Maintenance Manual 3600 Bar Code Label Printer P/N 062905-001
c 3 9 frank Intermec Corporation 6001 36th Avenue West P.O. Box 4280 Everett, WA 98203-9280 U.S. technical and service support: 1-800-755-5505 U.S. media supplies ordering information: 1-800-227-9947 Canadian technical and service support: 1-800-688-7043 Canadian media supplies ordering information: 1-800-268-6936 Outside U.S. and Canada: Contact your local Intermec service supplier.
hc nug c 3 Contributors Technical Writer: Robert Shaw Editor: Craig Thompson Technical Illustrator: George Wilson Technical Reviewers: Cathy Aragon Pixie Austin Daniel Clark John Cramer Allen Crowe Stephen Eckert Pat Helton Laura McCluer Ed Millet Art Millican Matt Roberts Joe Wade iii
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hc nug c 3 9 frank Contents Contents Before You Begin xi Safety Summary xi Warnings and Cautions xii Purpose of This Manual xii Additional Information xv 1 General Information Overview of the 3600 Printer 1-3 3600 Features 1-4 3600 Printer Specifications 1-4 Dimensions (no options installed) 1-4 Electrical Requirements 1-4 Printing Methods 1-4 Printing Speed 1-5 Printhead Specifications 1-5 Media Specifications 1-5 Ribbon Specifications 1-5 Environment 1-5 Self-Strip Specifications 1-5 Communications 1-
3600 Printer Maintenance Manual Principal Functional Parts 1-9 Basic Printer Setup and Operation 1-11 Front Panel Operation 1-11 Over-Temperature 1-11 Media or System Faults 1-12 Feed/Pause Pushbutton 1-12 Checking the Printer Configuration 1-12 DIP Switch Settings 1-13 Connecting the Printer to a Computer 1-13 Printing 1-14 Using Label Debut 1-14 Using Third-Party Software 1-14 Using the Printer Command Set 1-15 2 Preventive Maintenance Preventive Maintenance Actions and Intervals 2-3 Inspecting the Pri
hc nug c 3 9 frank Contents Adjusting the Printer 3-13 Adjusting the Print Bias for Print Quality 3-14 Adjusting the Print Intensity 3-15 Adjusting the Printhead Adjustment Lever for Print Quality 3-16 Adjusting the Label Mark Sensor 3-17 Adjusting the Label Gap Sensor 3-19 Adjusting the Label Taken Sensor 3-20 Aligning the Printer 3-21 Aligning the Rollers 3-22 Aligning the Printhead 3-23 Aligning the TTR Supply Hub 3-25 4 Troubleshooting About Troubleshooting and Repair 4-3 Troubleshooting Tips 4-3 Wh
3600 Printer Maintenance Manual 5 Remove and Replace Procedures Replacing Printer Components 5-3 Replacing the Lithium Battery 5-4 Replacing the Printhead 5-5 Replacing the Bezel PCB 5-6 Replacing the Main PCB 5-8 Replacing the Kanji/Katakana Option PCB 5-9 Replacing the Label Mark Sensor 5-10 Replacing the Label Taken Sensor 5-12 Replacing the Label Gap Sensor 5-13 Replacing the TTR Drive Roller and Gear/Pulley 5-15 Replacing the TTR Takeup Hub, Clutch/Pulley, and Belt 5-18 Replacing the TTR Supply Hub a
hc nug c 3 9 frank A Contents Appendix Functional Description of the 3600 Mechanics A-3 Functional Description of the 3600 Electronics A-4 Power Supply A-4 +5V A-4 +40V A-4 +24V A-4 Power Fail Detection A-5 Battery A-5 Battery Life Calculations A-5 Reset A-5 Motor Driver A-6 Processor A-7 Chip Selects A-7 TPU A-7 QSM A-8 Interrupt Priority Levels A-8 Crystal A-8 Memory A-9 Static RAM A-9 EPROM A-9 DRAM A-9 Communications Interface A-10 A/D Converter A-10 DIP Switches A-10 ASIC and I/O Option Interface A-
hc nug c 3 9 frank Before You Begin Before You Begin This section describes the purpose and arrangement of this manual to you. It is intended to bring to your attention, important general safety concerns, specific warnings and cautions, and sources of additional information. Safety Summary Your safety is extremely important. Read and follow all of warnings and cautions in this book before handling and operating Intermec equipment.
3600 Printer Maintenance Manual Warnings and Cautions The warnings and cautions in this manual use the following format and address the issues described: WARNING CAUTION Warning A warning alerts you of an operating procedure, practice, condition, or statement that must be strictly observed to avoid death or serious injury to the persons working on the equipment.
hc nug c 3 9 frank Before You Begin How This Manual Is Organized You will find the following information in the referenced section: For information about: Refer to: A basic description of the 3600 Chapter 1 - An illustrated overview of the 3600 printer; listing printer features, specifications, and options, identifying primary parts, and summarizing some setup and operating information. Scheduled cleanings and checks Chapter 2 - Actions, intervals, and illustrated preventive maintenance procedures.
3600 Printer Maintenance Manual Terms and Conventions The following terms and conventions occur throughout this manual. A complete glossary of terms is provided in the 3600 Bar Code Label Printer User’s Manual. Terms • “Backing” (or liner) refers to the silicon release portion of the media that carries the label. • “Host” refers to any computer that the printer is connected to. • “TTR” refers to the thermal transfer ribbon used when the printer is in thermal transfer rather than direct transfer mode.
hc nug c 3 9 frank Before You Begin Additional Information The following documents may be of interest or help to you in servicing the 3600 printer. 3600 Bar Code Label Printer User’s Manual (P/N 062732) Label Debut User’s Manual (P/N 062982) Data Communications Reference Manual (P/N 044737) The Bar Code Book by Roger C.
c 3 9 frank 1 General Information
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c 3 9 frank 1 General Information This chapter identifies basic features, options, and technical specifications of the 3600 printer. It names principal functional parts and reviews basic printer setup and operation. Overview of the 3600 Printer The Intermec 3600 is a microprocessor-based thermal printer that prints standard bar code or 2D symbology, human-readable characters, graphics, lines, and borders on 3-inch (7.62 cm) to 6.6-inch (16.8 cm) wide continuous feed label stock.
3600 Printer Maintenance Manual c 3 9 frank 3600 Features The 3600 printer’s features are summarized in the following list: • Print speed from 2 to 5 ips • Programmable, nonvolatile printer configuration • Bitmap font capabilities • Outline/vector font support • User selectable gap feature for fonts • 2D symbology support (Code One, PDF 417, and Maxicode) • 128k (standard), 512k (optional) storage memory • Autoselection of Intermec protocols • Printable control characters • Image banding
c 3 9 frank General Information 1 Printing Speed Maximum 5 ips (50.8 mm per second) Minimum 2 ips (127 mm per second) The print speed can be changed in 1 ips increments only: 2, 3, 4, or 5. Printhead Specifications Element size 0.00492 inch square (0.13 mm) Width 6.6 inches maximum print (168 mm) Resolution 203 dots per inch (8 dots per mm) # of Elements 1344 per printhead X dimensions 10 mil to 50 mil or 0.25 mm to 1.27 mm, 5 mil (0.
