TSC TDP-643R Plus series User manual

TDP-643R PLUS
SERVICE
MANUAL
DIRECT THERMAL BAR CODE PRINTER

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
- i -
Table of Contents
1. FUNDAMENTALS ABOUT THE SYSTEM ..............................................................1
1.1 Overview..........................................................................................................................1
1.1.1Front View..............................................................................................................1
1.1.2 Rear view ..............................................................................................................2
1.2 Printer Specification.........................................................................................................3
1.2.1 Printer....................................................................................................................3
1.2.2 Indicators and Button............................................................................................3
1.2.3 Communication Interface......................................................................................3
1.2.4 Power Requirement...............................................................................................4
1.2.5 Environment..........................................................................................................4
1.2.6 Dimensions............................................................................................................4
1.3 Communication Interface.................................................................................................5
1.3.1 Serial Interface ......................................................................................................5
1.3.2 Parallel Interface ...................................................................................................6
1.4 Available Bar Codes.........................................................................................................6
1.5 Effective Print Area..........................................................................................................7
2. SUPPLY SPECIFICATIONS....................................................................................8
2.1 Types of Paper..................................................................................................................8
2.2 Specifications...................................................................................................................8
3. ELECTRONICS.....................................................................................................10
3.1 Circuit Description.........................................................................................................10
3.2 MCU Pin Description.....................................................................................................12
3.3 Reset Circuit...................................................................................................................14
3.4 Memory System.............................................................................................................14
3.5 Sensor & key..................................................................................................................15
3.6 Real-Time Clock Circuit................................................................................................16
3.7 Decode Circuit ...............................................................................................................16
3.8 Thermal Head Drive/Protection and History Control Circuit........................................18
3.9 24V/5V Converter Circuit..............................................................................................19
3.10 Stepping Motor Driver /Protection Circuit...................................................................19
3.11 Communication (Serial & Parallel Port) Circuit..........................................................21
3.12 Cutter Drive Circuit......................................................................................................22
4. MECHANISM........................................................................................................23
4.1 Mainboard Replacement ................................................................................................23
4.2 Stepping Motor Driver IC Replacement ........................................................................25
4.3 Print Head Replacement.................................................................................................26

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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4.4 Stepping Motor Replacement.........................................................................................27
4.5 Gap Sensor Transmitter/Receiver Replacement.............................................................29
4.6 Platen and Teflon Tube Replacement.............................................................................30
5. TROUBLE SHOOTING.........................................................................................32
5.1 Error Messages...............................................................................................................32
5.2 Trouble Shooting............................................................................................................33
5.3 Self Test and Gap Sensor Calibration ............................................................................33
5.4 Initialization ...................................................................................................................33
5.5 Diagnosis Operation Procedure......................................................................................34
5.6 Testing Sensor ................................................................................................................34
5.6.1 Checking Gap Sensor..........................................................................................34
5.6.2 Checking Peel Off Sensor ...................................................................................34
5.7 Cleaning the Print Head .................................................................................................35

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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1. FUNDAMENTALS ABOUT THE SYSTEM
1.1 Overview
1.1.1Front View
Fig. 1-1 Front View of TDP-643R PLUS
1. ERROR Indicator
2. READY Indicator
3. FEED Button
4. Label Dispense Opening
1
2
3
4

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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1.1.2 Rear view
Fig. 1-2 Rear View of TDP-643R PLUS
1. Label Insert Opening
2. Power Switch
3. Power Jack
4. Centronics Interface Connector
5. RS-232 Port
1
2
3
4
5

