1 960624 00 20SM 20PX4i 20 20PX6i1403955131998

Service Manual
EasyCoder PX4i and

EasyCoder PX6i
Bar Code Label
Printers
Intermec Technologies Corporation
Corporate Headquarters
6001 36th Ave. W.
Everett, WA 98203
U.S.A.
www.intermec.com
The information contained herein is proprietary and is provided solely for the purpose of allowing
customers to operate and service Intermec-manufactured equipment and is not to be released, repro-
duced, or used for any other purpose without written permission of Intermec.
Information and specifications contained in this document are subject to change without prior
notice and do not represent a commitment on the part of Intermec Technologies Corporation.
© 2004 by Intermec Technologies Corporation. All rights reserved.
The word Intermec, the Intermec logo, Norand, ArciTech, CrossBar, Data Collection Browser,
dcBrowser, Duratherm, EasyCoder, EasyLAN, Enterprise Wireless LAN, EZBuilder, Fingerprint,
i-gistics, INCA (under license), InterDriver, Intermec Printer Network Manager, IRL, JANUS,
LabelShop, Mobile Framework, MobileLAN, Nor*Ware, Pen*Key, Precision Print, PrintSet, Route-
Power, TE 2000, Trakker Antares, UAP, Universal Access Point, and Virtual Wedge are either trade-
marks or registered trademarks of Intermec Technologies Corporation.
Throughout this manual, trademarked names may be used. Rather than put a trademark (™ or ®)
symbol in every occurrence of a trademarked name, we state that we are using the names only in an
editorial fashion, and to the benefit of the trademark owner, with no intention of infringement.
There are U.S. and foreign patents pending.
The name Centronics is wholly owned by GENICOM Corporation.
Kimdura is a registered trademark of Kimberly Clark.
Microsoft is a registered trademark of Microsoft Corporation.
Torx is a registered trademark of Camcar Division of Textron Inc.
TrueDoc is a registered trademark of Bitstream, Inc.
TrueType is a trademark of Apple Computer Inc.
Unicode is a trademark of Unicode Inc.
Valeron is a registered trademark of Valéron Strength Films, an ITW Company.
Windows is a trademark of Microsoft Corporation.
Contents
Contents
Before You Begin................................................................................................................. vii
Safety Summary ................................................................................................. vii
Safety Icons ....................................................................................................... vii
Global Services and Support .............................................................................viii
Warranty Information ............................................................................. viii
Web Support........................................................................................... viii
Telephone Support.................................................................................. viii
Who Should Read This Document? ........................................................ viii
Related Documents................................................................................. viii
Introduction ........................................................................................................................ ix
1 Models and Options

1.1
1.2
Identification..............................................................................................................2
EasyCoder PX4i Specifications ...................................................................................8
1.3 EasyCoder PX6i Specifications .................................................................................10
1.4 Measures EasyCoder PX4i ........................................................................................12
1.5 Measures EasyCoder PX6i ........................................................................................13
2 Front and Keyboard

2.1
2.2
Front........... .............................................................................................................16
Keyboard/Display ...................................................................................................17
2.3 Console pcb. ............................................................................................................21
3 Covers and Doors

3.1
3.2
Right-Hand Door ....................................................................................................26
Front Door...............................................................................................................27
3.3 Left-Hand Cover ......................................................................................................28
4 Chassis
4.1
4.2
Description ..............................................................................................................30
Center Section .........................................................................................................32
4.3 Bottom Plate ............................................................................................................32
4.4 Rear Plate .................................................................................................................33
5 Media Supply
5.1
5.2
Internal Supply ........................................................................................................36
Paper Sensor .............................................................................................................39
5.3 Three-inch Adapters .................................................................................................40
5.4 Media Roll Retainer .................................................................................................41
5.5 Fan-Fold Guides.......................................................................................................42
6 Label Slack Absorber

6.1
6.2
Description ..............................................................................................................46
Dismantling .............................................................................................................47
EasyCoder PX4i and PX6i Service Manual iii

Contents
7 Transfer Ribbon Mechanism

7.1
7.2
Description ..............................................................................................................50
Ribbon Supply Unit .................................................................................................51
7.3 Ribbon Rewind Unit................................................................................................54
7.4 Ribbon Sensor..........................................................................................................57
8 Print Unit
8.1 Description ..............................................................................................................60
8.2 Platen Roller ............................................................................................................67
8.3 Stepper Motor ..........................................................................................................70
8.4 Belts .........................................................................................................................72
8.5 Label Stop Sensor .....................................................................................................76
8.6 Printhead .................................................................................................................84
8.7 Headlift Sensor ........................................................................................................93
8.8 Headlift Mechanism .................................................................................................96
8.9 Ribbon Assist Roller ...............................................................................................100
8.10 Media Feed Principles ............................................................................................102
9 Liner Takeup Kit

9.1 Description ............................................................................................................106
9.2 Main Parts..............................................................................................................109
9.3 Liner/Batch Takeup Unit........................................................................................111
10 Label Taken Sensor

10.1 Description ............................................................................................................114
10.2 Installation .............................................................................................................115
10.3 Activating the LTS .................................................................................................116
10.4 Adjustment ............................................................................................................116
11 Paper Cutter
11.1 Description ............................................................................................................118
11.2 Installation .............................................................................................................119
11.3 Controlling the Cutter ...........................................................................................122
11.4 Media Load ............................................................................................................122
11.5 Servicing ................................................................................................................123
11.6 Spring Replacement ...............................................................................................124
12 Electronics Compartment
11.1 Introduction...........................................................................................................126
11.2 Accessing the Electronics Compartment .................................................................126
11.3 Main Parts..............................................................................................................127
13 Power Supply
13.1 Description ............................................................................................................130
13.2 Replacements .........................................................................................................133
13.3 Components ..........................................................................................................134
13.4 Schematics .............................................................................................................136
iv EasyCoder PX4i and PX6i Service Manual

Contents
14 Driver Board
14.1
14.2
Description ............................................................................................................138
Replacement ..........................................................................................................138
14.3 Components ..........................................................................................................140
14.4 Schematics .............................................................................................................142
15 CPU Board
15.1
15.2
Description ............................................................................................................144
Circuits ..................................................................................................................145
15.3 Connections ...........................................................................................................150
15.4 Test Points..............................................................................................................151
15.5 Startup ...................................................................................................................152
15.6 Components ..........................................................................................................153
15.7 Schematics .............................................................................................................155
15.8 Replacing the CPU board ......................................................................................164
16 Interfaces
16.1 Introduction...........................................................................................................166
16.2 Serial Communication Port "uart1:" ......................................................................167
16.3 USB Interface.........................................................................................................168
16.4 Bar Code Wand Interface .......................................................................................169
16.5 Installing an Optional Interface Board ...................................................................170
16.6 Serial/Industrial Interface Board .............................................................................174
16.7 Double Serial Interface Board ................................................................................184
16.8 IEEE 1284 Parallel Interface Board ........................................................................194
16.9 EasyLAN Ethernet Interface Board ........................................................................198
16.10 EasyLAN Wireless Interface Board .........................................................................203
17 Troubleshooting
17.1 Diagnosing ............................................................................................................ 210
17.2 No Reaction at Power Up ...................................................................................... 213
17.3 Printer Stops Working after Startup....................................................................... 214
17.4 CPU Board Failures .............................................................................................. 216
17.5 Power Supply Unit Failures ................................................................................... 218
17.6 Driver Board Failures ............................................................................................ 219
17.7 Console Errors ...................................................................................................... 220
17.8 Error Messages ...................................................................................................... 222
17.9 No Communication (general) ............................................................................... 224
17.10 No Serial Communication .................................................................................... 225
17.11 No Network Communication ............................................................................... 227
17.12 Sensor Malfunctions.............................................................................................. 231
Label Stop Sensor (LSS) ................................................................................. 231
Headlift Sensor ............................................................................................... 232
Label Taken Sensor (LTS) ............................................................................... 232
Ribbon Sensor ................................................................................................ 233
Paper Sensor ................................................................................................... 233
17.13 Printing Troubles ................................................................................................... 234
17.14 Transfer Ribbon Troubles ...................................................................................... 238
17.15 Liner Takeup Troubles ........................................................................................... 240
17.16 Memory Card Troubles ......................................................................................... 241
17.17 Paper Cutter Troubles............................................................................................ 242
EasyCoder PX4i and PX6i Service Manual v

Contents
A Program Overviews
Intermec Shell Overview ...................................................................................................246
Setup Mode Overviews (Fingerprint) ...............................................................................247
Setup Mode Overviews (IPL) ............................................................................................256
B Firmware Upgrading
Introduction......................................................................................................................262
General Principles .............................................................................................................262
Upgrading From a Memory Card ......................................................................................263
Upgrading From the Host .................................................................................................265
C Measuring the Break Torque

Measuring the Brake Torque .............................................................................................270
vi EasyCoder PX4i and PX6i Service Manual

Before You Begin
Before You Begin

This section provides you with safety information, technical support infor-
mation, and sources for additional product information.
Safety Summary
Your safety is extremely important. Read and follow all warnings and cau-
tions in this document before handling and operating Intermec equipment.
You can be seriously injured, and equipment and data can be damaged if
you do not follow the safety warnings and cautions.
Do not repair or adjust alone
Do not repair or adjust energized equipment alone under any circum-
stances. Someone capable of providing first aid must always be present for
your safety.
First aid
Always obtain first aid or medical attention immediately after an injury.
Never neglect an injury, no matter how slight it seems.
Resuscitation
Begin resuscitation immediately if someone is injured and stops breath-
ing. Any delay could result in death. To work on or near high voltage, you
should be familiar with approved industrial first aid methods.
Energized equipment
Never work on energized equipment unless authorized by a responsible
authority. Energized electrical equipment is dangerous. Electrical shock
from energized equipment can cause death. If you must perform autho-
rized emergency work on energized equipment, be sure that you comply
strictly with approved safety regulations.
Safety Icons
This section explains how to identify and understand dangers, warnings,
cautions, and notes that are in this document. You may also see icons that
tell you when to follow ESD procedures.
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.
A caution alerts you to an operating procedure, practice, condition, or
statement that must be strictly observed to prevent equipment damage
or destruction, or corruption or loss of data.
This icon appears at the beginning of any procedure in this manual
that could cause you to touch components (such as printed circuit
boards) that are susceptible to damage from electrostatic discharge
(ESD). When you see this icon, you must follow standard ESD guide-
lines to avoid damaging the equipment you are servicing.
Note: Notes either provide extra information about a topic or contain spe-
cial instructions for handling a particular condition or set of circumstances.
EasyCoder PX4i and PX6i Service Manual vii

Before You Begin
Global Services and Support

Warranty Information
To understand the warranty for your Intermec product, visit the Intermec
web site at http://www.intermec.com and click Service & Support. The
Intermec Global Sales & Service page appears. From the Service & Support
menu, move your pointer over Support, and then click Warranty.
Web Support
Visit the Intermec web site at http://www.intermec.com to download
our current documents in PDF format. To order printed versions of the
Intermec manuals, contact your local Intermec representative or distribu-
tor.
Visit the Intermec technical knowledge base (Knowledge Central) at
http://intermec.custhelp.com to review technical information or to request
technical support for your Intermec product.
Telephone Support
Contact your local Intermec representative. To search for your local repre-
sentative, from the Intermec web site, click Contact.
Who Should Read This Document?
This Service Manual provides you with in-depth information about the
EasyCoder PX4i and PX6i printers and how to maintain, repair, and trou-
bleshoot them. It is primarily intended for authorized service technicians.
Related Documents
The Intermec web site at http://www.intermec.com contains our current
documents that you can download in PDF format. To order printed ver-
sions of the Intermec manuals, contact your local Intermec representative
or distributor.
We recommend that the service technician keeps the following manuals
easily accessible in electronic or printed form:
• Intermec EasyCoder PX4i, User’s Guide (Fingerprint version)
• Intermec EasyCoder PX6i, User’s Guide (Fingerprint version)
• Intermec EasyCoder PX4i, User’s Guide (IPL version)
• Intermec EasyCoder PX6i, User’s Guide (IPL version)
• Intermec EasyCoder PX4i and PX6i, Spare Parts Catalog
• Installation Instructions for various options
• Intermec Direct Protocol v8.30 (or later), Programmer’s Reference Manual
• Intermec Fingerprint v8.00 (or later), Tutorial
• Intermec Fingerprint v8.30 (or later), Programmer’s Reference Manual
• IPL Programming, Reference Manual (rev. 007 or later)
• EasyLAN Interface Kit, Installation Instructions
• EasyLAN Wireless Interface Kit, Installation Instructions
• EasyLAN, User’s Guide
• EasyLAN Network Setup, User’s Guide
viii EasyCoder PX4i and PX6i Service Manual

Before You Begin
Introduction
This Service Manual is intended to facilitate installation, troubleshoot-
ing and repair of the Intermec EasyCoder PX4i and PX6i printers in the
versions delivered at the date of publishing. Thus, all information on the
Intermec Fingerprint (FP) firmware is based on version 8.30 and informa-
tion on the Intermec Programming Language (IPL) is based on version
2.30. The on-going product improvement can be followed in the Printer
Technical Bulletins from Intermec.
Note that even if the printers are technical identical (with the exception of
the keyboard overlay), Fingerprint and IPL make the printer work quite
differently and certain devices and options are not supported by IPL.
Generally, illustrations in this manual show printers with a Fingerprint-
compatible keyboard.
Please note that the operations described in this manual only should be car-
ried out by skilled and authorized personnel with proper training and full
understanding of written English. The printers contain wires and circuits
with up to 380V, which implies the risk of electrical shock. Moving parts
may also cause harm, if incorrectly manipulated.
It is assumed that the reader possesses reasonable skills in mechanics and
electronics and is familiar with the Intermec programming languages
(Fingerprint or IPL) and their related standard application programs.
It is also assumed that the reader has access to the standard tools of an
electronics workshop.
EasyCoder PX4i and PX6i Service Manual ix

Before You Begin
x EasyCoder PX4i and PX6i Service Manual

1 Models and Options
This chapter describes how to identify the various models in the EasyCoder
PX4/6i-series of printers, provides comprehensive technical specifications,
and gives all important measurements.
EasyCoder PX4i and PX6i Service Manual 1

Chapter 1 — Models and Options
1.1 Identification
Main Models
The EasyCoder PX4i and PX6i constitute a series of direct thermal/thermal
transfer printers, which can run either Intermec Fingerprint Programming
Language (FP) v8.30 (or later) or Intermec Programming Language (IPL)
v2.30 or later. Externally, the difference is visible on the keyboard overlay.
Fingerprint printers have 23 keys or a full alphanumeric keyboard and IPL
printers have 8 keys (see Chapter 2).
EasyCoder PX4i has a maximum print width of 112 mm (4.4 in).
EasyCoder PX6i has a maximum print width of 167.4 mm (6.59 in).
Printers running Fingerprint are available with an 8 dots/mm (203.2 dpi)
or 11.81 dots/mm (300 dpi) printhead density, whereas printers running
IPL only are available with an 8 dots/mm (203.2 dpi) printhead.
A number of options and accessories, such as cutter, internal liner takeup,
label taken sensor, and various types of interface boards, allow the printers
to be tailor-made or adapted for specific applications.
EasyCoder PX4i EasyCoder PX4i

Fingerprint model IPL model
EasyCoder PX6i EasyCoder PX6i

Fingerprint model IPL model
Note: Unless otherwise stated, illustrations in this manual show an Easy-

Coder PX4i running Intermec Fingerprint.
2 EasyCoder PX4i and PX6i Service Manual

To identify the printer, start by reading the machine label attached to the
rear of the printer. The machine label contains type, part number, serial
number, and signs of approval.
The printer can use any 90 to 265 VAC, 45 to 65Hz voltage. The switched
power supply eliminates the need for any manual voltage selector.
Machine
label

Options for EasyCoder PX4i

The EasyCoder PX4i can be fitted with a number of options:
• Label Taken Sensor (see Chapter 10)
• Integral Liner/Batch Takeup Unit (see Chapter 9)
• 3-inch Adapter (for media supply hub) (see Chapter 5)
• Media Roll Retainer (for media supply hub) (see Chapter 5)
• Fan-Fold Guides (see Chapter 5)
• Cutter (see Chapter 11)
• Real Time Clock Circuit (not IPL) (see Chapter 15)
• Alphanumeric keyboard (not IPL) (see Chapter 2)
• One or two interface boards of various types
(only one parallel board with IPL) (see Chapter 16)
• EasyLAN interface (Ethernet or Wireless) (see Chapter 16)
EasyLAN antenna
3-inch adapter
(included)
Alphanumeric Fan-fold guide

keyboard
(Fingerprint only)
Media
roll
Label taken sensor retainer
Cutter
Liner/batch takeup unit

Options for EasyCoder PX6i

The EasyCoder PX6i can be fitted with a number of options:
• Label Taken Sensor (see Chapter 10)
• Integral Liner Takeup Unit (see Chapter 9)
• 3-inch Adapter (for media supply hub) (see Chapter 5)
• Fan-Fold Guides (see Chapter 5)
• Cutter (see Chapter 11)
• Real Time Clock Circuit (not IPL) (see Chapter 15)
• Alphanumeric keyboard (not IPL) (see Chapter 2)
• One or two interface boards of various types
(only one parallel board with IPL) (see Chapter 16)
• EasyLAN interface (Ethernet or Wireless) (see Chapter 16)
EasyLAN antenna
3-inch adapters
(included)
Fan-fold guide
Alphanumeric
keyboard
(Fingerprint only)
Label taken sensor
#LOSED
/PEN
Cutter
Liner takeup unit

Interfaces
The printers are as standard provided with one serial RS-232 port, one
serial USB port, and one wand interface. The wand interface is not sup-
ported by IPL. In addition, one EasyLAN interface and one or two extra
interface boards can be fitted, see Chapter 14. IPL does only support one
EasyLAN interface and one parallel interface board.
Provision for Easy-

LAN antenna
Provision for Ether-
net connector
Provision for
one or two interface
boards (only the left
slot used with IPL)
Wand interface
(not used with IPL)
Serial Port (RS-232)
USB Port

Checking Hardware and Firmware

Finally, you may want to inspect the electronics compartment. To do so,
carefully follow the instructions in Chapter 12.
Always switch off the power and remove the power cord before removing
the cover over the electronics compartment! Dangerous voltage!
In the electronics compartment, check:

• Type of CPU board?
- Check number and size of Flash SIMMs.
- Check size of SDRAM SIMM.
• Any optional interface board fitted?
- Check type, straps, and optional circuits.
Refer to Chapters 15 and 16 for more information.
Being delivered with either Intermec Fingerprint v8.30 programming lan-
guage or IPL v2.30 (or later versions), the printer can easily be converted
from Fingerprint to IPL or vice versa using a firmware card or special
software. The keyboard overlay will also need to be replaced. The type of
firmware is indicated by the messages in the display window at startup.
Fingerprint only
If the printer is working and possible startup program can be interrupted,
the type of program in the printer can be identified. Connect printer
and computer, open a suitable communication program, and start up the
printer in Fingerprint’s immediate mode. The instruction FILES allows
you to check what files the various parts of the printer's memory contain.
The statements FONTS and IMAGES can be used for the same purpose
regarding fonts and images. Use the VERSION$ function to check version
of the Intermec Fingerprint firmware.
You can read the setup in the Setup Mode or using Intermec Shell, which
also allows you to print test labels containing the present setup values. To
enter Shell if a custom-made autoexec-file prevents access, lift the printhead
and press any key on the printer's keyboard (except the <Shift> key),
then turn on the power while continuing to press the key. When the Shell
countdown begins, release the key and press <Enter> to start Shell. Do not
forget to lower the printhead if you want to print anything, for example
test labels. Refer to the User’s Guide and to Appendix A in this Service
Manual for more information on the Setup Mode and the Intermec Shell
startup program.
If the printer still does not work, you may need to interview the user.
IPL only
The Test/Service part of the Setup Mode allows several types of test labels
to be printed (see the User’s Guide and Appendix A). IPL also has a number
of commands that return valuable information on the printer’s status (see
IPL Programming, Reference Manual).

1.2 EasyCoder PX4i Specifications

Printing
Print Technique Direct Thermal and Thermal Transfer
Printhead Resolution 8 dots/mm (203.2 dpi) or
11.81 dots/mm (300 dpi) Not supported by IPL
Print Speed (variable) 100 to 300 mm/sec. (≈ 4 to 12 in./sec.)
Print Width (max) 112 mm (4.4 in.)
Print Length (max) 32767 dots
= 409.5 cm (161.25 in.) at 203.2 dpi1
= 277.5 cm (109.23 in.) at 300 dpi1
Media Width (min/max) 25 to 120 mm (1 to 4.72 in.)
Media Roll Diameter (max) 213 mm (8.38 in.) Tear-off & Cut-off
205 mm (8.07 in.) Peel-off & batch takeup
Media Roll Core Diameter 38 to 40 mm (1.5 in.) or
76 mm (3 in.) with adapter fitted
Ribbon Width (min/max) 55 to 120 mm (2.16 to 4.72 in.)
Ribbon Roll Diameter (outer), max. 80 mm (3.15 in.) ≈ 450 m (1476 ft) length
Ribbon Roll Core Diameter (inner) 25 mm (1.00 in.)
Print Directions 4
Modes of Operation
Tear-Off (Straight-through) Yes
Cut-Off Option With cutter
Peel-Off (Self-strip) Option With rewinder
Internal Batch Takeup Option With rewinder
Fingerprint Firmware
Operating System Intermec Fingerprint v8.30 Incl. Direct Protocol
Smooth Fonts TrueDoc and TrueType fonts
Resident Scaleable Fonts 15 Unicode fonts2
Resident Bar Codes 59
Startup Program (std) Intermec Shell v8.2
IPL Firmware
Operating System IPL v2.30
Smooth Fonts 13 scaleable + 21 simulated bitmap
Physical Measures
Dimensions (W × L × H) 275 × 482 × 238 mm
(10.8 × 19.0 × 9.4 in)
Weight (excluding media) 12.85 kg (28.4 pounds)
Ambient Operating Temperature +5°C to +40°C (+41°F to +104°F)
Storage Temperature -20°C to +70°C (-4°F to +152°F)
Humidity 10 to 90% non-condensing
Electronics
Microprocessor 32 bit RISC
On-board Flash SIMMs 2 sockets for 4MB or 8MB each Std. 1 x 4MB
On-board SDRAM SIMM 1 socket for 16MB (Std. 16MB)

Power Supply
AC Voltage 90 to 265 VAC, 45 to 65 Hz
PFC Regulation IEC 61000-3-2
Power Consumption Standby 20W; Continuous, average 175W;
Peak 400W
Sensors
Label Gap/Black Mark/Out of Media Yes Variable position
Printhead Lifted Yes
Ribbon End/Ribbon Low Yes
Paper Sensor Yes
Controls
Indicator Lamps 3
Display 2 x 16 character LCD Background light
Keyboard (Fingerprint) 22 keys membrane-switch type
Keyboard (IPL) 7 keys membrane-switch type
Print (FP) or Feed/Pause (IPL) button 1
Beeper Yes
Data Interfaces
Serial 1 x RS-232 + 1 x USB
Bar Code Wand Yes Not supported by IPL
Connection for Optional Interface Boards 1 EasyLAN + 2 other (Fingerprint/DP) IPL: 1 other + 1 EasyLAN
Cutter Interface 1
Memory Card Adapter 1, for CompactFlash cards IPL: Not as memory
Accessories and Options
Integral Self-strip Unit with Liner Takeup Option3,4 For peel-off and batch
takeup
Media Roll Retainer Option5
Fan-fold Guide Option5
Cutter Option5
Label Taken Sensor Option3,4
Real Time Clock Option3,4 Not supported by IPL
RS-232 Cable Option
Parallel Interface Cable Option
Parallel Interface Board Option
Double Serial Interface Board Option3,4 Not supported by IPL
Serial/Industrial Interface Board Option3,4 Not supported by IPL
3,4
EasyLAN Ethernet Interface Option
EasyLAN Wireless Interface Option3,4
Built-in Alphanumeric Keyboard Option3,4 Not supported by IPL
5
External Keyboard Converter Option
CompactFlash Cards Option5 8MB-1GB
CompactFlash Protection Plate Option5
1
/. The max. print length is also restricted by the amount of free SDRAM memory.
2
/. Latin, Greek, and Cyrillic fonts according to Unicode standard are included.
3
/. Factory installed option
4
/. Field-installable kit. Installation should be performed by a service technician.
5
/. Operator-installable option.

