Metrologic MS7600 User manual

I
Service Manual
METROLOGIC INSTRUMENTS, INC.
MS7600 Horizon
®Series

II
Table of Contents
Section Name: Page #
1PRELIMINARY INFORMATION....................................................................................................................................1-1
1.1 PRODUCT SAFETY..............................................................................................................................................................1-1
1.1.1 Notices........................................................................................................................................................................1-1
2INTRODUCTION...................................................................................................................................................................2-3
2.1 INTRODUCTION............................................................................................................................................................2-3
2.2 MANUAL SCOPE.................................................................................................................................................................2-3
2.3 MANUAL SYMBOL KEY.....................................................................................................................................................2-3
2.4 GENERAL PRECAUTIONS...................................................................................................................................................2-4
2.4.1 PRODUCT ESD INFORMATION:.......................................................................................................................2-4
2.4.2 LASER SAFETY INFORMATION:.......................................................................................................................2-4
3THEORY & OPERATION...................................................................................................................................................3-1
3.1 BASIC DATA DECODING SECTIONAL SUMMARYS.........................................................................................................3-1
3.1.1 Photodiode (Detector) Summary:.........................................................................................................................3-1
3.1.2 Pre-Amplifier Sectional Summary:.......................................................................................................................3-1
3.1.3 Signal Processor Section Summary:.....................................................................................................................3-1
3.1.4 Decoder Section Summary:....................................................................................................................................3-1
4MS7600 HORIZON SCANNER HISTORY....................................................................................................................4-1
5BOARD REMOVAL & INSTALLATION ......................................................................................................................5-1
5.1 DISASSEMBLING THE UNIT................................................................................................................................................5-1
5.1.1 Optics Bench Removal.............................................................................................................................................5-1
5.2 DECODE BOARD REMOVAL &INSTALLATION...............................................................................................................5-2
5.2.1 Decode Board Replacement...................................................................................................................................5-2
5.3 SIGNAL PROCESSOR BOARD REMOVAL &INSTALLATION..........................................................................................5-2
5.3.1 Signal Processor Board Removal..........................................................................................................................5-2
5.4 VLD REPLACEMENT PROCEDURE...................................................................................................................................5-3
5.4.1 VLD Removal Instructions:....................................................................................................................................5-3
6PCB SPECIFICATIONS.......................................................................................................................................................6-5
6.1 SIGNAL PROCESSOR BOARD.............................................................................................................................................6-5
6.1.1 Signal Processor Board Functions.......................................................................................................................6-5
6.2 DECODE BOARD.................................................................................................................................................................6-6
6.2.1 DECODE Board Functions....................................................................................................................................6-6
7TROUBLESHOOTING.........................................................................................................................................................7-7
7.1 AUDIBLE INDICATORS...............................................................................................................................................7-7
7.2 VISUALINDICATORS..................................................................................................................................................7-8
7.3 FAILUREMODES...........................................................................................................................................................7-9
7.4 MS7320SERIES TROUBLESHOOTING GUIDE...............................................................................................................7-10
8SPECIFICATIONS & PINOUTS .......................................................................................................................................8-3
8.1 SCAN VOLUME SPECIFICATIONS (BASED ON 100% UPCBAR CODES).....................................................................8-3

III
8.2 DEPTH OF FIELD BY MINIMUM BAR CODE ELEMENT WIDTH.....................................................................................8-4
8.3SCANNER CONNECTOR/CABLE PINOUT CONNECTIONS...............................................................................................8-5
8.3.1 MS7320 Pinout Connections..................................................................................................................................8-5
8.3.2 Cable Connector Configurations..........................................................................................................................8-7
8.4 MS7600HORIZONSCANNER SPECIFICATIONS..........................................................................................................8-9
8.4.1 OPERATIONAL DESIGN SPECIFICATIONS ...................................................................................................8-9
8.4.2 OVERALL PHYSICAL DIMENSIONS .............................................................................................................. 8-10
8.4.3 ELECTRICAL CHARACTERISTICS ................................................................................................................. 8-10
8.4.4 ENVIRONMENTAL DETAILS ............................................................................................................................ 8-11
8.5 CAUTION AND SERIAL NUMBER LABELS.....................................................................................................................8-12
8.5.1 Labels...................................................................................................................................................................... 8-12
9SERVICING INFORMATION........................................................................................................................................9-13
9.1 LIMITED WARRANTY.......................................................................................................................................................9-13
9.2 METROLOGIC SERVICE LOCATIONS..............................................................................................................................9-14
9.3 PATENTS............................................................................................................................................................................9-15

