UBI EasyCoder 501 SA User manual

UBI EasyCoder 501 – Service Manual
1
0. INTRODUCTION
UBI EasyCoder 501
Service Manual
Edition 5, May 1997
Article No. 1-960320-04
0.1 Contents
Continued!
0. Introduction 0.1 Contents ..........................................................................................1
0.2 Preface ............................................................................................5
0.3 Notices and Approvals ....................................................................6
1. Models and Options 1.1 Identification ...................................................................................7
1.2 Specifications ................................................................................13
1.3 Measures .......................................................................................14
2. Front and Keyboard 2.1 Front .............................................................................................15
2.2 Display/Keyboard .........................................................................16
2.3 Display Contrast Adjustment.........................................................16
2.4 Slides ............................................................................................17
2.5 Keyboard Interface Board; Components Diagram .........................18
2.6 Keyboard Interface Board; Circuit Diagram ..................................19
3. Hatches and Doors 3.1 Right-Hand Door ..........................................................................20
3.2 Front Hatch ...................................................................................21
3.3 Left-Hand Cover ...........................................................................22
4. Rear Plate 4.1 Description....................................................................................23
4.2 Devices on Rear Plate ...................................................................24
5. Paper Supply 5.1 Internal Supply ..............................................................................25
5.2 External Supply.............................................................................28
6. Label Slack Absorber 6.1 Description....................................................................................33
6.2 Dismantling...................................................................................34
7. Transfer Ribbon Mechanism 7.1 Description....................................................................................35
7.2 Ribbon Unwind Unit .....................................................................35
7.3 Ribbon Rewind Unit .....................................................................37
7.4 Ribbon End Sensor........................................................................39
8. Print Unit 8.1 Different Models ...........................................................................41
8.2 Main Parts .....................................................................................41
8.3 Pressing Roller ..............................................................................43
8.4 Stepper Motor ...............................................................................44
8.5 Tear-Off Edge ...............................................................................46
8.6 Label Stop Sensor (LSS) ...............................................................47
8.7 Printhead .......................................................................................50
8.8 Headlift Mechanism ......................................................................58
9. Paper Rewind Kit 9.1 Description....................................................................................61
9.2 Main Parts .....................................................................................63
9.3 Paper Rewind Unit ........................................................................64
10. Ribbon Save Device 10.1 Working Principles........................................................................65
10.2 Control ..........................................................................................66
10.3 Maintenance..................................................................................66
10.4 Transfer Ribbons...........................................................................67
10.5 Main Parts .....................................................................................67
10.6 Print Unit Assy..............................................................................68
10.7 Headlift Mechanism ......................................................................77
10.8 Ribbon Rewind .............................................................................80
10.9 Connection Board .........................................................................81

UBI EasyCoder 501 – Service Manual
2
0.1 Contents, cont'd.
0. INTRODUCTION, cont'd
Continued!
11. Label-Taken Sensor 11.1 Description....................................................................................83
11.2 Installation ....................................................................................84
11.3 Adjustments ..................................................................................86
12. Paper Cutter 12.1 Description....................................................................................87
12.2 Control ..........................................................................................88
12.3 Cleaning........................................................................................88
12.4 Installation ....................................................................................89
12.5 Spring Replacement ......................................................................90
13. Memory Card Adapter 13.1 Description....................................................................................91
13.2 Installation ....................................................................................96
13.3 Memory Card Types .....................................................................98
13.4 Inserting a Memory Card ..............................................................99
13.5 Removing a Memory Card ............................................................99
14. Sensor Kit 14.1 Description..................................................................................100
14.2 Installation ..................................................................................101
15. Scalable Fonts Kit 15.1 Description..................................................................................102
15.2 Installation ..................................................................................103
16. Transformer Unit 16.1 Description..................................................................................104
16.2 Dismantling.................................................................................105
16.3 Mains Connection Diagram.........................................................106
16.4 Wiring Diagram ..........................................................................106
17. CPU Board 17.1 Access to CPU Board ..................................................................108
17.2 Overview ....................................................................................109
17.3 Circuits and Straps ...................................................................... 111
17.4 Connections ................................................................................118
17.5 Components Diagram..................................................................119
17.6 Circuit Diagrams:
1. CG16 Master Processor ...........................................................120
2. A/D and I/O Circuits ...............................................................121
3. Interfaces to Printer Devices ....................................................122
4. Data Shiftout to Printhead........................................................123
5. HPC Slave Processor...............................................................124
6. Stepper Motor Drives ..............................................................125
7. ROM Memory.........................................................................126
8. RAM Memory.........................................................................127
9. "uart1:" Interface Circuits ........................................................128
10. Sensor Interfaces ...................................................................129
11. Data to Printhead ...................................................................130
12. Power to Printhead ................................................................131
13. Power ....................................................................................132
17.7 Test Points ..................................................................................133
1. ADS ........................................................................................133
2. NHOLD ..................................................................................133
3. VEE ........................................................................................133
4. /RESET ...................................................................................133
5. P24..........................................................................................133
6. V24 ......................................................................................... 133
7. +40V .......................................................................................133
17.8 Testing the CPU Board ...............................................................134