1.3 EasyCoder PX6i Specifications

Printing
Print Technique Direct Thermal and Thermal Transfer
Printhead Resolution 8 dots/mm (203.2 dpi) or
11.81 dots/mm (300 dpi) Not supported by IPL
Print Speed (variable) 100 to 225 mm/sec. (≈ 4 to 8.85 in./sec.)
Print Width (max) 167.4 mm (6.59 in.)
Print Length (max) 32767 dots
= 409.5 cm (161.25 in.) at 203.2 dpi1
= 277.5 cm (109.23 in.) at 300 dpi1
Media Width (min/max) 76 to 170 mm (3 to 6.69 in.)
Media Roll Diameter (max) 213 mm (8.38 in.) Tear-off & Cut-off
205 mm (8.07 in.) Peel-off & batch takeup
Media Roll Core Diameter 38 to 40 mm (1.5 in.) or
76 mm (3 in.) with adapter fitted
Ribbon Width (min/max) 76.2 to 170 mm (3 to 6.69 in.)
Ribbon Roll Diameter (outer), max. 80 mm (3.15 in.) ≈ 450 m (1476 ft) length
Ribbon Roll Core Diameter (inner) 25 mm (1.00 in.)
Print Directions 4
Modes of Operation
Tear-Off (Straight-through) Yes
Cut-Off Option With cutter
Peel-Off (Self-strip) Option With rewinder
Fingerprint Firmware
Operating System Intermec Fingerprint v8.30 Incl. Direct Protocol
Smooth Fonts TrueDoc and TrueType fonts
Resident Scaleable Fonts 15 Unicode fonts2
Startup Program (std) Intermec Shell v8.2
IPL Firmware
Operating System IPL v2.30
Smooth Fonts 13 scaleable + 21 simulated bitmap
Physical Measures
Dimensions (W × L × H) 335 × 482 × 238 mm
(13.2 × 19.0 × 9.4 in)
Weight (excluding media) 14.8 kg (32.6 pounds)
Ambient Operating Temperature +5°C to +40°C (+41°F to +104°F)
Storage Temperature -20°C to +70°C (-4°F to +152°F)
Humidity 10 to 90% non-condensing
Electronics
Microprocessor 32 bit RISC
On-board Flash SIMMs 2 sockets for 4MB or 8MB each Std. 1 x 4MB
On-board SDRAM SIMM 1 socket for 16MB (Std. 16MB)

Power Supply
AC Voltage 90 to 265 VAC, 45 to 65 Hz
PFC Regulation IEC 61000-3-2
Power Consumption Standby 20W; Continuous, average 175W;
Peak 400W
Sensors
Label Gap/Black Mark/Out of Media Yes Variable position
Printhead Lifted Yes
Ribbon End/Ribbon Low Yes
Paper Sensor Yes
Controls
Indicator Lamps 3
Display 2 x 16 character LCD Background light
Keyboard (Fingerprint) 22 keys membrane-switch type
Keyboard (IPL) 7 keys membrane-switch type
Print (FP) or Feed/Pause (IPL) button 1
Beeper Yes
Data Interfaces
Serial 1 x RS-232 + 1 x USB
Bar Code Wand Yes Not supported by IPL
Connection for Optional Interface Boards 1 EasyLAN + 2 other (Fingerprint/DP) IPL: 1 other + 1 EasyLAN
Cutter Interface 1
Memory Card Adapter 1, for CompactFlash cards IPL: Not as memory
Accessories and Options
Integral Self-strip Unit with Liner Takeup Option3,4 For peel-off operation
5
Fan-fold Guide Option
Cutter Option5
Label Taken Sensor Option3,4
Real Time Clock Option3,4 Not supported by IPL
RS-232 Cable Option
Parallel Interface Cable Option
Parallel Interface Board Option
Double Serial Interface Board Option3,4 Not supported by IPL
3,4
Serial/Industrial Interface Board Option Not supported by IPL
3,4
EasyLAN Ethernet Interface Option
EasyLAN Wireless Interface Option3,4
Built-in Alphanumeric Keyboard Option3,4 Not supported by IPL
5
External Keyboard Converter Option
CompactFlash Cards Option5 8MB-1GB
5
CompactFlash Protection Plate Option
1
/. The max. print length is also restricted by the amount of free SDRAM memory.
2
/. Latin, Greek, and Cyrillic fonts according to Unicode standard are included.
3
/. Factory installed option
4
/. Field-installable kit. Installation should be performed by a service technician.
5
/. Operator-installable option.

1.4 Measures EasyCoder PX4i

Front View
MM

M
M

2

MM

MM
MM

MM MM
MM
$OT .O
Side View
MM

0APER SLOT
MM

2

M
MM

0APER SLOT
MM

MM MM
MM

MM
An optional paper cutter increases the printer’s total length by 28 mm (1.1 inches).
At least 90 mm (3.5 inches) of free space behind the printer is required for the connectors,
and for inserting and removing a memory card.

1.5 Measures EasyCoder PX6i

Front View
MM
M

M

2
MM

MM
MM

MM MM
MM
$OT .O
Side View
MM

0APER SLOT
MM

2

M
MM

0APER SLOT
MM

MM MM
MM

MM
An optional paper cutter increases the printer’s total length by 28 mm (1.1 inches).
At least 90 mm (3.5 inches) of free space behind the printer is required for the connectors,
and for inserting and removing a memory card.


2 Front and Keyboard
This chapter describes the keyboard and display fitted at the front of the
EasyCoder PX4i and PX6i printers in both Fingerprint and IPL versions,
the only differences being the designation on the overlay and the width of
the front moulding. Illustrations in this chapter shows an EasyCoder PX4i
running Fingerprint.

Chapter 2 — Front and Keyboard
2.1 Front
The moulded front part is attached to the center section using four #T20
screws and to the bottom plate using two #T20 screws. The front mould-
ing is provided with holes for mounting a cutter connector (4-pin female
DIN-type).
Keyboard/display assy.
Provision for cutter

connection
Front moulding
At the top part of the front moulding, there is a cavity for the keyboard/
display assy. This assembly is affixed using two 2 mm hexagon grub screws
underneath the keyboard part of the front moulding.

2.2 Keyboard/Display
The keyboard/display assy. is connected to J50 at the front of the CPU
board via a 10-p flat cable. This cable must be disconnected before the
keyboard/display can be removed.
The keyboard/display must be manipulated carefully when it is lifted out
of its cavity. Do not use any force! If the assembly seems to be stuck, open
the right-hand door and remove the left-hand cover to check that the grub
screws do not interfere with the brackets.
We also recommend you to remove the left-hand cover before you start
to fit the keyboard/display assy. back into the front moulding, because it
makes it easier to align the brackets with the grub screws.
The keyboard/display assy. consists of a plate with two brackets, a self-
adhesive membrane switch keyboard, an self-adhesive overlay, and a
console pcb. The membrane switch keyboard is connected to P2 on the
console pcb. via a semi-transparent cable running through a slot in the
plate.
Console pcb.
Keyboard plate
Membrane-switch
keyboard
Overlay (5 types)

Keyboard Overlays
The keyboard overlays are self-adhesive with a non-permanent adhesive
to allow easy replacement. Custom-made overlays could also be printed
and used to replace the standard overlays for customized applications or in
areas, where the English text is not acceptable. Pulling away an overlay and
replacing it with another is a simple operation that the customer easily can
perform himself. Use isopropyl alcohol to remove any adhesive residue.
There are three types of overlay for each printer model:
EasyCoder PX4i Fingerprint version
EasyCoder PX4i Fingerprint version, Alphanumeric keyboard (option)
EasyCoder PX4i IPL version

EasyCoder PX6i Fingerprint version
EasyCoder PX6i Fingerprint version, Alphanumeric keyboard (option)
EasyCoder PX6i IPL version

Keyboard
The keyboard is of membrane switch type and is glued to the keyboard
plate. There are 54 switches, but only 23 of these are used unless the
printer has an alphanumeric overlay (Fingerprint only). One switch is a
Shift key, that provides a dual functionality to each of the other keys. The
keys have fixed functions in the immediate and setup modes, but can also
be assigned various functions in Intermec Fingerprint programs. In IPL,
the keys are not user-programmable.
A flat cable connects the membrane-switch keyboard to P2 on the console
pcb.
Keyboard Plate
The keyboard plate keeps the assembly together and to affix it in the cavity
of the front moulding. There are one slot for the display and another for
the cable running from the membrane-switch keyboard to the console pcb.
Two brackets at the lower edge are used to connect the plate to the front
moulding using two 2 mm hexagon grub screws.

2.3 Console pcb.

The console pcb manages the keyboard, the display and two of the three
LED indicators using a slave processor. The communication to and from
the CPU board goes via an I2C bus on a 10-p flat cable. This cable is per-
manently affixed to the console pcb and connected to J50 a the front end
of the CPU board.
The display is a LCD display with background light. It has 2 × 16 charac-
ter with a 5 × 7 dots matrix. There is no display contrast adjustment.
The left-hand LED indicator (marked “Power”) shines green when the
power is on. Power on is also indicated by the display’s background light.
The center LED (marked “Status”) is solid green (OK), flashing green
(communicating) or solid red (error).
The right-hand LED (Intermec Readiness Indicator) is solid blue, flashing
blue, or off which indicates the readiness of the printer to work as a part of
a network solution (see the User’s Guide).
In Fingerprint, the Status LED is programmable using the instructions
LED ON and LED OFF. There is no such functionality in IPL.
Intermec Readiness
Indicator (blue)
Status LED (green or red)
Power On LED (green)
LCD display

22
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1-971653-30 Console pcb, Soldering Side

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1-971653-30 Console pcb, Component Side

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EasyCoder PX4i and PX6i Service Manual

IN-CIRCUIT SERIAL PROGRAMMING
VCC
V CC VCC
VCC V CC R4 P4
VPP 1
R5 2
R16
3
C21
4
R2
R3
5 VCC
15
16
DISP1
3 VDISP A K VCC 2 VC C
5
C4
R/W
4 RS GND 1
6 E DISPLAY
R1
R19
R20
R21
R22
R23
R24
R25
IC1
R15
PIC16F872
D0
D1
D2
D3
D4
D5
D6
D7
9 CLKIN INT/RB0 21 COLSH
D4
7
8
9
10 CLKOUT RB1 22 COL0
10
11
12
13
14
RB2 23 COL1
1 MCLR/VPP RB3 24 COL2
RB4 25 COL3
RB5 26 COL4
D4 2 RA0 RB6 27 COL5
D5 3 RA1 RB7 28
D6 4 RA2
KEYBOARD
D7 5 IC2 9 ROWS
RA3/VREF
E 6 11 ROW_CLK 8 7 COLUMNS
RA4/TOCKI RC 0 C1/
RS 7 R A5 RC 1 12 ROW_CLR 9 R
RC2 13 ROW_DATA P2
VCC 14 SC L 74AHC164
RC3 1 R26
RC 4 15 SDA 1
2 & 1D<0> 3 R2 7 2
R6 20 VCC RC5 16 NOTIFY
VCC 1D<1> 4 R28 3
T3 RC6 17 R/W
1D<2> 5 R29 4
8 GND RC7 18 SYSTEM
1D<3> 6 R30 5
VCC 19 GND
1D<4> 10 R31 6

R14
1D<5> 11 R32 7
1D<6> 12 R3 3 8
P1 1D<7> 13 R34 9
R17
R18
1 VCC=VCC;GND=GND1 R35 10
2 R36 11
3 RESET R37 12
4 LED2 R3 8 13
5 LED1 R39 14
R9
6 I2C_NOTIFY R40 15
7 R41 16
8 SDA
9
10 SCL
C6
C8
C10
C12
C14
C16
C18
C20
P3
R42
C5
C7
C9
1
C11
C13
C15
C17
C19
R43
2
1 AHCT14
2 3 AHCT14
4
IC50 IC 5 0
VCC=VCC;GND=GND1 VCC=VCC;GND=GND1
5 AHCT14
6 9 AHCT14
8
IC50 IC50
VCC=VCC;GND=GND1 VCC=VCC;GND=GND1
VC C VCC VCC
1-971653-30 Console pcb, Schematics

R50
R51
R52
R53
R54
R55
R56
R60
R61
R62
R63
R64
R65
R66
R70
R71
R72
R73
R74
R75
R76
3
3
3
1
1
1
VCC
IC1 IC2 IC50
R57
R67
R77
11 AHCT14
10
D50 D60 D70
IC50 L ED LED LED
VCC=VCC;GND=GND1
+
C2
C3
C1
C50
13 AHCT14
12
IC50
2
2
2
VCC=VCC;GND=GND1
23

3 Covers and Doors
This chapter describes the covers and doors on the EasyCoder PX4i and
PX6i printers. It covers the following topics:
• The right-hand door, that is, the doors that cover the print mechanism
and media compartment.
• The front door, that protects the front of the print mechanism.
• The left-hand cover that protects the electronics compartment.

Chapter 3 — Covers and Doors
3.1 Right-Hand Door

Description
The right-hand door gives access to:
• The media supply
• The ribbon supply
• The print mechanism
The right-hand door is fitted to the bottom plate using two hinges that
allow the door to be swung 180˚ downwards to a vertical attitude. The
door is kept shut using a magnetic lock. The door can easily be removed
from the hinges by pushing it forward until the snap-lock at the rear hinge
becomes disengaged.
At the inside of the door, there is a label showing how to load the media
and transfer ribbon.
Magnetic lock
Label
Hinges
Illustration shows the right-hand door of an EasyCoder PX4i. The door of the EasyCoder PX6i has a wider top part.
Adjustment
The hinges can be adjusted using two pairs of #T10 Torx screws visible
on the outside. Possibly, the other parts of the hinges, which are fitted to
the bottom plate, may require adjustment too. Shut the door, loosen the
screws slightly and align the door with the front moulding. Tighten the
screws and check that the door runs freely and is kept shut by the magnetic
lock.

3.2 Front Door

The front door gives access to:
• The front part of the print mechanism
• The paper cutter connector
• The optional label taken sensor
The front hatch is fitted to the bottom plate using two hinges of the same
type as those of the right-hand door. The front hatch is kept shut by a
snap-lock and can be swung down almost to a vertical position. The hatch
can be removed from its hinges by pushing it to the left until the snap-lock
on the right-hand hinge disengages.
The front hatch can be replaced by an optional paper cutter unit, see
Chapter 11.
Alignment is performed in the same way as the right-hand door, see the
previous page.
The front hatch can be removed by pushing it to the left when open
(illustration shows an EasyCoder PX4i).

3.3 Left-Hand Cover

The left-hand cover gives access to:
• The electronics incl. CPU board, AC connection, power supply, driver
board, and any optional interface boards.
• The motors, belts and pulleys of the media feed, ribbon feed, and the
optional liner/batch takeup unit.
The left-hand cover plate is fitted to the printer’s frame using a total of
eight #T10 Torx screws; four along the lower edge and another four along
the top.
The electronic compartment contains wires and components with
dangerous voltage (up to 380V). Make sure that the printer is switched
off and the power cord is disconnected, before the left-hand cover is
removed.
Before removing the left-hand cover, take standard precautions to avoid
causing any electrostatic discharges.
After having disconnected the power cord, open the right-hand door.
Using a #T10 Torx screwdriver, remove the four screws along the lower
edge first, then remove the four upper screws. Put the cover plate aside on
a soft cloth or similar material to avoid scratches.
Fit back the left-hand cover in reverse order. Before finally tightening the
screws, check that the cover is aligned with the front moulding and the
rear plate and that it does not interfere with the right-hand door.
#T10 Torx screws (x4)

4 Chassis
This chapter describes the center section, bottom plate, rear plate, hinges,
and rubber feet, of the EasyCoder PX4i and PX6i printers.

Chapter 4 — Chassis
4.1 Description
The printer’s chassis consists of three main parts:
• The center section
• The bottom plate Rear plate
• The rear plate
Center section
Hinges
(front door
or cutter) Bottom plate
Rubber foot (x4) Hinges

(right-hand door)
EasyCoder PX4i

The main differences between the chassis of EasyCoder PX4i and PX6i are
the widths of the bottom plate and the rear plate.
Rear plate
Center section
Hinges Bottom plate

(front door
or cutter) Rubber foot (x4) Hinges
(right-hand door)
EasyCoder PX6i

4.2 Center Section

The center section is where most parts are fitted, such as the print mecha-
nism, the transfer ribbon mechanism, the liner takeup unit, and the media
supply. The center section is fitted to the bottom plate by four #T20 Torx
screws and to the rear plate using three #T20 Torx screws and a bracket.
In the electronics compartment, the CPU board, the driver board, and
power supply unit are fitted to the center section.
4.3 Bottom Plate

The bottom plate is fitted to the center section using four #T20 Torx
screws and to the rear plate using three #T20 Torx screws. In case of Easy-
Coder PX6i, there are also two #T20 Torx screws holding the outer gable
of the print unit.
The electronic compartment contains wires and components with dan-
gerous voltage. Make sure that the printer is switched off and the power
cord is disconnected before the bottom plate is removed.
The bottom plate is fitted with four easily replaceable rubber feet. These
feet could be removed and the holes be used to bolt the printer to a frame,
table or similar. The holes have a diameter of 7.1 mm (0.28 inches). To
reduce noise, fit rubber dampeners between the table and the printer if you
bolt it in place.
When fitting a replacement foot, insert it through the bottom plate and
firmly press the pin so the rivet expands on the upper side of the plate.
The bottom plate is provided with two pairs of hinges for the front door or
cutter and for the right-hand door.
The two keyholes must not be used to bolt the printer to a frame, or the
bottom plate may be bent. These holes are intended for fixtures during
manufacturing.

4.4 Rear Plate

The rear plate is attached to the bottom plate using three #T20 Torx
screws and to the center section by two #T20 Torx screws. There is also a
bracket between the rear plate and the center section. The rear plate has a
number of slots for connectors, switches etc., as illustrated below.
Provision for EasyLAN Wireless antenna
Provision for EasyLAN Ethernet

connector
Provision for optional interface
board(s)
On/Off switch
CompactFlash memory card slot
Bar code wand Interface (not used with

IPL)
AC power cord receptacle
RS-232 serial interface
USB interface
Upper external media intake
Lower external media intake
Machine label


5 Media Supply
This chapter explains the rotating media supply hub with the 3-inch
adapter, the media roll retainer, and the paper sensor. Finally, it describes
how an external media supply can be used in an EasyCoder PX4i and PX6i
printer fitted with a fan-fold guide.

Chapter 5 — Media Supply
5.1 Internal Supply

Description
The internal media supply consists of a shaft with four or five modular
hubs. The shaft is screwed into a flange fitted to an almost circular plate
using two #T20 Torx screws. The plate is fitted to the center section using
four #T20 Torx screws. The hub modules are spring-loaded in order to
fit media roll cores with an inner diameter between 38 and 40 mm (1.5
inches).
A large crescent-shaped guide plate keeps the media roll aligned with the
print mechanism. Inside the guide plate and protruding through a slot in
the circular plate, the paper sensor is fitted to the center section.
Maximum diameter of an internal media roll is 213 mm (8.38 inches),
except in the case of peel-off and batch takeup operation when the diam-
eter is restricted to 205 mm (8 inches). Maximum width is 120 mm (4.72
inches) for EasyCoder PX4i and 170 mm (6.69 inches) for EasyCoder
PX6i.
#LOSED
/PEN

Paper sensor
Unwind unit
Hub modules
Guide plate

The media supply hub package can be dismantled by removing the #T20
Torx screw at the end of the shaft. Inside the outermost hub module, there
is a spring that presses the hub package towards a felt pad in order to break
the rotation. Else, the momentum of a large and heavy media roll might
cause excessive media to be unwound when the printing is stopped. The
brake torque should be 70 ±20 Nmm (see Appendix C).
The rotation of the code disc fitted at the innermost part of the hub pack-
age is detected by the paper sensor.
Be careful to fit the studs of the innermost hub module into the holes in
the code disc when the package is assembled.
Code disc
Flange
Hub modules
(4 in EasyCoder PX4i,
Plate 5 in EasyCoder PX6i)
Disc
Felt Pad
Shaft
(short in EasyCoder PX4i, Nylon disc
long in EasyCoder PX6i) Spring
Washer
#T20 Torx screw

5.2 Paper Sensor

Description
The paper sensor allows the firmware to detect when the diameter of the
remaining media becomes less than a value set in the Setup Mode.
In Fingerprint, this affects SYSVAR(46) which switches from 0 to 1.
Thus, a Fingerprint program can be created, that reads SYSVAR(46) and
uses it to issue for example audible alarms or error messages to notify the
operator of a pending out-of-media condition. A trap is also sent that can
be detected when the printer is connected to a network via an EasyLAN
interface.
In IPL, a trap is sent that can be detected when the printer is connected to
a network via an EasyLAN interface.
The sensor detects the saw-tooth shape of the code disc at the inner end of
the media supply hub. By comparing the rotation speed of the hub and the
print speed, the firmware can calculate the diameter of media roll.
The paper sensor assy is fitted to the center section using a #10 Torx screw
and is connected to J57 on the CPU board (see Chapter 15.3).
Adjustment
Refer to the chapter “Setting Up the Printer” in the User’s Guide for the
printer in question.
Replacement
• Switch off the power, disconnect the power cord, and remove the left-
hand cover.
• Disconnect the cable from J57 on the CPU board.
• Remove the crescent-shaped guide plate, which is held by three #T20
Torx screws.
• Remove the entire media supply unit which is held by four #T20 Torx
screws.
• Remove the single #T10 Torx screw that holds the sensor to the center
section.
• Carefully pull out the sensor and its cable through the hole in the center
section.
• Install a new sensor assembly in reverse order.

5.3 Three-inch Adapters

One or two adapters (standard accessories) can be fitted onto the media
supply hub in order to accept media rolls with 76 mm (3 inches) cores.
EasyCoder PX4i has one adapter and EasyCoder PX6i has two. Each
adapter is locked using a #T20 Torx screw. Be careful not to let the screw
hit the leaf springs or the cams of the hub modules.
3-inch adapter
#LOSED
/PEN
3-inch adapters

5.4 Media Roll Retainer

An optional media roll retainer can be pressed on the hub package (but
not on the adapter) of an EasyCoder PX4i in order to hold large media
rolls and to prevent the media from getting misaligned on the roll. The
retainer is not intended for EasyCoder PX6i
Media roll
retainer

5.5 Fan-Fold Guides

Description
Instead of an internal media roll, the EasyCoder PX4i and PX6i printers
can also use media from an external supply, for example an external roll or
a stack of fan-folded tickets. The media is inserted into the printer through
either the upper or lower slot in rear plate.
It is important that the media path is properly aligned in parallel with the
printer’s center section. Therefore, Intermec offers an optional “Fan Fold
Kit” consisting of a bracket with two guides that can be fitted in either the
upper or lower slot in the rear plate. The outer guide is adjustable for dif-
ferent media widths.
Max. Media Width (Fan-Fold Guides)

EasyCoder PX4i: 120 mm (4.72 in)
Min. Media Width (Fan-Fold Guides)

EasyCoder PX6i: 76.2 mm (3.00 in)
Fan-Fold Guides in upper

position (EasyCoder PX4i)

Installation
The bracket with the two guides can be fitted either at the upper or lower
slot in the rear plate, depending on how the media supply is located in
relation to the printer. The principles are the same for EasyCoder PX4i and
EasyCoder PX6i.
Insert the complete unit through the slot from the outside and attach it to
the rear plate using two #T20 Torx screws. In case of the upper position,
use the screws included in the kit, and in case of the lower position, use the
two existing screws that hold the rear plate to the bottom plate.
Adjustment
Adjust the position of the outer guide to fit the width of the media.