1-1
1PRELIMINARY INFORMATION
1.1 Product Safety
1.1.1 Notices
Notice
This equipment has been tested and found to comply with the limits for a Class A digitaldevice, pursuant to part 15 of
the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generates,uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference
to radio ortelevision reception, which can be determined by turning the equipment off and on, the useris encouraged to
try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Changes or modifications not expressly approved by the party responsible for compliance could void the user’s
authority to operate the equipment.
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This
device may not cause harmful interference, and (2) this device mustaccept any interference received, including
interference that may cause undesired
operation.
Notice
This Class B digital apparatus complies with Canadian ICES-003.
Remarque
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.
Caution
Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous
laser light exposure. Under no circumstances should the customer attempt to service the laser scanner. Never attempt to
look at the laser beam, even if the scanner appears to be nonfunctional. Never open the scanner in an attempt to look
into the device. Doing so could result in hazardous laser light exposure. The use of optical instruments with the laser
equipment will increase eye hazard.
Atención
La modificación de los procedimientos, o la utilización de controles o ajustes distintos de los especificados aquí, pueden
provocar una luz de láser peligrosa. Bajo ninguna circunstancia el usuario deberá realizar el mantenimiento del láser del
escáner. Ni intentar mirar al haz del láser incluso cuando este no esté operativo. Tampoco deberá abrir el escáner para
examinar el aparato. El hacerlo puede conllevar una exposición peligrosa a la luz de láser. El uso de instrumentos
ópticos con el equipo láser puede incrementar el riesgo para la vista.
Attention
L'emploi de commandes, réglages ou procédés autres que ceux décrits ici peut entraîner de graves irradiations. Le client
ne doit en aucun cas essayer d'entretenir lui-même le scanner ou le laser. Ne regardez jamais directement le rayon laser,
même si vous croyez que le scanner est inactif. N'ouvrez jamais le scanner pour regarder dans l'appareil. Ce faisant,
vous vous exposez à une rayonnement laser qú êst hazardous. L'emploi d'appareils optiques avec cet équipement laser
augmente le risque d'endommagement de la vision.

1-2
Achtung
Die Verwendung anderer als der hier beschriebenen Steuerungen, Einstellungen oder Verfahren kann eine gefährliche
Laserstrahlung hervorrufen. Der Kunde sollte unter keinen Umständen versuchen, den Laser-Scanner selbst zu warten.
Sehen Sie niemals in den Laserstrahl, selbst wenn Sie glauben, daß der Scanner nicht aktiv ist. Öffnen Sie niemals den
Scanner, um in das Gerät hineinzusehen. Wenn Sie dies tun, können Sie sich einer gefährlichen Laserstrahlung
aussetzen. Der Einsatz optischer Geräte mit dieser Laserausrüstung erhöht das Risiko einer Sehschädigung.
Attenzione
L’utilizzo di sistemi di controllo, di regolazioni o di procedimenti diversi da quelli descritti nel presente Manuale può
provocare delle esposizioni a raggi laser rischiose. Il cliente non deve assolutamente tentare di riparare egli stesso lo
scanner laser. Non guardate mai il raggio laser, anche se credete che lo scanner non sia attivo. Non aprite mai lo scanner
per guardare dentro l’apparecchio. Facendolo potete esporVi ad una esposizione laser rischiosa. L’uso di apparecchi
ottici, equipaggiati conraggi laser, aumenta il rischio di danni alla vista.