3600 Printer Maintenance Manual c 3 9 frank Communications Asynchronous RS-232C, RS-422, RS-485 interfaces Serial ASCII code Hardware (Ready/Busy) flow control XON/XOFF protocol Intermec Standard Block protocol Polling Mode D protocol Multi-Drop protocol Baud Rates: 1200, 2400, 4800, 9600, 19200 Fonts and Graphics 5x7, 7x9, 7x11, and 10x14 86XX compatible fonts 2 bitmap OCR fonts 3 bitmap fonts measured in point sizes 8, 12, and 20 1 outline font 12 monospaced bitmap fonts Kanji/Katakana bitmap font card
c 3 9 frank General Information 1 Factory Default Settings The following is a list of the factory default settings for the 3600 printer: Configuration Default Setting Preamble Character Disabled Postamble Character Disabled Auto-Transmit 1 Disabled Auto-Transmit 2 Disabled Auto-Transmit 3 Disabled Message Delay 0 ms Power-Up Mode Advanced mode End-of-Print Skip Distance 100 dots Top of Form 20 dots Media Sensitivity 420 Number of Image Bands 3 Maximum Label Length 1000 dots Prin
3600 Printer Maintenance Manual c 3 9 frank Coax Interface Allows connection of the 3600 printer to IBM coax systems. The 3600 emulates an IBM 3287 printer by connecting the printer to IBM 3270 Type A coax cable computer systems operating in the VTAM (CICS/IMS/TSO) or 8100 (DPPX) environments. Connection can be made to an IBM 3174/76/99 system controller/multiplexer.
c 3 9 frank General Information 1 Principal Functional Parts The following illustrations identify the common name and location of the major functional elements of the 3600 printer.
3600 Printer Maintenance Manual c 3 9 frank Media post TTR supply hub TTR takeup hub Po we r Ale rt Em pty /P au se Fe ed TTR roller /P au se Inte rme c 36 00 Tear bar Upper media guide Platen roller Self-strip/ liner roller Lower media Edge guide guide Thermal printhead TTR/ribbon Media roll Media roll retainer Media post Lower media guide Media access door Liner takeup hub Self-strip/ liner roller 1-10 Tear bar Printhead lift lever 3600M.
c 3 9 frank General Information 1 Basic Printer Setup and Operation Detailed operating instructions for the 3600 printer are contained in the user’s manual.
3600 Printer Maintenance Manual c 3 9 frank Media or System Faults If you are servicing a printer indicating a media or system fault, refer to Chapter 4, “Troubleshooting,” for information about the problem.
c 3 9 frank General Information 1 DIP Switch Settings The DIP switches on the rear panel of the printer control communications parameters, media type configuration, and test and service functions. To change settings, carefully position the plastic (breakable) switches to ON or OFF with a small straight-slot screwdriver. The printer is shipped from the factory in the standard configuration, with the 16 DIP switches set as shown in the following illustration.
3600 Printer Maintenance Manual c 3 9 frank Serial Port Settings Parameter Settings Description Baud Rate 1200, 2400, 4800, 9600, 19,200 The rate, in bits per second (bps) at which the host exchanges data with the printer. Parity Even, Odd, None Checks each transmitted character for errors. Protocol Intermec, XON/XOFF, XON/XOFF with status The type of network used to connect the printer, the host, and the rest of the data collection system.
c 3 9 frank General Information 1 Using the Printer Command Set You can also create labels by downloading formats (designs) and data created with the printer command set. The commands in the printer command set can perform any function or activate any feature of the 3600 printer.
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2 Preventive Maintenance
Preventive Maintenance 2 This chapter identifies scheduled maintenance actions and provides illustrated procedures for cleaning the 3600 printer. Preventive Maintenance Actions and Intervals Preventive maintenance consists primarily of scheduled cleanings, but also occassional performance checks and, possibly, adjustments based on those checks.
00 Printer Maintenance Manual Inspecting the Printer You should routinely inspect the printer and the rest of the data collection system. Your inspection needs to address the following and similar concerns: • Make sure the printer is properly grounded. • Make sure the printer’s AC power source is within tolerance. • Make sure the printer is clean. • Make sure the printer is away from liquids. • Inspect the work environment for cleanliness and arrangement.
Preventive Maintenance 2 Removing the Media Cover Most of the cleaning procedures require that you remove the media cover. To remove the media cover 1. Place your fingers in the space at the lower center edge of the media cover and pull the bottom of the cover away from the base of the printer. 2. Grasp the front of the media cover and lift the front of the cover upward.
3600 Printer Maintenance Manual Cleaning the Printhead Since the printhead must maintain close contact with the media to provide good print quality, cleaning media debris from the printhead is very important. Clean the printhead after every roll (or 6,000 inches) of media or whenever necessary. CAUTION Caution Do not use sharp objects such as knives or screwdrivers to scrape the printhead clean. Cleaning with sharp objects will damage the printhead.
Preventive Maintenance 2 3. Remove the media from the paper path and the ribbon (if installed) from the TTR supply and takeup hubs. 4. Use a cotton swab moistened with alcohol to remove any dirt, adhesive, or debris from the print surface on the bottom of the printhead. Po we r Ale rt Em pty /P au se Fe ed /P au se Inte rme c 36 00 Thermal printhead 3600M.012 5. Wait 5 to 10 seconds for the print surface to dry. Reload the media (and ribbon if used). 6.
3600 Printer Maintenance Manual Cleaning the Rollers and Tear Bar Cleaning the platen roller and the tear bar preserves print quality by ensuring close contact between the media and the printhead. The TTR roller, liner roller, and media roller are cleaned in the same fashion to minimize general debris and to maximize their efficiency. To clean the rollers and tear bar 1. Remove the media cover. 2. Raise the printhead by rotating the head lift lever clockwise until the printhead releases. 3.
Preventive Maintenance 2 Cleaning the Media Guides and Media Path Clean the media guides and media path regularly to keep debris off the media surface and printhead where irregularities can spoil print quality or damage the printhead. Cleaning the guides also helps prevent media skewing or improper tracking as it travels through the paper path, which can result in print problems. Always clean the media guides immediately after any label jam in the printer.
3600 Printer Maintenance Manual 5. Use a lint-free cloth moistened with isopropyl alcohol to clean the upper media guide. Be sure to remove all traces of debris. 6. Reload the media (and ribbon if used). 7. If you are finished cleaning, install the media cover. To clean the pinch rollers 1. Open the media access door. 2. Use a cotton swab moistened with isopropyl alcohol to clean the pinch rollers. Rotate the rollers to get any debris out of all of the grooves.
Preventive Maintenance 2 Cleaning the Label and Ribbon Sensors There are three label sensors and a ribbon sensor on the 3600 printer that require cleaning: the label taken sensor, the label mark sensor, the label gap sensor, and the ribbon motion sensor. To clean the sensors 1. Remove the media cover. 2. Raise the printhead by rotating the head lift lever clockwise until the printhead releases. 3. Remove the media from the paper path and the ribbon (if installed) from the TTR hubs. 4.
