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ALLEGRO TIIERMAL PRINTER MAINTENANCE MANUAL

Troubleshooting

4.3 Printer Cabling and Interfacing

When the printer receives data from any host system, it will not function properly with an incorrectly wired cable. Proper wiring diagrams can be found in the Appendix. Table 4-2) below, lists the signal lines that must be correctly wired for the printer to operate properly.

~w:'~<yW%jirf.~~
liM ·t,:mJYit 11k 1~
TX 2
RX 3
BUSY 20
Ground 7
Jumper 4to 5
Shield 1 Table 4-2. I/O Port Wiring

Each time the Printer is powered up, it will reset itself to default (pre-determined) interfacing parameters. The default values are in listed in Table 4-3.

[;L?:'S>'r1&1WW~~~ ;!~'n'i~v;':;P'~i1llt¥f_
;~k.i.,~60.-J.;" t iifu~0*J,di&U&Aid<k..0! ms:
Baud Rate 9600
Data Bits 8
Parity NONE
Stop Bits 1 Table 4-3. Printer Default Communication Parameten

Changing the positions on DIP Switch SWI (on the back of the Printer) sets the unit for applications needing settings other than the defaults. Table 2-2 lists all of the switch positions and their meanings.

53

ALLEGRO tHERMAL PRINTER MAINTENANCE MANUAL

Troubleshooting

4.4 Troubleshooting

Should the Printer malfunction and require service. the following procedures should be used to isolate and correct the malfunction.

4.4.1 Initial Steps

WARNING - AL WAYS UNPLUG the unit before attempting to replace any parts.

AL WAYS be sure that the Printer has been placed on a level. stable surface.

Before attemptiDgany service:

o Be sure the Printers power cord has been plugged into a known good outlet of the correct voltage.

• Be sure the unit has been installed in an area which is within acceptable environmental conditions See. 1.3) .

., Perform a visual inspection of the Printer. Excessive accumulation of dirt or dust should be removed (Sec. 3.4.1).

o Confirm that the Printer has been correctly loaded with media of an acceptable type (Sec. 3.2).

4.4~ Using the Troubleshooting Charts

After performing the initial checks and confirming that conditions are correct, follow the Problem Isolation Checklist (Sec. 4.4.3). The Checklist is designed to direct the Technician to the appropriate repair routine.

Always begin with Step 1, follow the instruction listed under Check. Item, and answer the question, either Yes or No, listed under Result. The Corrective Action will direct the Technician either to another step or to one of the Troubleshooting Procedures.

When using the Troubleshooting Procedures; again; always begin with Step 1 and proceed in the same way as with the Problem Isolation Checklist. The Corrective Action will direct the Technician either to another step or to a suggested repair.

54

ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

Troubleshooting

4.4.3 Problem Isolation Checklist

,. ~I

~_~r~~ DmW'l}'o~~~'f':'J;i1NZ'$'_
~ P, "J;,'k' g"il
~1<'l<i «« fui& **'
1. Tum power on. YES Go to Step 2.
Does the POWER light come on? NO Go to Procedure 1.
2. Turn power off. Hold down the FEED button
and, while holding, turn power back on. YES Go to Step 3.

Does the Printer print Test Labels? NO Go to Procedure 2.
3. Hold down the FEED button and, while Unit tests OK. If the
holding, press and release the ON problem was reported by
LINEIP AUSE button. an operator, have them
The Printer will print a Test Label. demonstrate the
malfunction. The problem
may appear intermittently,
or may be the result of
YES operator error.
Is the Test Label print quality good? NO Go to Procedure 3. ) .. ,

