Star Micronics TUP400 Series User manual

THERMAL PRINTER
TUP400 Series
TECHNICAL MANUAL
[SECOND EDITION]

NOTICE
•All rights reserved. Reproduction of any part of this manual in any form whatsoever, without
STAR’s express permission is forbidden.
•The contents of this manual are subject to change without notice.
•Alleffortshavebeenmadetoensuretheaccuracyofthecontentsofthismanualatthetimeofgoing
to press. However, should any errors be detected, STAR would greatly appreciate being informed
of them.
•The above notwithstanding, STAR can assume no responsibility for any errors in this manual.
© Copyright 1997 Star Micronics Co.,Ltd.

• First edition : Aug.1997
• Second edition : Jun. 1998 Add interface board Ver. 2
Model Name
TUP 4 5 2 V2 D — 24 NL
No Transparent Laser
Voltage
24 : 24 VDC
Interface
D: RS232C
C: Parallel
K: RS422A
Board type
None:Ver.1
V2:Ver.2
Mechanism type
2: 40 columns
Printer type
5: Guilotine Type Full Cutter
8: Guillotine Type Full Cutter + Presenter
TUP400-series thermal printer
INTRODUCTION
This manual was created as a reference for maintenance of the Thermal Printer TUP400 Series for
personnelwhoare responsibleforperiodic inspectionsortroubleshooting ofthatequipment. This manual
was written for maintenance personnel, and was not intended to be used by the general operator.
This manual is organized into the following chapters.
Chapter 1 Specifications and Operation
Chapter 2 Theory of Operation
Chapter 3 Parts Replacement and Related Adjustments
Chapter 4 Maintenance and Lubrication
Chapter 5 Parts Lists
1
5
4
3
2

This page was intentionally left blank.

CHAPTER 1
SPECIFICATIONS AND OPERATION
1. General Specifications ....................................................................................... 6
2. External Appearance .......................................................................................... 7
3. DIP-Switch Settings ............................................................................................8
4. Print-Density Adjustment ................................................................................. 11
5. Sensor Adjustment ........................................................................................... 12
6. HEX Dump Mode/Test Print..............................................................................13
7. Changing the Interface Board.......................................................................... 14
1

– 6 –
1. General Specifications
Printing method Line thermal direct
Resolution 8 dots/mm (H) ×8 dots/mm (V)
Printable width 50 mm in Line Mode; 80 mm in Page Mode
Printing speeds 2 Inches/sec and 1 Inch/sec
Printable characters Page mode: ANK, International, Slash zero
Line mode: ANK, International, Special, Block graphics, IBM special,
IBM block graphics, Chinese characters, Slash zero
NOTE: ANK is comprised of ASCII characters and Japanese katakana characters.
Character matrixes Page mode
Small 8×16
Standard 16×24
Wide 24×32
OCR-B 16×24
Chinese chara. 24×24
Line mode
IBM block graphic 12×24 or 12×32
Chinese chara. 24×24 (12×24)
All others 12×24
Bar Codes JAN, EAN, UPC, Code39, ITF, Code93, Code128, NW-7
Paper
Recommended brands TF50KS-E, TF62KS-E (Nippon Paper Industries)
KP50-HEAEX (New Oji Paper Co., Ltd.)
Width 82.5 mm(3.25 inches)
Thickness General thermal paper 60 to 85 µm
Roll diameters External 203 mm max. (8 Inch), Internal 32 mm (1.26 Inch)
Interface RS232C, RS422A, or Parallel
MCBF 5,000,000 Lines
Head longevity 100 Km or 1.0 x 108pulses(excludes damaged caused by dirt or foreign objects.)
(Missing dots is Max. 5%. However, there will be no missing dots up to 50Km.
This is the point where the thermal body resistor value varies more than 15% of the
initial value when continuously printing up to 12.5% of the printing rate.)
Cutter longevity 300,000 cuts (One piece max. paper thickness: 85 µm.)
Power supply DC 24 V ±7%
Power consumption Max. 120 W
Operating environment Temperature 5°C to 40°C
Humidity 25% to 80% (No condensation)
Storage environment Temperature -20°C to 60°C
Humidity 10% to 90% (No condensation)
Fig. 1-1 External Dimensions
164mm
164mm
299mm
254mm
356mm
Approximately 3.3kg
Approximately 3.1kg
254mm
TUP452 TUP482
0
-1

