TSC TDP-245 Series User manual

TDP-245
SERVICE
MANUAL
DIRECT THERMAL BAR CODE PRINTER

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1. OVERVIEW ......................................................................................................................................1
1.1 Front View...................................................................................................... 1
1.2 Rear View....................................................................................................... 1
1.3. Specification................................................................................................. 2
1.3.1. Printer ............................................................................................................ 2
1.3.2. LED............................................................................................................... 3
1.3.3. Button Operation............................................................................................ 3
1.4. Supply Specification.................................................................................... 7
1.4.1. Paper.............................................................................................................. 7
2. ELECTRONICS................................................................................................................................8
2.1. Circuit Description....................................................................................... 8
2.2. MCU Circuit and MCU PIN Description..................................................... 10
2.2.1. MCU PIN Description:..................................................................................11
2.3. Reset Circuit............................................................................................... 16
2.4. Memory Circuit........................................................................................... 17
2.5. Decoder Circuit .......................................................................................... 18
2.6. Memory Map ............................................................................................... 19
2.7. Print Head Circuit....................................................................................... 21
2.8. Stepping Motor Drive / Protection Circuit................................................ 22
2.9. Power Circuit.............................................................................................. 24
2.10. Parallel Interface Circuit .......................................................................... 25
2.11. Serial Interface Circuit ............................................................................. 27
2.12. USB Circuit ............................................................................................... 28
2.12.1. USB PIN Function ......................................................................................29
2.13. Sensor Circuit........................................................................................... 31
2.13.1. Gap and Black Mark Sensor ........................................................................31
2.13.2. Head Open Micro Switch ............................................................................32
2.13.3. Peel-off Sensor............................................................................................33
2.14. Cutter Drive / Protection Circuit.............................................................. 34
2.15 Summary of PCB connectors................................................................... 35
3. REPLACE and INSTALL IMPORTANT PARTS..............................................................................38
3.1. Replacing Top Cover.................................................................................. 38
3.2. Replacing Lower Cover and main PCB .................................................... 39
3.3. Replacing Platen Assembly....................................................................... 41
3.4. Replacing the Stepping Motor Assembly and Stepping Motor .............. 42
3.5. Replacing Label Guide Adjustment Knob Assembly .............................. 44
3.6. Replacing Gap/Black Mark Sensor Assembly ......................................... 46
3.7. Replacing Print Head Module Assembly.................................................. 47

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3.8. Replacing Head Open Micro Switch ......................................................... 48
3.9. Replacing Feed Button and Feed Button PCB......................................... 49
3.10. Set Up Memory Card................................................................................ 50
3.11. Peel-Off Installation (Option) Assembly ................................................. 51
3.11.1 Loading Label for Peel-off Mode (Option) ...................................................53
3.12. Cutter Module Installation (Option) ........................................................ 54
3.12.1 Loading Label in Cutter Mode......................................................................57
3.13 Internal Ethernet Print Server Module Installation (Option) .................. 58
4. PARTS LIST...................................................................................................................................61
4.1 Cover............................................................................................................ 61
4.1 Cover Drawing............................................................................................. 62
4.2. Main Board.................................................................................................. 63
4.2. Main Board Drawing................................................................................... 64
4.3. Top Inner Cover.......................................................................................... 65
4.3. Top Inner Cover Drawing........................................................................... 66
4.4 Lower Inner Cover....................................................................................... 67
4.4 Lower Inner Cover....................................................................................... 69
4.5 Stepping Motor Fixing Assembly............................................................... 70
4.5 Stepping Motor Fixing Assembly............................................................... 72
4.6 Option & Accessories................................................................................. 73
4.6 Option & Accessories Drawing.................................................................. 75
5. POWER ON UTILITIES ..................................................................................................................76
5.1. Gap/Black Mark Sensor Calibration.......................................................... 76
5.2. Gap/Black Mark Sensor Calibration；Self-test；Dump mode................ 77
5.3 Printer Initialization..................................................................................... 80
5.4 Black Mark Sensor Calibration .................................................................. 81
5.5 Gap Sensor Calibration .............................................................................. 81
5.6 Skip AUTO.BAS........................................................................................... 81
6. GAPAND BLACK MARK SENSOR SELECTION ..........................................................................83
7. TROUBLESHOOTING....................................................................................................................84
8. MAINTENANCE .............................................................................................................................87
Update History ..................................................................................................................................88