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ALLEGRO TIIERMAL PRINTER MAINTENANCE MANUAL

Troubleshooting

4.4.3.1 Procedure 1. - Printer Does Not Power Up.

~_~[\D_
Check Power Cord and outlet.
Be sure the Printer is correctly plugged into a
good outlet of the appropriate voltage. YES Go to Step 2.
Plug the Printer into a good
outlet with correct voltage,
1. Is the Printer plugged in correctly? NO and re-test.
Check the Printer fuse.
(One fuse on the 115 V model ~ two fuses on
the 230 V). YES Go to Step 3.
Replace the defective fuse
2. Is the fuse good? NO and re-test.
Remove any memory cartridges from the Replace the memory
Printer. Turn power ON. YES cartridge. Re-test.
3. Does the POWER light go on? NO Go to Step 4.
Remove the Printer's outer Cover (Sec. 6.1.1).
Remove the Front Panel Cover (Sec. ). Check
the ribbon cable from the Front Panel to J2 on
the Main Logic Board. Be sure the cable is
correctly plugged in (to both the Front Panel
and Main Logic PCB's) and is not chaffed or
damaged. YES 00 to Step 5.
Plug the cable in correctly.
Replace any damaged
4. Is the cable correct? NO cable. Re-test.
Replace the Front Panel P.C. Board and re-test.
YES UnitOK.
5. Does the Printer power up? NO 00 to Step 6.
Check TP2 on the Main Logic Board for the
presence of +5 Volts DC. YES Go to Step 8.
6. Is the voltage present? NO Go to Step 7.
Tum Power OFF. Disconnect the Power
connector from the Main Logic Board at 13.
Check connector 13, pins 3 and 4, for the Replace the Main Logic
presence of+5 Volts DC. YES Board and re-test.
7. Is the voltage present? NO Replace Power Supply. 56

ALLEGRO THERMAL PRINIER. MAINTENANCE MANUAL

Troubleshooting

F-


Tum Power OFF. Disconnect the Motor Power
connector from J9 on the Main Logic Board.
Tum power back ON.
YES Replace the Stepper Motor
8. Does the Printer power up? NO Go to Step 9.
Tum Power OFF. Connect the Motor Power
connector to J9. Disconnect the Printhead
connector from 17. Tum power back ON.
YES Replace the Printhead.
9. Does the Printer power up? NO Replace Power Supply. t I t

t I I

I

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

Trosbleshoottng

4.4.3.2 Procedure 2 - Printer Powers Up, But Will Not Print Test Labels.

i}!ka_~1!~l4I~4'%qT\~
YES 0010 Step 2.
On the attempt to print a Configuration Label;
1. did the label stock show any motion? NO Go to Step 8.
YES Go to Step 3.
2. Was anything at all printed on the label? NO Go to Step 4.
Unit tests OK. If the
problem was reported by an
operator) have them
demonstrate the problem -
it may be intermittent, or
YES the result of Operator error.
3. Is the print quality good? NO Go to Procedure 3
If Thermal Transfer media is loaded) confirm
that the correct ribbon is install~ and the
Printer set for Transfer mode. YES Go to Step 5.
Correct the setting or install
4. the proper ribbon. Re-test,
Are the Ribbon and Printer setting correct? NO
Remove any installed memory cartridge. Tum
power off. Hold down the FEED button and"
while holding, tum power back on. Replace the memory
YES cartridge.
5. Does the unit print Test Labels? NO Go to Step 6.
Rotate the Head Lift Lever to raise the
Printhead. Check to see that the Printhead
cable is properly plugged in. YES Go to Step 7
Plug in the connectors
6. Is the connector plugged in correctly? NO correctly. Re-test.
Remove the Printer's cover. Locate connector
17 on the Main Logic Board. Check that the
cable to J7 is plugged in and undamaged.
Replace the Printhead and
YES re-test.
Plug in or replace the cable.
7. Is the cable to the J7 connector correct? NO
Press the FEED button and listen for the sound
of the motor.
YES Go to Step 7.
8. Does the motor attempt to operate? NO Go to Step 10. 58

ALLEGRO IHERMAL PRINTER MAINTENANCE MANUAL

Troubleshooting

m1D_I&~'0flDlmz~~i~~
The Head Lift Lever should already be in the
DOWN position. Without lifting the lever, try
to pull the media back into the Printer.
YES Go to Step 10.
Does the Drive Roller finnly hold the media in
9. place? NO Replace the Drive Roller
Turn the Printer OFF. Try to tum the Drive Remove and clean or
Roller by hand. replace the Drive RoUer.
YES Re-test
10. Is the Drive Roller jammed? NO Go to Step 11.
Remove the Printer's cover. Replace damaged or broken
Locate the Timing Belt. YES belt.
II. Is the belt damaged, broken or slipping? NO 00 to Step 12.
Remove the Printer's cover.
Check Test Point TP3 on the Main Logic
Board. (Sec. 5.9.3) Replace the Stepper Motor.
YES Re-test
12. Is +24 Volts DC present? NO Go to Step 11.
Disconnect power from the Main Logic Board
by unplugging connector J3.
Check for +24 Volts DC on J3 between Pins I
and 2. Replace the Main Logic
YES Board.
13. Is +24 Volts DC present? NO Replace the Power Supply. 59