– 7 –
Fig. 1-2-b Internal Configuration (TUP482)
Arm
Printer head
Presenter
Fig. 1-2-a Internal Configuration (TUP452)
2. External Appearance
Printer head
Arm
Cutter

– 8 –
3. DIP-Switch Settings
DIP switches are located on the interface board and they differ according to the type of interface.
(1) Setting the DIP Switches
1. Turn the power supply OFF.
2. Remove the screw holding the ROM cover in place. (The screw is located at the base of the paper-roll holder.)
3. Remove the ROM cover to expose the main and interface PCBs
4. Set the DIP-switches on the interface board.
Fig. 1-3 DIP-Switch Settings
DIP Switches
VP4 (Black Mark Sensor)
EPROM
Main Logic Board
VP3 (Paper End Sensor)
Interface Board (RS-232C)
Fig. 1-4 Main Interface Board

– 9 –
2. DIP-switch values
(1) RS-232C interface
This board has a single 8-bit DIP switch.
Switch Setting ON OFF
1-1 Baud
1-2
1-3 Handshake DTR XON/XOFF
1-4 Data 8 bits 7 bits
1-5 Parity No parity Enabled
1-6 Parity Odd Even
1-7 DC1/DC3 Disabled Enabled
1-8 Power ON
Baud 1-1 1-2
2400BPS OFF OFF
4800BPS OFF ON
9600BPS ON ON
19200BPS ON OFF
Mode 1-8 ON Power On
DC1/DC3 Disabled Disabled Printer selected
DC1/DC3 Disabled ON Printer selected
OFF Printer de-selected
Addressable ON Printer de-selected
OFF Printer selected
*1 The old type is selected.

– 10 –
(2) RS-422A interface
This board had two DIP switches: one 8-bit switch and one 4-bit switch.
DIP switch #1 (8 bits):
Identical to the DIP switch on the RS-232C. (Bit 1-7 is disabled.)
DIP switch #2 (4 bits):
SW2-1 SW2-2 SW3-3 SW2-4
DC1,3 off ON ON ON ON
Address #1 OFF ON ON ON
#2 ON OFF ON ON
#3 OFF OFF ON ON
#4 ON ON OFF ON
#5 OFF ON OFF ON
#6 ON OFF OFF ON
#7 OFF OFF OFF ON
#8 ON ON ON OFF
#9 OFF ON ON OFF
#10 ON OFF ON OFF
#11 OFF OFF ON OFF
#12 ON ON OFF OFF
#13 OFF ON OFF OFF
#14 ON OFF OFF OFF
DC1,3 mode on OFF OFF OFF OFF
* DIP-SW #2 overrides the DIP-SW #1 DC1/3 setting (bit 1-7).
* DIP-SW #2 factory setting: All ON
(3) Parallel (Centronics) interface
The parallel-interface board has no DIP switches.

– 11 –
4. Print-Density Adjustment
Adjust the print density in accordance with the sensitivity of the paper being used.
Fig. 1-5 Print-Density Adjustment
1. The variable resistor is located to the left of the interface connector on the back side of the printer.
2. Use a phillips screw driver to rotate the variable resistor to adjust the print density. The variable resistor will
rotate approximately 180°.
If you are not getting a good print on the thermal paper with the density set to its maximum at 2 Inch/sec print
speed, set the print speed to 1 Inch sec.
CAUTION
Avoid setting density too high for sensitive paper types. Excessive dark values may cause the paper
to swell which will degrade the quality of the image.
Variable Resistor
Approx. 90
Light Dark
Approx. 90