3600 Printer Maintenance Manual 5. Pull down on the lower media guide to expose the label gap sensor. Using a soft bristle brush, remove all debris and dust from the label gap sensor. 6. Clean the label gap sensor with a cotton swab and alcohol. 7. Remove the electronics cover. 8. Very carefully clean the small ribbon motion optical sensor on the main PCB and the black and white encoder decal on the TTR supply clutch/encoder assembly with a cotton swab moistened with alcohol. 9.
3 Testing and Adjusting
c 3 9 frank Testing and Adjusting 3 This chapter contains procedures for testing the printer’s performance as a quality check during preventive maintenance, as a functional check when troubleshooting, and as part of the repair process after replacing a printer component. This chapter also contains procedures for making adjustments and alignments that ensure the printer is operating normally.
3600 Printer Maintenance Manual c 3 9 frank Running Test and Service Mode at the Printer Note: When the printer is placed in Test and Service mode, it prints out a hardware configuration label, regardless of its initial DIP switch settings, and remains in Test and Service mode until the power is switched off and the DIP switches are reset. Momentarily pressing the Feed/Pause button during a test will cause the test to halt.
c 3 9 frank Testing and Adjusting 3 Test and Service Switch Settings Top Bank O = OFF 1 = ON OFF TESTS ON Test Prints Configurations Hardware Software Test Labels Print Quality Pitch Page Single Page All Pages Format Single Format All Formats UDC Single UDC All UDCs Font Single Font All Fonts Data Line Print 1 2 3 4 5 6 Bottom Bank 7 8 1 2 3 4 5 6 7 8 O O O O O O O O O O O O O O 1 O O O O O O O O O O A O O O O O A O O O 1 O O O 1 O O O O O O 1 O O O O O O O O O O A O O O O O
3600 Printer Maintenance Manual c 3 9 frank Test and Service Configuration Settings Top Bank Bottom Bank OFF O = OFF 1 = ON ON 1 2 3 Label Rest Point Adjust Forward Adjust Backward O 1 1 86XX Emulation Advanced Mode 10 Mil 15 Mil 1 X Forms Adjust Adjust Forward Adjust Backward 1 Y Forms Adjust 1 4 5 6 7 8 1 3 4 5 6 7 8 N N N N N N N N N N O 1 O 2 1 O O 1 O 1 1 1 1 1 N N N N N N N N N N O 1 1 N N N N N 1 O N: Number. Least significant bit first. 3600M.
c 3 9 frank Testing and Adjusting 3 Printing Test Labels The test labels can be used for checking printhead alignment, printhead bias, dots out of specification, label tracking, and ribbon wrinkling. The examples show the DIP switch settings that select the illustrated label. Hardware Configuration The hardware configuration label is the first label printed when you enter Test and Service mode. This label serves as a configuration reference as well as an alphanumeric and alignment print test.
3600 Printer Maintenance Manual c 3 9 frank Software Configuration This three-label set lists current configuration parameters that are set from the host computer. It also lists defined pages, formats, graphics, fonts, and installed options. This label serves as a configuration reference as well as an alphanumeric and multiple label alignment and print test. 1 2 PRINT SPEED - 3.
c 3 9 frank Testing and Adjusting 3 Format This label, which can be a test of a single format or can provide a two-label sample of all the formats, has bar codes and human-readable fields that you can use to determine whether the printer you are testing is attaining the best print quality possible using a particular format.
3600 Printer Maintenance Manual c 3 9 frank Font This is a multiple-label test of the available fonts. You can test a single font (Font 20 shown) or all of the fonts. An all-font test will use a lot of media. It is better that you test one font at a time to make your determinations.
c 3 9 frank Testing and Adjusting 3 Running Test and Service Mode From a Host Computer When conducting Test and Service mode functions from a computer, hardware diagnostic information is uploaded to the host from the printer. The following table describes the commands you would issue from a host terminal to run the Test and Service mode. To select Test and Service mode from Print mode, send T from the host terminal.
3600 Printer Maintenance Manual c 3 9 frank Test and Service Mode Command Descriptions (continued) Command Code Test Description S Transmit Printhead Resistance Values* Transmits the average, maximum, or minimum printhead dot resistance value back to the host. Each value is a numeric data string separated by a comma. T Transmit Label Taken Sensor Value Transmits the label taken sensor output back to the host. Values can range from 00 to FF.
c 3 9 frank Testing and Adjusting 3 5. A good test will result in the following printout : 3600M.029 6. To enter normal print mode again, switch the printer power off and then on again. If this test does not work, recheck after you make sure that the DIP switches are set to the default configuration and that the printer cable is securely plugged into COM1 of your PC.
3600 Printer Maintenance Manual c 3 9 frank Adjusting the Print Bias for Print Quality Adjust the bias with a straight-slot screwdriver if the printhead is not making even contact with the media. Using different width media, especially narrow media, can result in uneven contact or a spot where there is no media between the printhead and the platen roller. Extra wear and damage can occur if narrow media is used for extended periods with incorrect bias. To adjust the bias adjust screw 1.
c 3 9 frank Testing and Adjusting 3 Adjusting the Print Intensity Note: Before you adjust print intensity, verify the sensitivity rating for the media matches the rating set in the printer. Use the darkness adjust control in combination with the darkness adjust command d to fine-tune the intensity of print on your customer’s labels. The fine adjustments compensate for variations in the media (“lot to lot”), the printhead, or the printer.
3600 Printer Maintenance Manual c 3 9 frank Adjusting the Printhead Adjustment Lever for Print Quality The printhead adjustment lever is located at the end of the printhead pivot bracket. It allows fine-tuning of the printhead fore/aft position. The printhead adjustment lever provides three stops forward movement of the printhead and three stops backward movement from center position in 0.006-inch increments.
c 3 9 frank Testing and Adjusting 3 Adjusting the Label Mark Sensor The mark sensor detects the mark on the back of continuous media stock. The output is then used to determine the start of print point. This sensor is located under the label pathway across from the platen roller. Two adjustments affect the performance of this sensor, its physical position and sensitivity.
3600 Printer Maintenance Manual c 3 9 frank 3. Slide the mark sensor into a position that centers it over the label mark as the media passes by. It is adjustable from the inboard edge of the extrusion to one half of the paper path width toward the outboard edge. To adjust the label mark sensor potentiometer sensitivity 1. Remove the electronics cover 2. Switch on the printer power. 3. Enable the printer for mark sensing using the T{2} command. 4.
c 3 9 frank Testing and Adjusting 3 Adjusting the Label Gap Sensor The label gap sensor output enables the software to determine the leading edge of a label by detecting the label gap. The label gap is the space between labels on the backing material. This reading enables the printer to properly position the start of print point.
3600 Printer Maintenance Manual c 3 9 frank Adjusting the Label Taken Sensor The label taken sensor output enables the software to determine that a label has been taken by detecting the label’s presence. To perform this procedure, you need the following tools: • Digital multimeter • #2 Phillips screwdriver • Small straight-slot screwdriver To adjust the label taken sensor 1. Remove the media cover and the electronics cover. 2.
c 3 9 frank Testing and Adjusting 3 Aligning the Printer The following procedures provide instructions for aligning the rollers, aligning the printhead, and aligning the ribbon supply hub on the 3600 printer. Note: These alignments should be made in the sequence given. Performing them out of order can introduce and not solve printing problems. WARNING CAUTION CAUTION Warning Always disconnect the power cord before removing the electronics cover unless a procedure requires the unit be energized.