ALLEGRO THERMAL PRINTER MAJNTENANCE MANUAL

Troubleshooting

4.4.3.3 Procedure 3. ~ Poor Print Quality

fLvI~I.~m4dItlt\i~~~lI
Press the ON LINEIP AUSE and the
FEED buttons together and, while holding
the FEED button, release ON
LINFJP AUSE. The Printer should print
Test Labels.
YES Go to Step 2.
1. Is anything printed on the Test Label ? NO 00 to Step 7.
YES Clean the Printhead (Sec 3.4.2).
Does the Test Label show random spots,
2. streaks or gaps? NO Go to Step 3.
YES Go to Step 4.
3. Is the print blurred or smeared? NO 00 to Step 5.
Perfonn the Tag Stock
YES Adjustment (Sec. 5.5).
Direct Thermal - Use stock with
a lower Reaction Temperature
(Sec 5.2).
Is the media thicker than standard Thermal Transfer - install a new
4. (4 mil)? NO ribbon of the correct type.
Perform the Direct Thermal
YES Stock Adjustment (Sec. 5.6)
Did the loss in print quality occur after
changing from Thermal Transfer to Direct
5. Thermal Media? NO Go to Step 6.
Printhead is in a skewed position
- use the Printhead Adjustment
screws to straighten the Printhead
YES (Sec.5.6)
Does the print gradually fade across the
6. width of the label? NO Go to Step 7. 60

ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

Troubleshooting

I'


Does the print suddenly stop across the
7. width of the label? NO Go to Step 8.
Open the Printer's door. Rotate the Head
Lift Lever to raise the Printhead. Check
the cable which plugs into the Printhead.
(See Sec. 6.4)
YES 00 to Step 9.
Plug the cable in correctly and
8. Is the cable correctly plugged in? NO re-test,
Remove the Printer's cover.
Locate connector J7 on the Main Logic
Board. Replace the Printhead. (Sec.
YES 6.2).
Plug in the cable correctly and
9. Is the cable correctly plugged in? NO re-test. 61

ALLEGRO THERMAL PRINTER MAINlENANCE MANUAL

Troubleshooting

62

5.

Adjustments

• Printhead Alignment

• Non-Standard Stock

• Sensors

ALLEGRO nrERMAL PRINTER MAINTENANCE MANUAL

A.q;uslments

64

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

A4/ustments

5 .. 1 Introduction

, .. I

This chapter discusses the adjustments that might sometimes be necessary to keep the Printer at maximum performance, Most often, adjustments are needed when the label stock being used varies significantly from the standard size of 4 in. width and 4 mil thickness. There are also adjustments that should be made when major components, such as the Printhead, have been replaced.

5.2 Controlling Print Quality

In order to offer the greatest flexibility, the Printer operates in both Direct Thermal and Thermal Transfer modes. However, due to the differences in these two technologies. some "fine tuning" may be required to maintain the highest print quality. These adjustments are discussed below.

The two most important factors that determine print quality are the amount of heat applied to the Printhead, and the position of the Printhead relative to the label media.

Applied Heat

The heat that must be generated. by the Printhead depends on the Reaction Temperature of the Print Media or Th.ennal Transfer Ribbon. The reaction temperature is the amount of heat needed to tum the media black. or to transfer an image from the ribbon. Many low cost types of direct thermal stock have very high reaction temperatures - it takes a great deal of heat to make clear images on this type of paper. On the other hand, Thermal Transfer Ribbons have a relatively low Reaction Temperature. The Printer has limits placed in the range of possible heat adjustments. in order to prevent settings that could damage the Printhead. The applied heat may be controlled either by adjusting the Darkness potentiometer. or by increasing the burn time through software. (For more information on adjusting burn time with software, see the Programmer's Manualfor AUegro, Prodigy and Prodigy Plus, "Label Format Commands".)

PriDthead Position

The Printer has been factory set to produce good print quality with most media However, when using stock other than the recommended 4 mil thickness, the Prlntbead position, ribbon, and media tracking may all require slight adjustments in order to maintain highest quality.

6S

ALLEGRO TIIERMAL PRINTER MAINTENANCE MANUAL

A.djustments

5.3 When Adjustments are Needed

Adjustments must be considered when dealing with any of the following situations:

• Narrow Stock

When using stock narrower than the standard 4 in. width, an adjustment may be needed to prevent the Printhead from rubbing on the Drive Roller.