– 12 –
5. Sensor Adjustment
You must adjust the paper sensor for the paper quality and the black mark print.
Fig. 1-6 Sensor Adjustment
1) Remove the screw on the underside of the paper-roll holder and remove the ROM cover.
2) Turn ON the power supply while holding down the push switch on the Near-end Sensor Board.
Remove the push-switch within 3 seconds after the "HU" LED on the Near-end Sensor Board lights.
CAUTION
If you continue holding the push switch for more than 3 seconds, the "PE" LED will light and you will not
be able to make any adjustments.
3) Black Mark Sensor
• Insert a piece of paper into the mechanism’s sensor area. Set it anywhere but the book mark area.
• Rotate the variable resistor VR4 on the main logic board until the "HU" LED on the Near-end Board lights.
Paper End Sensor
• Insert a piece of paper into the mechanism’s sensor area. Set it anywhere but the book mark area.
• Rotate the variable resistor VR3 on the main logic board until the "PE" LED on the Near-end Board lights.
4) After the LED lights, press the RESUME switch.
VR4
EPROM
Main Logic Board
VR3
Interface Board

– 13 –
6. HEX Dump Mode/Test Print
You can enter the HEX Dump Mode and run Test Prints by turning ON the power supply while pressing the RESUME
switch. The HEX Dump mode prints the data sent from the host computer in HEX data format.
1) Turn ON the power supply while pressing the RESUME switch.
2) Release the RESUME switch using the following timing to set each mode.
Releasing at a: HEX Dump Mode
Releasing at b: Test Print
2 Sec
ab
HU Lights PE Lights
Near-end Sensor Board LED

– 14 –
7. Changing the Interface Board
You can change the printer’s interface by replacing the interface board.
Fig. 1-7 Changing the Interface Board
1. Turn the power supply OFF.
2. Remove the 2 Interface Board Screws.
3. Remove the Interface Board.
4. Insert the new Interface Board by pushing it along the guides.
Push until the connector is completely inserted.
5. Attach the 2 screws to attach the Interface Board to the printer.
(Note)
The printer will automatically recognize the new Interface Board when it has been changed.

CHAPTER 2
THEORY OF OPERATION
This chapter describes the operating principles of the circuitry and printer mechanism.
1. Block Diagram ................................................................................................... 16
2. Main Logic Board ..............................................................................................18
2-1. Data I/O Circuitry .................................................................................................. 18
2-1-2.RS-422A Interface............................................................................................ 19
2-1-3. Parallel Interface.......................................................................................... 20
2-2. Editing and Printing ............................................................................................. 21
2-2-1. Editing .......................................................................................................... 21
2-2-2. Thermal Head............................................................................................... 21
2-2-3. Head Current Control .................................................................................. 22
2-3. Feed-Motor Drive Circuit...................................................................................... 23
2-4. Power-On Reset Circuit ....................................................................................... 24
2-5. +5V Line Voltage Detector Circuit....................................................................... 25
3. Printer Mechanism ............................................................................................26
3-1. Thermal Head........................................................................................................ 26
3-2. Paper-Feed Mechanism ....................................................................................... 26
3-3. Sensor ................................................................................................................... 27
2

– 16 –
1. Block Diagram
The following is the block diagram for this printer.
(16)
(16)
(8)
(8)
(16)
24V
Data (Host Computer)
Near-end
Sensor Board
RESUME
Switch
Main Logic Board
Gate Array
CPU
DC-DC Coverter
Power Supply Unit
EPROM
128 k x 16 Bit (Ver. 1)
250 k x 16 Bit (Ver. 2)
PS-RAM
128 x 16 BitPS-RAM
S-RAM
8K x 8 BitS-RAM
Chinese Char. ROM
256 k x 16 Bit (Ver. 1)
512 k x 16 Bit (Ver. 2)
EEPROM
Head Driver
Motor Driver
Cutter Driver
Sensor Circuit
Presenter
Driver
Thermal
Head
Print Mechanism
Paper
Feed
Motor
Cutter
Sensor
Presenter
Interface Board
RS-232C, RS-422A, Parallel
Fig. 2-1 Block Diagram