UBI EasyCoder 501 – Service Manual
3
0.1 Contents, cont'd.
Continued!
0. INTRODUCTION, cont'd
18. "UART1:" 18.1 Connector and Cables..................................................................135
18.2 RS 232C......................................................................................136
18.3 RS 422 ........................................................................................138
18.4 20 mA Current Loop ...................................................................140
19. Optional Interface Boards 19.1 Description.................................................................................. 143
19.2 Installation ..................................................................................144
20. Serial Interface Board 20.1 Description.................................................................................. 145
20.2 Straps ..........................................................................................146
20.3 Connector Configuration .............................................................147
20.4 Components Diagram..................................................................148
20.5 Circuit Diagrams .........................................................................149
21. RS 422/485 Interface Board 21.1 Description..................................................................................151
21.2 Straps ..........................................................................................153
21.3 Connector Configuration .............................................................155
21.4 Components Diagram..................................................................156
21.5 Circuit Diagram ..........................................................................157
22. Parallel Interface Board 22.1 Description.................................................................................. 158
22.2 Straps ..........................................................................................159
22.3 Connector Configuration .............................................................160
22.4 Components Diagram..................................................................161
22.5 Circuit Diagram ..........................................................................162
23. Industrial Interface Board 23.1 Description.................................................................................. 163
23.2 Straps ..........................................................................................164
23.3 Connector Configuration .............................................................165
23.4 Components Diagram..................................................................166
23.5 Circuit Diagrams .........................................................................167
24. Print Quality Adjustment 24.1 Test Labels ..................................................................................169
24.2 Possible Printout Troubles ...........................................................172
24.3 Mechanical Adjustments .............................................................173
25. Test Mode 25.1 Description.................................................................................. 178
25.2 EasyCoder/EasyPak 501 .............................................................178
25.3 EasyCoder/EasyPak 501, Test Mode Diagram ............................179
25.4 EasyCoder/EasyPak 501 E & SA ................................................180
25.5 EasyCoder/EasyPak 501 E, Test Mode Diagram.........................182
25.6 EasyCoder/EasyPak 501 SA, Test Mode Diagram.......................183
26. Trouble Shooting 26.1 Printer “Dead”.............................................................................184
- Mains power failure ..................................................................184
- Power supply failure .................................................................184
- Transformer and cabling failure ................................................185
- CPU board failure ..................................................................... 186
26.2 Single Function Failure ...............................................................188
- No display function ...................................................................188
- No keyboard reaction ................................................................188
- Error messages transmitted or displayed....................................189
- No memory backup storage.......................................................190
- No communication (general) .....................................................190
- No communication (standard serial interface) ...........................191
- Label (ticket) gap or black mark not detected ............................192
- Printhead lift sensor out of order ...............................................192
- Ribbon-end sensor out of order .................................................193

UBI EasyCoder 501 – Service Manual
4
0.1 Contents, cont'd.
0. INTRODUCTION, cont'd
26. Trouble Shooting, cont'd. 26.3 Printing Troubles.........................................................................194
- No printout at all .......................................................................194
- Overall weak printout................................................................ 195
- Overall too strong printout (bleeding)........................................195
- Weak or missing printout of some dots .....................................195
- All or most dots printed.............................................................196
- Printed line along dot row at startup ..........................................196
- Paper feed does not work .......................................................... 196
26.4 Transfer Ribbon Troubles............................................................198
- Transfer ribbon gets wrinkled....................................................198
- Transfer ribbon breaks .............................................................. 198
26.5 Paper Rewind Troubles ...............................................................199
26.6 Ribbon Save Device Troubles .....................................................200
- No transfer ribbon is saved........................................................200
- Transfer ribbon is not properly rewound ...................................200
- Jammed receiving face materials...............................................201
- Ribbon gets wrinkled or bad printout ........................................201
26.7 LTS Troubles .............................................................................. 202
26.8 Real-Time Clock Troubles ..........................................................202
26.9 Cutter Troubles ........................................................................... 203
26.10 Memory Card Adapter Troubles..................................................204
26.11 Sensor Kit Troubles.....................................................................205
26.12 Serial Interface Board Troubles ...................................................206
26.13 RS 422/485 Interface Board Troubles..........................................206
26.14 Parallel Interface Board Troubles ................................................207
26.15 Industrial Interface Board Troubles ............................................. 207
Appendix 1 Software Diagrams:
UBI Shell for EasyCoder Printers Without Keyboard..............................208
UBI Shell for EasyCoder Printers With Keyboard ..................................209
EasyCoder 501: Setup Overview ............................................................220
EasyCoder 501 E & SA: Setup Mode Overview, Part 1 ..........................211
EasyCoder 501 E & SA: Setup Mode Overview, Part 2 ..........................212
Appendix 2 Measuring the Break Torque ..................................................................213
Informationinthismanualissubjecttochangewithoutpriornoticeanddoesnotrepresentacommitment
on the part of UBI Printer AB.
© Copyright UBI PTC AB 1997. All rights reserved. Published in Sweden.
EasyCoder, LabelShop and EasyPak are trademarks of United Barcode Industries.
Bitstream is a registered trademark and Speedo is a trademark of Bitstream, Inc.
Centronics is a registered trademark of Centronics Data Computer Corp.
IBM is a registered trademark of International Business Machines Corporation.
Torx is a registered trademark of Camcar Division of Textron Inc.
TrueType is a trademark of Apple Computer Inc.
Windows is a trademark of Microsoft Corporation.