Media Load
Load the media according to the illustrations below.
The external supply should be protected from dust, sand, grit and other
particles that may damage the printhead or impair the printout qual-
ity.
Note: If the printer is to be permanently used with an external media

supply only, the entire internal media supply unit could easily be removed
(see Chapter 5.1).

6 Label Slack Absorber
This chapter describes the label slack absorber fitted as standard in the
EasyCoder PX4i and PX6i printers. It covers the following topics:
• Description
• Dismantling

Chapter 6 — Label Slack Absorber
6.1 Description
The label slack absorber compensates for sudden jerks at the media, for
example when high speed printing is started and stopped. When the
printing starts, the tension is increased and the absorber is pulled forward/
upward. As soon the heavy media roll starts to rotate, the tension decreases.
The spring-loaded absorber can then return towards its original position.
During the printing, the absorber will flutter back and forth, compensating
for the variations in tension.
To facilitate media load, the label slack absorber can be rotated 180° clock-
wise. It can be locked in open position using a snap-lock. Remember to
unlock the slack absorber before starting to print.
An adjustable edge guide is fitted on the label slack absorber to prevent
media misalignment. The guide is fitted as standard, but can be removed
to facilitate media load when there are other means of guiding the media,
for example a media roll retainer or fan-fold guides (see Chapter 5).
Slack absorber
Edge
guide

6.2 Dismantling
The label slack absorber unit is fitted to the center section using two #T20
Torx screws inserted through the center section from the electronics com-
partment. The shaft should be screwed into the flange with a tightening
torque of 5 Nm.
EasyCoder PX4i
#T20 Torx screws (2x)
Flange
Torsion spring
#T10 Torx screw
Spacer
#T10 Torx screw
Grip (green)
Edge guide
(green)

EasyCoder PX6i
#T20 Torx screws (2x)
Flange
Torsion spring
#T10 Torx screw
Spacer
#T10 Torx screw
Grip (green)
Edge guide
(green)

7 Transfer Ribbon Mechanism
This chapter describes the mechanism that drives the thermal transfer
ribbon in the EasyCoder PX4i and PX6i printer. It covers the following
topics:
• Description
• Ribbon supply unit
• Ribbon rewind unit
• Ribbon sensor

Chapter 7 — Transfer Ribbon Mechanism
7.1 Description
The thermal transfer ribbon mechanism is standard in EasyCoder PX4i
and PX6i. The mechanism consists of three main parts:
• Ribbon supply unit (see Chapter 7.2)
• Ribbon rewind unit (see Chapter 7.3)
• Ribbon sensor (see Chapter 7.4)
Adjustment of the ribbon assist roller to remedy wrinkling of the ribbon is
described in Chapter 8.9.
Ribbon Rewind Unit
Ribbon Supply Unit Ribbon Sensor

7.2 Ribbon Supply Unit

Description
The ribbon supply unit is the same for EasyCoder PX4i and EasyCoder
PX6i with the exception of the strength of the spring in the spring brake.
It is used to accommodate the fresh supply of thermal transfer ribbon. For
optimum printout quality and trouble-free operation, only original transfer
ribbon from Intermec should be used.
The unit is designed to keep the ribbon tight all the time in order to avoid
wrinkling, which would ruin the printout. It consists of a shaft on which
a hub is fitted. The hub can pivot ± 1.3° on the shaft and the hub can be
moved sideways between 6 fixed positions.
Adjustment
It is most important for avoiding ribbon wrinkling that the pivoting point
of the hub is centered in relation to the ribbon width. Therefore, the shaft
is provided with six grooves which correspond to the standard widths of
Intermec transfer ribbons (see table below). The three innermost grooves
are used with EasyCoder PX4i, whereas the three outermost grooves only
are used with the wider EasyCoder PX6i. By compressing the hub, its
snap-lock will disengage from the presently engaged groove and the hub
can be moved sideways to another position. Make sure that the snap-lock
has engaged a groove by trying to move the hub without compressing it.
Ribbons with a width less than 55 mm (2.16 inches) can be used provided
they are wound on a core with a width of at least 45 mm (1.77 inches).
Ribbon Width Position (groove) Note

55-60 mm (2.16-2.36 in) 1:st (innermost) PX4i only
88-90 mm (3.5 in) 2:nd All
110 mm (4.3 in) 3:rd All
130 mm (5.1 in) 4:th PX6i only
154 mm (6.0 in) 5:th PX6i only
≤ 166 mm (6.5 in) 6:th (outermost) PX6i only

Working Principles
The ribbon supply is braked by a spring affixed to the printer’s center sec-
tion, partly enveloped by a sleeve affixed to the shaft. Initially, the spring
expands towards the inner wall of the sleeve, thereby breaking the rotation
of the shaft. When the bobbin is forced to rotate (that is, when the ribbon
is unwound), the breaking spring is compressed. After approximately half
a turn, the diameter of the spring has been compressed enough to allow
the sleeve to slip. The brake torque should be 55 ±5 Nmm (see Appendix
C). The sleeve is filled with ball bearing grease. If the brake torque deviates
from the recommended value, replace the grease. We recommend Castrol
Sinplex 2. The expected interval between replacing the grease is 8 to 10
million print cycles.
When the rotating force ceases, the spring tends to pull back the ribbon,
keeping it tight.
Grub screw
Brake sleeve
Torque spring
(differs between
models)
Grub screw
Locking washer
Locking washer
Ball bearing
Fixing ring
Flange
Ball bearing
Shaft
Grooves
Code disc
Pivot assy.

Replacement
The unit is attached to the center section by two #T20 Torx screws
inserted from the media compartment side.
#T20 Torx screw
#T20 Torx screw

7.3 Ribbon Rewind Unit

Description
The ribbon rewind unit is the same for EasyCoder PX4i and EasyCoder
PX6i. It pulls the transfer ribbon around the printhead and winds it up on
a cardboard core. The unit is driven via a belt by the same stepper motor
that drives the platen roller.
The rewind unit is provided with a friction brake in order to keep the
ribbon tight.
Adjustment
There is no manual adjustment of the ribbon rewind unit other than the
tension of the belt to the stepper motor (see Chapter 8.4).

Working Principles
The ribbon rewind unit is driven by the same motor that drives the platen
roller in the print unit via a belt that engages the timing belt pulley. The
torque spring allows the stepper motor to drive the rewind hub rotate
counter-clockwise only. When the media is fed back, the ribbon will not
move.
The torque spring arrangement automatically compensates for the gradu-
ally increasing diameter of the used ribbon on the rewind hub, so the
ribbon will always be fed at the same speed as the media.
Timing belt pulley

Flange
Torque spring
Bobbin
Brake sleeve
Slide
bearing
Bobbin plate
Locking
washers (x3)
Grub screw
Flange
Ball bearing
Shaft
Ball bearing
Slide bearing
Slide bearing

Replacement
The ribbon rewind unit is fitted to the center section using two #T20 Torx
screws inserted from the media compartment. One of the screws runs in a
crescent-shaped slot to allow adjustment or removal of the belt.
• Remove the left-hand cover as described in Chapter 3.3.
• Remove the two #T20 Torx screws and the single washer that hold the
ribbon rewind unit.
• Free the belt from the pulley of the rewind unit.
• Pull out the unit into the media compartment.
• Do not dismantle the ribbon rewind unit.
• Fit the new ribbon rewind unit in reverse order, making sure that the
belt is properly attached to the pulley, but do not tighten the screws.
• Adjust the tension of the belt as described in Chapter 8.5.
• Tighten the screws.
Belt
Pulley (hidden)
Washer & #T20 Torx screw
#T20 Torx screw

7.4 Ribbon Sensor

Description
The ribbon sensor is fitted to the center section from the media compart-
ment side and is partly enclosed by the ribbon supply unit (see Chapter
7.2). The sensor consists of a plastic housing with a LED and a photoelec-
tric sensor plus a cable.
The light from the LED is intermittently blocked by the saw-toothed edge
of the rotating code disc. The signals from the sensor allow the firmware
to detect the speed with which the bobbin rotates and compare it with
the speed of the media feed. Thus, both “out of ribbon” and “ribbon low”
conditions can be detected.
If no bobbin rotation is detected during media feed, the Fingerprint
firmware assumes an error condition (error 1027 “Out of transfer ribbon”)
provided the printer is set for thermal transfer printing. In IPL, the error
message “Ribbon out” is displayed.
The ribbon sensor is connected to J56 on the CPU board (see Chapter
15.3).
Ribbon sensor
#T10 Torx screw
Ribbon supply unit
Replacement
• Remove the cover over the electronics compartment as described in
Chapter 3.3, taking all precautions against electric shock.
• Remove any transfer ribbon from the ribbon supply unit.
• Remove the ribbon supply unit as described in Chapter 6.2.
• Disconnect the sensor’s cable from J56 on the CPU board.
• Remove the #T10 Torx screw that holds the sensor to the center section.
• Install a replacement sensor unit in reverse order.

Adjustment (Fingerprint)
Low diameter
In the Setup Mode (see Appendix A), it is possible to specify the diameter
(in millimeters) of the ribbon supply roll, when a ribbon low condition
should occur. By default, this parameter is set to 0, which disables the
function. To enable it, enter the desired value.
The status of the ribbon sensor can be polled by reading SYSVAR(26) in a
Fingerprint application program. SYSVAR(26) returns 0 if the diameter of
the ribbon supply roll is greater and 1 if it is less than the value entered in
the Setup Mode. A trap is also sent that can be detected when the printer is
connected to a network via an EasyLAN interface.
Note that a full forward rotation of the supply bobbin must have been
completed. If not, 0 will be returned.
Note: When the ribbon low function is enabled, error condition 1083
“Ribbon low” is reported every tenth time SYSVAR(26) = 1 is detected in
connection with a PRINTFEED.
Sensitivity
• Enter the Setup Mode and follow the path:
Media/Paper Type/Transfer/Ribbon Sensor
• In the Ribbon Sensor menu, press <Enter> to perform a Testfeed.
• The printer will feed out a few labels and feed the ribbon accordingly.
• While the ribbon mechanism is operating, the ribbon sensor is
autoadjusted and the resulting adjustment value is shown in the lower
line of the menu (read-only).
Adjustment (IPL)
In the Setup Mode (see Appendix A), it is possible to specify the value
in millimeters of the ribbon supply roll for the ribbon sensor. When the
diameter of remaining ribbon supply roll reaches the set value, an SNMP
trap is sent to the printer’s home page, provided the printer has an optional
EasyLAN connection. Range: 0-80 with preset values at an interval of 5. A
value larger than 80 sets the ribbon sensor to 0. Default value: 0
The ribbon low sensor can also be set using an IPL command:
<STX><SI>kn<ETX>
There is no facility for adjusting the sensitivity of the ribbon sensor in IPL.

8 Print Unit
This chapter describes the print unit of the EasyCoder PX4i and PX6i
printer and explains how to adjust the various functions and replace part
subject to wear. It covers the following topics:
• Description
• Platen roller
• Stepper motor
• Belts
• Label stop sensor
• Printhead
• Headlift sensor
• Headlift mechanism
• Media feed principles

Chapter 8 — Print Unit
8.1 Description
The print unit is partly integrated with the ribbon rewind unit (see Chap-
ter 7.3) and optional liner/batch takeup unit (see Chapter 9).
EasyCoder PX4i
Provision for liner/batch
Ribbon rewind unit takeup unit
Print unit
EasyCoder PX6i
Ribbon rewind unit
Provision for liner takeup
unit
Print unit
#LOSED
/PEN

The main parts of the print unit are:

• The rubber-coated platen roller drives the media forward under the
printhead and provides the necessary counter-pressure.
• The stepper motor drives the platen roller via one belt and the ribbon
assist roller and the ribbon rewind unit via another. The liner drive roller
is idle, unless a liner/batch takeup kit is fitted, see Chapter 9.
• The tear bar makes it easier to tear off continuous and pre-perforated
media stock. It is also used for peel-off (self-strip) operation.
• The label stop sensor (LSS) controls the media feed and checks for out-
of-paper conditions.
• The printhead produces the heat that melts the “ink” on the transfer
ribbon or blackens the direct thermal paper in patterns that make up the
text, graphics, or bar codes.
• The headlift mechanism presses the printhead against the media or
transfer ribbon, or raises the printhead to allow media and ribbon load.
The print unit is a self-contained module and attached to the printer's
center section by means of four #T20 Torx screws. There are also a number
of cables running from the print mechanism to the driver and CPU boards
(see Chapters 14.1 and 15.3), which are not illustrated.
The ribbon rewind unit is driven by a belt from the motor of the print
unit via an idle pulley attached to the inside of the center section. The liner
drive roller (fitted underneath the platen roller) is either idle or driven by a
belt to the optional liner/batch takeup stepper motor. These belts have to
be removed before the print unit can be pulled out.

EasyCoder PX4i
The parts of the EasyCoder PX4i print unit, as seen from the media
compartment side of the center section, are illustrated below. Cables are
excluded.
Pressure arm
Stepper motor Belt to ribbon
rewind unit
Printhead
position
adjustment
Pulleys Printhead
pressure
adjustment
Printhead lift
lever
Edge guide
Platen roller
(barely visible)
Tear bar
Liner drive roller
LSS adjustment screw
Printhead with
bracket

EasyCoder PX6i
The parts of the EasyCoder PX6i print unit, as seen from the media
compartment side of the center section, are illustrated below. Cables are
excluded.
Pressure arm
Stepper motor Belt to ribbon
rewind unit
Printhead
position
adjustment
Pulleys
Printhead
pressure
adjustment
Printhead
lift lever
Platen roller
Edge
guide
Tear bar
Liner drive roller
LSS adjustment
Printhead with screw
bracket

EasyCoder PX4i
This overview illustrates the various parts in the print unit except cables.
The idle pulley fitted to the center section and the ribbon rewind unit are
not included. Note that many of the parts illustrated here are not available
as separate spare parts, but must be bought as ready-assembled units.

EasyCoder PX6i
This overview illustrates the various parts in the print unit except cables.
The idle pulley fitted to the center section and the ribbon rewind unit are
not included. Note that many of the parts illustrated here are not available
as separate spare parts, but must be bought as ready-assembled units.

The parts of the print mechanism fitted inside the electronics compart-
ment in an EasyCoder PX4i printer are illustrated below.
CPU board Driver board
Ribbon
rewind unit
Idle roller
Pulley & belt

(liner drive
roller)
Pulley & belt
Stepper motor (platen roller)
Stepper motor (platen roller & ribbon
(liner takeup) rewind unit)

8.2 Platen Roller

Description
The platen roller is coated with silicon rubber. It is imperative that the
roller is kept clean and is free from uneven wear or dents. The platen roller
is identical to the liner drive roller, so these rollers could be switched. The
same applies to the pulleys and belts. It is normal that the platen roller
needs to be replaced after a period of time depending on print volume and
other circumstances.
If the platen roller is manually rotated, while the power is switched
on, the stepper motor may work as a generator and damage the stepper
motor driver on the driver board (see Chapter 14). A typical example
is when the operator tears out media that has stuck on the platen roller
without switching off the power first.
Replacement
This description also applies to the liner drive roller.
• Switch off the power to the printer and disconnect the power cord.
• Open the front and right hand doors.
• Remove the cover over the electronics compartment, which is held by
eight #T10 Torx screws, see Chapter 3.3.
• Remove the tension of the belt to the ribbon rewind unit by loosening
the two #T20 screws that holds the ribbon rewind unit.
• Dismantle the stepper motor from the bracket by removing the two
#T20 Torx screws.
• Free the belt from the pulley of the ribbon rewind unit and manipulate
the stepper motor so it comes free from both belts. Remove the stepper
motor.
• Remove the belt from the pulley of the platen roller.
• Insert a 2 mm hexagon key through the semicircular slot in the front
plate and loosen the grub screw that holds the pulley on the shaft of the
platen roller.
• Using a #T20 screwdriver, remove the bracket that holds the outer end
of the platen roller and pull out the entire package.
• Reassemble in reverse order using a fresh set of roller and bearings.
When fitting back the pulley on the platen roller shaft, check that
the distance between the pulley and the inner gable of the print unit
becomes 5 mm (0.2 inches.)
• When putting back the stepper motor, fit the short belt first, while
letting the long belt hang loosely on the idler in a loop, through which
you can insert the pulley of the stepper motor. Do not put the long belt
around the pulley of the ribbon rewind unit until you have fitted the
stepper motor to the bracket and checked that both belts are engaged by
the stepper motor’s pulleys.
• Adjust the tension of the belts as described in Chapter 8.4 and put back
the cover.

EasyCoder PX4i
In the illustration below, the upper parts of the print unit and the label
stop sensor have been removed to improve visibility.
#T20 Torx screw

Belt to ribbon
rewind unit
Stepper motor
#T20 Torx
screw
Belt to platen roller
Pulley
Ball bearing
Plastic bearing
Spacer
Platen roller
Spacer
Plastic bearing
Ball bearing
Bracket
#T20 Torx screw

EasyCoder PX6i
In the illustration below, the upper parts of the print unit and the label
stop sensor have been removed to improve visibility.
#T20 Torx screw

Belt to ribbon
Stepper rewind unit
motor
#T20 Torx
screw
Belt to platen roller
Pulley
Ball bearing
Plastic bearing
Spacer
Bracket
Platen roller
Ball bearing
Plastic bearing
Bracket
#T20 Torx screw

8.3 Stepper Motor

Description
The stepper motor drives the platen roller via a short belt and the ribbon
assist roller and the ribbon rewind unit via another, longer belt. A freely
rotating pulley attached to the printer’s center section makes the outside of
the longer belt drive the ribbon assist roller.
The stepper motor is driven in microsteps (8 microsteps per full step) at all
speeds.
The stepper motor is fitted by two #T20 Torx screws to a bracket, which in
its turn is attached to the print unit gable by three #T20 Torx screws. The
pulleys of the stepper motor are permanently glued to the motor’s shaft.
Replacement
Replace the stepper motor as follows:
• Switch off the power and disconnect the power cord.
• Disconnect the cable to the stepper motor from the driver board.
the two #T20 screws that hold the unit, see Chapter 7.3.
#T20 Torx screws.
motor.
the pulleys.
• Connect the cable of the stepper motor to upper connector along the
inner edge of the driver board (P10).
• Adjust the tension of the belts as described in Chapter 8.4 and put back
the cover.
Refer to illustration on the next page!

In the illustration below, most parts of the print unit have been omitted to
improve visibility.
Note: The bracket does not need to be removed from the inner print unit
gable when the stepper motor is replaced.
#T20 Torx
screws (×2)
Stepper motor
Ribbon rewind unit and
ribbon assist roller belt
Idle roller with shaft

(fitted to center section)
Bracket Ribbon assist roller pulley

(do not
remove!)
Platen roller belt
Platen roller pulley
Inner print unit gable

8.4 Belts
Description
The print unit has at least two timing belts, one that drives the platen
roller and another that drives the ribbon assist roller and the ribbon rewind
unit. There is also a third belt if an optional liner/batch takeup unit is
fitted (see Chapter 9). The belts are subject to wear and may need periodi-
cal replacement. Properly adjusted tension and alignment of the pulleys
will increase time between replacements.
Replacement
• Switch off the power and disconnect the power cord.
the two #T20 screws that hold the unit, see Chapter 7.3.
#T20 Torx screws.
motor.
• Replace the defective belt or belts.
the pulleys.
• Adjust the tension of the belts as described later in this chapter and put
back the cover.
Refer to illustration on the next page!

#T20 Torx
screws (×2)
Stepper motor Ribbon rewind unit and

ribbon assist roller belt
Ribbon rewind unit
Platen roller belt

Adjustment; Platen Roll Belt

Oversized holes allow the position of the stepper motor relative to the
bracket to be adjusted so the tension of the belt does not become too tight,
causing unnecessary wear. Check that the platen roller can be rotated freely
by the belt, which should flex just a little when you press it with your
finger.
#T20 Torx screw
Stepper motor pulley #T20 Torx screw
Stepper motor
Belt
Platen roller pulley

Adjustment; Ribbon Rewinder Belt

The belt should be adjusted so it neither jump the cogs nor becomes sub-
ject to unnecessary wear.
Before adjusting this belt, check the tension of the platen roller belt as
described on the previous page.
Slightly loosen the two #T20 Torx screws that hold the flange of the
ribbon rewind unit.
Turn the ribbon rewind unit so the belt becomes tight, yet will flex slightly
when you press it with a finger. Tighten the screws.
Check that the parts can rotate freely and without any unpleasant sound
and that the belt does not jump the cogs when you rotate the ribbon
rewind unit forcefully.
The ribbon return roller should be easy to rotate manually. Once the
motor starts, the belt will be tight and will drive the ribbon assist roller.
If the idler roller starts to squeak, lubricate the inside of the belt with a
small quantity of grease.
#T20 Torx screw
inside media
compartment
Ribbon rewind
unit pulley Idler roller
Ribbon assist
#T20 Torx screw roller pulley
inside media
compartment
Belt
Stepper motor pulley
Stepper motor

8.5 Label Stop Sensor

Description
The label stop sensor (LSS) controls the media feed and consists of a slid-
ing carriage on which two photoelectric sensors are fitted. Both sensors
are identical and contain one light-emitting diode and one light-sensitive
receiver. The distance from the light path between the two parts of the LSS
to the dot line on the printhead is 46.3 mm (1.82 inches). The sensors can
be moved up to 50 mm (1.97 inches) out from the inner edge of the media
path using a screw protruding through the lower outer gable of the print
unit. In EasyCoder PX6i, this screw is only accessible when the locking
handle is folded down. The label stop sensor is hidden inside the print
mechanism and covered by two plastic guide plates, which can be removed
for cleaning.
Working Principles
The label stop sensor serves a number of purposes, depending on how the
printer is set up in regard of media type in Fingerprint and IPL respec-
tively:
Label (w gaps)/Gap
A beam of light is emitted from the diode in the lower part and received
by the sensor in the upper part. The firmware detects the front of each
label, that is, when the light is completely interrupted by the opaque
label, as opposed to the semi-transparent liner in the gaps between labels.
If no label has been detected during a media feed corresponding to more
than 150% of the set label length, a “next-label-not-found” condition is
assumed. If a renewed print operation gives the same result, an “out-of-
paper” condition is assumed.
Ticket (w mark)/Mark
Normally, a beam of light is emitted from the diode in the lower part. The
beam is reflected back to the sensor in the lower part by the white media,
or is absorbed by a black mark. The firmware detects when the front edge
of a black mark passes the sensor, that is, when light starts to be absorbed.
If no mark has been detected during a media feed corresponding to more
than 150% of the set ticket length, a “next-label-not-found” condition is
assumed. If a renewed print operation gives the same result, an “out-of-
paper” condition is assumed.
By switching the cables from the upper and lower part of the LSS on the
CPU board, black marks on top of the media can be detected.
Ticket (w gaps)/Gap
The light is emitted from the diode in the lower part and received by the
sensor in the upper part. The light will either pass uninterrupted through
a detection gap in the media or be blocked by the non-transparent ticket.
The firmware detects the rear edges of detection gaps, that is, when the
light starts being interrupted. If no ticket has been detected during a media
feed corresponding to more than 150% of the set ticket length, a “next-
label-not-found” condition is assumed. If a renewed print operation gives
the same result, an “out-of-paper” condition is assumed.