2-3
2INTRODUCTION
2.1 INTRODUCTION
The MS7600 Horizon® series is Metrologic’s next generation in-counter laser barcode scanner. This compact, hands-
free scanner is designed with a dense20-line omnidirectional scan pattern that helps provide fast, efficient throughput
with a high first pass read rate.
SCANNER INTERFACE
MS7620-13 RS232, IBM 46xx, OCIA, Aux High Impact
Plastic Top
MS7620-37 RS232, Light Pen, Keyboard Wedge, Stand-Alone Keyboard,
USB, Aux
MS7625-13 RS232, IBM 4680, OCIA Stainless
Steel Top
MS7625-37 RS232, Light Pen, Keyboard Wedge, Stand-Alone Keyboard,
USB, Aux
2.2 Manual Scope
This guide provides a way to perform service repairs. It contains an overview of the scanner with detailed information
about troubleshooting, functionality, and scanner performance.
2.3 Manual Symbol Key
TABLE 1-MANUAL SYMBOLOGY
Caution!
Important Additional Information.

2-4
2.4 General Precautions
** ESD PREVENTION STEPS MUST BE USED DURING ANY
MODIFICATIONS AND/OR REPAIRS TO THIS UNIT! **
2.4.1 PRODUCT ESD INFORMATION:
This product containsESD sensitive components, or ‘Electrostatic Discharge’ sensitive electronic parts. Electrostatic
discharge is defined as the transfer of charge between bodies at different electrical potentials.
Electrostatic discharge has the ability to modify the electrical characteristics of a semiconductor device, possibly
degrading or even destroying it. Electrostatic discharge also may upset the normal operation of an electronic system,
causing equipment malfunction or failure.
2.4.2 LASER SAFETY INFORMATION:
Use of controls or adjustments or performance of procedures other than those specified herein may result in
hazardous radiation exposure. Under no circumstances should the customer attempt to service the scanner. Never
attempt to look at the laser beam, even if the scanner appears to be nonfunctional. Doing so could result in hazardous
radiation exposure.
The MS7320 unit is rated as a CLASS IIA laser product, as defined by The U.S. Federal Laser Product Performance
Standard (FLPPS): Title 21 of the Code of Federal Regulations; Part 1000; [Parts 1040.10 and 1040.11].
CLASS I, II, and IIA lasers are defined as:
CLASS I: cannot emit laser radiation at known hazard levels (typically continuous (CW): 0.4microwatts at visible
wavelengths). Users of a Class I laser products are generally exempt from radiation hazard controls during operation
and maintenance (but not necessarily during service).
CLASS II: low power visible lasers, which emit above Class I levels but emitting a radiant power not above 1mW. The
concept is that the human aversion reaction to bright light will protect a person.
CLASS IIA is a special designation that is based upon a 1000 second exposure and applies only to lasers that are "not
intended for viewing" such as a supermarket laser scanner. These laser are emitting light in the visible wavelengths (0.4
to 0.7 mm) with power not above 1mW.

3-1
3THEORY & OPERATION
3.1 Basic Data Decoding Sectional Summarys
3.1.1 Photodiode (Detector) Summary:
3.1.1.1 Receives the optical signal reflected off the bar code
3.1.1.2 Converts into electrical signal (current) of about 100 nanoamps
3.1.2 Pre-Amplifier Sectional Summary:
3.1.2.1 Part of the Signal processor board, usually contained ina shielded area of the PCB with the Photodiode.
3.1.2.2 Converts the electrical current to a voltage signal
3.1.2.3 Voltage signal is amplified by a factor of 1000
3.1.2.4 Ambient light noise is filtered out. Resultant signal is routed to the mother board to primary signal
processing circuitry
3.1.3 Signal Processor Section Summary:
3.1.3.1 Converts analog waveform into a digital signal that can be used by the microprocessor
3.1.4 Decoder Section Summary:
3.1.4.1 Decoding algorithm decodes digital signals into ASCII characters
FIGURE 2.4-1VLD LASER AND BARCODE DATA PATHS