UBI EasyCoder 501 – Service Manual
5
0.2
Preface
0. INTRODUCTION, cont'd.
This Service Manual is intended to facilitate installation, trouble-
shooting and repair of the UBI EasyCoder 501 series of printers in
theversionsdeliveredatthedateofpublishing.Earlierversionsare
generally not described in this manual, but the on-going product
improvement can be followed in the Printer Technical Bulletins
from UBI PTC AB.
This Service Manual is supplemented by the following types of
publications, which the service technician also should keep easily
available:
•UBI EasyPak; Getting Started (for three different models)
•UBI EasyCoder 501; Operator's Guide (multilingual)
•UBI EasyCoder 501; User's Manual
•UBI Shell Standard and Enhanced; Startup Manuals
•UBI EasyCoder 501; Technical Manual
•UBI EasyCoder 501; Spare Parts & Options
•UBI EasyCoder 501; Installation Instructions
(for various options)
•UBI Direct Protocol; Programmer's Guide
•UBI Fingerprint; Programmer's Guide
•UBI Fingerprint; Reference Manual
•UBI Stand-Alone Concept; Operating Instructions
•UBI Windows Driver; Installation Instructions
Pleasenotethattheoperationsdescribedinthismanualonlyshould
be carried out by skilled and authorized personnel with proper
training and full understanding of written English. The printers
contain wires and circuits with 115/230V AC voltage, which
implies the risk of electrical shock. Moving parts may also cause
harm, if incorrectly manipulated.
Itisassumedthatthereaderpossessesreasonableskillsinmechan-
ics and electronics and is familiar with the UBI Fingerprint
programming language and its related standard application pro-
grams. It is also assumed that the reader has access to the standard
tools of an electronics workshop.

UBI EasyCoder 501 – Service Manual
6
0.3
Notices and Approvals
0. INTRODUCTION, cont'd
FCC Notice
United States of America
WARNING:
This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with
theinstructionsmanual,maycauseinterference toradio communications.Ithasbeentestedandfound tocomply withthe
limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide
reasonableprotectionagainstsuchinterferencewhenoperatedinacommercialenvironment.Operationofthisequipment
inaresidentialareaislikelytocauseinterferenceinwhichcasetheuserathisownexpensewillberequiredtotakewhatever
measures may be required to correct the interference.
DOC Notice
Canada
Canadian Dept. of Communication
REGULATIONS COMPLIANCE
(DOC-A)
This digital apparatus does not exceed the class A limits for radio noise emissions from a digital apparatus as set out in
the radio interference regulations of the Canadian Department of Communication.
✳ ✳ ✳
Ministère des Communications du Canada
CONFORMITE DE REGLEMENTS
(DOC-A)
Le présent appareil numérique n´émet pas de bruits radio-électriques dépassant les limites applicables aux appareils
numériques de classe A prescrites dans le règlement sur brouillage radioélectrique édicté par le Ministère des
Communications du Canada.
VDE Notice
Germany
Reparaturenoder sonstige Eingriffe, die sich nichtaufnormaleBedienungder Maschine beziehen, dürfen ausschließlich
nur von einem ausgebildeten, zuständigen Fachmann vorgenommen werden.