Var. Length Strip and Fix Length Strip/Continuous

The light is emitted from the diode in lower part and received by the
sensor in the upper part. The beam will either be blocked by the media
or be completely uninterrupted when the printer runs out of continuous
stock. The firmware assumes an out-of-paper condition if the light has not
been interrupted within a media feed corresponding to 150% of the set
length.
General
The information on where the gaps or marks are presently positioned
relative the LSS (and thereby also relative the dot line on the printhead) is
saved as an “invisible” file in the flash memory’s file operating system (see
Chapter 15.2). However, if the printhead is raised, or if the power is inter-
rupted during printing, this file may be cleared, which will affect any labels
between the LSS and the dot line. In this case, readjust the LSS using a
TESTFEED operation (Fingerprint) or by pressing the <Feed/Pause>
button (IPL).
Note (Fingerprint only): It is possible to decide if the media feed data

should be cleared or not when the printhead is raised using the Fingerprint
instruction SYSVAR(28). By default, the media feed data are not cleared.
The LSS checks for gaps or marks at every dot of positive media feed (feed
out/print), but gaps or marks are ignored at negative media feed (retract).
Gaps and black marks up to 170 dots (21.3 mm/0.84 inches) are allowed.
Testing the LSS
In the Print Defines part of the Setup Mode, you have two ways to test the
label stop sensor if you encounter a detection problem; LSS Auto and LSS
Manual.
The menus only provide indications from the label stop sensor unit. The
testing menus can determine if the sensor unit is not physically in position,
is blocked by dust or stuck labels, or is defective in some way. Furthermore,
this is an aid if media has detection complications.
Note: There is no way to adjust the LSS-function; the menus only indicate
values from the LSS obtained by performing a testfeed operation.
LSS Auto is the quick and normal way to determine if the label stop sensor
works properly and is able to detect gaps, slots, or black marks.
LSS Manual shows the actual setting provided by the latest testfeed
operation. It is also possible to try other settings. LSS Manual is primarily
intended for service and is not described in the User’s Guide.
LSS Auto
• Check that the printer is set up for the type of media loaded in your
printer.
• Perform a testfeed by simultaneously pressing the <Shift> and <Feed>
keys on the printer’s keyboard (Fingerprint) or by pressing the <Feed/
Pause> key (IPL).
• Make sure that there is a label—not a gap or mark—at the LSS.

• Check that the media is routed as close to the center section as the
guides allow.
• Enter the Setup Mode and go to Setup Mode→Print Defines→LSS
Test→LSS Auto (Fingerprint) or Setup Mode→Test/Service→LSS
Test→LSS Auto (IPL).
• The menu should look like this with the cursor placed in the center:
LSS Auto
• Gap or slot detection:

Lift the printhead and pull out the media slowly. When the LSS detects
a gap or a detection slot, the cursor moves to the right.
LSS Auto
• Black mark detection:

Lift the printhead and pull out the media slowly. When the LSS detects
a black mark, the cursor moves to the left.
LSS Auto
• It is possible to refresh the centered cursor position by pressing the <d>

key.
• If the cursor behaves as described above, the LSS is working and is prop-
erly aligned with the gaps, slots, or black marks.
• If the cursor does not react on a gap, slot, or black mark, check this:
- Is the LSS laterally aligned with the slots or black marks?
- Are both the upper and lower part of the LSS aligned with each
other?
- Is the transfer ribbon properly loaded so it does not interfere with the
LSS?
- Are the sensors clean from dust and the LSS guides free from stuck
labels or other objects that will interfere with the light that goes from
one part of the LSS to the other? If not, clean as described in the
User's Guide.
- Does the media have some kind of preprint that can disturb the
detection?
- Is there too little difference between the black marks and the sur-
rounding areas?
- Does the liner have too little transparency?
- Does the LSS work with another type of media? (Remember to
change the Media Type setup and perform a new testfeed.)

LSS Manual
The LSS Manual option shows the actual setting given by the automatic
testfeed. The cursor on the lower line indicates the response on the actual
testfeed values for the Gain (sensitivity) and Drive (intensity).
LSS [G: 2]D: 6
You can toggle between gain (G) and drive (D) using the <`> and <_> keys
and decrease or increase the value using the and <a> keys respec-
tively.
Note: Changing the gain and drive does not reset the LSS. It only affects
the testing. Once you leave the LSS Manual node, the values obtained by
the automatic testfeed become effective again.
If there are preprinted areas on the liner or cut-out slots etc., it can disturb
the automatic testfeed. To identify the problem, manually move the media
can check the response from the sensor in detail on the display. The solu-
tion is often to move the sensor sideways to a position where the preprint
or similar is not disturbing.
Other problems, such as low gap opacity, semi-transparent labels when
using gap detection, or black marks that do not absorb the light suffi-
ciently, can also be identified by changing the gain and drive manually.
If there is no dust or other things mechanically interfering with the LSS,
check the hardware by changing first the gain and secondly the drive
values. If the cursor is positioned in either the extreme left or right position
and refuses to move, check cables, replace the LSS, or—as a last resort—
replace the CPU board.
Sensitivity Adjustment
The LSS should always be adjusted when the user changes to another
brand (sometimes even a new batch) of media, and when a defective sensor
has been replaced. This is especially the case with self-adhesive labels on
liner, because the transparency of the liner may vary and the difference
between labels and gaps may be too small. Before starting the adjust-
ment, check that both the upper and lower sensor are clean and free from
obstructions and that the edge guides are adjusted so as to guide the media
with a minimum of play. Also check that both parts of the LSS are in the
same lateral position and aligned with any gaps or black marks.
Fingerprint only
As standard, there are four ways to adjust the LSS:
• Performing a TESTFEED by simultaneously pressing the “Shift” and
“Feed” keys on the printer’s built-in keyboard.
• Selecting the TESTFEED option in Intermec Shell.
• Selecting the TESTFEED option in the Setup Mode.
• Executing a TESTFEED statement in a Fingerprint program.
The printer feeds out 1.5 times the set label length or less while testing
all levels of the LSS at each millimeter of media feed. The LSS is adjusted
according to the result of the check and a full label is fed out according to
the present feedadjust setup.

The label stop sensor/black mark sensor can be turned off for a specified
amount of media feed using the LBLCOND statement, see Intermec Fin-
gerprint v8.xx Programmer’s Reference Manual.
IPL only
The sensitivity of the LSS is configured at startup. To force adjustment of
the sensitivity (corresponding to a TESTFEED in Fingerprint), raise and
close the printhead and then press the <Feed/Pause> key.
Adjustment of the LSS Lateral Position
The label stop/black mark sensor (LSS) can be laterally adjusted within a
range of 0 to 50 mm (1.96 inches) from the inner edge of the media path
by means of a screw accessible through the outer lower gable. Turning the
screw clockwise will move the LSS inwards and vice versa. The position of
the LSS in relation to the media is best checked by looking head on into
the print unit when the printhead is raised. Align the centerpoint of the V-
shaped upper sensor with the center of the slots or marks to be detected.
The linear markings on the lower guide plate can also be used for position-
ing of the LSS as they are spaced with an interval of exactly 1 cm (0.39
inches) from the edge that guides the media. This method is especially
useful for black marks (measure the lateral position of the black marks with
a ruler before loading the media.)
If using irregularly shaped labels, align the LSS with the front tips of the
labels.
).
/54
).
/54

Removing the Guide Plates

The LSS guide plates will need to be removed for occasional cleaning,
replacement and when replacing a defective sensor.
• To remove the upper guide plate, just pull it straight out.
• To remove the lower guide plate, disengage the snap-lock (accessible

through a slot in the lower gable) using for example a screwdriver and
lift the outer end of the guide plate. Then pull it out.
When cleaning the guide plates, use a soft cloth moistened with isopropyl
alcohol. Do not use any other type of chemicals. Blow the sensors free
from dust.
Isopropyl alcohol [(CH3)2CHOH; CAS 67-63-0] is a highly flammable,
moderately toxic, and mildly irritating substance.

Replacing the Sensors

To remove the LSS bracket from the carriage, for example in connection
with cleaning or replacing a sensor, proceed as follows:
• Switch off the power, remove the power cord and remove the cover over
the electronics compartment.
• Remove the upper and lower plastic guide plates.
• Adjust the LSS to approximately center position.
• Disconnect the cables from J54 and J55 on the CPU board.
• Disengage the snap-lock, using a screwdriver from the media compart-
ment side, and push the outer end of the LSS bracket upward. Then
pull the bracket out from the carriage, taking care not to damage the
cables.
Note! The snap-lock is fragile.
• Remove the two #TX8 Torx screws that hold the defective sensor and
replace it.
LSS bracket
Upper sensor
Lower sensor
Snap-lock
Carriage

To reassemble the LSS, proceed as follows:

• Thread the cables through the hole in the inner gable.
• Place the inner, lower corner of the bracket into the groove in the car-
riage, almost at the innermost end.
• Tilt the bracket up at the outer end and push it inwards so the inner
notch in the bracket engages the carriage.
• Press down the outer end of the bracket, so the snap-lock engages the
outer notch.
• Press the bracket inwards as far as it goes and check that the bracket is
secured by the snap-lock.
• Connect the cable from the lower sensor to J54 (marked “GAP”) and
the cable from the upper sensor to J55 (marked “BM”) on the CPU
board.
• Put back the guide plates, the electronics compartment cover, and the
power cord.
• Adjust the lateral position of the LSS.
Connect to J55
on CPU board
Connect to J54
on CPU board
Inner notch
Outer notch
Snap-Lock

8.6 Printhead
Description
The printing is produced by the thermal printhead, which consists of a
line of very small, closely spaced resistors on a ceramic tile fitted across the
media path. When a current is led through the resistors, commonly called
“dots,” these will be heated very quickly. When the current is shut off, the
dots cool down just as fast.
As the media is fed past the dots, the hot dots will produce a number of
black spots on heat sensitive (direct thermal) media, or on other face mate-
rials via a thermal transfer ribbon. The spots can be combined into bitmap
patterns, which make up characters, bar codes, images, lines, and boxes.
The direct thermal printing method requires special media coated with a
thin layer of heat-sensitive chemicals. As the media is fed past the dots, the
heat from the dots will make the chemicals react, producing a dark salt,
which makes up the imprint under each dot.
In the thermal transfer printing method, a special “ink”-coated transfer
ribbon is used. When the ribbon is heated by a dot on the printhead, the
“ink” melts and sticks to the receiving face material, where the ink imme-
diately becomes solid again, producing a black spot. Transfer ribbons nor-
mally do not smear at room temperature, neither before nor after printing.
Nor do the printed labels smear, even if the printout may be smudged by
extensive rubbing if an unfortunate combination of ribbon and face mate-
rial is used. The thermal transfer method makes it possible to use a wide
range of face materials for printing, for example papers, boards, plastics,
foils, etc. However, an original transfer ribbon from Intermec should
always be used.
Information on how to switch between direct thermal and thermal transfer
printing is provided in the User’s Guide.
The basis for all measures and positioning in both the Fingerprint and IPL
programming languages is the size of printhead dots.
In an 8 dots/mm (203.2 dpi) printhead, each dot has a nominal size of
0.125 mm (4.92 mils). This means that a heated dot under standardized
conditions will produce a black spot which has a diameter of 0.125 mm
(4.92 mils).
In an 11.81 dots/mm (300 dpi) printhead (Fingerprint only), each dot
has a nominal size of 0.086 mm (3.33 mils). This means that a heated dot
under standardized conditions will produce a black spot which has a diam-
eter of 0.086 mm (3.33 mils).
Depending on dot temperature, exposure time, media and ribbon charac-
teristics, etc., the spot may actually be somewhat smaller (weak print) or
larger (black print), but that does not affect the calculation of distances,
sizes, and positions.
At startup, the printer auto-detects the printhead density as well as the
head resistance. The printhead can also be checked using the Finger-
print instructions HEAD, FUNCTEST, and FUNCTEST$. In IPL, the
number and size of the dots in the printhead is returned to the host by the
command <STX><ESC>H<ETX>.

The printhead is fitted to a bracket using two screws. The printhead, the
printhead ribbon break shaft, and the bracket are always delivered as a
complete assembly and must not be dismantled. Two hooked fingers at
the rear of the bracket are fitted over the headlift shaft so as to hold the
printhead in place. A U-shaped tab on either side of the bracket engage
the platen roller bearings when the printhead is closed, making sure that
the printhead becomes properly aligned with the platen roller. There are
no facilities for adjusting the position of the printhead relative the platen
roller, neither longitudinally nor laterally.
There are two sets of cables in a harness running to the printhead:
• The innermost cable is used for the power to the printhead and is con-
nected to P5 on the driver board.
• The outermost cable is used for data to the printhead and is connected
to J40 on the CPU board.
Note: It is important that the cable harness does not prevent the printhead
from moving or adjusting itself when it is lowered.
“Finger”
Cable harness
Bracket
Label
“Finger”
Printhead ribbon
break shaft
Printhead
Illustration shows the printhead of an EasyCoder PX4i.

The printhead of EasyCoder PX6i looks in principle the same but is wider.

Print Window PX4i

The EasyCoder PX4i has an 8 dots/mm (203.2 dpi) printhead or, in the
Fingerprint version only, an 11.81 dots/mm (300 dpi) printhead.
8 dots/mm Printhead
Density 8 dots/mm (203.2 dots per inch)
Print width 112 mm (4.4 inches)
Number of dots 896
Dot size 0.125 mm (4.92 mils)
MM IN
0RINT 7IDTH
MAX MM IN
$OT LINE
ON PRINTHEAD
&%%$ $OT

$OT $)2%#4)/.
-EDIA 7IDTH
MM IN

11.81 dots/mm Printhead (not IPL)

Density 11.81 dots/mm (300 dots per inch)
Print width 112 mm (4.4 inches)
Number of dots 1322
MM IN
0RINT 7IDTH
MAX MM IN
$OT LINE
ON PRINTHEAD
&%%$ $OT

$OT $)2%#4)/.
-EDIA 7IDTH
MM IN

Print Window PX6i

The EasyCoder PX6i has an 8 dots/mm (203.2 dpi) printhead or, in the
Fingerprint version only, an 11.81 dots/mm (300 dpi) printhead.
8 dots/mm Printhead
Density 8 dots/mm (203.2 dots per inch)
Print width 167.4 mm (6.59 inches)
Number of dots 1344
MM IN
0RINT 7IDTH
MAX MM IN
$OT LINE
ON PRINTHEAD
&%%$ $OT

$OT $)2%#4)/.
-EDIA 7IDTH
MM IN

11.81 dots/mm Printhead (not IPL)

Density 11.81 dots/mm (300 dots per inch)
Print width 167.4 mm (6.59 inches)
Number of dots 1984
MM IN
0RINT 7IDTH
MAX MM IN
$OT LINE
ON PRINTHEAD
&%%$ $OT

$OT $)2%#4)/.
-EDIA 7IDTH
MM IN

Replacing the Printhead

The printhead is a consumable part subject to wear from both the thermal
paper or transfer ribbon, and from the rapid heating and cooling process
during printing. Thus, it will require periodical replacement depending on
print volume, type of print media, amount of energy to the printhead, and
several other factors.
To replace a defective or worn printhead, proceed as follows:
• Switch off the power.
• Open the front and right-hand doors.
• Turn the printhead lift lever to “Open” position.
• Remove any media and/or transfer ribbon from the print unit.
• Carefully pull the printhead bracket away from the magnet in the lift
arm.
• Disconnect the hooked fingers at the rear of the bracket from the
headlift shaft and pull out the printhead as far as the cables allow.
• Disconnect the two cables from the printhead.
Note the snap-lock on the inner connector. Pull at the connectors, not at
the cables!
• Connect the cables to the replacement printhead assy with the ribbon
cable to the right.
• Insert the printhead assy into the print unit, fitting the bracket’s fingers
over the headlift shaft.
• Check so the cables will not interfere with the transfer ribbon, prevent
the printhead from moving freely, or have become jammed between
parts in the print unit.
• Turn the printhead lift lever to “Closed” position, so the magnet engages
the printhead bracket.
• Switch on the power. The printer’s firmware automatically measures the
printhead resistance at power-up.
• Load media and, if so required, transfer ribbon again.
Refer to the illustrations on the next page! Detailed step-by-step illustra-
tions can be found in the User's Guide, Chapter “Maintenance.”

EasyCoder PX4i
EasyCoder PX6i

Precautions
Some simple measures can be taken by the user to prevent premature wear-
out:
• Clean the printhead regularly, as described in the User’s Guide. Not only
will a dirty printhead produce an inferior printout, but any residue on
the dots will prevent heat to dissipate through the media.
• Follow the Intermec’s recommendations regarding Paper Type or Media
Sensitivity setup. Too much energy to the printhead will wear it out
rapidly.
• Do not use higher Print Speed setting than necessary.
• Low ambient temperature requires more energy to the printhead dots
than room temperatures and will therefore cause more wear to the
printhead. High print speed accelerates the wear. Thus, at low tempera-
tures, select as low a print speed as acceptable.
• In Fingerprint, do not use a higher Contrast setting than necessary, espe-
cially not in combination with the highest Label Constant or Ribbon
Constant settings.
• In IPL, do not use a higher Darkness setting than necessary.
• Do not use a higher printhead pressure than necessary.
• Never print outside the media path. Dots that are not in contact with
the media will not be cooled properly.
• When using media with less than full width, be careful to adjust the
printhead lift arm so there is an even pressure across the media. Not
only will an uneven pressure impair the printout quality, but it may also
prevent the dots from being properly cooled. Moreover, a sharp outer
media edge in direct contact with the printhead may cause excessive
mechanical wear on some dots, which may be visible when printing on
wider media later.
• When using preprinted labels or labels with some type of varnish or
non-standard top coating for direct thermal printing, use original
Intermec labels or inks recommended by leading manufacturers of direct
thermal media. The labels must not contain any aggressive substances
such as chloride or grinding substances such as titanium dioxide.
• Only use transfer ribbons recommended by Intermec.

8.7 Headlift Sensor

Description
The purpose of the headlift sensor is to detect whether the printhead is
raised or lowered. To avoid the risk of overheating the printhead dots,
printing can not be performed when the sensor detects that the printhead
is raised (the media serves to cool the printhead). An ever so slightly raised
printhead would also impair the printout quality. Thus, it is important that
the printhead is properly lowered and a sufficient pressure is applied before
the sensor detects a “Closed” condition.
The photoelectric sensor is attached to the electronics compartment side
of the inner print unit gable by means of two #T10 Torx screws. When the
printhead is raised, a beam of light is interrupted by an arm connected to
the headlift shaft. This is detected by the firmware so an error message will
be returned if you try to print a label. In Fingerprint, error message 1022
“Head Lifted” will be returned if you try to print a label with the printhead
lifted. In IPL, the error message “Print Head Up/Press Feed” is displayed.
The headlift sensor is connected to J58 (marked “HEADL”) on the CPU
board.
The arm that blocks the light through the sensor is attached to the headlift
shaft using a #T10 Torx screw. If the screw is not tightened sufficiently or
if the arm is not fitted in the correct angle, a malfunction will occur.
Adjusting the Sensor Arm
• Perform an adjustment of the printhead pressure as described in Chapter
8.8.
• Without switching off the power, remove the cover over the electronics
compartment.
The electronics compartment contains wires and circuits with danger-
ous voltage. Take precautions to avoid electrical shock, short-circuits,
and electrostatic discharges.
• Place a 1 mm (0.04 inches) thick feeler gauge between the printhead
and the platen roller and lower the printhead. Be careful not to damage
the delicate printhead dots!
• Loosen the #T10 Torx screw that holds the sensor arm.
• In case of Fingerprint printers, run the program listed on the next page.
• Move the sensor arm from open position towards closed position until
the Error LED goes out, which indicates the correct position.
• Tighten the screw and check that the arm runs freely inside the fork-
shaped sensor.
• Put back the cover.

#T10 Torx Screw Headlift shaft
Sensor Arm
“Printhead Open“
position
“Printhead Closed” position

Sensor
In Fingerprint, run this program which assists you in adjusting the headlift
sensor arm:
Status LED red = Printhead open.
Status LED off = Printhead closed.
The correct position is exactly when the Status LED goes off.
You can break the program execution either by pressing <Shift> + <Pause>
on the printer's keyboard or by transmitting the character X (uppercase!)
from the host.
NEW
10 BREAK 1, 88
20 BREAK 1 ON
30 ON BREAK 1 GOSUB 1000
40 LED 1 OFF
50 WHILE (PRSTAT AND 1)=0: WEND
60 LED 1 ON
70 WHILE (PRSTAT AND 1)=1: WEND
80 GOTO 40
1000 BREAK 1 OFF
1010 END
RUN
In IPL, check that the sensor is properly adjusted using the Label Path
Open Sensor Value command (<STX>L<ETX>), see IPL Programming,
Reference Manual.

Sensor Replacement
Before replacing the sensor, check that the sensor arm is properly adjusted
and that the sensor is free from dust, paper shreds, and other things that
can block the light.
Replace the sensor as follows:
• Switch off the power, remove the power cord, and remove the cover over
the electronics compartment.
• Check that the printhead is lowered.
• Remove the #T10 Torx screw that holds the front of the sensor.
• Raise the printhead.
• Remove the #T10 Torx screw that holds the rear of the sensor.
• Pull out the sensor and disconnect its cable from the CPU board.
• Reassemble in reverse order. The sensor’s cable should be connected to
J58 (marked “HEADLIFT”) on the CPU board.
• In Fingerprint, check that the sensor works properly using a PRSTAT
statement, see Intermec Fingerprint v8.xx, Programmer’s Reference
Manual.
• In IPL, check that the sensor works properly using the Label Path Open
Sensor Value command (<STX>L<ETX>), see IPL Programming, Refer-
ence Manual.

8.8 Headlift Mechanism

Description
The headlift mechanism is an integrated part of the print unit. The mecha-
nism is activated by the green printhead lift lever at the outside of the
upper part of the print unit. The knob is fitted on a shaft, which has a disk
with an eccentrically fitted pin on the inside of the upper, outer gable of
the print unit. This pin activates a fork-shaped pressure adjuster, that via
a linkage is connected to the headlift shaft. The pressure adjuster is fitted
with a spring and an adjusting screw. Thus, the operator can easily apply
more or less pressure of the printhead against the platen roller depending
on type of media, print method, media thickness, and other circumstances.
The headlift shaft is connected to the headlift sensor arm on the inside
of the print unit (see Chapter 8.7.) On the headlift shaft, the S-shaped
headlift arm is also fitted. At the tip of the headlift arm is a magnet that
engages the printhead bracket. The arm can be moved along the headlift
shaft, so the pressure can be applied laterally at the center of the media
path, even when narrow media are used. The hooked fingers of the
printhead bracket are hung on the headlift shaft. The concept allows the
printhead to align itself vertically to the platen roller, while maintaining a
fixed alignment in the other two dimensions.
Return spring Headlift shaft

Sensor arm
Pressure adjuster
Linkage
Headlift arm
Eccenter
Printhead pressure Printhead lift lever

grub screw
(factory-adjustment) EasyCoder PX4i

Return spring
Sensor arm
Headlift shaft
Pressure adjuster
Headlift sensor
Linkage
Headlift arm
Printhead lift lever
Printhead pressure
grub screw
(factory-adjustment)
EasyCoder PX6i

Printhead Pressure Adjustment

The pressure of the thermal printhead against the ribbon or media is fac-
tory adjusted. However, the use of thicker or thinner media than normal
could require the printhead pressure to be readjusted.
Turn the green adjustment knob clockwise for increased pressure, or coun-
terclockwise for less pressure. Print a few labels, preferably test labels, and
check the printout. Increased pressure generally gives a blacker printout
and vice versa. Repeat until the desired result is obtained.
To find the basic setting, proceed as follows:
• Remove the transfer ribbon (if any).
• Load the printer with full width media and close the printhead.
• Adjust the headlift arm to center position.
• Turn the green adjustment knob counterclockwise until it feels loose (no
pressure left).
• Take up the slack in the green knob until you notice an increased resis-
tance.
• Using a 2 mm hexagonal key, loosen the factory adjustment grub screw
(see illustration on the previous page) until the printhead starts to come
up.
• Carefully tighten the grub screw until you just start noticing a small
resistance when trying to pull out the media.
It is possible to apply very high printhead pressure using the factory
adjustment grub screw. Such high pressure may damage the printhead,
the platen roller, and the headlift arm.
Do not use a higher printhead pressure than necessary, because it may
increase the wear of the printhead and thus shorten its life.
• Apply some locking fluid on the grub screw.
• Raise and lower the printhead.
• EasyCoder PX4i:
Turn the knob 4 full turns clockwise. Each turn increases the pressure by
approx. 1 kp to a total of 4 kp (39.2 N).
EasyCoder PX6i:
Turn the knob 5 full turns clockwise. Each turn increases the pressure by
approx. 1 kp to a total of 5 kp (49.0 N).
• Fine-adjust using test labels and the trial-and-error method (if necessary
after having loaded the transfer ribbon again).
Refer to the illustrations on the next page!