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1. OVERVIEW
1.1 Front View
1.2 Rear View
Top Cover Open Lever
Feed Button
Power LED
Clear Window
1. USB Interface
2. Centronics Interface
3. RS-232 Interface
4. Power Jack
5. Power Switch
6. Rear Paper Guide
1 2 3 4 5
6

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1.3. Specification
1.3.1. Printer
Item
Description
Mechanism
Head Density
Max. Print Width
Max. Print Length
Printing Speed
Printing Method
203 dpi
108 mm
1000 mm ( 39”)
2, 3, 4 and 5 ips selectable
2, 3 ips selectable for peel-off function
Direct thermal
Enclosure
Structure
Dimensions
Operation Panel
Double-walled plastic
Standard Model: 240mm(L) x 200mm(W) x 164mm(H)
One feed button and one indicator LED (green, orange,
red )
Hardware
Sensors
Gap transmissive sensor (offset 6 mm from center)
Black mark reflective sensor (position adjustable)
Head open micro switch
Memory
On-board flash ROM 2M bytes as standard
DRAM (2M bytes)
Interface
RS232 (max. baud rate 19,200 bps)
USB: V1.1
Centronics
Power
AC input: 100-240V universal switching power supply
DC output: 24V 3.75A(external adapter)
Firmware
Type Font
8 alpha-numeric bitmap fonts, 1 true type font
Rotation
0, 90,180 and 270 degrees
Barcode Format
1D bar code
Code 39, Code 93, Code 128UCC, Code128 subsets
A.B.C, Codabar, Interleave 2 of 5, EVN-8, EAN-13,
EAN-128, UPC-A, UPC-E, EAN and UPC2(5) digits
add-on, MSI, PLESSEY, POSTNET, China POST
2D bar code
PDF-417, Maxicode, DataMatrix, and QR code

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Command Sets
TSPL2, EPL2, DPL and ZPL
Environment
Operation
Temperature: 5℃~ 40℃
Relative Humidity: 25% ~ 85% (Non Condensing)
Storage
Temperature: -40℃~ 60℃
Relative Humidity: 10% ~ 90% (Non Condensing)
Others
Dealer Option
Peel-off panel assembly, memory card (2, 4, 6 and 8M
bytes).
Liner-less paper printing capability
Guillotine cutter: 118 mm width
Full cut: Paper thickness: 0.06 to 0.19mm, 500,000 cuts
Partial cut: Paper thickness: 0.06~0.12mm, 500,000
Cuts
Paper thickness: 0.19mm, 200,000 cuts
User Option
Keyboard display unit (KP-200, KU-007 series), External
LAN adapter, External roll mount (O.D. 214 mm with 1” or 3”
core).
1.3.2. LED
LED Color
Description
Green/ Solid
This illuminates that the power is on and the device is
ready to use.
Green/ Flash
This illuminates that the system is downloading data
from PC to memory and the printer is paused.
Amber
This illuminates that the system is clearing data from
printer.
Red / Solid
This illuminates printer head open, cutter error.
Red / Flash
This illuminates a printing error, such as paper empty,
paper jam, or memory error etc.
1.3.3. Button Operation
Feed
Press the button when the LED is green.
It feeds the label to the beginning of the next label.