4-1
4MS7600 HORIZON SCANNER HISTORY
MS7600 PROTOTYPE –
MS7600 A –
MS7600 B –
NEW SANYO VLD

5-1
5BOARD REMOVAL & INSTALLATION
THE MS762X ELECTRONICS ARE ESD SENSITIVE! ESD
SAFETY PROCEDURES MUST BE FOLLOWED WHILE
HANDLING THE MS762X UNIT WITH ANY ELECTRONICS
EXPOSED!!
5.1 Disassembling the unit
5.1.1 Optics Bench Removal
5.1.1.1 Remove the outer cover to reveal the inner
cover by lifting up on the edges of the
cover.
5.1.1.2 Remove the four (4) Torx screws that hold
the inner cover on(Figure 5.1.1-1).
5.1.1.3 Left the inner cover off by using the straps
provided (Figure 5.1.1-1).
5.1.1.4 Using a Philips head screwdriver remove
the screw and washer from the center of
the optics bench(Figure 5.1.1-2).
5.1.1.5 Carefully lift the optics bench from the
unit.
5.1.1.6 While the optics bench is part way out
from the case, unplug the flex cable from
the signal processor and the motor from
the decode board.
5.1.1.7 Remove the damaged optics bench from
the case trying not to disturb the EAS
wire. Discard damaged optics bench.
FIGURE 5.1.1-1
TORXSCREWS
LIFT STRAPS
TORXSCREWS
SCREW AND WASHER
EAS WIRE
FIGURE 5.1.1-2

5-2
5.2 Decode board Removal & Installation
5.2.1 Decode Board Replacement
5.2.1.1 Open Unit by following steps from 5.1.1.1
up to 5.1.1.6
5.2.1.2 Disconnect beeper cable from Decoder
Board (J4 connector)
5.2.1.3 Close outside connector covers and release
Decoder Board by pulling it in vertical
direction. Be careful with EAS wire.
5.2.1.4 Replace board and assembly unit in
reverse mode it was disassembled.
5.3 Signal Processor Board Removal & Installation
5.3.1 Signal Processor Board Removal
5.3.1.1 Open Unit by following steps from 5.1.1.1
up to 5.1.1.3
5.3.1.2 Unplug from the signal processor the flex
cable coming from the Decoder Board
(connector J1) and the VLD (connector J2)
5.3.1.3 Remove two screws that attach the Signal
Processor board to the Bench plastic case
(Figure 5.3.1-1)
5.3.1.4 Replace defective board by a new one
(MTLPN 46-46648)
5.3.1.5 Adjust VLD output power by fixing the
‘Select by test resistor’ (SBT shown in
Figure 5.3.1-1) R71 to get a output laser
power based on the table of Figure (Figure
5.3.1-2)before the output window. By
increasing the SBT the output power
decreases and vice versa.
5.3.1.6 Assembly unit in reversed mode as it was
disassembled.
OUTPUT WINDOW CRISTAL
STANDARD
(90%TRANSMISSION)
DIAMONEX
(72-78%TRANSMISSION)
SAPPHIRE
(85% TRANSMISSION)
OUTPUT POWER MAX: 1060
TYPICAL : 1000
MAX: 1440
TYPICAL : 1200
MAX: 1150
TYPICAL : 1100
FIGURE 5.3.1-2
FIGURE 5.3.1-1
SBT ( R71)

5-3
5.4 VLD Replacement Procedure
5.4.1 VLD Removal Instructions:
5.4.1.1 Open the case to gain access inside the
unit. (Follow Steps 5.5.1.1 up to step
5.1.1.5)
5.4.1.2 Put bench aside the bottom case without
disconnecting motor wire and flex cable
from the decoder board.
5.4.1.3 Power up the unit and mark with an easy
erasable marker the beam point generated
by the laser onto the joystick mirror
located at the center of collector mirror. A
circle round the laser beam would fit.
5.4.1.4 Power off and remove the damage VLD
from its bracket (You may need to use a
hand tool like pliers)
5.4.1.5 Connect a new VLD (MTLPN 46-46649)
and place it into its bracket ( Do not glue
yet).
5.4.1.6 Place a SBT (R71) resistor between 30 K
Ohms and 43 K Ohms (Normally a value
of 36 K Ohms would fit when using a
STANDARD Output window, 33 K Ohms
would fit when using a SAPPHIRE Output
window and 30 K Ohms would fit when
using a DIAMONEX Output window)
5.4.1.7 Power on and measure laser power output
with the Laser Power Meter (MTLPN: 45-
550). Power should fit the one in Figure
5.3.1-2 out of the VLD.
5.4.1.8 If out of range, power off, change SBT and
follow steps 5.4.1.6& 5.4.1.8 until power
out of the VLD matches specifications
5.4.1.9 With VLD into bracket, power on and
place laser beam at the previous mark at
the joystick located a middle of Collector
mirror (Figure 5.4.1-1).
5.4.1.10 Use a half-transparent paper to check out
output pattern as specified in Figure 5.4.1-
2
FIGURE 5.4.1-2
FIGURE 5.4.1-1