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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1.2 Printer Specification
1.2.1 Printer
Type
Direct Thermal Printing
Resolution
203 DPI ( 8 dots per mm)
Printing speed
1.5”, 2”, or 3”/sec
Font styles
Five alphanumeric Fonts from 0.059”H (1.5 mm) to 0.23”
(6.0mm), expendable vertically and horizontally up to 8X.
Smooth fonts may be download from Windows label
design software
Bar Codes
Code 39, Code 93, Code 128 UCC, Code 128 (Subsets A,
B, C), Codabar, Interleaved 2 of 5, EAN-8, EAN-13,
UPC-A, UPC-E, EAN and UPC with 2 digits add-on
2D bar codes
PDF-417, Maxicode, DataMatrix
Graphics
Mono PCX format
1.2.2 Indicators and Button
Indicators
READY, ERROR
Button
FEED
1.2.3 Communication Interface
Communication
RS-232C (DB-9) at 2400, 4800, 9600, 19200 baud rate and
standard Centronics interface.
Character set
ANSI ASCII character set
Word Length
7 or 8 data bits, I start bit, 1 or 2 stop bits, and even, odd or
none parity.
Handshaking
Xon/Xoff and DSR/DTR
Input Buffer
60KB

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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1.2.4 Power Requirement
Input Voltage
Switching power, 100-240 VAC, 50-60 Hz
Output Voltage
24 VDC
Circuit Protection
2A maximum
1.2.5 Environment
Operation Temperature
41OF~ 95OF ( 5OC ~35OC)
Storage Temperature
-4OF ~ 140OF ( -20OC ~60OC)
Operation Humidity
30%~85% non-condensing
Storage Humidity
20%~95% non-condensing
Ventilation
Free air movement
1.2.6 Dimensions
Size
220 mm (W) x 263 mm (L) x 180 mm (H)
8.3”(W) x10.3”(L) x 7.1”(H)
Weight
1.67kg

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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1.3 Communication Interface
The TDP-643R PLUS bar code printer is designed to work with any kind of
computer device that is capable of generating ASCII output data. Depending on
the model, the printer can be connected to a computer via its standard RS-232 or
Centronics interface.
1.3.1 Serial Interface
The serial port of TDP-643R PLUS bar code printer is factory set to 9600 baud,
no parity, 8 data bits and one stop bit using Xon/Xoff protocol as well as
DSR/DTR handshaking.
When using an MS-DOS computer, you may want to include the following two
lines in your AUTOEXEC.BAT file in order for the computer to automatically
execute the commands when turned on:
MODE COM1: 96,N,8,1
MODE LPT1:=COM1;
The commands above will configure and direct the serial output to COM1 serial
port. If you are to use different ports, make appropriate substitutions.
The following table shows the pin assignments of the TDP-643R PLUS RS-232
serial interface. Cable: DB9 Male to DB9 Female (PC) straight pin to pin
connection or DB9 male to DB25 Female.
25
pin
9
pin
Host
function
9
pin
Printer
Function
3
2
RxD
2
TxD
2
3
TxD
3
RxD
20
4
DTR
4
N/C
7
5
GND
5
GND
6
6
DSR
6
RDY
4
7
RTS
7
N/C
5
8
CTS
8
RDY

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SERVICE MANUAL
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1.3.2 Parallel Interface
Connector Type: Centronics 36-pin
Pin
Function
Transmit
1
/Strobe
Host
2-9
Data 0~7
Host
10-11
Busy
Printer
12
Paper empty
Printer
13
Connect to 5V DC
Printer
14-16
N/C
---
17
Ground
---
18
N/C
---
19-30
/ERROR
Printer
31
Ground
---
32
N/C
Printer
33-35
Ground
---
36
N/C
---
1.4 Available Bar Codes
Code 39
Code 93
Code 128 UCC
Code 128, Subsets A, B, and C
Codabar
Interleaved 2 of 5
EAN-8, EAN-13, EAN-128
UPC-A, UPC-E
EAN and UPC with 2 digits add-on
UPC Shipping container code
Maxicode
PDF-417
DataMatrix

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SERVICE MANUAL
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1.5 Effective Print Area
Label/Ticket Length
12mm~2286mm
Effective Print Length
10mm~2284mm
Label/Ticket Width
25.4mm~114mm
Effective Print Width
23.4mm~112mm
No Print Area
1mm