• Tag Stock and Stiff Media

When stock that is thicker than 4 mil is in use, the Printhead can be moved forward. providing a slightly larger gap and allowing the thicker media to move freely along the media path.

• Direct Thermal Stock

Direct Thennal media generally requires greater heat than Thermal Transfer media in order to produce a comparable image. The print "bum point" can be moved closer to the Drive Roller, where the heat is greater.

• Printhead Mounting Assembly

The Printhead mounting system is designed so that there is normally no need to align a newly installed Printhead. However, if the Head Mount Assembly has been removed (for example, when replacing the Drive Roller), this adjustment should be performed,

• Electrical Adjustments

It is normal for the Printer's Edge Sensors to occasionally need small electrical adjustment to keep the sensor's sensitivity in the correct range. It may also sometimes be necessary to confirm the Power Supply voltage levels or ground.

NOTE - Unless otherwise stated, all adjustments should be performed with label stock that is at least 4 in. (102mm) wide. If the media that will normally be used is of a different size, make the standard adjustments first (using 4 in. media), and then fine tune the adjustments using the stock size that will be actually used.

66

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

I·. I

5.4 Adjusting for Narrow Stock

I:

. \

This adjustment should be performed when the stock to be used is narrower than 3.5 in. (89 mm). The parts involved in the adjustments are shown in Fig. 5~1 and 5-2.

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"

PAUl ~NJ U)JNT

FIXED

HlJUSTABlE

f'

f£AI) SlfPOHT PlATE ~AO SlPPOU ADJUST SCJfW

RIBBOI SHiElD

Fig. 5-1. Printhead Mount AMembly

The Head Support Plate, shown in the figure above, is designed to support the outer end of the Printhead. when narrow stock is in use. Engaging the Support Plate ensures that the Printhead does not contact the Drive Roller. which would potentially damage the Printhead and prematurely wear out the Drive Roller.

67

ALLEGRO THERMAL PRINTER MAINlENANCE MANUAL

Adjustments

To Adjust for Narrow Stock:

o Loosen the two screws that attach the Head Support Plate and Ribbon Shield to the Printhead Mount frame. Leave the left side screw slightly snugged.

• Load a supply of 4 in. wide label stock. (See Sec. 3.2.2.1 for stock loading instructions). Turn the Head Lift Lever to the DOWN position to engage the Printhead.

• Push down the right side of the Head Support Plate until the Plate just contacts the Bearing Block Mounting Bracket

• Turn the Head Support Adjustment Screw until it just contacts the Bearing Block Mounting Bracket.

• Tighten the two screws to secure the Head Support Plate and Ribbon Shield.

NOTE - The same screws secure both the Head Support Plate and Ribbon Shield, so that moving one could cause the other to move. Be aware, and avoid this if possible.

68

ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

5.5 Adjusting for Stiff or Tag Stock

~' . The horizontal position of the Printhead is set by turning the right and left Head Adjustment

~. Screws, which move the corresponding side of the Printhead in or out. When using stock that is much thicker than 4 mil, adjusting the Printhead away from the Roller may improve print quality. Note -This is a sensitive adjustment - A small tum can make a large difference in the print quality. Adjust these screws no more than 114 turn at a time until the print is satisfactory.

CAUTION: Do not turn the head adjusting screws more than 2 complete turns in either direction. Damage to the head mount assembly will result if the adjustment screws are turned too far.

5.6 Adjusting for Direct Thermal Stock

When the Printhead is set-up for use with thermal transfer stock, the Printhead burn point is set at a position on the roller where the ribbon separates from the label while the wax ink is still hot enough to be in a liquid state.

When direct thermal stock is used, the Printhead bum point should be moved slightly back, to a point where there is greater contact with the roller, causing heat to transfer to the media more efficiently.

For best results when using direct thermal label stock, turn both of the two head adjust serews 1/4 turn clockwise. Figure 5-2 is a partial cut-away view from the right side of the Printer, showing the Adjustment Screw Location. This adjustment will move the Printhead 0.006 in .. (O.lSmm) back on the roller. Remember to adjust back to the original position when returning to Thermal Transfer media.

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69

ALLEGRO nIERMAL PRINTER MAINTENANCE MANUAL

5.7 Adjusting for Printhead Alignment

The Printhead is precisely positioned on mount plate locating pins that are set at the factory. The locating pins should ensure correct alignment of all future replacement heads - it should not normally be necessary to re-align each new Printhead. However, if the Printhead mount assembly has been removed or disassembledt and there has been a consequent loss of print quality, the following alignment procedure may be required. Performing all steps, in the order given, should eliminate any problems with print quality.