3600 Printer Maintenance Manual c 3 9 frank Aligning the Rollers You should perform this procedure every time an outboard plate is removed or replaced. To perform this procedure, you need the following tools: Note: If the printer you are servicing has upper outboard plate Intermec Part No. 062476-002 installed, you need to replace it with a new upper outboard plate Intermec Part No. 063225-001 before you can perform the following roller alignment. • Roller alignment tool, Intermec Part No.
c 3 9 frank Testing and Adjusting 3 6. When the tool fits properly on all of the rollers and the bushing, tighten the screws on the outboard plate that you are aligning. 7. Reattach the front bezel cover. Ensure that the media access door operates properly (snaps firmly shut) after the front bezel cover is installed. 8. Install the electronics cover. 9. Reload media (and ribbon if used). 10. Install the media cover and the power cord. 11. Switch on printer power and check for proper operation.
3600 Printer Maintenance Manual c 3 9 frank Note: This is a change in procedure from previous printhead alignment instructions that directed the printhead adjustment lever to be in the neutral/center position during alignment. 4. Install the printhead alignment tool and press the printhead assembly down on the platen roller. Align the tool with the notches in the heat sink and the printhead. 5. Alternately tighten the two 9/64 inch printhead yoke screws until secure. 6. Remove the printhead alignment tool.
c 3 9 frank Testing and Adjusting 3 Aligning the TTR Supply Hub You should align the TTR supply hub only if you are experiencing ribbon wrinkle on full width ribbon after the rollers and printhead have been aligned. To perform this procedure, you need the following tools: • TTR supply hub alignment tool, Intermec Part No. T43149 • #2 Phillips screwdriver To align the TTR supply hub 1. Switch off the printer power. 2. Remove the media cover and the electronics cover. 3.
3600 Printer Maintenance Manual c 3 9 frank Note: If this adjustment does not eliminate ribbon wrinkling, try readjusting the ribbon supply hub and realigning the printhead. 8. When an alignment is achieved that eliminates the ribbon wrinkling, tighten the two screws on the hub adjustment plate. 9. Remove the tool and retest for ribbon wrinkling. 10. After the printer is correctly adjusted, switch off the power and reattach the electronics and media covers.
4 Troubleshooting
Troubleshooting 4 This chapter provides you with information that will help you determine why a printer may not be working and how to get it working again. About Troubleshooting and Repair Use the information in this chapter to identify the cause of a failing printer. It is assumed that a printer is not working and that the troubleshooting actions referenced in the user’s manual were not used, failed to clear the problem, or pointed to a printer malfunction.
3600 Printer Maintenance Manual Troubleshooting Checklist If the host receives an error message or a functional problem with the printer is encountered, the user’s manual starts with the following: 4-4 • Check whether the printer sends an error code to the host in response to a command. • If an error code is sent, find it in the “Error Codes” table in this chapter. Try the solution given for the respective error code to attempt to correct the problem.
Troubleshooting 4 Error Handling This section describes how the 3600 printer handles certain error conditions it may encounter in printer or programming commands. Error codes sent to the host, the problem the code is reporting, and the usual solution are listed in a table at the end of this section. Syntax Errors The 3600 printer responds to syntax errors in the messages it receives from the host by attempting to execute the commands. It does not ignore a command with a syntax error.
3600 Printer Maintenance Manual Invalid Numeric Character Errors If non-numeric characters are included within a numeric data string in a command, the printer disregards them and continues to process the rest of the valid numeric characters. However, if a non-numeric character begins the numeric data string, the printer uses a default value for the affected command.
Troubleshooting 4 Printer Errors Error Code Problem Solution 00 No error. 01 Invalid bar code check character. Verify the bar code check character modifier used in the bar code program command. 02 Invalid number of bar code characters (Code UPC/EAN). Verify the number of bar code characters used in the bar code program command. 04 Bar code check character within numeric field marks. Check the bar code program command for accuracy.
3600 Printer Maintenance Manual Printer Errors (continued) Error Code Problem Solution 32 Non-immediate command or data received after buffer full. Allow the printer to empty the buffer contents before sending commands or data. 33 Invalid field delimiters. Check for all pairs of field delimiters, and make sure both are numeric or both are alphanumeric. 34 Invalid escape command. Correct the escape command syntax. 35 Invalid data shift command. Correct the shift command syntax.
Troubleshooting 4 Printer Operation Problems If a printer is not operating correctly, try locating the problem and implementing the solution from the following table: Symptom Possible Causes Solution No power or loss of power. AC power cable is damaged or disconnected. Make sure the power cable is plugged into both the printer and an outlet or power strip. Replace the cable if it is damaged. Printer circuit breaker tripped. Turn the printer off and then back on again (determine why it tripped).
3600 Printer Maintenance Manual Print Quality Problems If labels are not printing properly, try locating the problem and implementing the solution in the following table: Symptom Possible Causes Solution Blotches on labels. Dirty printhead. Clean the printhead. Dirty media path or rollers. Clean the media path. Poor quality label or ribbon stock. Use only Intermec label and ribbon stock to ensure superior print quality and product performance. Darkness adjust control is set incorrectly.
Troubleshooting 4 Symptom Possible Causes Solution Print quality is poor. Incorrect media sensitivity. Change sensitivity setting to match the type of media you are using. If sensitivity is set correctly, try changing the dark adjust. The darkness of label print is too light or too dark. Properly set the darkness adjust control. Printhead, platen roller, or label path are dirty. Clean printhead, platen roller, and label path. Uneven print contrast (density). Adjust the bias adjust screw.
3600 Printer Maintenance Manual Communications Problems If a printer is not receiving downloaded data, consider the causes and solutions in this section. Symptom Possible Causes Solution Printer does not communicate with the host. Serial port is incorrectly configured. Make sure the printer’s serial port settings match those of the host. Print a software test configuration label to check the serial port settings. Disconnected, damaged, or incorrect I/O cable. Check the connections at both ends.
Troubleshooting 4 To check for communications problems 1. Check the cabling from the printer to the host system. 2. Check the interfacing of the devices that are communicating with the printer. 3. Check the printer for proper electrical operation of the serial communications port. 4. Test to see that the host system is not overrunning the printer’s input buffers. 5. Check to see that the data string being sent to the printer contains the correct information.
3600 Printer Maintenance Manual Electromagnetic and Radio Frequency Interference Noise induced in interface cables can result in the printer receiving false data. This condition may cause the printer to skip printing a label or lockup. Sources of electromagnetic interference (EMI) and radio frequency interference (RFI) are radio transmitters, ignition systems, and relays. To eliminate the effects of EMI and RFI, use low capacitance, twisted pair, shielded cables.
Troubleshooting 4 AC Power Problems (Surges, Sags, Spikes, Noise, and Outages) Most environmental problems involve the AC power line. In the 3600 printer, 115V supply voltages can range from 90 to 132 VAC. Outside the U.S., 230V supply voltages can range from 180 to 264 VAC. Voltage overages or underages can result from poor utility regulation to in-plant loading of the power service. Use a power line monitor, such as the BMI 4800, to look for power service problems.