5-4
5.4.1.11 Use a Reflective paper and check out that
reflexion laser light gets to the photodiode
window at the signal processor board.
5.4.1.12 Once the alignment is fixed up, glue VLD
by using LOCTITE 406 and accelerator
LOCTITE 7455 to fast cure the glue.
5.4.1.13 Clean the mark at the joystick (Be careful
and do never touch Collector mirror with
fingers)
5.4.1.14 Assembly unit by following steps defined
in 5.1.1.5 in reverse order.

6-5
6PCB SPECIFICATIONS
6.1 Signal Processor Board
6.1.1 Signal Processor Board Functions
•Receives the optical signal reflected off the bar code.
•Converts received optical signal into electrical signal (current) of about 100 nanoamps.
•Converts the electrical signal (current) to a suitable voltage signal level for the Decode board.
•Discriminates and filters out all unwanted signals and noise.
46-46648 BOTTOM SIDE VIEW
46-46648 –TOP SIDE VIEW

6-6
6.2 Decode Board
6.2.1 DECODE Board Functions
•Decoding algorithm decodes digital signals into universal ASCII character data.
•The ASCII character data is then transmitted to the Host Computer System.
•Stores unit configuration information, including all possible other configuration modes in it’s memory.
46-46647 TOP SIDE VIEW
46-46647 BOTTOM SIDE VIEW

7-7
7TROUBLESHOOTING
7.1 AUDIBLE INDICATORS
When the MS7600 scanner is in operation, it provides audible feedback. Thesesounds indicate the status of the scanner.
Eight settings are available for the tone of the beep (normal, 6 alternate tones and no tone) plus three volume
settings. To change the tone or volume, refer to the Changing the Beeper Tone & Volume section of this manual.
One Beep
When the scanner first receives power, the green LED will turn on, then the red LED will
flash and the scanner will beep once. (The red LED will remain on for the duration of the
beep.) The scanner is ready to scan.
When the scanner successfully reads a bar code, the red LED will flash and the scanner beeps
once (if programmed to do so). If the scanner does not beep once and the green light does not
flash, then the bar code hasnot been successfully read.
Razzberry Tone
This tone is a failure indicator. Refer to “Failure Modes".
Three Beeps -During Operation
During operation of the scanner, the red LED will flash while the scanner simultaneously
beeps three times (while going into programming mode). The red LED will continue to flash
until the unit exits program mode. Upon exiting program mode, the scanner will beep three
times and the red LED will stop flashing.
When configured, 3 beeps can also indicate a communications timeout during normal
scanning mode.
When using one-code-programming, the scanner will beep three times (the current selected
tone), followed by a short pause then by a high tone and a low tone. This tells the user that
the single configuration bar code has successfully configured the scanner.
Three beeps will also occur during a manual adjustment of the beeper tone. With each short
depression of the Multi-Function Button, the new tone will be heard, followed by a short
pause then two more of the new current tones.
Three Beeps -On Power Up
This is a failure indicator. Refer to “Failure Modes”.
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7-8
7.2 VISUAL INDICATORS
There is a red LED and amber LED on the front of the MS7600. When the scanner is on, the flashing or constant
illumination of the LEDs indicates the status of the current scan and the scanner.
No Red or Amber LED
The LEDs will not be illuminated if the scanner is not receiving power from the host or
transformer.
Steady Amber
When the laser is active, the green LED is illuminated. The green LED will remain
illuminated until the laser is deactivated.
Steady Amber and Single Red Flash
When the scanner successfully reads a bar code, the red LED will flash and the scanner will
beep once. If the red LED does not flash or the scanner does not beep once, then the bar code
has not been successfully read.
Steady Amber and Steady Red
After a successful scan, the scanner transmits the data to the host device. Some
communication modes require that the host inform the scanner when data is ready to be
received. If the host is not ready to accept the information, the scanner's red LEDwill remain
on until the data can be transmitted.
Flashing Amber then Flashing Red
This indicates the scanner is in program mode. A razzberry tone indicates that an invalid bar
code has been scanned in this mode.
Or
If the unit is in sleep mode, each LED will flash once every 15
seconds.
Steady Red, Amber Off
This indicates the scanner may be waiting for communication from the host.

