ALLEGRO TIlERMAL PRINTER MAINTENANCE MANUAL

5.7.3 Prmthead Fine Adjustment

o Print a few labels with Bar Codes rotated at either 90e or 2700, and inspect the print quality. Imperfections in the print will be more evident in the rotated Bar Code images. If the print quality is less than satisfactory, go to step 2.

Rotated Bar Codes are available on the Ribbon Test Label. To produce this label:

• Simultaneously press the PAUSE and FEED buttons. The Printer will generate a label with a Bar Code in normal rotation.

• Press the STOP/CANCEL button.

• Press the PAUSE button. The Printer will generate a label with Bar Codes in 90e rotation.

• With a 1116" (1.59mm) hex key; turn the left and right Head Adjustment Screws (Fig. 5-2) either clockwise or counter-clockwise 1/4 to 112 turn at a time) until the desired print quality is achieved.

Never turn these screws more than 112 turn at a time or more thaD 2. full turns in total.

• Adjusting the head position often moves the Bearing Block out of contact with the Head Support Plate. Loosen the two screws that secure the Bearing Block Mounting Bracket. Push the Bearing Block back until it just contacts the Head Support Plate.

o Tighten the two mounting screws to secure the Bearing Block and Mounting Plate .

., Sometimes performing the Printhead Fine Adjustment can slightly change the stock and ribbon tracking settings. Feed a few labels and look for any return of ribbon wrinkling. If there is any sign of ribbon tracking problems, return to Section 5.7.2 Ribbon Feed and Tracking Adjustment, and repeat the adjustment.

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ALLEGRO TIIERMAL PRINTER MAIN1ENANCE MANUAL

A.41ustments

s. 7.4 Printhead Pressure and Support AdjustmeDt

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The function of the Head Support Plate is to support the outer end of the Printhead when narrower media is being used. Without this support, the Printhead would press on the drive roller. causing poor print quality, premature wear and possible Printhead damage. The head support plate is needed only when the media width is less thaD 3.5ft•

Pressure for the Printhead is provided by two springs in the head mount assembly. These springs apply a constant force on the Printhead, If media that is less than 3.5 in. (89 mm.) wide is to be used, the Printhead Support Plate should be adjusted. Figure 5-4 shows the assembled Printhead Mount. Figure 5-1 illustrates the relevant parts of the Printbead Mount in an exploded view.

To adjust:

o Loosen the two screws securing the Head Support Plate to the Printhead MOWlt. Leave the screw on the left side slightly snug (Fig. 5-4)

• Load a supply of the media to be used. Tum the Head Lift Lever to the DOWN position to engage the Printhead.

• Turning the Head Support Adjustment Screw will raise and lower the right side of the Printhead. Turn the Adjustment Screw clockwise until the print on the right side of the label begins to degrade.

.. Tum the Adjustment Screw back 1I4 turn counter-clockwise to set the correct adjustment.

• Finally, tighten the two mounting screws to secure the Head Support Plate.

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

5.8 Sensor Adjustments

The Printer contains a pair of sensors in the media path which merit discussion. Both the Label Edge Sensor and the Reflective Edge Sensor are designed to operate without adjustment. However, if components in either sensors circuit have been replaced, the sensor may need a setup adjustment. Procedures for adjusting both sensors are given below.

5.8.1 Label Edge Sensor Adjustment

o Remove the Printer's outer cover to expose the Main Logic Board (Sec. 6.1).

• Remove a few labels from their backing, and locate the Media Sensor (Fig. 5-5).

• Place the label bacldDg material between the "fingers" of the sensor.

f) Connect a Multi-meter to the Main Logic Board - the black lead connects to the heat sink, and red lead to Test Point TP I

... Adjust potentiometer RP2 until the meter shows a reading of between 0.15 and 0.35 volts DC.

• Press the FEED button. The Printer may feed a few labels while it aligns itself. Afterwards. it will feed one label each time the Feed button is pressed. When a label is in place in the sensor, the voltage at TPI should be greater than 2.0 "olts DC.

• Replace the Printers cover.

Label BEicking

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Fig. 5-5 Insert the Label Bac:king between tbe Se.sor "finlenii.

