:
• Check media is loaded, head is closed and error light is off.
• Check baud rate.
• Replace cable to terminal.
Label Jam:
• Open head release latch.
• Generously apply alcohol to printer in area of jammed label.
Never use any sharp objects on printer mechanism
as it could damage the print head. Use only alcohol,
the supplied cleaning pen and /or a cotton swab for
cleaning the printer.