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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2. SUPPLY SPECIFICATIONS
2.1 Types of Paper
Two types of media are available for TDP-643R PLUS: label and tag.
In TDP-643R PLUS, there are two types of sensors for paper: gap sensor and black
mark sensor.
Label and tag can be further classified into direct thermal type or thermal transfer
type.
2.2 Specifications
Items
Label
Paper Width
Max.114mm
Min. 25.4mm
Length (Pitch)
10 ~ 2286mm
Thickness
0.06 mm –0.25 mm
Max. Roll Diameter
(1” core)
5" (127mm)
Roll Up Method
Print surface wound outside as standard
Paper Core ID.
25.7±0.3mm
Note: (1). The width and thickness quoted above are said of the label plus its
backing paper.
(2). Likewise, the approval of label entails that of its backing paper.
(3). In the peel off mode, the minimum pitch is 35mm.
(4). In the cutter mode, it is required the paper be wound outside. Otherwise, paper
jam tends to result.
(5). In the cutter mode, the paper thickness is 0.2 mm at maximum, the
paper weight is 100 g/m2at maximum.
(6). Paper shape is as shown on next page.
(7) Tag is 0.2mm in thickness, and is less than 240g/m2in weight.

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SERVICE MANUAL
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TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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3. ELECTRONICS
3.1 Circuit Description
Fig. 3.1 MCU Circuit Diagram
The above is the MCU circuit diagram.
The main board of TDP-643R PLUS includes five system blocks:
A. Memory System (decoder & memory block)
B. Motor System (stepping motor and cutter block)
C. Print head System
D. Communication Port System (serial & parallel port block)
E. Power System
F. Sensor System

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SERVICE MANUAL
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The figure below shows the PCB system area:
Fig. 3.2 System Block of PCB
MCU
Memory
System
Power System
Communication
Port System
Real Time
Clock
Cutter System
Motor System
Decoder
System
Print Head
System
Sensor
System

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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3.2 MCU Pin Description
Port
I/O
Initial
High
Low
Function
Instruction
PA0
I
Pull Up
RXD0
RXD for RS232
PA1
O
TXD0
TXD for RS232
PA2
I
Pull Up
PA2
RTS for RS232
PA3
O
PA3
CTS for RS232
PA4
O
TXD1
DI for TPH
PA5
O
SCK1
CLK for TPH
PA6
O
Pull Up
Active
/CS2
/CS2
PA7
O
Pull Up
Active
/CS3
/CS3
PA8
I
Active
IRQ2
Power down
PA9
I
Pull Up
Active
IRQ3
USB_INT
PA10
O
Pull Up
Active
/CS0
/CS0
PA11
O
Pull Up
Active
/CS1
/CS1
PA12
O
/WRL
/WRL
PA13
O
/WRH
No use
PA14
O
/RD
/RD
PA15
O
Pull Up
Enable
PA15
/LAT for TPH
PB0
O
A16
A16
PB1
O
A17
A17
PB2
O
/RAS
/RAS
PB3
O
/CASL
/CASL
PB4
O
/CASH
/CASH
PB5
O
RDWR
RDWR
PB6
O
A18
A18
PB7
O
A19
A19
PB8
O
A20
A20
PB9
O
A21
A21
PC0~PC1
5
O
A0~A15
A0~A15
PD0~PD1
5
I/O
D0~D15
D0~D15
PE0
O
PWM
Enable
TIOC0A
GAP LEVEL
PE1
I
Pull Up
PE1
KEY3
PE2
I
Pull Up
Enable
PE2
CASE OPEN
PE3
I
Pull Up
Enable
PE3
/STTOBE for Centronic port
PE4
O
PWM
Enable
TIOC1A
DCM for DC motor enable
PE5
O
Pull Up
Enable
PE5
STB1 for TPH
PE6
I
Pull Up
Enable
PE6
DC SENS for DC sensor
PE7
O
Pull Up
Enable
PE7
STB2 for TPH
PE8
I
Pull Up
PE8
KEY2
PE9
I
Pull Up
PE9
KEY1
PE10
O
Pull Up
Enable
PE10
STB3 for TPH
PE11
I
Pull Up
Enable
PE11
CT SENS for cutter sensor
PE12
I/O
Pull Up
PE12
SUSPEND for USB