3600 Printer Maintenance Manual Miscellaneous Problems The following information identifies some possible printer problems and what might be their cause. 4-16 • Problems with printer-to-computer communications, motor control, or media advance may be caused by a faulty main PCB assembly.
5 Remove and Replace Procedures
Remove and Replace Procedures 5 This chapter contains illustrated instructions for removing and replacing key components of the 3600 printer. Replacing Printer Components When a printer component needs replacing, use the appropriate following procedure. See Chapter 7, “Replacement Parts,” for a complete list of spare parts. After replacing a component, refer to Chapters 2 and 3 for the procedures to complete the repair by ensuring that you leave the printer performing at its optimum level.
3600 Printer Maintenance Manual Replacing the Lithium Battery To replace the lithium battery, you will need the following parts and tools: WARNING • 1.75AH 3.6V AA lithium battery, Intermec Part No. 586229 • ESD grounding strap • #2 Phillips screwdriver Warning There is danger of explosion if the battery is incorrectly replaced. Replace it only with the same or equivalent type battery recommended by the manufacturer. Discard used batteries according to the manufacturer’s instructions.
Remove and Replace Procedures 5 Replacing the Printhead To replace the printhead, you will need the following parts and tools: • 6.6-inch 5 mil printhead, Intermec Part No. 061611S-001 • ESD grounding strap • Medium straight-slot screwdriver To replace the printhead 1. Switch off the printer power and remove the power cord. 2. Remove the media cover. 3. Raise the printhead. Remove media and ribbon if loaded. 4.
3600 Printer Maintenance Manual 5. Use a straight-slot screwdriver to loosen the printhead retaining screws, located in the center of the printhead heatsink. The screw is easier to loosen if you place one of your fingers underneath the printhead, between the printhead and the platen roller. Pull the printhead away from the printer (since it is a tight fit, you may need to pull it out from the outboard side rather than from the front). 6.
Remove and Replace Procedures 5 4. Lift the front bezel cover away from the printer and lay it on a flat surface. 5. Use the #2 Phillips screwdriver to remove the two screws that hold the bezel PCB/cover plate assembly to the front bezel cover. 6. Being careful not to break the switch stem or the button cap, pull the Feed/Pause button cap off of the switch on the bezel PCB. Retain the yellow button cap for installation onto the replacement bezel PCB. 7.
3600 Printer Maintenance Manual Replacing the Main PCB To replace the main PCB, you will need the following parts and tools: • 3600 main PCB assembly, Intermec Part No. 061591S-005 or 06159E-005 • ESD grounding strap • #2 Phillips screwdriver To replace the main PCB assembly 1. Switch off the printer power and remove the power cord, the media cover, and the electronics cover. 2.
Remove and Replace Procedures 5 Replacing the Kanji/Katakana Option PCB To replace a Kanji/Katakana PCB, you will need the following parts and tools: • 3600 Kanji/Katakana PCB, bitmap font, Intermec Part No. 060689-001 or 3600 Kanji/Katakana PCB, outline font, Intermec Part No. 060690-001 • ESD grounding strap • #2 Phillips screwdriver To replace the Kanji/Katakana PCB 1. Switch off the printer power and remove the power cord, the media cover, and the electronics cover. 2.
3600 Printer Maintenance Manual 3. Unplug the Kanji/Katakana PCB from the main PCB using a gentle rocking motion while pulling it away. 4. Install the new Kanji/Katakana PCB onto the main PCB, making sure the pins are properly aligned with the connector and that the Kanji/Katakana PCB is fully seated before tightening the screws. 5. Install the electronics cover, the media cover, and the power cord, and check the printer for proper operation.
Remove and Replace Procedures 5 5. Disconnect the label mark sensor cable from the main PCB, remove the cable from the two plastic clips, and push it through the cutout in the main deck plate. Slide the sensor out from the extrusion. Remove the cable from the plastic cable clip on the extrusion. Label mark sensor 3600M.049 6. Insert the new label mark sensor into the extrusion.
3600 Printer Maintenance Manual Replacing the Label Taken Sensor To replace the label taken sensor, you will need the following parts and tools: • Label taken sensor cable assembly, Intermec Part No. 059496-002 • ESD grounding strap • #1 and #2 Phillips screwdriver To replace the label taken sensor 1. Switch off the printer power and remove the power cord. 2. Remove the media cover, the electronics cover, and the front bezel cover (refer to “Replacing the Bezel PCB” earlier in this chapter). 3.
Remove and Replace Procedures 5 Replacing the Label Gap Sensor To replace the label gap sensor, you will need the following parts and tools: • Label gap cable assembly, Intermec Part No. 059495-001 • ESD grounding strap • Small straight-slot screwdriver • 12-inch shank #2 Phillips screwdriver To replace the label gap sensor 1. Switch off the printer power and remove the power cord, the media cover and the electronics cover. 2. Raise the printhead. Remove media and ribbon if loaded. 3.
3600 Printer Maintenance Manual Upper media guide Label gap sensor Label gap sensor housing Lower media guide Locking tabs Lift spring 3600M.052 6. Use a small straight-slot screwdriver to lift up on each of the two molded tabs that secure the label gap sensor. Slide the label gap sensor from its housing and replace it with the new label gap sensor. The label gap sensor should snap into place. 7. Slide the upper media guide plate back together with the lower media guide plate. 8.
Remove and Replace Procedures 5 Replacing the TTR Drive Roller and Gear/Pulley To replace the TTR drive roller or the TTR drive gear/pulley or both, you will need some or all of the following parts and tools: • TTR drive roller, Intermec Part No. 061543-002 • TTR drive gear/pulley, Intermec Part No. 061563-002 (white) • Retaining E-rings, Intermec Part No. 501401 • Retaining snap ring, Intermec Part No. 501409 • Roller alignment tool, Intermec Part No.
3600 Printer Maintenance Manual 5. Remove the TTR drive gear/pulley retaining E-ring. Retain the washer located between the E-ring and the TTR drive gear/pulley. Discard the old E-ring. 6. Remove the retaining snap ring that secures the printhead lift lever to the cam assembly shaft. Pull the printhead lift lever off of the printhead lift shaft. Discard the old snap ring.
Remove and Replace Procedures 5 To replace the TTR drive roller and TTR drive gear/pulley 1. Position the TTR drive gear/pulley with the correct washer installed between the gear/pulley and the main deck plate. 2. Insert the TTR drive roller with a new retaining E-ring and the other washer through the main deck plate and into the gear/pulley. 3.
3600 Printer Maintenance Manual Replacing the TTR Takeup Hub, Clutch/Pulley, and Belt To replace the TTR takeup hub, TTR takeup clutch/pulley, and TTR takeup drive, you will need some or all of the following parts and tools: • TTR takeup hub, Intermec Part No. 061562-005 • TTR takeup clutch assembly, Intermec Part No. 062927S-001 (white) • 2.800ID x .210 drive belt (O-ring), Intermec Part No. 501462-003 • Retaining snap rings, Intermec Part No.