UBI EasyCoder 501 – Service Manual
7
1.1
Identification The EasyCoder 501 printers come in three different main models, which easily can be identified by their external appearance.
EasyCoder 501
has a single Print button on its front panel.
EasyCoder 501 E (Enhanced)
has a setup keyboard with 22 programmable keys.
EasyCoder 501 SA (Stand-Alone)
hasafullQWERTYkeyboardwithadditionalcontrolkeysadapted
for the UBI Stand-Alone program.
Continued!
Print
Power Ready Error
EasyCoder 501
1. MODELS AND OPTIONS
Caps Ins Del
456
Power Ready Error
EasyCoder 501 SA
Shift
ZXCVBNM,.
Space
ASDFGHJKL+
Clear
0
Enter
QWERTYUIOP123
Alt Pause Save Feed Esc
789
<>[]^;:ÖÄØ
§@~£'_*?–ÅÆ
|"#$%&/()=ÜßÙ
ÉÈÀ
Çѵ
Print
F1 F2 F3 F4 F5
Pause
Setup
Feed
Enter
789
456
123
.0C
Print
Power Ready Error
EasyCoder 501 E

UBI EasyCoder 501 – Service Manual
8
230V
0
MADE IN SWEDEN
Type
Art. No.
Ser. No.
115/230 V 2.6/1.3 A 50–60 Hz
TA
230V
0
MADE IN SWEDEN
Type
Art. No.
Ser. No.
115/230 V 2.6/1.3 A 50–60 Hz
TA
230V
0
MADE IN SWEDEN
MADE IN SWEDEN
Type
Art. No.
Ser. No.
115/230 V 2.6/1.3 A 50–60 Hz
TA
0
230V
MADE IN SWEDEN
Type
Art. No.
Ser. No.
115/230 V 2.6/1.3 A 50–60 Hz
TA
Themachinesignontheprinter'srearplateprovidesinformationon
type, article number and serial number.
Thevoltageswitchindicatesthemainsvoltageforwhichtheprinter
is set up (115 or 230 V AC). Always check this switch before
connecting the printer!
Youcanalsodetectiftheprinterisfittedwithanyoptionalinterface
board by means of the additional connectors on the rear plate:
For further inspection of interfaces, the Electronics compartment
must be opened, as explained later in this chapter.
1. MODELS AND OPTIONS, cont'd.
1.1
Identification, cont'd.
Voltage Switch
2 x DB25:
Serial Interface Board or
RS 485 Interface Board
1 x 36-p Centronics:
Parallel Interface Board 1 x DB25 + 1 x DB15: Industrial Interface Board
Continued!
Machine Sign

UBI EasyCoder 501 – Service Manual
9
1. MODELS AND OPTIONS, cont'd.
1.1
Identification, cont'd.
Continued!
Open the right-hand door. Here you can easily see if the printer is
fitted with any of the following options or accessories:
• Transfer Ribbon Mechanism (see chapter 7)
• Paper Rewind Kit (see chapter 9)
• Label Slack Absorber or Guide Shaft (see chapter 6)
• Label Rewind Guide (see chapter 8.5)
• Label Roll Retainer (see chapter 5)
• 3" Bobbin Adapter (see chapter 5)
• Ribbon Low/Paper Low Sensors (see chapter 14)
• Ribbon Save Device (see chapter 10)
• Guides for external paper supply (see chapter 5)
Thedoorcanberemovedforeasieraccess.Pushitforwarduntilthe
hinges disengage (snap-locked).
IMPORTANT PRINTHEAD AND RIBBON INFORMATION
The use of any thermal transfer ribbons, other than those supplied by UBI, will invalidate
the printhead warranty. UBI thermal transfer ribbons are engineered specifically for this printhead.
The quality of thermal and thermal transfer media supplies in this printer is also of great importance
for the quality of printing bar codes and a long life of the printhead. UBI has carefully matched the
paper we recommend/provide to the needs of this printer. We therefore strongly advise of using
only UBI recommended/provided supplies to ensure a high quality printing.
TEAR-OFF
Ribbon Save Device
(notillustrated)
Paper Rewind Kit
Thermal Transfer Mechanism
Paper/Ribbon Low Sensors
(notvisible) External Guides
Label Rewind Guide
Label Slack Absorber
(or Guide Shaft)
3" Adapter
Label Roll Retainer

UBI EasyCoder 501 – Service Manual
10
1. MODELS AND OPTIONS, cont'd.
1.1
Identification, cont'd.
Continued!
A Paper Cutter Unit is easily recognized by the extension on the
printer'sfront,wherethecutterreplacesthefronthatch(seechapter
12).
By opening the front hatch (or the optional cutter unit fitted in its
place), you can check if the printer is fitted with a Memory Card
Adapter(seechapter13)and/oraLabel-TakenSensor(seechapter
11).
F1 F2 F3 F4 F5
Pause
Setup
Feed
Enter
789
456
123
.0C
Print
Power Ready Error
EasyCoder 501 E
Paper Cutter Unit
Label-Taken Sensor
Memory Card Adapter
inside