7-9
7.3 FAILURE MODES
Flashing Amber and One Razzberry Tone
This indicates the scanner has experienced a laser subsystem failure. Return the unit for
repair at an authorized service center.
Flashing Amber and Red and Two Razzberry Tones
This indicates the scanner has experienced a motor failure. Return the unit for repair at an
authorized service center.
Continuous Razzberry Tone with Both LEDs Off
If, upon power up, the scanner emits a continuous razzberry tone, then the scanner has an
electronic failure. Return the unit for repair at an authorized service center.
Three Beeps -On Power Up
If the scanner beeps 3 times on power up then, the nonvolatile memory that holds the scanner
configuration has failed. Return the unit for repair at an authorized service center.
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7-10
7.4 MS7320 Series Troubleshooting Guide
TABLE 2-TROUBLESHOOTING CHART
SYMPTOMS POSSIBLE CAUSE(S) SOLUTION
No LEDs, beep or motor
spin.
No power is being supplied to the
scanner
Check transformer, outlet and power strip. Make
sure the cable is plugged into thescanner
No LEDs, beep. No power is being supplied to the
scanner from host
Some host systems cannot supply enough current
to powerMS7600. Use the power supply included
with the scanner.
3 beeps on power up. Non-volatile RAM failure Contact a Metrologic Representative, if the unit
willnot hold the programmed configuration
Continuous razz tone on
power up.
RAM or ROM failure Contact a Metrologic Representative, if the unit
willnot function
Razz tone and green LED
flash at power up. VLD failure
Contact a Metrologic Representative
Razz tone and both LEDs
flash at power up. Scanner motor failure
Contact a Metrologic
Representative
There are multiple scans
upon presentation of a bar
code.
Same symbol timeout set too
short
Adjust same symbol timeout fora longer time
The unit powers up, but
does not beep
Beeper disabled. No volume is
selected. No tone selected
Enable beeper. Select volume. Select tone

7-11
TROUBLESHOOTING GUIDE (CONTINUED)
SYMPTOMS POSSIBLE CAUSE(S) SOLUTION
Scanning a particular symbology
that is not enabled
UPC/EAN, Code 39, interleaved 2 of 5, Code 93,
Code 128 and Codabar are enabled by default.
Verify that the type of bar code being read has
been selected
The unit powersup, but
does not scan and/or beep
The scanner has been
programmed fora character
length lock, or a minimum
length and the barcode being
scanned does not satisfy the
programmed criteria.
Verify that the bar code being scanned falls into
the programmed criteria. (Typical of Non-
UPC/EANcodes. The scanner defaults to a
minimum of 4 character bar code.)
The unit scans a bar code,
but locks up afterthe first
scan (red LED stays on)
The scanner is configured to
support some form of host
handshaking but is not receiving
the signal
If the scanner is setup to support ACK/NAK,
RTS/CTS, XON/XOFF or D/E, verify that
the host cable and host are supporting the
handshaking properly
The unit scans,but the data
transmitted to the host is
incorrect
The scanner’s data format does
not match the host system
requirements
Verify that the scanner’s data format matches that
required by the host. Make sure that thescanner is
connected to the proper host port
The print quality of the bar code
is suspect
Check the character length lock.
Scanner beeps at some bar
codes and NOT for others
of the same bar code
symbology
The aspect ratio of the bar code
is out of tolerance
Check print mode. The type ofprinter could be
the problem. Change print settings. Forexample
change to econo mode or high speed