Remove and Replace Procedures 5 5. Pull out on the TTR takeup hub to release the clutch/pulley assembly. Retain the thin washer located between the TTR takeup hub and main deck plate. 6. Remove the TTR takeup clutch/pulley assembly and TTR drive belt. Note: Do not remove the motor plate or subplates. Changing the position of these plates can alter factory alignment and cause ribbon wrinkling or self-strip problems. 7.
3600 Printer Maintenance Manual Replacing the TTR Supply Hub and Adjusting Plate To replace the TTR supply hub, the TTR supply hub adjusting plate, or both parts, you will need some or all of the following parts and tools: • TTR supply hub, Intermec Part No. 061562-004 • TTR supply hub adjusting plate, Intermec Part No. 062603-001 • Retaining snap rings, Intermec Part No. 501410 • Ribbon supply hub alignment tool, Intermec Part No.
Remove and Replace Procedures 5 To replace the TTR supply hub and TTR supply hub adjusting plate 1. Remove the two Phillips screws securing the TTR supply hub adjusting plate to the TTR subplate and install the new adjusting plate in its place. 2. Install the thick steel washer removed in Step 5 above. Align the TTR clutch encoder with the opening in the main deck plate and slide the TTR supply hub back through the TTR clutch/encoder, the nylon washer, the motor plate, and the TTR subplate.
3600 Printer Maintenance Manual Replacing the Platen Roller and Gear The platen roller and platen roller gear can be replaced separately or at the same time. To replace the platen roller, the platen roller gear, or both parts, you will need some or all of the following parts and tools: • Platen roller, Intermec Part No. 061542-003 • Retaining E-ring, Intermec Part No. 501401 • Platen roller gear, Intermec Part No. 061557-003 • Retaining snap ring, Intermec Part No.
Remove and Replace Procedures 5 Snap ring Platen roller gear Washer E-ring Platen roller Tear bar Tear bar support Lower outboard plate 3600M.057 To replace the platen roller and platen roller gear 1. Loosen the motor as necessary to mesh the platen roller gear with the motor pinion gear and TTR drive gear/pulley upon reassembly. 2.
3600 Printer Maintenance Manual Replacing the Liner Drive and Takeup Components To replace any combination of the liner takeup hub, liner reverse gears, liner drive roller, liner takeup clutch/pulley, liner reverse shaft, liner drive gear/pulley, and liner drive belt, you will need some or all of the following parts and tools: • Liner takeup hub, Intermec Part No. 061562-005 • Liner drive roller, Intermec Part No. 061568-002 • Liner reverse gears 1 and 2, Intermec Part No.
Remove and Replace Procedures Liner reverse gear 1 5 Liner takeup hub Thin washer Snap ring Thick washer Main deck plate Liner takeup hub Liner drive roller Liner reverse gear 1 Liner drive gear/pulley Subplate Liner reverse gear 2 Motor plate 3600M.
3600 Printer Maintenance Manual 6. You can replace the liner takeup hub and/or liner reverse gear 1 now. 7. Install the thick washer removed in Step 5 between the liner takeup hub and the main deck plate. Position liner reverse gear 1 between the motor plate and the liner takeup subplate and check for proper engagement with liner reverse gear 2. 8. Insert the liner takeup hub through the main deck plate, reverse gear 1, and the subplate.
Remove and Replace Procedures 5 3. Remove the liner drive gear/pulley retaining E-ring. Retain the washer located between the E-ring and the liner drive gear/pulley. Discard the old E-ring. 4. Loosen the motor as necessary to disengage the pinion gear from the liner drive gear/pulley to facilitate disassembly. 5. Remove the liner drive roller, sliding the liner drive gear/pulley off of the roller shaft. Retain the washer between the roller and main deck plate.
3600 Printer Maintenance Manual To replace liner reverse gear 2, the liner takeup clutch/pulley, liner reverse shaft, liner drive gear/pulley, and liner drive belt 1. If not already done, perform Steps 1 through 5 of the preceding liner roller replacement procedure. 2. Remove the retaining snap ring that holds the liner reverse shaft, takeup clutch/pulley, and reverse gear 2 in place. Retain the washer located between the snap ring and subplate. Discard the old snap ring.
Remove and Replace Procedures 5 3. Remove the liner takeup hub and reverse gear 1 as described in Steps 4 and 5 of that procedure (page 5-24). 4. Push the liner reverse shaft through the main deck plate, sliding off the takeup clutch/pulley and reverse gear. Separate the drive belt from the drive gear/pulley and clutch/pulley. 5. You can replace the liner drive gear/pulley, liner drive belt, takeup clutch/pulley, liner reverse shaft, or reverse gear 2 now.
3600 Printer Maintenance Manual Replacing the Stepper Motor To replace the stepper motor, you will need the following parts and tools: • Main stepper motor and cable assembly, Intermec Part No. 061551-002 • ESD grounding strap • #2 Phillips screwdriver To replace the stepper motor 1. Switch off the printer power and remove the power cord, the media cover, and the electronics cover. 2. Unplug the motor cable from the main PCB and remove the motor from the motor plate and motor mount bracket.
Remove and Replace Procedures 5 Replacing the AC Plug/Input Filter To replace the AC plug and input filter assembly, you will need the following parts and tools: • 3600 line AC plug and filter assembly, Intermec Part No. 060246-001 • ESD grounding strap • #1 and #2 Phillips screwdriver • Needlenose pliers To replace the AC plug and input filter 1. Switch off the printer power and remove the power cord, the media cover, and the electronics cover. 2.
3600 Printer Maintenance Manual Replacing the Power Switch/Circuit Breaker To replace the power switch and circuit breaker assembly, you will need the following parts and tools: Note: The 220-volt printer uses a 1 amp power switch/circuit breaker and the 115-volt printer uses a 2 amp power switch/circuit breaker. • AC power switch/circuit breaker, Intermec Part No. 501273-001 (2A) or AC power switch/circuit breaker, Intermec Part No.
Remove and Replace Procedures 5 4. Compress the tabs that hold the power switch secured to the back plate and push it out of the main deck plate. 5. Install the power switch by pushing the new receptacle into the cutout in the main deck plate. 6. Reattach the two push-on connectors removed in Step 3. 7. Install the electronics cover, the media cover, and the power cord, and check the printer for proper operation.
3600 Printer Maintenance Manual 3. Remove the two screws holding the transformer to the base plate and slide the transformer toward the front of the printer to free it from the metal tabs, lifting it away from the printer. 4. Install the replacement transformer and push it toward the back of the printer securing it under the tabs in the printer main deck plate. 5. Secure the transformer to the printer main deck plate with the two screws removed in Step 3. 6.
6 PCB Drawings and Schematics
PCB Drawings and Schematics 6 This chapter contains the assembly drawings, parts lists, and schematic diagrams for the 3600 main PCB. PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 1/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------1 1 061590-003 PCB,MAIN,3600 2 0.001 RL 046766 LBL.STK..23HX1.50L,4-HI.