Figures 5~1 and 5-2 illustrate the portions of the Printhead mounting assembly that are involved in the adjustment procedures.

There are four adjustments required to align the Printhead, They are:

o Stock TnekiDg Adjustment

• Ribbon Feed and Tracking Adjustment

• Printhead FiDe Adjustment

• Printhead Pressure and Support Adjustment

BEARI NG BLOCK

o

If AD SlPP(JlT PLATE

J{lL ER BEAR III

BEARI*" BLOCK ~

MOUNTING BRACKET

OlNT I NG SCREWS

o

o 0

Fig. S-l. Printhead, right side view - Adjustment details.

70

ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

5.7.1 Stof;k Tracld.ng Adjustment

For proper performance, it is critical that the stock move evenly through the media path. Any skewing will affect the print quality, and in some cases can cause jamming. The Stock Tracking Adjustment must be done with the printer power ON and a full roll of 4" (102mm) stock installed.

• Load the stock in the no11118l way. but keep the Media Retainer in the DOWN position.

"

~I.

• Use the FEED button to feed a few labels. At first the edge of the stock may move in and out as the media advances. After a few labels the stock should begin to track at a stable position.

• At this point, slightly bend the Media Guide Plate up or down to adjust the tracldng position to within approximately 0.3 in. (8 mm.) of the center plate. Bending the Plate down will move the tracking position closer to the Center Plate) while bending up will move the tracking position farther from the Center Plate.

(NOTE - It is suggested that a small object. such as a pen or pencil, should be placed between the Guide Plates. This will prevent bending the Plates so close together that the media will no longer feed smoothly.)

• Rotate the Media Edge Guide to the UP position. and stop feeding labels.

71

ALLEGRO THERMAL PRINlER MAINTENANCE MANUAL

A4iustments

5.7.2 Ribbon Feed aDd Traeking Adjustment

This adjustment must be performed with the printer power ON, a full roll of 4tt (l02mm) stock, and a rfbbon installed. (See Chapter 3. Fig 3-2 for Ribbon Loading instructions). Complete the steps for installing the ribbon, except. do Dot secure the ribbon to the Ribbon Take-Up Hub.

• Press the FEED button several times and check to see if any wrinkling or bagging of the ribbon occurs as it moves from the supply hub and goes under the Printhead assembly. Ifrippling or bagging does occur, go to step 2. lfno wrinkling is observed, go on to the Printhead Fine Adjustment procedure, Section 5.7.3.

• The next step is to adjust the tension and position of the Ribbon Supply Hub.

Maintaining an even tension will help eliminate ribbon wrinkling. On the shaft Support Bracket, slightly loosen (but do not remove) the four screws securing the bracket to the Center Plate (Fig. 5-3).

• Apply moderate pressure up or down on the Ribbon Supply Hub or the Shaft Support Bracket while pressing FEED to advance labels. The object is to reposition the Supply Hub so that ribbon tension is even across entire width of the media path. An even tension should eliminate any ribbon wrinkling.

Apply Pressure Her~

Fie. 5-3 Adjusting Ribbon Tension.

72

ALLEGRO THERMAL PRINTER MAINiENANCE MANUAL

Adjustments

I~' •

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~r";
'~~,~,
, •
, Once the bracket is positioned properly, re-tighten the four screws that attach the bracket to the Center Plate. Feed three or four more labels to re-check the ribbon. Make certain that the ribbon does not ripple or bag.

Feed ribbon and labels together from the front of the printer. Check the ribbon to be sure that the ribbon and label edges stay aligned. If the ribbon overlaps one edge of the paper stock, the ribbon and paper are not following the same path. Should this happen" the Ribbon Shield position may need to be adjusted. If the ribbon shows no overlap; proceed to the Printhead Fine Adjustment procedure, Section 5.7.3.

e To adjust the Ribbon Shield, gently push the ribbon out of the way and loosen (but do not remove) the screw securing the left side of the Head Support Plate and Ribbon Shield (Fig. 5-4).

• Press the FEED button to advance labels, while moving the left side of the Ribbon Shield up or dovvn until the edges oflabels and ribbon track together.

Printhead Support Plate

Printhead Support 'ustment Screw

Mounting Screws (2)

Ribbon Shield

Fig. 54 Printhead Support Plate aDd RJbbon Shield - detaU.

73