Adjustment knob
(green)
EasyCoder PX4i
Adjustment knob
(green)
#LOSED
/PEN
EasyCoder PX6i

8.9 Ribbon Assist Roller

Description (EasyCoder PX4i and PX6i)
The purpose of the ribbon assist roller is to help the ribbon rewind unit to
keep the transfer ribbon tight, thereby avoiding ribbon wrinkling, which
could ruin the printout. The angle of the ribbon assist roller relative to the
printhead is adjustable.
The ribbon assist roller is subject to very little wear and is expected to last
as long as the printer as a whole. Replacement involves removing the belt
and pulley as well as the upper, outer gable of the print unit (see illustra-
tions in Chapter 8.8.)
Adjustment (EasyCoder PX4i and PX6i)
If the ribbon becomes wrinkled, a few checks should be performed before
the ribbon assist roller is readjusted:
• Is the printhead pressure properly adjusted?
• Is the green edge guide correctly positioned?
• Is there anything that may interfere with the transfer ribbon, for exam-
ple the printhead cables.
If the wrinkling problem remains, proceed as follows:
• Using a #T20 Torx screwdriver, loosen the locking screw that runs in the
crescent-shaped hole in front of the headlift lever.
• Insert a #T20 Torx screwdriver as illustrated on the next page. By turn-
ing the screwdriver, you can move the outer end of the roller back and
forth:
- Turn the screwdriver clockwise to move the end of the roller forward.
- Turn it counterclockwise to move the end of the roller rearward.
• If the ribbon gets wrinkled at the inner edge, you should move the end
of the roller slightly rearward, that is, rotate the screwdriver counter-
clockwise and vice versa.
• Select an appropriate layout, for example a test label, and print it repeat-
edly while carefully moving the end of the roller back or forth, depend-
ing on which side the wrinkling has occurred.
• When the wrinkling ceases, continue the movement ever so slightly to
create a small safety margin. The movement is best detected by the rela-
tion between the roller bearing and the hole through the upper gable.
Another method is to determine the positions where wrinkling starts at
either side and adjust the roller to the middle.
• You will need to print several labels before a new adjustment has any
noticeable effect.
• When you are satisfied that the problem is cleared, tighten the locking
screw and test again by printing several more labels. Readjust if neces-
sary.
Refer to the illustrations on the next page!

EasyCoder PX4i
Ribbon assist roller
#T20 Torx locking screw
#T20 Torx screwdriver

EasyCoder PX6i
Ribbon assist roller
#LOSED
/PEN
#T20 Torx locking screw
#T20 Torx screwdriver
Wrinkling Turn Screwdriver

Inner side Counterclockwise
Outer side Clockwise

8.10 Media Feed Principles

Fingerprint only
The Start and Stop Adjust parameters in the Fingerprint Setup Mode con-
trol how the media will be positioned in relation to the printhead when the
printing starts and after the printing is completed, respectively. By default,
the Start and Stop Adjust parameters are both set to 0, which is suitable for
tearing off the media against the tear bar, for example between labels or at
the perforation in a pre-perforated continuous stock. However, because the
dot line on the printhead is situated 15.7 mm (0.62 inches) back from the
tear bar, the printing will not start at the top of the label but further back
along the media path.
MM
$EFAULT 4EAR OFF
3TART !DJUST
3TOP !DJUST
$OT ,INE ON 0RINTHEAD

4EAR "AR
,ABEL 3TOP
3ENSOR
Note: Due to several factors, media feed measurements are not exact and
may vary somewhat between applications and individual printers. There
is inevitably a small amount of slippage between media and platen roller,
which in its turn is affected by printhead pressure, type of media or liner,
thickness of the media, roll size, type of media supply device, etc. The
platen roller may be worn, giving it a slightly smaller diameter and/or less
friction. There is also a certain amount of inexactness in the media feed
mechanics and belts and so on. Therefore, the operator cannot expect to
reach exact Start and Stop Adjust values simply by calculation. Use the
measurements given in this chapter to calculate rough starting points and
use the trial-and-error method to find values that give the desired result.

In many cases, it is desired to start the printing immediately at the top

of the label. Actually, what you want to do is to pull back the edge of the
media to the dot line. You can do this by means of a negative Start Adjust
value, for example -108 dots = 13.5 mm/0.53 inches for a 8 dots/mm
(203.2 dpi) printer. Be careful not to enter too large a value, or the media
may come loose from platen roller.
MM
4EAR OFF PRINT AT TOP OF LABEL
3TART !DJUST AT DPI
3TOP !DJUST AT DPI

4EAR /FF %DGE
,ABEL 3TOP
3ENSOR
When using peel-off operation, the labels would drop from the liner and
get stuck on for example the desk if you use the default Start Adjust value
0. Use a Stop Adjust value of around -40/-60 (= 5.5 mm/0.22 inches)
instead: that is, after the printing is completed 5.5 mm/0.22 inches less
of media feed than normal will be performed. However, if you still want
to print from the top of the label, you must compensate by a Start Adjust
value of around -80/-115 (= 10.0 mm/0.39 inches).
MM
0EEL OFF PRINT AT TOP OF LABEL
3TART !DJUST AT DPI
3TOP !DJUST AT DPI

4EAR "AR
,ABEL 3TOP
3ENSOR
A special case is tickets with black marks. It is recommended to place the

black mark adjacent to the perforation or the intended tear-off line. If the
black mark is placed further down the media, this must be compensated
for by a negative Stop Adjust setting.

IPL only
In IPL, the media feed is affected by the mode of operation. There are
three such modes:
• Tear-off (straight-through)
(default)
• Peel-off (self-strip)
(enabled/disabled by <STX><SI>Tn<ETX> command)
• Cut-off
(activated/deactivated when the cutter is enabled/disabled in the Setup
Mode or by <STX><SI>Cn<ETX> command)
Each mode has a fixed amount of media feed, which can be fine-adjusted
using the Label Rest Point parameter in the Setup Mode (See Appendix A,
Setup/Media/Lbl Rest Point) or an <STX><SI>fn<ETX> command.
The type of detection is decided by the Media Type parameter in the Setup
Mode (See Appendix A, Setup→Media→Media Type).

9 Liner Takeup Kit
This chapter describes the optional liner takeup unit and covers the follow-
ing topics:
• Description
• Main parts
• Liner/batch takeup unit

Chapter 9 — Liner Takeup Kit
9.1 Description
The liner takeup kit is an optional factory-installed device that makes
it possible to auto-dispense self-adhesive labels from the liner (peel-off/
self-strip operation), and—in case of EasyCoder PX4i—also to wind up
printed labels, tickets, or continuous stock internally (batch takeup opera-
tion.) The kit consists of two or three main parts:
• A stepper motor that drives the liner drive roller in the print unit and
the liner/batch takeup unit. The liner drive roller is fitted as standard
even when the kit is not installed.
• A liner/batch takeup unit that takes up the spent liner or the printed
media to be rewound for later use.
• A guide plate (EasyCoder PX4i only) that replaces the tear bar when
labels or other types of printed media are wound up internally (see
below). When not used, the guide plate is fitted using one #T20 Torx
screw at the rear of the media compartment.
When no rewind unit is fitted, the hole through the center section is cov-
ered by a plate held by two #T20 screws.
Rewind guide
(position when not fitted)
Tear bar
Rewind guide
The batch takeup guide plate is only used in EasyCoder PX4i.

EasyCoder PX4i; Peel-Off (Self-strip) Operation
&BTZ
$P
EFS1
9J
The liner takeup unit can accommodate the liner from a full roll of labels.
EasyCoder PX4i; Batch Takeup Operation
&BTZ
$P
EFS1
9J
The batch takeup unit can accommodate approximately 1/4 to 1/3 of a full
label roll depending on media thickness.

EasyCoder PX6i; Peel-Off (Self-strip) Operation
D
#LOSE
/PEN
The liner takeup unit can accommodate the liner from a full roll of labels.

9.2 Main Parts

The stepper motor is fitted to the printer’s center section using a motor
support plate. It drives the liner/batch takeup unit and the liner drive roller
in the print unit via two belts. The tension of these belts can be slightly
adjusted by moving the stepper motor and/or support plate before the
screws are tightened.
The takeup unit is fitted with a brace, that holds the liner or media. The
unit is fitted to the printer’s center section using two #T20 Torx screws
inserted from media compartment.
A break shaft in front of the takeup unit guides the liner or media under
the slack absorber.
The stepper motor is connected to P11 on the driver board, see Chapter
14.
EasyCoder PX4i
Stepper motor
Motor support plate

Belt to liner/batch takeup unit
Belt to
liner drive roller
Tension roller
Liner/batch takeup unit
Break shaft Brace

EasyCoder PX6i
Stepper motor
Motor support plate
Belt to liner takeup unit
Belt to
liner drive roller
Tension roller
Liner takeup unit

Break shaft
Brace

9.3 Liner/Batch Takeup Unit

The liner/batch takeup unit is fitted to the printer’s center section from
the media compartment side using a flange with two bearings. The flange
is held by two #T20 Torx screws. On the inner side of the center section
is a pulley, which is part of a two-way spring brake. The pulley is held by a
snap ring.
On the outer side, the hub and its attached gable are fitted. The rotation is
controlled by the spring brake which works the same way as in the ribbon
supply unit (see Chapter 7.2). Thereby, it is possible to wind up liner or
media manually without running the motor. The spring brake also takes
up sudden jerks. A plate helps to hold possible takeup cores. The assembly
is held together by snap rings and a pin inserted through the rewind hub
and its shaft.
Note: The Liner Takeup Unit of an EasyCoder PX6i is not able to rewind
printed labels—only to wind up liner.
The wind-up torque should be 310 to 380 Nmm and the slip torque 30
to 70 Nmm. Refer to Appendix 2 for a description of how to check the
torque. If the wind-up torque deviates from the recommended value,
replace the entire spring brake assy.
EasyCoder PX4i
Bearing
Flange
Snap ring
Snap ring Bobbin gable

Bearing
Pulley Bearing
Bearing
#T10 Torx Pin
screws (x2)
Flange
Spring
Brake sleeve Bobbin
Shaft
Snap ring Bobbin plate
Spring brake assy. Bearing

EasyCoder PX6i
Bearing
Flange
Snap ring
Pulley Snap ring

Bearing Bearing
Bobbin gable
Bobbin
plate
Bearing
#T10 Torx
screws (x2)
Flange
Spring
Brake sleeve
Snap ring
Pin Bobbin
Shaft
Spring brake assy. Bearing

10 Label Taken Sensor
This chapter describes the optional label taken sensor and covers the fol-
lowing topics:
• Description
• Installation
• Activating the LTS
• Adjustment

Chapter 10 — Label Taken Sensor
10.1 Description
The label taken sensor (LTS) is an optional device, which enables the
printer's firmware to detect if the latest printed label, ticket, tag etc. has
not been removed and hold the printing on the next label until the present
label has been taken away from the outfeed area.
The label taken sensor is usually factory-fitted, but it is also available as a
kit for upgrading of existing printers by an authorized service technician. It
cannot be fitted in combination with a paper cutter.
The label taken sensor consists of a photoelectric sensor with a bracket and
a connection cable. The sensor is fitted inside the front door, see illustra-
tion below.
Label taken sensor
The photoelectric sensor emits a narrow beam of light, which will be

reflected back to the sensor by any label, ticket, tag, piece of strip, or liner,
that has not been removed from the outfeed area.
The LTS is connected to J53 on the CPU board. The sensitivity is adjusted
in the Setup Mode, see Chapter 10.4.
The point of detection of the LTS is situated 10 mm (0.39 inches) outside
the inner edge of the media path and 22 mm (0.87 inches) in front of the
dot line on the printhead.

10.2 Installation
The Label Taken Sensor Kit consists of:
• One Reflecting Sensor assy. with cable and connector
• One Sensor Bracket
• One Screw
• One Installation Instructions booklet
The only tools needed are a set of Torx screwdrivers.
Install the label taken sensor this way:
• Open the right-hand doors and remove the left-hand cover as described
in Chapter 3.3.
The electronic compartment contains wires and components with
dangerous voltage (up to 380V). Make sure that the printer is switched
off and the power cord is disconnected, before the left-hand cover is
removed.
• Using the screw included in the kit, fit the sensor/bracket assembly to
the inner wall of the print unit as shown by the two illustrations below.
Fit the cable underneath the top part of the bracket, as illustrated below.
LTS cable
LTS
#T10 Torx screw
• Slip the cable of the label taken sensor through the hole in the center
section of the printer into the electronics compartment.
• Connect the cable to J53 on the CPU board. Be careful so the cable
does not interfere with any moving mechanical parts or the transfer
ribbon.
• Put back the left-hand cover, connect the power cord and switch on the
power.

10.3 Activating the LTS

In Fingerprint, the label taken sensor is enabled using the instruction
LTS& ON.
In IPL, the self-strip mode must be enabled. This can also be done by
executing the following commands:
<STX>R<ETX> (Enter print/configuration mode)
<STX><SI>t1<ETX> (Enable self-strip)
10.4 Adjustment
The sensitivity of the Label Taken Sensor (LTS) may need to be adjusted
according to the ambient light conditions and the reflective characteristics
of the back side of the media.
Fingerprint
The sensitivity can be adjusted in the Setup Mode (see Appendix A), or by
using setup files or setup strings (see Intermec Fingerprint v8.xx, Program-
mer’s Reference Manual). In the Setup Mode, the LTS setup options are
only displayed if an optional label taken sensor is installed in the printer.
• LTS Adjust:
Press <Enter>. A label is fed out. Remove the label and press <Enter>
again. A menu shows the sensitivity automatically selected by the firm-
ware and the range in which the LTS will work. Press <Enter> again and
you will proceed to the LTS Test menu.
• LTS Test:
Press <Enter>. A label is fed out. Remove the label and a new label
should be fed out automatically. Repeat until you are sure the LTS
works properly. Then press <Enter> to stop and exit.
• LTS Value:
Press <Enter>. You can enter a new value in the range indicated in the
LTS Adjust menu (see above). Min/max values are in the range 0-10.
IPL
The sensitivity can be adjusted in the Setup Mode (see Appendix A).
• In the Setup Mode, select the Configuration option.
• Select LTS Calibration and press the T key.
• Press <Enter>
• A number of labels are fed out. Remove the labels and press <Enter>.
• The sensor has now been automatically adjusted and the resulting
sensitivity is displayed as a numeric value in the range of 8 to 14.

11 Paper Cutter
This chapter describes the optional paper cutters for EasyCoder PX4i and
PX6i. The chapter covers the following topics:
• Description
• Installation
• Controlling the cutter
• Media load
• Servicing
• Spring replacement

Chapter 11 — Paper Cutter
11.1 Description
The EasyCoder PX4i and PX6i can easily be fitted with an optional cutter
unless the printer is not already fitted with an label taken sensor (see
Chapter 10). The cutter unit is fitted on the same hinges as the front door,
which it replaces, and is connected by a single cable to the DIN-connector
on the printer’s front.
The cutter is available both as a factory-installed option and as a field-
installable upgrading kit.
The cutter is intended to cut through continuous non-adhesive paper strip

or through the liner between labels. It must not be used to cut through any
kind of adhesive or other soft material, that may stick to the cutting parts
and render the cutter inoperable or even damage the electric motor.
Maximum paper thickness is 175 µm (≈ 175 g/m2) for normal paper-based
materials.
Minimum practical copy length is 38.1 mm (1.5 inches.)
The cutter increases the total weight of EasyCoder PX4i and PX6i respec-
tively by approx. 1.0/1.65 kg (2.2/3.6 pounds). In both cases, the length is
increased by 28 mm (1.1 inches).
The cutter can be tilted forward in order to facilitate cleaning and media
load.
The cutting edge will rotate to home position when the power is
switched on and when the printer is rebooted. Always keep the cutter
unit in closed position during operation

11.2 Installation
• Switch off the power and remove the power cord.
• Open the printer’s front door.
• Hold the printer firmly and press the front door sideways to the left so
as to disengage the hinges.
• Remove the door completely.
0RESS
SIDEWAYS
• If the printer is fitted with a label taken sensor (LTS), it has to be

removed before the cutter can be fitted, see Chapter 10.

• Fit the cutter unit to the vacant hinges. Make sure that the locking plate
snaps into the groove of the right-hand hinge and that the angled plate
at the bottom of the cutter is inserted under the printer’s bottom plate.
• Connect the cable from the cutter unit to the DIN socket on the print-
er’s front.
DIN socket
0RESS
SIDEWAYS
• Tilt the cutter unit upwards until it locks into place. If the cutter does
not lock properly, the hinges of the cutter unit may need to be adjusted
using a #T10 Torx screwdriver.
• Connect the power cord and switch on power. The cutter will perform
an idle cycle in order to occupy its home position.
• Switch off the power. Tilt down the cutter and route the media through
the cutter unit between the guide plates (see illustration above). Then
tilt the cutter up again and lock it in closed position. Check that the
printhead is lowered and switch on the power. Now the printer is ready
for operation.

Hinge
Guide plates
(insert media between the plates)
Hinge
EasyCoder PX4i Cutter
Hinge
Guide plates
(insert media between the plates)
Hinge
EasyCoder PX6i Cutter

11.3 Controlling the Cutter

Fingerprint
The cutter is activated by CUT or CUT ON statements, see the Intermec
Fingerprint v8.xx, or the Intermec Direct Protocol v8.xx manuals. Applica-
tion programs may have related facilities for operating the cutter.
The edge will cut through the media approx. 37 mm (1.5 inches) in front
of the printer’s dot line. The following values are recommended for cut-
ting:
Type of Cutting 8 dots/mm 11.81 dots/mm

printhead printhead
Cut between labels w. gaps
Start adjust: - 287 dots - 424 dots
Stop adjust: + 176 dots + 260 dots
Cut fix and variable length strip (no liner!)
Start adjust: - 294 dots - 434 dots
Stop adjust: + 298 dots + 440 dots
IPL
The cutter can be enabled/disabled in the Configuration part of the setup
mode or using the command <STX><SI>Cn<ETX>, where n= 0 dis-
ables the cutter and n=1 enables it. When the cutter is enabled, the media
feed is automatically adjusted for cut-off operation.
When the cutter is not enabled, a cut operation (advance label and cut)
can be executed using the command <STX><SO><ETX>.
Also see IPL Programming, Reference Manual.
11.4 Media Load

Load media following the descriptions in the User’s Guide for Media Load/
Cut-Off operation (optionally with Quick-Load guides). The cutter is held
by a snap lock and can be tilted forward to facilitate media load. Always
engage the printhead in order to hold the media before closing the cutter.

11.5 Servicing
The cutter mechanism becomes accessible when the cover is opened.
The cutter shears will need to be cleaned from adhesive residue if the cutter
has been used for cutting through labels, something that is not advisable.
Use isopropyl alcohol (see warning text on the container), but be careful
only to apply it where there is any adhesive residue so you do not dissolve
the lubrication.
Do not force the spring-loaded anvil blade open more than 5-10 mm
(0.2–0.4 inches), or the spring may be damaged. Refer to Chapter 11.6 for
information on how to replace the spring.
Switch off the power or disconnect the cutter before cleaning. Keep fin-
gers away from cutting parts!
Fingerprint only
If the following errors occur, clean the shears from adhesive residue.
• 1701 “Cutter error1”
A cut has been performed but the shear has stopped on its way back to
home (bottom) position.
The cutter has failed to cut after several attempt (3 is default) and the
shear has returned to home (bottom) position.
The cutter has failed to cut and the shear has stopped before returning
to home (bottom) position.
If the cutter cable connector has come loose from DIN connector, Error
37, “Cutter device not found” or Error 1059, “Cutter does not respond” will
occur.
If the microswitch in the cutter assy is faulty, Error 1704, “Cutter open” will
occur, even if the cutter in fact is closed.
IPL only
IPL reports if the cutter has failed to return to home position by display-
ing the message “Open&shut cutter.” Follow that instruction. If the error
persists, clean the shears from adhesive residue and check the microswitch.

11.6 Spring Replacement

The spring that presses the anvil blade against the rotating shear may
eventually get slack, especially if the anvil blade is forced open, for example
during cleaning. A slack spring must be replaced as follows:
• Remove the right-hand gable of the cutter (two #T20 Torx screws).
• Remove the right-hand gable of the cutter mechanism (two #T20 Torx
screws + three Posidrive screws).
• Replace the spring and assemble in reverse order, making sure to put
back all the washers.

12 Electronics Compartment
This chapter describes how to access the electronics compartment and

shows the main parts.
The electronics compartment contains wires and circuits with high
voltage. Before removing the left-hand cover or the bottom plate, make
sure that the power is off and the power cord is disconnected from the
printer.
Before starting to work inside the electronics compartment, take stan-
dard precautions for avoiding electrostatic discharges.

Chapter 12 — Electronics Compartment
12.1 Introduction
The Electronics Compartment is off limits to the normal user, but for the
authorized service technician, it contains a number of parts of great inter-
est:
• The stepper motor and timing belts of the platen roller and ribbon
rewind unit.
• The stepper motor and belts of the optional liner/batch takeup unit.
• The headlift mechanism and sensor.
• The CPU board.
• The driver board.
• The power supply unit.
• Optionally one or two extra interface boards and/or one EasyLAN
board.
12.2 Accessing the Electronics Compartment

To gain access to the electronics compartment, remove the left-hand cover
as described in Chapter 3.3.

12.3 Main Parts

This is what you may see when you remove the front/left-hand cover from
an EasyCoder PX4i or PX6i printer.
Power supply Optional EasyLAN board Driver board Ribbon rewind unit
(behind CPU board)
Stepper motor
(platen &
ribbon rewind)
Optional CPU board Stepper motor Platen roller Liner drive roller
interface boards (liner/batch belt and pulley belt and pulley
takeup)
Headlift sensor


13 Power Supply
This chapter describes the power supply unit (PSU) which is fitted in the
electronics compartment, see Chapter 12.
The chapter covers the following topics:
• Description
• Replacement
• Components
• Schematics
printer.
Before touching the driver board, take precautions to avoid any electro-
static discharges.

Chapter 13 — Power Supply
13.1 Description
The Power Supply Unit (PSU) is identical in all EasyCoder PX4i and
PX6i-series printers. It is situated inside the electronics compartment
between the CPU board and the center section.
No attempt to repair this unit is allowed. Never replace a blown fuse, but
replace the entire PSU.
The power supply unit is primary-switched with power correction factor
controller so as to comply with the CE regulations, which require a sinus-
shaped load curve. It is designed for input voltages in the range of 90 to
265 VAC, 45 to 65Hz. There is no manual switch.
The PSU delivers 20W at standby and 400W peak. Typical consumption
during printing is approximately 100W. The PSU produces 24 VDC only;
all other voltages are transformed from 24 VDC by the driver board and
CPU board. The CPU board controls the PSU over the I2C bus via the
driver board, where also identification and error signals are transmitted to
the CPU board. Voltage and temperature are monitored and the unit is
over-current protected.
The working principles of the PSU are illustrated by this diagram:
6$#
0OWER 3UPPLY "OARD
6!#
(Z
7 STANDBY
7 PEEK
4EMP -ONITOR
0OWER &AIL
-AINS
"OOSTER &ORWARD
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2ECTIFIER 6
0ULSE 7IDTH 0ULSE 7IDTH

-ODULATOR -ODULATOR
W 0OWER &ACTOR #ONTR &ORWARD
4EMPERATURE #ONTROL

0OWER &AIL )NTERRUPT
#ONTROL 6OUT
6

Power Factor Control

The power factor control transforms the AC input voltage to 385 VDC
by sensing the shape of the curve of the input voltage and chopping it to
short pulses, where the pulse amplitude follows the shape of the curve. The
booster is protected by two 7A fuses.
Forward Converter
The forward converter transforms 385 VDC to 24 VDC 0-17A. The 24
VDC is the bulk voltage. Other voltages needed for internal devices are
converted from 24 VDC by the driver board and the CPU board.
Connections
P2 24 VDC to driver board.
P3 Temperature and power fail signals to driver board
X1 Input voltage 90 to 265 VAC, 45 to 65Hz
Overheating Protection
The power supply unit is fitted with a sensor that will shut down the unit
in case of overheating (Power Fail Interrupt or PFI) and another sensor
that will warn the main CPU if the power supply is getting hot (Notify).
A Power Fail Interrupt (PFI) signal will warn the logics so valuable data
can be saved before power is lost. Before a print operation is executed,
the Notify signal is checked. If the Notify signal is activated, a warning is
shown in the display and the main CPU will reduce the power consump-
tion to avoid shutdown by detaining the printing until the Notify signal is
deactivated.
Primary switched power supplies are generally difficult to repair. If one
component fails due to aging or overload, a number of other compo-
nents will also break as a consequence. They are hard to troubleshoot,
because the PSU often is “dead” or the fuses blow immediately. It is
also impossible to guarantee the life of a repaired PSU, because com-
ponents may still work but be on the verge of failing. Thus, if a fuse
blows, do not attempt repairing the PSU, but replace the entire unit!