3600 Printer Maintenance Manual PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 2/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" R8 5.8 4.3 F " R9 4.7 5.9 F " R10 1.3 1.5 F " R12 4.0 4.5 F " R13 4.0 4.6 F " R14 3.3 5.8 F " R15 6.8 5.0 F " R16 6.6 5.0 F " R17 1.3 5.3 F " R19 4.5 4.0 F " R20 6.7 3.
PCB Drawings and Schematics 6 PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 3/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" R71 1.3 5.1 F " R72 1.3 5.2 F " R95 4.3 3.3 F " R110 4.4 1.2 F " R118 3.7 1.3 F " R131 8.9 4.3 F " R133 9.2 4.0 F " R134 8.5 4.0 F " R145 3.7 1.0 F " R146 3.5 0.8 F " R153 3.
3600 Printer Maintenance Manual PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 4/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" R93 2.0 1.6 F " R94 3.7 5.4 F " R102 5.9 0.9 F " R103 5.9 0.1 F " R109 5.9 1.1 F " R111 5.9 0.3 F " R112 9.7 3.8 F " R130 3.2 0.2 F " R139 4.5 0.2 F " R140 5.9 1.5 F " R154 3.
PCB Drawings and Schematics 6 PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 5/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------25 5 556648 R34 RES,S/M,FILM,.12W,5%,390 OHM 3.0 6.0 F " R115 9.2 4.4 F " R123 10.7 4.3 F " R132 9.2 4.1 F " R143 9.2 3.5 F 26 9 556650 R105 RES,S/M,FILM,.12W,5%,470 OHM 5.9 1.
3600 Printer Maintenance Manual PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 6/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" C125 9.7 2.6 F " C140 4.1 0.2 F 44 1 561018-001 C123 CAP,AL,ELCTLT,R/L,63V,12000UF 8.1 2.0 F 45 1 561908 C53 CAP.AL.R/L 16V 4700. UF 6.7 0.4 F 46 2 563602 C46 CAP.
PCB Drawings and Schematics 6 PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 7/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" C48 5.0 1.3 F " C50 5.5 0.8 F " C51 4.7 1.0 F " C58 4.9 5.7 F " C60 4.4 1.3 F " C61 8.9 4.4 F " C62 5.4 0.1 F " C64 9.8 2.8 F " C67 10.7 3.3 F " C70 10.7 3.2 F " C72 10.5 2.
3600 Printer Maintenance Manual PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 8/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" C78 4.1 4.8 F " C79 5.3 5.4 F " C80 4.5 4.2 F " C83 2.4 3.4 F " C84 3.2 3.4 F " C85 2.0 5.3 F " C86 5.8 5.7 F " C87 6.3 4.4 F " C88 6.8 4.4 F " C89 5.6 4.4 F " C90 4.0 2.
PCB Drawings and Schematics 6 PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 9/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" D42 4.8 0.8 F " D43 5.8 1.0 F " D44 5.3 0.1 F " D45 4.6 1.4 F " D46 4.6 0.9 F " D47 4.6 0.8 F 59 4 564206 D1 DIODE,S/M,TYPE MMBD301 1.9 0.6 F " D2 1.8 0.6 F " D4 3.5 6.
3600 Printer Maintenance Manual PL# 061591-003 TITLE: PCB ASSY,MAIN,3600 PAGE 10/10 PL REV: D 02231995 RUN DATE: Feb 23 15:19:02 -------------------------------------------------------------------------------ITEM QTY/UM PART NO. REFDES DESCRIPTION X Y F/B -------------------------------------------------------------------------------" U18 4.0 3.2 F 85 1 578211-001 U3 IC,S/M,TYPE MC68332,MICPRCS 4.7 4.9 F 86 3 578245-001 U2 IC,S/M,LM293,DUAL VOLT COMPTR 4.0 1.1 F " U27 10.4 3.6 F " U31 2.8 0.
3600M.
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7 Replacement Parts
Replacement Parts 7 This chapter contains a list of 3600 printer replacement parts referenced to illustrations. Replacement Parts The following table is a copy of the 3600 service parts matrix with illustration references added. It lists the 3600 printer parts that can be ordered for replacement by the part number indicated. Each part on the list has an ID number corresponding to a callout on the illustration showing its location.
3600 Printer Maintenance Manual ID No. Part Number Description 17, 27 059012-009 PLATE, FRONT COVER 18, 20, 21, 40, 66, 155 526036 SCREW, PHP, W/INT STAR 6-32 X .375 19, 54 059052S-001 PCB ASSY, BEZEL 22 059387-003 BRACKET, HINGE 23 060315-002 ROLLER, PINCH 24 061581-001 SHAFT, PINCH ROLLER 25 501445 RING.RTN. .125 DIA. E-RING, ZINC 26, 44 061579S-003 DOOR ASSY, MEDIA ACCESS 28, 95 061555-001 EXTRUSION, PRINTED SPAN 29, 116 521118-001 WASHER, SPRING, CONL .175 X .
Replacement Parts ID No. Part Number Description 61 585525-001 585525-002 XFMR, 3600, 47-63HZ, 100V/120V XFMR, 3600, 47-63HZ, 200V/240V 62 041776 JUMPER AY, .25 TERM. LUGS, 4-IN 63 060246-001 FILTER ASSY, LINE AC 64 506103 WASHER, LOCK, EXT. STAR, NO. 65 501273-001 CIRCUIT BREAKER, SWITCH, 2 AMP 65 501273-002 CIRCUIT BREAKER, SWITCH, 1 AMP 67 506111 WASH. LOCK. SPLIT, NO. 4 68 060544-001 GASKET, ESD, RS232 CONNECT 69 507659-001 SCREW, JACK, 4-40X .
3600 Printer Maintenance Manual ID No. Part Number Description 101 061902-001 ARM, MEDIA BRAKE 102 062352-002 BELT, FLAT POLYURETHANE, 1.75 ID 103 061900-003 DRUM, MEDIA BRAKE 104 062746-002 BUSHING, MEDIA ARM 105 506022 WASHER, NYLON, .257ID X .
Replacement Parts 7 ID No. Part Number Description 144 061551-002 CABLE ASSY, MOTOR MAIN STEPPER 147 059102-002 BRACKET, MOTOR MOUNT 148 061554-004 PLATE, MOTOR 149 061584-002 SUBPLATE, LINER TAKEUP 151, 154 505359-001 SCREW, W/CONE WASH, 8-32X1 153 061588-002 GEAR, LINER REVERSE 156 062603-001 PLATE, HUB ADJUST 157 061583-002 SUBPLATE, TTR 158 061574S-001 CLUTCH, ASSY, SELF STRIP LINER TAKE-UP, 3600 SPARE 159 506040-007 WASHER, FLAT SST 446 X .
4 3 1 2 5 6 7 8 12 14 13 9 15 10 11 3600M.
16 17 26 18 19 20 23 22 3600M.
32 33 31 30 29 27 34 28 48 35 47 36 37 39 46 38 40 43 41 45 44 3600M.
71 49 70 50 69 51 52 68 53 67 66 65 64 63 62 61 60 59 54 58 57 56 55 3600M.
72 77 76 78 73 75 79 74 98 97 96 80 95 94 93 92 91 90 85 89 86 88 84 83 82 87 3600M.
101 100 102 103 99 104 105 106 107 108 109 110 111 112 113 123 122 114 124 120 121 115 119 118 116 3600M.