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

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Potentiometer RP2

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Test Point TPI

Potentiometer RPI

Heat Sink

Fig. 5-6 Mal .. Logic Board. Sem.or Adju8tme .. t Points

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Adjustments

ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

5.8.2 ReOective Edge Sensor Adjustment

The Reflective Edge Sensor detects the motion and position of label stock by sensing the presence of a "carbon black" line on the back side of the label. Since the sensor operates by detecting interruptions in a beam of infra-led light, this line must be a non-reflecting flat black that will absorb the infra-red beam.

This adjustment should be performed with power on, 4 in. width label stock loaded, and the Printer connected to a host termiDal. The labels used in the procedure must be reDeetive type, with a black line on the back.

o Remove the Printer's cover to expose the Main Logic Board (Sec. 6.1).

• Remove a few labels from their backing, and locate the sensor.

• Place some of the label backing material between the "ficgers" of the sensor so that black line on the label back is Dot within. the sensor.

G Connect a Multimeter to the Main Logic Board. Connect the black lead (Common) to the heat sink, and red lead (positive) to Test Point TPI (Fig. 5-6).

• Set the Printer to ReOeetive Senior mode. (Note - Changing the sensing mode requires that the Printer be connected to a host unit. Sending the command string "<CTL> B rtf from the host unit switches the Printer to Reflective sensing mode. (A sample program to send this command string may be found in Appendix Sec. A2.0). See the Programmer's Manualfor AUegro, Prodigy, and Prodigy Plus (part No. 88- 2054-01) for further information on using command strings.

(I Adjust potentiometer RPl until the meter reads 0.75 Volts DC.

• Press the FEED button. The Printer may feed a few labels while it self-aligns. It will then feed one label each time the button is pressed. When the reflective black mark is in place within the sensor, the voltage at TPI should be greater than 2.0 volts DC.

tD Replace the Printer's cover.

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

5.9 Electrical Checks

Three electrical tests may occasionally be needed, since incorrect voltage levels or bad grounds can generate many problems in the Printer. These are tests of the ground, the 5 Volt and the 24 Volt supply voltages) which are discussed below. If the ground or the voltage levels are not within the required tolerances, refer to Section 4, Troubleshooting, and follow the procedures listed .

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5.9.1

Ground Test

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Connect a Voltmeter to the Printer in the following way: Connect the Common lead (black) to the heat sink located at the base of the Main Logic Board. Set the meter to measure the range around 10m V. Connect the' Positive lead (red) to the left side lead of capacitor C45, located near the top of the Main Logic Board.

•

The voltage measured should be less than IOmV. If the voltage reading is above 10m V ~ or if it shows large fluctuations, re-connect the Common lead to the heat sink and then re-measure. If the voltage is still wrong, check the components connected to the heat sink - one of them may be defective.

Test. Point TPI

Capacitor C45

Heat Sink

Test Point TP3

Fig. 5-7 Main Loaie Board - Test points.

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ALLEGRO lHERMAL PRINTER. MAINTENANCE MANUAL

Adjustments

5.9.2 5 Volt Supply Test

o Connect a Voltmeter to the Printer in the following way: Connect: the Common lead (black) to the heat sink located at the base of the Main Logic Board (Fig. 5-7).

• Connect the Positive lead (red) to test point TP2 on the Main Logic Board.

• Acceptable voltage will be between 4.75 and S.2S Volts DC.

5.9.3 24 Volt Supply Test

o Connect a Voltmeter to the Printer in the following way: Connect the Common lead (black) to the heat sink at the base of the Main Logic Board.

• Connect the Positive (red) lead to test point TP3 on the Main Logic Board (Fig. 5~ 7).

• Acceptable voltage will be between 21.5 and 26.5 Volts DC.

CAUTION - Shorting the voltage probes with this relatively large voltage could cause damage to the meter or the Printer.

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:: 6. Removal and Replacement

• Printhead

• Circuit Boards

• Sensors

• Electro-mechanical Parts

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ALLEGRO TIlERMAL PRlN1ER MAINTENANCE MANUAL

Removal and REplacement

PIN: 510391

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ALLEGROTHERMALP~RMAThITENANCEMANUAL

Removal and Replacement

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6.0 Introduction

$" Even with the best design, manufacture and owner maintenance, occasionally parts will need

% • replacement. This section provides detailed removal and replacement procedures for the parts that most

$ often need service. The manual also contains complete assembly drawings and part numbers, so that

~. . any missing or defective part may be replaced.