Physical Appearance
The PSU comes as a complete unit consisting of a large metal bracket to
which the following parts are factory-fitted:
• Plastic protection sheet
• Power supply pcb (attached to the bracket using four #T10 Torx screws
and washers)
• AC power cord socket (attached to the bracket using two #T10 Torx
screws and nuts)
• On/off switch (attached to the bracket using snap-locks)
• Label
The bracket is fitted to the center section and rear plate using a total of five
#T20 Torx screws.
Protection Sheet
(shown separately)
Bracket
On/Off Switch
Label
Power cord
socket
PSU Board
Power supply unit (simplified drawing)

13.2 Replacement
• Take precautions to avoid any electrostatic discharges.
• Switch off the printer and disconnect the power cord and all interface
cables on the rear plate.
• Remove any interface board connected or attached to the CPU board.
• Disconnect all cables from the CPU board and remove it (see Chapter
15.3). The CPU board is held to the PSU bracket using four #T20
screws and one hexagonal spacer.
• Disconnect the cables that run between the PSU and the driver board.
• Remove the three #T20 Torx screws that hold the PSU assy to the center
section and two #T20 Torx screw that hold it to the rear plate.
• Do not dismantle the PSU. Replace the entire unit!
• Assemble in reverse order. Fit the top screw at the rear plate first.
Fit this screw first!

PSU assy
Cables to driver pcb

13.3 Components
1-971632-25 Power Supply Unit; Component side

1-971632-25 Power Supply Unit; Soldering side

13.4 Schematics
TY1
Q1
1-971632-25 Power Supply Unit; Schematics

14 Driver Board
This chapter describes the driver board which is fitted in the electronics
compartment, see Chapter 12.
• Description
• Replacement
• Components
• Schematics
printer.
Before touching the driver board, take precautions to avoid any electro-
static discharges.

Chapter 14 — Driver Board
14.1 Description
While the power supply unit (PSU) transforms the AC input voltage to
24 VDC, the driver board converts the 24 VDC to various voltages and
distributes them to CPU board, stepper motors, cutter, and printhead.
The driver board is connected to the PSU via two cables (see Chapter
13). One cable, connected to P2, supplies the driver board with 24 VDC
and the other one, connected to P3, contains temperature and power fail
signals.
The driver board converts the 24 VDC to various voltages required by the
printer and distributes them as follows:
P1 24 VDC to CPU board and control signals between driver board and
CPU board
P5 24 VDC to thermal printhead
P7 0-12 VDC to fan (presently not used)
P10 33 VDC to platen roller/ribbon rewind stepper motor
P11 33 VDC to liner/batch rewind unit stepper motor
P12 24 VDC to cutter interface
At start-up, the PIC processor on the driver board checks that the 24 VDC
to the printhead and 33 VDC to the stepper motors are within allowed
limits. If any extreme values are found, an error condition occurs.
14.2 Replacement
• Take precautions to avoid any electrostatic discharges.
• Switch off the printer and disconnect the power cord
• Disconnect all cables to the driver board.
• From the media compartment, remove the two #T20 Torx screws that
hold the driver board assembly.
• The driver board and its plate come as an assembled spare part. Do not
dismantle any further. Do not attempt to repair a faulty driver board,
but replace it with a new one, unless you know for sure that you have
made the fuse blow by causing a short-circuit (see Chapter 17.6).
• Assemble in reverse order.

The driver board and its attachment plate come as an assembled spare part.

14.3 Components
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1-971652-26 Driver Board; Soldering Side

33V STEP UP 24VS
24V POWER IN 24V TPH OUT
R57
24V 24V_PH
142
P2 Q1 P5
1 1 C26
2 2 5V
R56
+
+
3 3 VSTM
L5
C22
C1
C2
4 4
C20
C21
Q4 C6 5 C44 C45
5 5 VSTM
R69
R67
6 6 VCP
+
+
7 R68 7 C43
+
R66 Z2
C11
C12
C32
C33
8 8 R59 C7
9
C36
10 15V D6 VSTM
R60
U5
C70
CP1 37
1 8
CP2 38
VCP 36
VDD 16
VBB 43
VBB 25
COMP VREF
VREG 32
2 7
+
VFB VCC R55 C35
R61 6 RESET_N
3 SENSE OUT Q5 27 RESET_N OUT1A 6
4 5 C8 42 SLEEP_N STEPPER 2
R/C GND
F1
4A
C71 UC3845B C85 41 ENABLE_N
P11
R52
4 HOME_N OUT1B 40
24V Q1 GATE DRIVE R58 R50 1
ADSTM MS1 20 MS1
MS 2 19 MS2 2
A3977 OUT2A 18 3
C23
R62
Z1 STEP2_N 31 STEP 4
C72
C86
24VS
C66
C27
R51
15V DI R 5 DIR U4
R54A
R54B
R54C
R54D
R53A
R53B
R53C
39V R64 C28 OUT2B 28
26 SR_N
14.4 Schematics
3
4
14 REF
D4 D5 9 PFD SENSE1 3
D1
L1
U7
L2
L3
L4
5V
10 RC1 SENSE2 21 C64
24VS 5V
2
24VS U6 15 RC2
U2
R48A
R48B
R48C
CPU CON C25 C29 D3 R26

C24 1 3 9 8
VIN VOUT AHCT14
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
C61
C83
C84
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34
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12
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23
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R47
3 VCP 5V 5 6
R49A
R49B
R49C
AHCT14
C62
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4
5
6
R31
7 TPHV U2 R28
8 DRIVER_IO10 3 4
R19
R20
R21
R22
R23
R24
R25
AHCT14
9 5V
10 STMC4 VSTM
11 STMC3
R32
12 STMC2 U2 C60 C41 C42
R29
13 STMC1 1 AHCT14
2
+
+
R35
14 DIR_I U2 C40
C9
C10
C30
C31
15 PIC_RESET 5V STEP1 11 AHCT14

10 STEP1_N
16 DIR_I STEP2
R33
17 STEP1
STEP2 U2
18 13 12 STEP2_N
AHCT14
CP1 37
CP2 38
VCP 36
VDD 16
VBB 43
VBB 25
19
VREG 32
R11
20 DRIVER_IO4 ISR CONNECTOR U8
21 DRIVER_IO5 RESET_N 27 RESET_N OUT1A 6
5V 2 STEPPER 1
22 DRIVER_IO6 P8 1 42 SLEEP_N
1 4 DIR
AHCT1G32
D2
23 DRIVER_IO7 41 ENABLE_N
1-971652-26 Driver Board

R8
24 D 1 OUT1B 40
P10
4 HOME_N
25 CUT 2 1
5V MS1 20 MS1
26 HOME BC847B Q2 3 24VS 2
5V MS 2 19 MS2
27 P24EN C 4 A3977 OUT2A 18 3
PSU_INT_N B 5V R75 STEP1_N 31 STEP
28 5 4
PSU_NOT_N R71 DI R
R9
29 CUTTER 5 D IR U3
30 U1 R74 OUT2B 28
R36
Q8 26 SR_N
31 SDA PIC16F872 P12
R12
32 1 4 RE F
Q6 1 MOTOR+
33 SCL 24VS 9 CLKIN INT/RB0 21 PFI_DET SENSE1 3
D8 C37 2 MOTOR- 9 PFD
34 10 CLKOUT RB1 22 PSU_NOT_N R72
23 R70 Q7 3 HOME:COM C59
5V RB2 PSU_INT_N 5V 10 RC1 SENSE2 21
C80
1 MCLR/VPP RB3 24 P24ON 4 1 5 RC 2
R73 5 HOME:NO
R40A
R40B
R40C
25 HOMESW R77
R5
RB4
R37
RB5 26 P24EN C38

R6
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
PGND
C81
C82
AD24V 2 RA0 RB6 27 B

R76
1
2
ADSTM 3 28 C
R1
R2
RA1 RB7
33
34
35
11
12
13
22
23
24
44
CUT 4 RA2 C5 8
PSU CTRL 5
R4
RA3/VREF
R38
R39
R41A
R41B
R41C
C52
C56
C57
5V 6 RA4/TOCKI RC0 11 CUTMOTOR

P3 HOME 7 RA5 RC1 12 BRAKE
Q9
1 RC2 13 FAN_PWM
TEMP_MON 5V 14
2 RC3 S CL
15 FAN
3 RC4 SD A 24VS
4 PFI_DET 20 VCC RC5 16 RESET_N P7
17 MS1
R7
RC 6 FAN+
C50
8 18 MS2 R17 1
GND RC7
C51
2 FAN-
R15
19
R3
GND
Q3
+
C4 GNDC1 GNDC2 GNDC3
C34
R16

15 CPU Board
This chapter describes the CPU board which is fitted in the electronics
compartment, see Chapter 12.
• Description
• Circuits
• Connectors
• Test points
• Startup
• Components
• Schematics
• Replacement
Note: Devices and file systems, such as "/c:" or "uart1:", are only used in
Fingerprint. Some may also exist in IPL, but are hidden to the user.

printer.
Before touching the CPU board, take precautions to avoid any electro-
static discharges.

Chapter 15 — CPU Board
15.1 Description
The CPU board is a four-layer board with most of its circuits surface-
mounted. Inside the laminate are a combined VCC layer (5V/3.3V/2.5V)
and a GND layer. The front and back sides are signal routing layers.
The hardware contains of the following main functions:
• Processor core
• Thermal printhead driver
• Stepper motor control logic
• Sensor drivers
• Communication, such as UART, USB, etc.
• Flash memory SIMM for the firmware and non-volatile storage
• SDRAM SIMM for working memory
• A/D converter for sensor adjustment, etc.
• Compact Flash memory card expansion
• Expansion bus
• PCI bus (custom)
.ETWORK
CARD

0#) BUS
5!24
CUSTOM
7AND I"UTTON "EEPER

3ENSORS
#05 03!
!$ CONVERTER
2)3# CORE 40( LOGIC
-EMORY CONTROLLER 3$2!- 3TEPPER LOGIC 40(
0#) INTERFACE )NTERRUPT
#ONSOLE
#LOCK )# MASTER

-(Z &INISHER

#05 BOARD )# BUS
"US ISOLATION %%02/- 035-OTOR
INTERFACE

&LASH MEMORY #OMPACT &LASH #,)# %XP INTERFACE 53"
3TEPPER CONTROL SIGNALS
3UPPORT LOGIC
"OARD ID /PTIONAL BOARD
2ESET
0OWER CONVERSION 6 )N
/PTIONAL BOARD 6
6
ONLY ONE OPTIONAL 6
BOARD IN 0& SERIES
1-971630-26 CPU board; Block Diagram

(numbers refer to schematics in Chapter 15.7)

15.2 Circuits
Components mentioned in this chapter are marked with gray in the draw-
ing below.
0/ *
* *
*
24# 02/'2!- +%9

5
#/-0!#4 &,!3(
0ROCESSOR
5
0 3UPPORT
#HIP
"//4 &,!3(
Processor (U13)
The processor is a 32-bit RISC offering about 125 MIPS at the internal
clock speed 96MHz. The internal bus speed is twice the external bus speed
at 48MHz. The processor has several features, such as integrated SDRAM
controller, PCI bridge, DMA, UART, timers, etc.
Support Chip (U30)
The PSA (Processor Support ASIC) is a programmable logic device, which
is programmed by the firmware at each startup. It contains most of the
printer-specific and other logic functions, such as
• Printhead data and strobe control
• Stepper and DC motor logic
• Sensor interface
• Timers and interrupt control
• Control logic for bar code wand and the electronic key/RTC
• I2C master
• Beeper signal generation
• Interface to A/D converter, console, finisher, etc.

Flash Memory (J20 and J21)

There are two sockets for Flash SIMMs (marked “BOOT FLASH” and
“EXP FLASH”). A SIMM (Single Inline Memory Module) must always
be fitted in J20 since this bank is the Bootbank. As standard, a single 4MB
flash SIMM is fitted. It contains the following sectors:
Device1 Size Type Used for
– 128K Boot Startup
1
/c 2048K User file system or Kernel FP: Customer’s programs, files, images
IPL: Formats, images, fonts
/c 1856K User file system FP: Customer’s programs, files, images
IPL: Formats, images, fonts
– 32K TMP area Media feed info, odometer value, etc.
– 32K Parameters Media feed info, odometer value, etc.
1
/. Devices are used in Fingerprint, but are hidden in IPL.
2
/. This sector can be used for the kernel or for the file system (/c). If it is used for the file
system, the kernel is placed in the file system under the /c/boot directory, which is the
normal configuration, enabling the size difference between 2048K and the real kernel
size to be used in /c. Refer to the Intermec Fingerprint v8.xx, Programmer’s Reference
Manual for a complete list of files stored in /c and /rom by default. The kernel includes
Fingerprint or IPL firmware, bar codes, standard fonts, standard images, Intermec Shell,
auxiliary programs, default setup values, and the EasyLAN home page files.
The flash memory retains its content at power off without any battery
backup. It consists of sectors that can be erased and written to over and
over again. This is done automatically in the background. At power-up,
the flash memory is reorganized to avoid fragmentation. Before a sector is
erased, its content will be copied to a temporary area as a safety measure
if something should go wrong, for example a power failure. For the /c file
system in Fingerprint, this area is 64K and is included in the sectors in the
table above. For the parameters, it is the 32K TMP sector.
The Boot sector is necessary for Intermec Fingerprint or IPL to start.
There is a boot sector in all flash SIMMs at delivery, but the firmware
will only accept the boot sector of a SIMM fitted in J20 (marked “BOOT
FLASH”). The boot sector is only protected when the flash SIMM is fitted
in socket J20 (”BOOT FLASH”). If you move flash SIMMs from one
CPU board to another, make sure that the SIMM containing the boot
sector is fitted in J20 (“BOOT FLASH”) on the other board, or the boot
sector will be overwritten.
The Intermec Fingerprint firmware is either stored in the /c file system
or in a dedicated area on the boot flash (2MB large). If it is stored in
the file system, removing or exchanging an EXP FLASH in J21 may
render the printer unstartable. To cure this condition, use a Compact-
Flash card containing an upgrade file (kernel) to reload the firmware.
As illustrated in the table above, a total nominal capacity of 3904K is used
for the /c file system (MIFS, or FOS) and fonts. In Fingerprint, practically,
around 2MB are available to the user (about 200-400K less if the kernel is
in the dedicated area).
Exactly which fonts, images, files, and programs are stored in the
Fingerprint file system may vary between customers and applications.

The parameters sectors store the PFSVARs (see SETPFSVAR Fingerprint

statement), odometer values, and a few other “invisible” files with data,
that are required for the printer to start up with the same settings as when
it was shut off, for example information on the position of label gaps in
relation to the LSS.
The printer’s permanent memory can be expanded by fitting a second
4MB or 8MB flash memory SIMMs in sockets J21. 4MB and 8MB flash
SIMMs can be mixed at will. Flash SIMMs are custom-made and can only
be ordered from Intermec.
Note: The first time the printer is started with a SIMM in J21 (“EXP
FLASH”), the memory is not increased to enable cloning the first SIMM.
The expansion is not done until the second time the printer is started.
Flash Memory Available to the User
J20 (Boot) J21 (Exp) J20 (Boot) J21 (Exp) SUM

4MB SIMM – 1.8MB – 1.8MB
4MB SIMM 4MB SIMM 1.8MB 4MB 5.8MB
8MB SIMM – 5.8MB – 5.8MB

SDRAM Memory (J10)

The SDRAM memory (Synchronous Dynamic Random Access Memory)
is the printer’s temporary memory (Fingerprint device "tmp:"). It will lose
its content when the power is switched off or at a power failure. Thus, it
should only be used for data that can easily be recreated or that are only
relevant for one power-on cycle. It is much faster than the flash memory.
Therefore, at startup the kernel is copied from the Flash memory to the
SDRAM, where the various instructions are executed.
One SDRAM SIMM (standard size 16MB) must always be installed in
socket J10 (SDRAM0-1).
The SDRAM is also used for the font cache and various buffers. The
remainder is used for the two print image buffers where the bitmap pat-
terns are stored prior to printing. One buffer is used for the label that is
being printed, while the other receives the bitmap for next label as the
Intermec Fingerprint instructions are processed. By switching between the
buffers, batch printing without stopping between labels can be achieved.
The size of the buffers depends on two factors:
• Number of physical dots on the printhead.
• Present label length setup value in dots.
Calculate the buffer size according to this formula:
(No. of dots / 8 + 4) × (Media length in dots) = Buffer size in bytes
(Buffer size in bytes) / 1024 = Buffer size in kbytes
Buffer size in kbytes × 2 = Memory requirement in kbytes
Example:
The number of dots on the 8 dots/mm printhead of an EasyCoder PX4i is 896.
“Media; Length” is set to 1500 dots (= 187.5 mm/7.38 inches)
[[(896 / 8) + 4) × (1500)] / 1024] × 2 = 340 kbyte total
Regardless of memory size there is an absolute print length limit of 32,767
dots (4,095 mm/161.2 inches).

Electronic Key Circuit (J30), Fingerprint-only option

The optional electronic key circuit is an iButton which contains a real-time
clock. It has a built-in battery backup with a life of at least 10 years. When
the printer is on, the circuit is power-supplied via the CPU board and will
not consume any power from the battery. The circuit also contains 4Kbits
(500 bytes) of battery backed-up memory for the devices "lock:" and "stor-
age:".
The Electronic Key Circuit (J30) contains an integrated lithium bat-
tery. Replace only with original Electronic Key Circuits from Intermec.
Dispose of used Electronic Key Circuits according to local regulations
for lithium batteries.
Since the communication between the RISC processor and the electronic
key circuit is comparatively slow, the content of the key circuit is copied
to SDRAM at startup and used from there. At power off, the content is
read back to the key circuit, provided there is time enough. Thus, there is
a small risk that new data may be lost, before it has been saved back to the
electronic key circuit. The original data in the electronic key circuit will
not be damaged, if the read-back process should fail.
Memory Card Adapter (J22)
The CPU board has a built-in memory card adapter which can use
standard Type I CompactFlash memory cards with a size of 8MB to 1GB
(thickness 3.3 mm/0.13 in.). It is not suited for other types of memory or
I/O cards! Cards marked “CF+” and Type II cards (thickness 5.0 mm/0.20
in.) cannot be used.
In Fingerprint, CompactFlash cards can be used to expand the printer’s
memory (device "card1:"). IPL does not support CompactFlash cards as a
means of expanding the memory.
Memory cards are only detected by the firmware at startup and must thus
be inserted in the memory card adapter before the power is switched on
or the printer is rebooted. Memory cards must only be emoved when the
power is off.
Preprogrammed CompactFlash Memory Cards
There are four types of preprogrammed CompactFlash memory cards from
Intermec.
• Font Cards
Font stored in font cards can only be used while the card is present in the
printer’s memory card adapter.
• Font Install Cards (Fingerprint only)
Install additional fonts in the printer’s memory. These fonts can be used
without the card being present.
• Firmware Cards
Install a new firmware kernel in the printer including standard fonts. Used
for upgrading the firmware or switching between Fingerprint and IPL.
• Configuration Cards
Configures a CPU board for the type of printer in which it is installed, see
Chapter 15.8, or changes the printer’s EasyLAN setup.

15.3 Connections
The following connectors on the CPU board are used in the printer for
communication with various devices and sensors.
0/
#/.3/,%
0#)
*
2)""/.
*
0/7%2
*
*
*
0 *
02).4(%!$
7!.$
23
*
*
'!0 *
* *
(%!$,)&4 "-
*
53"
*
%80 "/!2$
*
0!0%2 * ,43 * &).)3(%2
Left side (from top down)

J59 Bar Code Wand (not supported by IPL)
J61 RS-232
J60 USB
Bottom (from left to right)
J62 Expansion board connection (optional interface boards)
J57 Paper Sensor
J53 Label Taken Sensor (option)
J51 Finisher (not used)
Top (from left to right)
J84 PCI (EasyLAN interface, option)
J50 Console (keyboard, display, and print or feed/pause button)
Right side (from top down)
J56 Ribbon Low sensor
J52 Power from driver board
J40 Data to printhead
J55 LSS (gap)
J54 LSS (black mark)
J58 Headlift sensor

15.4 Test Points

The CPU board is provided with many test points. Only those of immedi-
ate interest to the field service technician are shown below. If further test-
ing or servicing is required, exchange the CPU board and return the faulty
board to a service center.
0/
$%"5'
*
&
7!.$
0
6
$/.%
2
6
'.$
Test Points
If available, use an oscilloscope to measure the various voltages. When
using for example a multimeter, a fluttering value may indicate an errone-
ous voltage.
GND Ground
2.5V 2.5V –> GND (max ± 0.2V)
3.3V 3.3V –> GND (max ± 0.2V)
5.0V R718 –> GND (max ± 0.2V)
24V F70 left side –> GND (allowed deviation ± 2V)
(If no voltage on the left side, check the right side. If voltage
there, fuse is blown; else cable, driver board, or PSU trouble.)
DONE High level = U30 programmed, see Chapter 15.5
DEBUG Startup check, see Chapter 15.5
WAND Use an oscilloscope. OK if there is a pulse train when the wand is
reading a bar code.

15.5 Startup
The prerequisite for the printer to start is that a flash memory SIMM with
a boot sector is fitted in J20. A SDRAM SIMM must also be installed in
J10.
At power up, the printer starts executing code in the boot sector and one of
the following sequences will be performed:
1. A Compact Flash card with a firmware is recognized.
- The firmware will be copied from the memory card to the internal
SDRAM.
- The processor will start to execute code from SDRAM.
- The firmware on the memory card will be copied to the internal flash
memory.
2. A valid firmware is recognized in the internal flash memory.
- The firmware will be copied to SDRAM and the processor will start
execute code from SDRAM.
If the printer is fitted with an EasyLAN interface, there are also facilities
for updating the firmware from the printer’s home page.
After the initial boot sequence is performed, the number of steps will be
taken before the printer starts, which includes programming the support
chip (U30). The startup procedure can be followed on the printer’s display.
You can also follow the startup from the host provided a strap is temporar-
ily fitted at J23 (DEBUG) on the CPU board. Connection between printer
and host should use the default serial communication setup (9600 baud, 8
bits, parity none, 1 stop bit) on the standard serial port "uart1:". For each
of the steps, either “OK” or “Fail” is returned on "uart1:". In addition,
some other useful information is also returned.
Refer to Appendix B for information on how to upgrade the firmware.