127 125 128 129 130 131 132 133 134 166 135 126 144 136 137 165 145 138 164 139 140 141 142 143 146 147 148 161 160 159 149 158 150 157 163 156 137 155 162 154 133 152 153 3600M.
A Appendix
Appendix A This appendix describes the theory of operation for the 3600 printer. Functional Description of the 3600 Mechanics This section describes the basic mechanical functionality of the 3600 printer. The 3600 printer has a sheet metal frame (base plate and main deck plate) to which mechanical and electrical components are attached. The printer holds, moves, routes for contact by the printhead, and stores label stock and ribbon by electronically controlled mechanical means.
3600 Printer Maintenance Manual A media supply assist roller and brake assembly are part of the media supply post function. The free spinning roller reduces the drag of the media core over the stationary supply post, allowing the media to turn smoothly during printing. When printing stops, the media slackens under the upper media guide, causing the media brake pedal and brake arm to lower onto the rubber contact strip on the brake drum, which inhibits media roll momentum by stopping the assist roller.
Appendix A Power Fail Detection The power fail detection circuitry consists of IC U31, diodes D7, D8, D9, and D11 and various resistors and capacitors. Diodes D7 and D8 rectify the incoming 12 VAC, and R101 and R107 act as a divider. D9 is a zener diode used to prevent the input on U31 from exceeding +5V. D11 is a 1.235V reference. When the voltage at pin 3 of U31 exceeds 1.235V, the output is pulled up by a 10K resistor, R183. R104 adds some hysterisis to help filter out noise or brownouts.
3600 Printer Maintenance Manual Motor Driver The motor driver circuit of the 3600 consists of ICs U2, U21, U17, and U19; discreet parts Q16, Q1, Q3, Q4, Q6, Q11, Q12, Q13, Q14; and associated diodes, resistors, and capacitors. The eight D-MOS FETs make up a dual full-bridge motor driver. There are four FETs to drive each motor phase. There are two FETs at each end of each motor phase. When a phase is driven or turned on, one FET on each end of a phase is turned on.
Appendix A Processor The processor used in the 3600 is a MMC68332 32-bit integrated microcontroller. Based on the MC68020, the MC68332 contains four peripheral modules: CPU32, a 32-bit central processing unit; TPU, a complex, programmable time processor unit; QSM, a queued serial module; and SIM, a system integration module. The MC68332 was chosen for its 32-bit processing power along with its high level of integration.
3600 Printer Maintenance Manual Channels 7 and 8 These outputs control the front panel LEDs. They can be set to high, low, or square wave outputs. The square wave output frequency is programmable. Channel 9 This output is reserved. It has RXD as an input for autodetection of the serial communications parameters. Channel 10 This is an input for the ribbon sensor. The channel detects transitions on the input.
Appendix A Memory The MC68332 has separate address busses and data busses. All I/O is memory mapped and the SIM chip selects are used to select program space, data space, and I/O. Static RAM The 3600 comes with 128K of battery backed static RAM. The RAM is configured as 128Kx8. The chip select for accessing SRAM should be configured to at least one wait state. The RAM can also be upgraded to 512K x 8 by swapping the component at location U6.
3600 Printer Maintenance Manual Communications Interface The communications interface for the 3600 follows the Intermec Standard Data Connector standard. J1 is a 25 pin D-sub connector that supports both RS-232 and RS-485 interfaces. U1 is the RS-485 driver/receiver and U22 and U4 are the RS-232 driver and receivers. To further enhance the interface to support DTR/RTS flow control, the DTR pin is driven with the PIN 14 signal.
Appendix A Chip Select Generation GALs U23 and U25 are designed to take the MC68332 bus control signals and convert them into ASIC and I/O option control signals. A state machine governs the timing of the signals and also dictates that the /OPTION_ASICCS from the processor be programmed for two wait states. I/O Option Connector The I/O option connector J8 is a 40-position pin field. Two chip selects, /OPTION∗ and /BOKI/O∗, are used to select either the board identification number or the data port.
3600 Printer Maintenance Manual Timing Row Name Formula Min Max 1D 2V 3D 4D 5C 6C 7D 8D 9V 10C 11C 12C 13C 14V 15D 16D 17D 18D 19D 20D 21C 22D 23C 24C 25D 26D 27D 28D 29C 30D 31C 32D 33D 34D 35D 36D 37C Tclsa Tco Tchav Tsy Trah Taist Tclsn Tsy Tpd Tasc Tasr Tras Tds Tsy Tpd Tpd Tco Tpd Tco Tpd Tcas Tclsa Trp Tcah Tco Tpd Tco Tchav Tasr Tco Trpc Tco Tco Tclsn Tclsa Tco Trp [3,30] [2,10] [2,39] [Tsy [15, ] [5, ] [3,30] Tsy [3,15] [0, ] [0, ] [80, ] [25, ] [4,12] Tpd Tpd Tco Tpd Tco Tpd [20, ] [3,30] [
Timing Diagram 0ns 100ns 200ns 6 clk S0 SW 400ns 500ns 600ns 13 S2 !clk 300ns S4 D1 S0 D2 S2 D0 S4 D3 S0 D4 SW D5 SW D6 D0 refresh 35 7 1 34 cs 31 11 12 5 29 23 25 37 32 27 26 36 ras 21 24 10 18 17 33 30 cas 15 16 addsel 19 20 dsack 28 row col row Appendix 3600M.
3600 Printer Maintenance Manual Functional Description of the 3600 Software This section describes the basic software functionality of the 3600 printer. Band Buffering and Font Caching Image band buffering and font caching allow Intermec printers to image and print labels at the same time. Virtually any label length can be accommodated due to the circular system of using image memory.
Appendix A The ideal setting keeps imaging just ahead of printing. This ideal setting can be found by the proper selection of image bands and print speed for the label format being printed. Image Band Example The following example shows a format print using image bands. The label is 5 inches long and is divided into five image bands. The printer is configured for three image bands, which means that three bands will be imaged before printing begins.
3600 Printer Maintenance Manual The third 1 inch of the label is imaged into the third image band. Printing begins from the first image band, as indicated by the arrow. At this point, all three available image bands have been filled. The first band will be reused after it has been completely printed. When the first image band is emptied (printed), the fourth band is imaged into it. Printing continues from the second image band.
Appendix A The final 1 inch of the label is imaged into the second image band. Printing continues from the third band. At this point, the label has been completely imaged but printing has not finished. After the third image band is emptied, printing continues from the first image band. Imaging of a second label could begin in the third image band while the first label is still printing.
3600 Printer Maintenance Manual Font Caching Most of the imaging time during text creation is spent converting character description data into character images. The remainder of the time is used to copy the character images into image RAM. Font caching helps to eliminate the reimaging of characters that have already been used. With font caching, a character is imaged into the cache the first time it is requested. It is then copied from the cache into the appropriate area of image RAM.
Appendix A Font Caching Flow Chart Request for character Character already exists in cache Check cache for requested character Available memory is returned Image character in allocated cache Character does not exist in cache Allocate memory in cache for character No memory is available Image character in reserve cache Return requested character 3600M.