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W ARNlNG - Unless otherwise indicated, before proceeding with any removal or replacement procedure, turn power OFF and UNPLUG the Printer. Failure to do so could result in serious injury or damage to equipment.

P~:510391 83

ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

RemOllQl and Replacement

6.1 Cover Removal and Replacement

When servicing the Printer, the first step is almost always removal of the outer cover. Use the following procedure:

Removal

o Tum the Power Switch OFF, and unplug the Printer's power cord.

• Remove the two screws on the upper, inside cover which attach the cover to the center plate.

• Gently pull outwards and up at a point in the center of the cover below the memory module slot. Slowly move the cover straight up to remove it.

[ CAUfION - The i??~~ must NOT be removed from tb.C top first. Doing so can damage the cover. a

Cover Screws

Fig. 6-1 Cover SCftW locadon

PIN": .510391 84

ALLEGRO TIlERMAL PRINTER MAINTENANCE MANUAL

Replacement

Removal and Replacement

o To replace, gently slide the cover straight down onto the Printer, and see that the groove at the rear of the cover slides into place around the back panel.

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• When it is almost in place, gently pull outward on opposite sides of the bottom of the cover . This will widen it and allow it to pass over the catch that holds the cover in place.

With the cover fully in place, replace and tighten the two screws on the upper inside part of the cover.

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Fig. 6-2 Cover catch locatio ••

PIN: 510391

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

R£moval and Replacement

6 .. 2 Tear Bar

Removal

o Place thumbs or fingers firmly against the tear bar plate.

.. Press in on the plate while sliding it upwards, until it disengages .

., Pull the plate straight out to remove.

Replacement

Ftc. 6-3 Tear Bar removal

Reverse the above steps to re-install.

PIN: 510391

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ALLEGRO~PRThITERMAunENANCEMANUAL

Removal and Replacement

6.3 Printbead Replacement and Adjustment

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Removal

o Tum the Power Switch OFF, and unplug the Printer's power cord.

• Unload the label stock and remove the ribbon (ifiDstalled). See Sec. 3.2.4.

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• Tum the Head Lift Lever counter-clockwise to the Down position.

G While looking into Printhead area from the side, place a small flat-head screwdriver into the notch in the side of the Printhead plug, and gently move the screw driver back and forth to loosen the plug.

.. Using needle-nosed pliers, carefully disconnect the Printhead cable from the Printhead. Be especially careful not to damage the ribbon cable.

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Printhead

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Printhead Plu/::

Fig.6-4 Unplugging the Priuthead Cable.

PIN: 51039l

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ALLEGRO THERMAL PRINTER MAINTENANCE MANUAL

Removal and Replacement

«& The Printhead mounting screw is located inside a small circular opening on the top of the Printhead assembly. Loosen the mounting screw. (Note -This is a captive screw that stays with the mounting assembly - Do not attempt to remove it completely; loosen the screw only until it disengages from the Printhead.)

C4UTION - To prevent damage to the Printer from static electrical discharge, the technician should always ground himself by touching the Printer chassis before handling the Printhead.

Fig. 6-5 Printhead Mountio, Screw location.

• To release the Printhead, turn the Head Lift Lever fully clockwise, and slide the Printhead out from the side of the assembly, being careful not to scratch the printing surface of the Printhead.

P!N:510391

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ALLEGROTHERMALP~RMAnnENANCEMANUAL

Removal and Replacement

Replacement

• Carefully slide a replacement Printhead into the assembly, making sure that the dowel pins on the Printhead bracket fit into the hole on the left side of the Printhead and the slot on the right side of the Printhead. Make sure the Printhead is flush with the head mount bracket.

Hole

Printhead Socket

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Fig. 6-6 Printbead positioning holes.

CD Secure the Printhead to the mechanism by tightening the Printbead mounting screw. Be careful not to over-tighten the screw.

e Insert the Printhead cable and press it in until it snaps into place.

Adjustment

Use the Self Test function to generate test print labels. Adjust the Darkness Pot, (See Fig. 3-1 for location) until the new Printhead achieves the same print contrast as the original.

NOTE - The Locating pins on the mount assembly act to automatically position the Printhead.

Normally there will be no need to make any alignment adjustments after installing a new Printhead. However, should a replacement perform poorly, there are some adjustments that may help improve performance. These are discussed in Sec. 5.3 ~ Adjustments.

PIN: 510391 89