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Pause
Press the feed button during printing.
The printing job is suspended.
Gap/Black Mark
Sensor Calibration
1.Turn off the power switch.
2. Hold on the button then turn on the power switch.
3 Release the button when LED becomes red and blinking.
(Any red will do during the 5 blinks).
It will calibrate the gap/black mark sensor sensitivity.
The LED color will be changed as following order：
Amber red (5 blinks) amber (5 blinks) green
(5 blinks) green/amber (5 blinks) red/amber (5
blinks) solid green
It calibrates the sensor and measures the label length.
Note:
Please select gap or black mark sensor by GAP or BLINE
command prior to calibrate the sensor.
For more information about GAP and BLINE command,
please refer to TSPL2 programming manual.
Gap/Black Mark
Sensor Calibratio,
Label Length
Measurement,
Self Test and enter
Dump Mode
1.Turn off the power switch.
2. Hold on the button then turn on the power switch.
3. Release the button when LED becomes amber and blinking.
(Any amber will do during the 5 blinks).
The LED color will be changed as following order.
Amber red (5 blinks) amber (5 blinks) green
(5 blinks) green/amber (5 blinks) red/amber (5
blinks) solid green
It calibrates the sensor and measures the label length
and prints internal settings then enter the dump mode.
Note:
Please select gap or black mark sensor by GAP or BLINE
command prior to calibrate the sensor.
For more information about GAP and BLINE command,
please refer to TSPL2 programming manual.

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Printer
Initialization
1. Turn off the power switch.
2. Hold on the button then turn on the power switch.
3. Release the button when LED turns green after 5 amber
blinks. (Any green will do during the 5 blinks).
The LED color will be changed as following:
Amber red (5 blinks) amber (5 blinks) green
(5 blinks) green/amber (5 blinks) red/amber (5
blinks) solid green
Always do gap/black mark sensor calibration after
printer initialization.
Force Black Mark
Sensor Calibration
1. Turn off the power switch.
2. Hold on the button then turn on the power switch.
3. Release the button when LED turns green/amber after 5
green blinks. (Any green/amber will do during the 5 blinks).
The LED color will be changed as following:
Amber red (5 blinks) amber (5 blinks) green (5
blinks) green/amber (5 blinks) red/amber (5
blinks) solid green
Force Gap Sensor
Calibration
1. Turn off the power switch.
2. Hold on the button then turn on the power switch.
3. Release the button when LED turns red/amber after 5
green/amber blinks. (Any red/amber will do during the 5
blinks).
The LED color will be changed as following:
Amber red (5 blinks) amber (5 blinks) green (5
blinks) green/amber (5 blinks) red/amber (5
blinks) solid green

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Skip AUTO.BAS
1. Turn off printer power.
2. Press the FEED button and then turn on power.
3. Release the FEED button when LED becomes solid green.
The LED color will be changed as following:
Amber red (5 blinks) amber (5 blinks) green (5
blinks) green/amber (5 blinks) red/amber (5
blinks) solid green
4. Printer will be interrupted to run the AUTO.BAS program.

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1.4. Supply Specification
1.4.1. Paper
Item
Specification
Type
Label (Continuous , Die-cut , Fan-fold)
Wound Type
Outside wound
Width
20mm ~ 112mm (0.79”~ 4.4”)
Length
(Peel-off and cutter mode)
10mm ~ 1000mm (0.4”~ 39”)
25.4mm ~ 1000mm (1”~ 39”)
Thickness
0.06mm ~ 0.19mm (max. 150g/m**2)
Roll Diameter
Max. 5”
Roll Core Diameter
25.4mm ~ 76.2mm (1”~ 3”)
Gap Height
Min. 2 mm (min.)
Black Mark Height
Min. 2 mm (min.)
Black Mark Width
Min 8 mm (min.)

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2. ELECTRONICS
2.1. Circuit Description
Fig. 2.1 Circuit Diagram
The main board of printer includes 9 system blocks:
1. MCU.
2. Memory System.
3. Decoder System.
4. Print Head System.
5. Motor System.
6. Power System.
7. Communication Interface System.
8. Sensor System.
9. Cutter System.

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The following figure shows the PCB system
Sensor System
Cutter System
Memory System
Motor System
Print
Head
System
Power System
Decoder System
Communication
Interface System
USB System
MCU

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2.2. MCU Circuit and MCU PIN Description
Fig. 2.2 MCU PIN Description Diagram

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2.2.1. MCU PIN Description:

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2.3. Reset Circuit
Fig. 2.3 Reset Circuit Diagram
80945 reset IC is used to detect the voltage. When the driving voltage is lower than
4.5VDC, reset will be enabled.

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2.4. Memory Circuit
Fig. 2.4 Memory Circuit Diagram
This is the memory circuit. The U6 & U7 are 2M Byte FLASH ROM and U8 is 2M
Byte DRAM.