C900 J81
J50
TMS
R905
R923
R922
R847
R925
R920
R200
R921
R300
R924
R202
R892
R129
R127
R128
R126
R125
R124
R123
R904
PP32
R215 TDI
J30
R216 R926 CCLK TCK
R137 R983
J24 J2 3 R217
J56
R138
R218 R139
PP56
R985
R219 R140
R981
R141
U20
R220 R980
R221 R142
R978 PP55
R143
R222 R977
R144
C953 R975
R895 R145
R146 R974
U92 R147 R973
R148 R972
R231 R970
R149
R894
R232 U13 R969
R150
R233 R967
J84
R893 R151
R234 R152 R966
U22
R153 R989
R235
R154 R990
R236 R992
R155
C955 R156 R993
R157 R995
R223 R996
R158
PSU_INT_N
R937 R224 R159 R998

R225 R130 R965
R963
R226
R962
R227 R960
C12
J52
U21
R228 R959
J22
R265 R229 C11 R999
15.6 Components
R938 R230 R957

R110
Y10
R955
C954 D0 R954
R952
R101
C921 R951
U72
R935
R936 R237
1
R238 C10
R136
R239 U11 F70
J20
R939
J21
J10
R240
R100
R241 C712
PSA_TDO
U23
J83 R242
D50 R243
C700
K R244
R102
R103
C975
C974
A NC
U81 C956

R915
R914
C963
R934
C951
R245
R621 R246
C R897 L402
T80 R247
C540
B E
U80
L 52 WAND R206 R896
R913 R248
U91
L415
U31
R912 R249
R911 R898 PP52
U24
R250
R430
R500 C952 U30

R251 L400
J59
L51 R252
C961
C957 2.5V
PP51 R431
L50
1
35
R432
R932
R317 R321 R325
INIT
C976
R301 R313 R433
U26
PROG
U90 R318 R322 R326

R302 R314
R323
U42
R303 R327 R315 R434

R324 R328
J40
R253 R304 R316

C938 DONE R435
R254
L64 R255 R309 R305 PP30 R436
C66 R256 R310 R306
C64 R623 R203 R311 R437
R339
L63 R307
C966
R611 R312
C63 R308 R319
U25
R625 R257
R438
L67 R402 PP54
B
C65 R615 R204

PP31
P P4 0
U32
R405
U43
R320 R439
T42
R624
E
L62 U40 PP53

R613 C958
U61
1-971630-51 CPU Board; Component Side

B60 R401 R700 R701
B
J61
R619 C964 R440
R610
A
L66 R404
T41
E
K
PP50
R411
R410
C405
C403
R614 R717
D40
R720
NC
R400
J62
R629 R721 R716
B
L61 R620
R408 R409
C
R612
C701
R719 R722
T40
R403
E
B
R705
C401 R723
C
L65
T44
E
R406 R702 C703
R618
C
T43
C702 R706
E
L68 R407 J55
R510
C400 R708 R703
C402
U51 R414
B
R418 R421
R718
C972
R709
U70
R601
R600
C
R417 L70
T47
E
EXP1_INT_N C704
R420 R419
R422
C404
R413 R707
B
RP60
R710
R704
U50
C
R416 R423 R424

T46
E
R521
J54
C511
R520
R412 PP41
R509
U41
B
R603 USB_INT_N
C971
C406
C
C709
R522
R523
R604
T45
E
R415
R602 U60 C708 C
D72 B E
R712
R711
L6 0 THY70
C973
EXP2_INT_N U52 C
J60
D71 T71 D70 T70
C967
C62 B E J58
C710
34
68
T1 3.3V GND K C K R715
A NC B E A NC K
C965 C60 R605 C61 C507 C508 A NC
R724
R525
R526
C512
R713 R714
C706
L74 Z70
R524
C716
C509
C510
C705
MH71 Y60 PP58 MH70

PP57 U71 L72 T72 L71 J51
J 57 J 53
C717
PP59
153
R902
154
R903
R900
C530
R537
R536
R535
R534
R533
C533 R910
R530 R901
R329
R207
R210
R209
R208
R815 R873
R982 C915 C914 C913 C912 C911
R984 R811 R881
R831 R874
R515
C504
R532
R531
C531
C532
R986 R827 R882
C984 C983 C982 R814
R979 R875 R883 C992
C901
R514
C916
C503
R810
R830 R876 R884 C977
R931 R976
C981
C980
R826
R987 R836
C990
C902
C917
C988
R929 R846
R890
R889
R845 R855
R971 R848
R930 R844 R856
R549 C538 R968 R843 R849
R832
C903
C918
R547 R933 C979
R988 R135 R842 R857
R899 R841 R850 C978
R548 R134
R546
R991 R840 R858
C991
C904
C919
C989
C539 R133 R839 R851
R994
R132 R813 R877
R997 R131 R809 R885
C905
C920
C987 R201 C986 R829 R878
R964 C985 R825 R886
R961 C910 R812 R879

C909 C908 C907 C906 R808 R887
R958 R828 R880
R111 R824 R888
R956
R838 R859
R953 R837 R852
C711
R860
R950 R835 R853
C715
R834
R861
R854
C932 C931 C930 C929
R862
R863
C933
R807
C944 C943 C942 R803
R823
R819
R425
R872
C934
C948
R806 R871
R426 C407 R802 R864
C939
C922
C408 R822 R865
R427 R866
R818
C968
R429 R867
C935
C949
R428 C409 C410 R441 R868
C940
C923
R833 R869
R870
C969
C950
C936
C941
C924
C947 C946 C945
R805
C937
R801
C928 C927 C926 C925 R821
C970
R817
R333
C32
R804
R800
R336
C31
R337
R338
R820
R816
1-971630-51 CPU Board; Soldering Side

C30
R927
R335
R334
R928
C33
R513
C502
C513
R512
C501
R628
R518
R519
R627
R626
R539
C707
C535 R540 R538
C718
R542
C714
C713
R541 R725
R544
C537
C506
R516
C505
R517
C534 R545 R543 C536

UART<5..0>
TDI
1
0
2
4
5
CLOCK DRIVER
3.3V
TCK
TMS
TDI
ID_N
PCST1
CPU
CS2_N
CS0_N
DMA_N
ACK_N
ADS_N
PCST2
PCST0
U11
INT1_N
INT0_N
M_WR_N
M_RD_N
TRST_N
EJ_TMS
CF_CS_N
CPU_TDO
7 VCC CLKA R101
PSA_CS_N
M_WAIT_N
BUS_EN_N
EJ_DBOOT
1 CPU_CLK 3.3V
XTALIN
EXP1_CS_N
PCI_INT_N
PCI_RES_N
3
DMA_DONE_N
PCI_GNT2_N
PCI_REQ2_N
Y10 CLKB
5 R102 SD_CLK
XTALOUT
4
CLKC
6 R103 PSA_CLK
12Mhz OE/FS
199
198
197
196
195
194
193
192
191
190
189
188
187
186
185
184
183
182
181
180
179
178
177
176
175
174
173
172
171
170
169
168
167
166
165
164
163
162
161
160
159
158
157
208
207
206
205
204
203
202
201
200
8
2 R136 CLIC_CLK
G ND
R100 CY2071A
GND20
GND19
VCCI7
VCCI6
GND18
VCCI5
GND17
GND16
INT1_N
INT0_N
VCCO16
M_OE_N
VCCO15
VCCO14
VCCO13
MODE
M_WE3_N
M_WE2_N
M_WE1_N
M_WE0_N
M_CS5_N
M_CS4_N
M_CS3_N
M_CS2_N
M_CS1_N
M_CS0_N
SPI_SCK
UART_RX0
UART_TX0
M_WAIT_N
SPI_MOSI
SPI_MISO
SPI_SS_N
JTAG_TCK
JTAG_TMS
JTAG_TDO
JTAG_TDI
EJTAG_TMS
PCI_RST_N
(INCL M_A(22..17))
M_245_OE_N
DMA_RDY0_N
EJTAG_DCLK
PCI_GNT2_N
PCI_REQ2_N
D SD_OE_N 1 SD_245_OE_N PCI_GNT1_N 156
DB_CPU_ID_N
EJTAG_DBOOT
EJTAG_PCST2
EJATG_PCST1
EJATG_PCST0
JTAG_TRST_N
DB_CPU_DMA_N
DB_CPU_ACK_N
DB_CPU_ADS_N
SD_WE_N R137 2 SD_WE_N PCI_CLK 155 PCI_CLK
SD_CAS_N R138 3 SD_CAS_N PCI_GNT0_N 154 PCI_GNT0_N 3.3V
D SD_BE0_N R139 4 SD_BE0_N PCI_REQ0_N 153 PCI_REQ0_N
SD_BE1_N R140 5 152 PCST0 R123
SD_BE1_N PCI_AD31 31
6 GND1 VCCO12 1 51
7 1 50 PCST1 R124
VCCO1 GND15
15.7 Schematics
SD_CS0_N R141 8 SD_CS0_N PCI_AD30 149 30

SD_CS1_N R142 9 1 48 PCST2 R125
SD_CS1_N PCI_AD29 29
SD_RAS_N R143 10 SD_RAS_N PCI_AD28 147 28
1
11 146 ID_N R126
SDRAM SIMM SD_S0_N PCI_AD27 27
12 SD_S1_N PCI_AD26 145 26
R144 13 144 ACK_N R127
2 M_A2 PCI_AD25 25
3 R145 14 M_A3 PCI_AD24 143 24
R146 15 142 PCI_CBE3_N ADS_N R128
3.3V 3.3V 4 M_A4 PCI_BE3_N
SDRAM_SIMM 16 GND2 VCCO11 141
17 140 DMA_N R129
VCCO2 GND14
1 VSS1 VSS5 41 5 R147 18 M_A5 PCI_AD23 139 23
2 42 16 R148 19 13 8 R130
0 D0 D16 6 M_A6 PCI_AD22 22 22
8 3 D8 D24 43 24 7 R149 20 M_A7 PCI_AD21 137 21
4 44 17 R150 21 13 6 R131
1 D1 D17 8 M_A8 PCI_AD20 20 21

9 5 D9 D25 45 25 9 R151 22 M_A9 PCI_AD19 135 19
6 46 R152 23 134 R132
VCC1 VCC5 10 M_A10 PCI_AD18 18 20
2 7 D2 D1 8 47 18 11 R153 24 M_A11 PCI_AD17 133 17
8 48 26 25 132 R133
10 D10 D26 OUT_CLK PCI_AD16 16 19
3 9 D3 D19 49 19 26 GND3 VCCI4 131
R134
11 10
11
D11
VSS2
D27
VSS6
50
51
27
12
27
28
VCCI1
M_A12
RC32332 GND13
PCI_BE2_N
130
12 9 PCI_CBE2_N
18
R135 D
2 12 SDA0 CLK 0 52 SD_CLK SD_A12 R154 29 SD_A12 PCI_FRAME_N 12 8 PCI_FRAME_N 17
3 13 SDA1 CKE0 53 SD_CKE 30 SD_CKE PCI_IRDY_N 127 PCI_IRDY_N
14 54 SD_CS2_N 31 126 PCI_TRDY_N R832
4 SDA2 SDA13 15 SD_CS2_N PCI_TRDY_N 16
5 15 SDA3 SDA14 55 SD_CS3_N 32 SD_CS3_N PCI_DS_N 125 PCI_DS_N
16 56 R155 33 124 PCI_STOP_N R833
VCC2 VCC6 SD_BE2_N
U13 PCI_STOP_N 15
6 17 SDA4 RAS* 57 SD_RAS_N R156 34 SD_BE3_N PCI_LOCK_N 123 PCI_LOCK_N
18 58 SD_CAS_N R157 35 122 PCI_PERR_N R834
7 SDA5 CAS* 13 M_A13 PCI_PERR_N 14
8 19 SDA6 J10 DQM2 59 SD_BE2_N 36 GND4 VCCO10 121
20 60 SD_BE3_N 37 120 R835
9 SDA7 DQM3 VCCO3 GND12 13
21 VSS3 VSS7 61 14 R158 38 M_A14 PCI_SERR_N 119 PCI_SERR_N
22 62 20 R159 39 11 8 PCI_PAR R836
4 D4 D20 15 M_A15 PCI_PAR 12
12 23 D12 D28 63 28 16 40 M_A16 PCI_BE1_N 117 PCI_CBE1_N
24 64 21 41 116 R837
5 D5 D21 17 M_A17 PCI_AD15 15 11
13 25 D13 D29 65 29 18 42 M_A18 PCI_AD14 115 14
26 66 43 114 R838
VCC3 VCC7 19 M_A19 PCI_AD13 13 10
6 27 D6 D22 67 22 20 44 M_A20 PCI_AD12 113 12
28 68 30 45 112 R839
14 D14 D30 21 M_A21 PCI_AD11 11 9
7 29 D7 D23 69 23 46 GND5 VCCO9 111
30 70 31 47 110 R840
15 D15 D31 VCCO4 GND11 8
31 VSS4 VSS8 71 22 48 M_A22 PCI_AD10 109 10
32 72 SD_WE_N 49 108 R841
10 SDA8 EW* 10 M_D10 PCI_AD9 9 7
11 33 SDA9 CS0* 73 SD_CS0_N 11 50 M_D11 PCI_AD8 107 8
1-971630-26 CPU Board; Core (Schematics #1)

SD_A12 34 74 SD_CS1_N 51 106 PCI_CBE0_N R842
SDA10 CS1* 20 M_D20 PCI_BE0_N 6
13 35 SDA11 NC2 75 RESET_N 52 COLD_RES_N PCI_AD7 105 7
36 76 R843
VCC4 VSS9 5
14 37 SDA12 NC3 77
38 78 R844
NC1 NC4 4
SD_BE0_N 39 DQM0 PD1 79 SD_PD1
M_D12
M_D19
M_D13
M_D18
M_D14
GND6
VCCO5
M_D17
M_D16
VCCI2
M_D15
MAST_CLK
M_D31
M_D0
M_D30
GND7
VCCO6
M_D1
M_D29
M_D2
M_D28
M_D3
M_D27
M_D4
VCCP
GNDP
M_D26
M_D5
GND8
VCCI3
245_DT_R_N
M_D25
M_D6
M_D24
M_D7
GND9
VCCO7
M_D23
M_D8
M_D22
M_D9
M_D21
NMI_N
PCI_AD0
PCI_AD1
GND10
VCCO8
PCI_AD2
PCI_AD3
PCI_AD4
PCI_AD5
PCI_AD6
SD_BE1_N 40 80 SD_PD0 R845

DQM1 PD 0 3
R846
2
70
71
72
73
74
75
76
77
78
79
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
D D R847
1
31
30
3
12
19
13
18
14
17
16
15
1
7
0
29
2
28
27
4
26
5
25
6
24
23
8
22
9
21
M_D<31..0>
M_A<22..1>
3
1
0
2
4
5
6
CPU_CLK D PCI_AD(31..0)
R110
R111
C10 + C11 C12
BUS_DIR_N
155
BUS/ADDRESS D<15..0>
156
ISOLATOR/DRIVER
U20 A<25..1>
19 G3
R215
0
3EN1[BA]
1 3EN2[AB]
R216
8
M_D<31..0> AHC245
1 R217 BOOT FLASH EXP FLASH COMPACT FLASH
0 9 2
11 1
8 8 12
7 13 R218
1 9 3.3V 3.3V 3.3V 3.3V 3.3V 3.3V
3.3V 9 6 14
5 15 R219
2 2
COMPACTFLASH
10 4 16 1 V SS1 A14 37 14 1 VSS1 A14 37 14
1 26
R220 GND1 CD1* CF_CD1_N
3 3 17 10 0 2 D0 A7 38 7 0 2 D0 A7 38 7
2 18 3 39 3 39 3 2 D3 D11 27 11
11 8 D8 A15 15 8 D8 A15 15
R221 4 40 4 40 4 3 D4 D12 28 12
VCC=3.3V;GND=DGND 3 1 D1 A16 16 1 D1 A16 16
5 4 D5 D13 29 13
R200
R201
9 5 D9 V SS 5 41 9 5 D9 VSS5 41 5 30
R222 6 D6 D14 14
11 6 VCC1 NC1 42 6 VCC1 N C1 42 6 31
U21 7 D7 D15 15
2 7 D2 NC2 43 2 7 D2 NC2 43 7 32
BUS_EN_N 19 G3
R223 CF_CS0_N CS0* CS1* CF_CS1_N
4 10 8 D10 NC3 44 10 8 D10 NC3 44
3EN1[BA] 9 45 9 45
8 A1 0 VS1* 33 CF_VS1_N
3 D3 NC4 3 D3 NC4
BUS_DIR_N 1 3EN2[AB]
R224 10 46 10 46
9 ATASEL* IORD* 34 CF_RD_N
12 11 D11 VCC5 11 D11 VCC5
AHC245 10 A9 IOWR* 35 CF_WR_N

1
11 VSS2 A24 47 24 11 VSS2 A24 47 24
11 36
9 11 R225 12 48 12 48 A8 WE*
4 2
5 8 A8 A17 17 8 A8 A17 17
12 A7 INTRQ 37 CF_INTRQ
12 8 12 1 13 A1 A18 49 18 1 13 A1 A18 49 18 J22
7 13 R226 14 50 14 50
13 VCC1 VCC2 38
5 13 9 A9 A19 19 9 A9 A19 19
6 14 15 51 15 51
14 A6 CSEL* 39
13 2 A2 V SS 6 2 A2 VSS6
R227 15 A5 VS2* 40 CF_VS2_N
6 5 15 6 16 VCC2 A20 52 20 16 VCC2 A20 52 20
16 41
A4 RESET* RESET_N
14 4 16 10 17 A10 A21 53 21 10 17 A10 A21 53 21
17 42
R 228 J20 J21 A3 IORDY CF_IORDY
7 3 17 14 3 18 A3 A22 54 22 3 18 A3 A22 54 22
2 18 19 55 19 55 3 18 A2 RFU1 43
15 11 A11 A23 23 11 A11 A23 23
R229 20 56 20 56 2 19 A1 RFU2 44
VCC=3.3V;GND=DGND 7 4 A4 VCC6 4 A4 VCC6
1 20 A0 DASP* 45 CF_DASP_N
21 VSS3 NC5 57 21 VSS3 NC5 57 21 46
R230 0 D0 PDIAG* CF_PDIAG_N
15 4 22 D4 NC6 58 4 22 D4 NC6 58 22 47
1 D1 D8 8
12 23 D12 NC7 59 12 23 D12 NC7 59
24 60 24 60 2 23 D2 D9 48 9 R265
U22 5 D5 NC8 5 D5 NC8
1 25 61 25 61
CF_IOCS16_N 24 IOCS16* D10 49 10
13 D13 V SS 7 13 D13 VSS7
EN CF_CD2_N 25 CD2* GND2 50
11 C1
26 VCC3 FCS0* 62 FL_CS0_N 26 VCC3 FCS0* 62 FL_CS2_N
MTG1
MTG2
AHC574
6 27 D6 FCS1* 63 FL_CS1_N 6 27 D6 FCS1* 63 FL_CS3_N
9 12 R231 28 64 BUS_WR_N 28 64 BUS_WR_N
1D 8 14 D14 SYSWR* 14 D14 SYSWR* MASTER MODE
8 13 7 29 D7 SYSRD* 65 BUS_RD_N 7 29 D7 SYSRD* 65 BUS_RD_N WHEN CSEL*=GND
7 14 R 232 30 66 30 66
8 9 15 D15 VCC7 15 D15 VCC7 D D
9 6 15 31 VSS4 RESET* 67 RESET_N 31 VSS4 RESET* 67 RESET_N
5 16 R233 32 68 VPP_EN 32 68 VPP_EN
D 10 10 12 A12 VP P 12 A12 VPP
11 4 17 5 33 A5 PD0 69 FL_B_PD0 5 33 A5 PD0 69 3.3V C_2
3 18 R234 34 70 FL_B_PD1 34 70
4 11 13 A13 PD1 13 A13 PD1
12 2 19 6 35 A6 VSS8 71 6 35 A6 VSS8 71
R235 36 72 36 72 R206
VCC=3.3V;GND=DGND 4 VCC4 NC9 VCC4 NC9
R236
12 U91
R237 D D D D 5 9
U23 5 1
3.3V 10 8 CF_CS1_N
1 3.3V AHC32
EN R238
11 C1
13 CLIC VCC=3.3V;GND=DGND
AHC574 R239
5 9 1D 12 6 1 U91
13 8 13
CLIC_CLK
R240 4 4
6 7 14 14 1
ID_CS_N
CF_CS_N
RESET_N
5 6 CF_CS0_N
BUS_WR_N
BUS_RD_N
14 6 15
R889
R890
R892
R893
R894
R895
R207
R241 AHC32
7 5 16 7
39
38
37
36
35
34
VCC=3.3V;GND=DGND
44
43
42
41
40
15 4 17
3 18 R242 SD_PD1 CF_CS_N
16 15
24 2 19 SD_PD0
R243
IO28
IO27
IO26
IO25
IO24
IO23
VCC=3.3V;GND=DGND 16 PCI_RES_N
JTAG
IO_GCK2
IO_GCK1
IO_GTS1
IO_GTS2
VCCINT2
R244 3.3V PROGRAMMING

24
PCI_DET_N 1 IO_GCK3 IO_GSR 33 ARESET_N PORT
U90 R245 FL_B_PD1 2 I O1 IO22 32 CF_WR_N
U24 17 U26 FL_B_PD0 3 IO2 XC9536XL IO21 31 CF_RD_N
SD_CLK 2 1
1 EN R246 25 13 1 3 9 FL_CS0_N 4 GND1 IO20 30 0
ADS_N 3 1 11 C1
25 0
24 14 G 2 10 FL_CS1_N PSA_DONE 5 IO3 IO19 29 1
LVC02 0 3
VCC=3.3V;GND=DGND AHC574 R247 1 11 FL_CS2_N PSA_INIT_N 6 IO4 IO18 28 2 J2 4
DMUX
17 9 1D 12 18
CS0_N 15 0 12 FL_CS3_N PSA_PROG_N 7 IO5
U92 IO17 27 3 1 VCC
R208
R209
R210
25 8 13
1-971630-26 CPU Board; Flash Interfaces (Schematics #2)

R248 AHC139 8 IO6 VCCIO 26 2 G ND
18 7 14 19 VCC=3.3V;GND=DGND CLIC_TDI 9 TDI GND3 25 CLIC_TCK 3 CLIC_TCK
19 6 15 U26
R249 CLIC_TMS 10 TMS TDO 24 CLIC_TDO 4 CLIC_TDO
20 5 16 20
22 3 1 3 7 EXP2_CS_N DEBUG CLIC_TCK 11 TCK IO16 23 4 CLIC_TDI 5 CLIC_TDI
21 4 17 0
R250 21 2 G 2 6 USB_CS_N CLIC_TMS 6 CLIC_TMS
22 3 18 21 0 3
1 5 J2 3
23 2 19 DMUX
R251 CS2_N 1 0 4 ID_CS_N
VCC=3.3V;GND=DGND 22 AHC139
M_A<15..1> 1
IO7
IO8
IO9
IO10
IO11
IO12
IO13
IO14
IO15
VCCINT1
GND2
VCC=3.3V;GND=DGND 3.3V
R252 2
U25 23
3.3V 1 3.3V D
19 & EN
R253
1
12
13
14
15
16
17
18
19
20
21
22
D
AHC541
7
6
5
R202 9 11 R254 D
1 2
D(15..0)
2 8 12
R255
R203
R204
3 7 13 3
M_RD_N 6 14 D
M_WR_N 5 15 R256 BUS_RD_N
4 16
3 17 R257 BUS_WR_N
PSA_RES_N
P24EN
VPP_EN
USB_RES_N
EXP1_RES_N
EXP2_RES_N
2 18
VCC=3.3V;GND=DGND
D