– 17 –
(1) Main Logic Board
The interface board relays data from the host computer to the main logic board. The main logic board’s CPU
temporarily stores the data into local RAM.
It then reads out the data, edits it according to the control program stored in the board’s ROM, and prints the results
by issuing the appropriate drive signals to the printer mechanism.
[Block Description]
a. CPU: HD641300F, CMOS single-chip computer
Controls overall printer operation.
b. EPROM
Contains the program and character fonts (other than Chinese characters) for CPU control.
c. PS-RAM: 128 K ×16 bits
Used as the work area and data buffer
d. S-RAM 8 K ×8 bits
Saves format data and externally defined characters.
e. EEPROM: 1024 bits
Stores printer settings. Settings can be changed by software. (Used in place of dip-switches.)
f. Gate array
Executes various types of signal processing.
g. Drivers
ThevariousdriversconvertsignalsreceivedfromtheCPUandgatearrayintothedrivesignalsthatdirectlycontrol
the printer mechanism.
h. DC-DC converter
Converts 24V to 5V.
(2) Interface board
Interfaces the main board with the host computer.
There are three versions, each for a different interface type: RS-232C, RS-422A, or Centronics parallel.
(3) Near-end sensor board
a. Checks the amount of paper remaining on the paper roll.
b. Used to adjust the sensor.
c. Displays errors using the LED.
(4) RESUME Switch
a. Used to set paper.
b. Used in HEX Dump output and test prints.
(5) Printer Mechanism
The printer mechanism is composed of the thermal head, paper feed motor, cutter sensors and presenter (only on the
TUP482.)

– 18 –
2. Main Logic Board
2-1. Data I/O Circuitry
The main logic board relays data back and forth to the host computer via the interface board.
2-1-1. RS-232C Interface
Fig. 2-2 RS-232C Interface
Data from host to printer passes through the IC1 on the interface board from the RXD terminal and is input to the CPU on
the main logic board.
IC1 converts the RS-232C and TTL voltage levels.
The CPU converts the input serial data to parallel data and stores that data in the memory buffer memory. It also converts
the internal parallel data to serial data and outputs that to the IC1.
The CTS line is hardware-connected, but the connection is not recognized by software. (The printer does not monitor the
signal.)
D2O
D1O
R1I
R2I
D2I
D1I
R1O
R2O
B12
B14
A15
B15
ACKDTR
R-CH
TXD
RXD
CTS
TXD0
RXD0
RXD1
CN3 CN1
IC1
CN9 IC10
IC5
Gate
Array CPU
HD151232FP
RS-232C Interface Board Main Logic Board
B12
B14
A15
B15

– 19 –
2-1-2. RS-422A Interface
Fig. 2-3 RS-422A Interface
Data flow from host to printer passes from the RD terminal to the IC1 on the interface board and is input to the CPU.
The IC1 converts the RS-422A and TTL voltage levels.
The CPU converts the input serial data to parallel data and stores that data in the memory buffer memory. It also converts
the internal parallel data to serial data and outputs that to the IC1.
D2O
D1O
D2EN
D2I
D1EN
D1I
ERROR
ACK
RD (+)
RD (–)
CS (+)
CS (–)
RS (–)
RS (+)
SD (–)
SD (+)
CN3 CN1
IC1
+
–
+
–
Gate
Array
CN9 IC10
R2I
+
R2I
–
R1I
+
R1I
–
D2O
D2O
D1O
D1O
RXD0
TXD0
RXD1
CPU
IC5
A15
B15
A10
B12
B14
A15
B15
A10
B12
B14
MC34051
RS-422A Interface Board Main Logic Board

– 20 –
2-1-3. Parallel Interface
Fig. 2-4 Parallel Interface
The host computer sends eight bits of data for DATA 1 - 8 to the CN3 connector when the BUSY signal is LOW (printer
is ready).
The data passes through the interface board and gate array, then moves into the CPU.
PrintersignalsfromtheCPU(ACK,ERROR,SELECTED,PAPEROUT,etc.)pass throughthegatearrayandareoutput
the appropriate connector pins.
DATA 1
DATA 2
DARA 3
DATA 4
DATA 5
DARA 6
DATA 7
DATA 8
STROBE
BUSY
ACK
ERROR
SELECTED
PAPER OUT
A4
B4
A5
B5
A6
B6
A7
B7
A13
A12
B12
A10
A11
B11
CN3
CPU
CN1
IC5
CN9
A4
B4
A5
B5
A6
B6
A7
B7
A13
A12
B12
A10
A11
B11
Gate Array
IC10
LS05
IC1
CD0
CD1
CD2
CD3
CD4
CD5
CD6
CD7
CSTB
BUSY
ACK
ERROR
SELECT
POUT
Parallel Interface Board Main Logic Board