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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PE13
O
Pull Up
Enable
PE13
STB4 for TPH
PE14
I/O
PE14
RTC I/O
PE15
I
Pull Up
Enable
PE15
HEAD SENS
PF0
I
PF0
Vdet for TPH Voltage detect
PF1
I
PF1
TM for TPH temperture
PF2
I
Enable
PF2
MEM load & Hardware version
PF3
I
PF3
CT DETECT
PF4
I
PF4
PEEL SENS
PF5
I
PF5
RIBBON SENS
PF6
I
PF6
BM SENS
PF7
I
PF7
GAP SENS
NMI
I
Pull Up
NMI
No use
/RESETP
I
Pull Up
Active
/RESETP
/RESET
/WDTOVF
O
/WDTOVF
No use
IRQ0: NO USE
IRQ1: NO USE
IRQ2: Power down
IRQ3: USB_INT
IRQ4: NO USE
IRQ5: NO USE
IRQ6: NO USE
IRQ7: NO USE
Other define
1. System Crystal is 16 MHz.
2. USB Crystal is 48MHz.
3. RTC Crystal 32.768KHz.
4. MCU mode is mode 1.(16-bit space) ( MD0 is high, MD1 is low. )
Clock mode is PLL ON x 4. (MD2 is low, MD3 is High.)

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SERVICE MANUAL
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3.3 Reset Circuit
Fig. 3.3 Reset Circuit
This is the reset circuit .The TS809CXA IC outputs the system reset signal of
“LOW” when the driving voltage is lower than 4.63V (Typical).
3.4 Memory System
Fig. 3.4 FLASH ROMS and DRAM Diagram
This is the memory circuit. The U8 is 2M Byte FLASH ROM and U10 is 2M Byte
DRAM.

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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3.5 Sensor & key
Fig. 3.5 Semsor & Key Circuit Diagram
A.
JP1 is the connector which connects to the LEDs and Keys.The signal of LED is High
when the LED is bright; otherwise, it is low.
The signal of the key is low when the keys is press; otherwise, it is high.
B.
JP2 is the connector which connects to the gap sensor.
The gap sensor is a penetrable sensor. the gap sensor signal voltage is low when the
gap is detected; otherwise, it is high.
C.
JP4 is the connector which connects to the gap emitter level, the gap level is a emitter
source intensity control signal. It is a PWM signal.
Memory card
connector
Memory card
connector

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SERVICE MANUAL
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3.6 Real-Time Clock Circuit
Fig. 3.6 Real-Time Clock Circuit
HT1381 is serial time keeper.
3.7 Decode Circuit
Fig. 3.7 Decode Circuit

TDP-643R PLUS BAR CODE PRINTER
SERVICE MANUAL
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CS0: (0000 0000 ~ 003F FFFF)
CS1: (0040 0000 ~ 007F FFFF)
CS2: (0080 0000 ~ 00BF FFFF)
CS3: (00C0 0000 ~ 0FFF FFFF)
ROM1: (0000 0000 ~ 001F FFFF)
ROM2: (0020 0000 ~ 003F FFFF)
Memory card :(0040 0000~007F FFFF)
Download ROM: (0800 0000 ~ 09F FFFF)
DRAM: (0100 0000~011F~FFFF)
Other Map
Address
Bit
Function
00C0 0000
MOTOR DATA
0
PHASE1
1
PHASE2
2
I0
3
I1
4
/CT EN
5
DC PHASE
6
TPH EN
7
BUZZER
00E0 0000
/CENTRONIC DATA
0
P_D0
1
P_D1
2
P_D2
3
P_D3
4
P_D4
5
P_D5
6
P_D6
7
P_D7