D0
TCK
PSA_TDO IBUTTON
M_RD_N
ADS_N
0
TCK
PSA_CS_N
PSA_CLK
CPU_TDO
PSA_TDO
M_D<31..0> 5V
3.3V 2.5V
31
30
3
10
11
12
19
13
18
14
17
16
15
1
7
20
29
2
28
27
4
26
5
25
6
24
23
8
22
9
21
R329
3.3V J30
199
198
197
196
195
194
193
192
191
190
189
188
187
186
185
184
183
182
181
180
179
178
177
176
175
174
173
172
171
170
169
168
167
166
165
164
163
162
161
160
159
158
157
208
207
206
205
204
203
202
201
200
DATA
2 IBUTTON
R300
G ND
TCK
TDI
TDO
TMS
GCK3
GCK2
IO140
IO139
IO138
IO137
IO135
IO134
IO133
IO132
IO131
IO130
IO129
IO128
IO127
IO126
IO125
IO124
IO123
IO122
IO121
IO120
IO119
IO118
IO117
IO116
IO115
IO114
IO113
IO111
IO110
IO109
IO108
IO107
GND24
GND23
GND22
GND21
GND20
GND19
VCCO16
VCCO15
VCCO14
VCCO13
CCLK 1
IO136_NC
IO112_NC
VCCINT12
VCCINT11
VCCINT10
1 GND1 VCCO12 156 PP32
TMS 2 TMS CCLK 155 PSA_CS_N
M_WR_N 3 IO1 DOUT_IO106 154 D
SENSOR ADJUST DMA_N 4 IO 2 DIN_IO105 153 0
DMA_DONE_N 5 IO3 IO104 152 CON_IO1
ACK_N 6 IO4 IO103 151 CON_IO2
7 IO5_NC IO102 150 CON_IO0
R 30 9 M_WAIT_N 8 IO 6 IO101_NC 149 CON_NOT_N
PL_PRE 0
CF_INTRQ 9 IO7 IO100 148 RL_INST A/D-CONVERTER
R310 CF_IORDY 10 IO8 IO99 147 PSU_INT_N
1
11 GND2 IO98 146 PSU_NOT_N
R311 12 VCCO1 GND18 145 5V
2
13 VCCINT1 VCCO11 144 U31
R312 PSA_RES_N 14 IO9 VCCINT9 143
3 GAP_SEN 1 20
INT0_N 15 IO10 IO97 142 P24EN CH0 5V
PL_GAIN(3..0) BM_SEN 2 19
INT1_N 16 IO11 IO96 141 9 CH1 NC
TPH_RES 3 18 AD_CS_N
EXP2_INT_N 17 IO12 IO95 140 8 CH2 CS*
R313 RL_SEN 4 17 AD_DI
RL_PRE 0 EXP1_INT_N 18 IO13 IO94 139 7 CH3 DI
PL_SEN 5 16 AD_CLK
19 GND3 IO93 138 6 CH4 CLK
R314 THERM 6 15
1 IBUTTON 20 IO14 GND17 137 CH5 SARS
LTS_INST 7 14 AD_DO
21 IO15 IO92 136 5 CH6 DO
R315 8 13
2 WAND 22 IO16 IO91 135 4 CH7 SE*
3 .3 V 9 12
BEEP 23 IO17 IO90 134 3 COM REF
R 316 10 11

3 USB_INT_N 24 IO18 IO89 133 2 GND AGND
RL_GAIN(3..0) 25 GND4 IO88 132 1
26 VCCO2 GND16 131 TLC0838
BM_DIODE R 3 17
0
S CL 27
28
IO19
VCCINT2
XC2S30, XC2S50, XC2S100,
PSA
XC2S150 &XC2S200
PINS WITH _NC NOT USED IN XC2S30
VCCO10
IO87
130
129 0
D D
R318 SDA 29 IO20 VCCINT8 128
1
TPH_GAIN2 30 IO21 IO86 127 14
R319 TPH_GAIN1 31 IO22 IO85 126 13
2
32 GND5 IO84 125 12
R320 TPH_GAIN0 33 IO23
U30 GND15 124 C30
3
TPH_MEAS_EN 34 IO24 IO83 123 11
BM_DRIVE(3..0)
TPH_CAL2 35 IO25 IO82 122 10
R321 TPH_CAL1 36 IO26 IO81 12 1 AD_DO
BM_PRE 0 DRIVER_IO(14..0) R 334
TPH_CAL0 37 IO27 IO80 120 AD_CLK 3.3V
R322 38 VCCINT3 IO79 119 AD_DI
1
39 VCCO3 VCCINT7 118
R323 40 GND6 VCCO9 117 5V R335
2
FIN_IO2 41 IO28 GND14 116
U32
8
R324 FIN_IO1 42 IO29 IO78 115 AD_CS_N

3 R333
FIN_NOT_N 43 IO30 IO77 114 TPH_STRB_N RL_SEN 3
BM_GAIN(3..0)
44 IO31_NC IO76 113 TPH_LATCH_N 1 RL_DIG
FIN_IO0 45 112 TPH_CLK C32 2
GAP_PRE R 325 IO32 IO75_NC
0
3 46 IO33 IO74 111 1
4
R326 2 47 IO34 IO73 110 2

1
1 48 IO35 IO72 109 3
R327 0 49 IO36 IO71 108 4 D D PP30
2 LM393M
50 M1 INIT_N_IO70 107
1-971630-26 CPU Board; PSA (Schematics #3)

R328 51 GND7 PROGRAM_N 106
3
52 M0 VCCO8 105
GAP_GAIN(3..0) 2.5V
DONE C31
LTS_SEN R301
7 PROG R339
R302 INIT 3.3V
IO37
IO38
IO39
IO40_NC
IO41
IO42
IO43
IO44
IO45
IO46
IO47
IO48
IO49
IO50
IO51
IO52
IO53
IO54
IO55
IO56
IO57
IO58
IO59
IO60
IO61
IO62
IO63
IO64_NC
IO65
IO66
IO67
IO68
IO69
VCCO4
M2
NC1
NC2
GND8
VCCO5
VCCINT4
GND9
VCCINT5
GCK1
VCCO6
GND10
GCK0
GND11
VCCINT6
VCCO7
GND12
GND13
DONE
6 R337
R303 PSA_INIT_N
5 R338
PSA_PROG_N
70
71
72
73
74
75
76
77
78
79
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
R 3 04
100
101
102
103
104
4 PSA_DONE U32
PL_SEN R336 5
R305 7 PL_DIG
3
7
8
6
5
C33 6
R306 TPH_DATA(8..1)
2
LM393M
R307 D
1
PL_INST
D PP31
3
1
7
6
5
4
2
0
R308
LTS_DIG
HEADLIFT
0
PL_DIG
RL_DIG
LTS_GAIN(7..0)
3
1
2
0
BM_DRIVE(3..0) 3
1
2
0
BM_GAIN(3..0)
3
1
2
0
GAP_GAIN(3..0)
3
1
2
0
RL_GAIN(3..0)
157
DOT RESISTANCE TEST CIRCUIT THERMAL PRINT HEAD (TPH)
158
5V
TPHV R425 L400
TPH_CAL0 5V_TPH
TPH_CAL1 D40
TPH_CAL2 R426 R427
PP40 SDA
R403 R 404 R405 R428 R 429
THE CORRESPONDING SCL
DIODE ON PSU L402
BOARD MUST BY OF THERM
C
C
C
SAME TYPE C408 C409
R400 B R401 B R402 B C407
T40 T41 T42 J4 0
U42 R430 1 I2CDATA
E
E
E
2 THERM1
D 1 3 I2CCLK
19 & EN D 4 THERM2
D D D R431
AHCT541 5 STROBE1
TPH_STRB_N 2 18 6 STROBE2
24V_S TPH_LATCH_N 3 17 7 LATCH
R432
TPH_CLK 4 16 8 VCC
R408 U40 1 5 15 9 CLOCK
2 6 14 10 VCC
E
R409 3 2 7 13 R433
IN OUT 3 11 DATA1
R407 4 8 12 12 G ND
B T44 C403 ADJ R 410 5 9 11 13 DATA2
R434
VCC=5V;GND=DGND 14 G ND
C
15 DATA3
C
C401
C405 16 G ND
TPH_MEAS_EN R406 B R435
T43 17 DATA4
C400
D R 411 18 G ND
R436 19 DATA5
E
20 G ND
C402
21 DATA6
D U43 R437 22 GND
D C404 23 DATA7
+ 1 24 G ND
D 19 & EN 25 DATA8
R438
AHCT541 26 G ND
R422 9 11
R418 R419 8 12
7 13 R439
TPH_GAIN0 6 14
TPH_GAIN1 PP41 5 15
TPH_GAIN2 2 18 R440
6
8
7 3 17
R415 R416 R417 3 U41 8 4 16
R423 L415
1 VCC=5V;GND=DGND GND_TPH
TPH_DATA<8..1>
2
LM358M R424 D
C
C
C
C406
4
R 412 B R413 B R414 B R420 R421
T45 T46 T47 D
E
E
E
C_1
D D D D D D D
U41
5
7 R441 TPH_RES
6
1-971630-26 CPU Board; Thermal Printhead Interface (Schematics #4)

LM358M C410

SENSORS BLACKMARK
5V
J54
BM_SEN R512
1
PP52 2
I2C INTERFACES BM_PRE BM_DIODE 3
PP53 C501
4
C513
CONSOLE FINISHER PSU/

5V 5V 24V_S MOTOR DRIVERS D PP54 D GAP
TPHV GAP_PRE 5V
CON_IO2 R530 R534 J50 24V_I J55
FIN_IO2 R 538 R542 J51 5V PP50
GAP_SEN R513
R531 R535 1 1 1
CON_IO1 2 R539 R543 J52 PP51 C502 2
FIN_IO1 2 F70
R532 R536 3 3 1 3
CON_IO0 4 R540 R544 4
FIN_IO0 4 2
R537 5 5 C700 + 3
CON_NOT_N R533 6 R541 R545
FIN_NOT_N 6 4
7 7 5 D RIBBBON LOW
8 8 6 5V
9 RL_PRE
C530
C531
C532
C533
9 7 J56
C534
C535
C536
C537
10 10 10 8 PP55 R514
RL_SEN 1
9 PP56 2
11 10 C503 RL_INST 3
D 12 11
D 13 C504 4
12 R515
D D 14 13
SDA 14
0 15
SCL 1 16 D D
2 17 PAPER LOW
3 18 5V

5V 19 PL_PRE J57
5V 4 20
5V 5V U51 PP57 PL_SEN R516
U50 5 21 1
6 22 PP58 2
24C02A LTC1694 7 C505 PL_INST
R509 R510 DRIVER_IO<14..0> 23 3
1 A0 VCC 8 1 VCC SMBUS1 5 24 C506 4
2 7 R517
A1 WP 8 25
3 A2 SCL 6 3 N/C P24EN 9 26
4 GND SDA 5 27
2 4 PSU_INT_N R546 R548
GND SMBUS2 28
29 D D HEADLIFT
PSU_NOT_N R547 R549
30 5V
D 31 J58
32
HEADLIFT
C538
C539
D PSU_INT_N 33 1
34 2
R518 R519 3
D 4
5
24IGND D
D D
5V LTS
5V
WAND B EEPER
J53
5V U8 0 R521
U52 1
BEEP 9 =1 2
L50 R524
10 8 LM567 3
J59
C
1-971630-26 CPU Board; Internal Interfaces (Schematics #5)

AHC86 1 OUT FILTER OUT 8 LTS_DIG 4
VCC=5V;GND=DGND R525 R526
1 L51 R500 2 5 R522 B
IN FILTER TONE
2 T1
D B60
+
+
3 C507 C508 3 4
TONE IN VCC
4 1
E
5 U80 U80 2 LTS_INST

L 52 C509 6 TIME CAP GND 7
6 WAND
12 =1 D50 4 =1 R523
MTG1 13 11 5 6 BUZZER LTS_SEN R520
C512
MTG2 AHC86 AHC86
VCC=5V;GND=DGND VCC=5V;GND=DGND
C510
C511
R621 C540
WAND
C_2 D D D
PP59
D
159
EXP BUS
160
3.3V
5V 24V_S
J62
3.3V USB 1
U60 Y60 35
R600
R601
2
USBN9604 24Mhz
36
R605
3
USB_CS_N 1 CS* CLKOUT 28 M_WAIT_N 37
BUS_RD_N 2 RD* XOUT 27 4
BUS_WR_N 3 WR_SK XIN 26 BUS_RD_N 38
USB_INT_N 4 INTR MODE0 25 J60 5
5 DRQ MODE1 24 BUS_WR_N 39
1
C60
C61
6 23 R603 NC
+
DACK* GND C6 2 VDD 6
7 22 R602
2 D-
A0_ALE_SI VCC 3 40
0 8 D0_SO GND 21 D+ 0 7
USB_INT_N 1 9 D1 D- 20 4 GND 1 41
10 19 R604
2 D2 D+ MTG1 8
3 11 D3 V3.3 18 MTG2 2 42
4 12 D4 AGND 17 3 9
5 13 D5 RESET* 16 43
6 14 D6 D7 15 4 10
USB_RES_N L60
5 44
7 11
6 45
D 7 12
D C_2 C_2 46
8 13
9 47
14
10 48
11 15
D<15..0> 49
12 16
13
4
50
A<24..1> 17
14 51
15 18
UART<5..0> 52
1 19
2
1
53
0
2
4
5
3 20
3.3V 5V 4 54
21
U61 5 55
RP60 6 22
R610
R611
R612
R613
R614
R615
2 26 7 56
C64 GND VCC C6 5 C66 RS232 8 23
28 27 3.3V 57
BUS NO. CPU PINS RS232 25 C1+ V+ 9 24
C63
C1- 10 58
L68
0 - UART_RX0 - R XD 1 4 11 25
1 - UART_TX0 - TXD 3 C2+ V- R626 R627 R628 12 59
2 - SPI_MOSI - CTS
C2- D 26
L61
3 - SPI_MISO - RTS 24 5 60 SPARE
4 - SPI_SCK - D SR 23 T1IN T1OUT 6 27 SPARE
5 - PCI_GNT1_N - DTR 22 T2IN T2OUT 7 S DA 61 S DA
T3IN T3OUT L62
19 10 28
17 T4IN T4OUT 12 J61 SCL 62 SCL
T5IN T5OUT 1 29 SA1
L 63
2 TXD EXP1_RES_N 63 RESET
16 3 RX D EXP1_CS_N 30 CS
21 R1OUTB 8 4 DSR EXP1_INT_N 64 INT SLOT 1
R1OUT R1IN L64
20 9 5 GND 31 DREQ
3.3V 18 R2OUT R2IN 11 6 DT R NC 65 DACK
R3OUT R3IN 3. 3 V 7 CTS EXP1_INT_N 32 DACK
L65
15 8 RTS 66 DREQ
R623 13 MBAUD 14 EXP2_INT_N NC
EN* SHDN* 9 33 IN T SLOT 2
R620 MTG1 EXP2_CS_N 67 CS
L66
1-971630-26 CPU Board; External Interfaces (Schematics #6)

R624 EXP2_RES_N
MAX3237E MTG2 34 RESET
R 625 R 629 R618 R619
68 SA1
L67
EXP2_INT_N
D D
REFERENCE - IBM STANDARD DB9
D C_2 1 DCD - DATA CARRIER DETECT
D 2 RD - RECEIVE DATA
3 SD - TRANSMIT DATA
4 DTR - DATA TERMINAL READY
5 SG - SIGNAL GROUND
6 DSR - DATA SET READY
7 RTS - REQUEST TO SEND
8 CTS - CLEAR TO SEND
9 RI - RING INDICATOR

24V TO 5V CONVERTER
24V_I
L72 24V_S
D71
R711
R712
C
R708 R710 B
U70 T71
D
4 DTC VCC 12 D7 0
E
R709 3 R713 G T72
FB
5V
C
C1 8 L70
6 RT
C702 C703 E1 9
5 CT C705
S
C2 11 B R718
C701 1 10 T70
R702 1IN+ E2
+ 2 1IN-
R716 R720 R722 2
E
16 2IN+
C
15 2IN- REF 14 C716 + C717 C706

THY70
13 7 L74 Z70
OC GND
A
R701 R703 R706 3 C708

TL594 +
1
R724
R700 R704 R705 R707
C704
D72
R714 R715 R717 C718
R719 R721 R723 C707
R725

L71 D
24IGND
1-971630-26 CPU Board; Power (Schematics #7)

5V TO 3.3V 5V TO 2.5V
5V 3.3V 5V 2.5V MOUNTHOLE AT MH70 MOUNTHOLE CLOSEST TO 24V SOURCE
U71 U72 MH71
LOWER LEFT ON PCB SHORT CIRCUIT DIGITAL GROUND (D)
3 VIN VOUT
2 3 VIN VOUT
2
3 .3 V 2.5V WITH MH70 IN THIS POINT AND IN
C713 GND/ADJ C714 GND/ADJ TAB C715
THIS POINT ONLY!
C709 + + C710 + C712
C711
1
1
4
GND
D D D C_2 D C_1
D D
161
MISC PULL-UPS
BUS PULL-UPS 3 .3 V 3 .3 V
162
3.3V 3 .3 V
R816
31 R896
R800 EXP1_INT_N
30
R817
29 R897
R801 EXP2_INT_N
28
R818
27 R898
R848
R849
R850
R851
R852
R853
R854
R855
R856
R857
R858
R859
R860
R861
R862
R863
R864
R865
R866
R867
R868
R869
R870
R871
R872
R873
R874
R875
R876
R877
R878
R879
R880
R881
R882
R883
R884
R885
R886
R887
R888
R802 USB_INT_N
26
R819
25 R899
R803 PSU_INT_N
24
1
7
2
4
5
6
8
9
R820
10
11
12
13
14
15
16
17
18
19
23
20
21
22
23
24
25
TMS R910
A(25..1) R804
22
1
7
0
2
4
5
6
8
9
R821
10
11
12
13
14
15
21 R931
R805 CON_NOT_N
D(15..0) 20
R822
19 R932
R806 FIN_NOT_N
18
R 823
17 R933
R807 PSU_NOT_N
3.3V 16
R824
15 R920
R808 M_WAIT_N
14
R825
13 R921
R809 DMA_DONE_N
12
R826
11 R922
R810 INT0_N
10
R 827
9 R 923
R811 INT1_N
R950
R951
R952
R953
R954
R955
R956
R957
R958
R959
R960
R961
R962
R963
R964
R965
R966
R967
R968
R969
R970
R971
R972
R973
R974
R975
R976
R977
R978
R979
R980
R981
8
R828
7 R924
R812 CS0_N
6
R829
1
7
0
2
4
5
6
8
9
5 R925
30
31
10
11
12
13
14
15
16
17
18
19
CS2_N
20
21
22
23
24
25
26
27
28
29
R813
4
PCI_AD(31..0) R830
3 R926
R814 SD_OE_N
2
R 831
1 R927
R815 SD_CS0_N
0
M_D(31..0) SD_CS1_N R928
SD_CS2_N R929
3.3V SD_CS3_N R930
PCI_GNT2_N R 982
PCI_REQ2_N R983
MISC PULL-DOWNS
J81 5V
R903
R900
R901
PCI_INT_N R984
1 TRST_N PCI
2 PCI_GNT0_N R985
TDI 1 41 CF_INTRQ R934
3 0 PCI_AD0 SCA80 PCI_AD1 1
4 2 VSS1 PCI_AD2 42 2 R986
R905 R904 PCI_REQ0_N
5 CPU_TDO 3 3 PCI_AD3 VCC1 43 EJ_DBOOT
6 4 4 PCI_AD4 PCI_AD5 44 5 R987
PCI_CBE3_N
EJTAG 7 EJ_TMS 6 5 PCI_AD6 PCI_AD7 45 7
8 6 VSS2 PCI_CBE_N0 46 PCI_CBE0_N R988
D PCI_CBE2_N
9 TCK 8 7 PCI_AD8 VCC2 47
10 9 8 PCI_AD9 PCI_AD10 48 10 R989
PCI_FRAME_N
11 E_RESET_N 11 9 PCI_AD11 PCI_AD12 49 12
12 10 VSS3 PCI_AD13 50 13 R990
PCI_IRDY_N
13 14 11 PCI_AD14 VCC3 51
14 15 12 PCI_AD15 PCI_CBE_N1 52 PCI_CBE1_N R991
PCI_TRDY_N
PCI_PAR 13 PCI_PAR PCI_SERR_N 53 PCI_SERR_N
14 VSS4 PCI_PERR_N 54 PCI_PERR_N R992
PCI_DS_N
R902 PCI_LOCK_N 15 PCI_LOCK_N VCC4 55
PCI_STOP_N 16 PCI_STOP_N PCI_DEVSEL_N 56 PCI_DS_N R993
PCI_STOP_N
PCI_TRDY_N 17 PCI_TRDY_N PCI_IRDY_N 57 PCI_IRDY_N
18 VSS5 PCI_FRAME_N 58 PCI_FRAME_N R994
PCI_LOCK_N
PCI_CBE2_N 19 PCI_CBE_N2 VCC5 59
16 20 PCI_AD16
J84 PCI_AD17 60 17 R995
PCI_PERR_N
18 21 PCI_AD18 PCI_AD19 61 19
D 22 VSS6 PCI_AD20 62 20 R996
PCI_SERR_N
21 23 PCI_AD21 VCC6 63
1-971630-26 CPU Board; Pull-ups (Schematics #8)

22 24 PCI_AD22 PCI_AD23 64 23 R997
PCI_PAR
PCI_CBE3_N 25 PCI_CBE_N3 PCI_AD24 65 24
RESET GENERATOR 26 VSS7 PCI_AD25 66 25 R998
PCI_CBE1_N
26 27 PCI_AD26 VCC7 67
3.3V 27 28 PCI_AD27 PCI_AD28 68 28 R999
PCI_CBE0_N
29 29 PCI_AD29 PCI_AD30 69 30
3.3V 30 VSS8 PCI_AD31 70 31 R935
CF_DASP_N
R914 3.3V PCI_REQ0_N 31 PCI_REQ_N0 VCC8 71
PCI_GNT0_N 32 PCI_GNT_N0 PCI_CLK 72 PCI_CLK R936
U81 CF_PDIAG_N
PCI_INT_N 33 PCI_INT_N PCI_REQ_N2 73 PCI_REQ2_N
5 34 VSS9 PCI_RST_N 74 PCI_RES_N R937
E_RESET_N 4 VDD CF_VS1_N
MR* 35 TCK VCC9 75
36 TMS NC1 76 R938
R911
R912
R ESET 3 CF_VS2_N
U80 37 TDO SCL 77 SCL
C
RESET* 1 ARESET_N
2 38 VSS10 SDA 78 SD A R939
CF_CD1_N 1 =1 R915 GND CF_IOCS16_N
39 TDI PCI_DET_N 79 PCI_DET_N
CF_CD2_N 2 3 R913 B
T80
AHC86 TPS3825 40 TRST_N 24V 80
VCC=5V;GND=DGND
D
E
J83
1 EXT.RESET
2 D
D

3.3V DECOUPLING/BYPASS CAPACITORS
C900 + 3.3V
3.3V
2.5V
C911 C913 C915
C912 C914
C982 C983 C984
D C 921 +
C938 +
D 3.3V
3.3V 3.3V C929 C930 C931 C932
2.5V
193
183
173
163
203
C942 C943 C944
C901 7 D D
151 C916 3.3V D
D 2.5V
2.5V
197
184
170
208
3.3V
C933
C902 C988
17 141 156
197
181
171
C990 C917
12
C948
C922 C939 13 143
C934
C903 27 144
CPU 131 C918
C949
U13 C923 C940
26 PSA 3.3V 28 PSA 2.5V 128
C935
130
C904 C989
37 121 C991 C919 U30 U30
C950

C924 C936 C941
117 38 118
C905
39
C920
47 111
76
66
91
C937
D
59
69
82
89
99
105 D
3.3V D D 2.5V
D
C945 C946 C947
78
53
65
92
C906 C908 C910
C907 C909
C985 C986 C987
3.3V D D
D C925 C926 C927 C928
3.3V 5V
U90
11
12 1 13
C951 C 967 3.3V
U81 RESET GENERATOR U52 LM567 LVC02
VCC=3.3V;GND=DGND
C961 3.3V C968 C992 C977 U 90

U26 AHC139 U31 A/D 8
1
9 10
U92 LVC02
C953 C974 C969 C978 C979 VCC=3.3V;GND=DGND
U20 AHC245 U11 CLOCK DRIVER U42 AHCT541

U90
CLIC 5
C954 C975 C970 C980 C981 1
1-971630-26 CPU Board; Bypass/Decoupling (Schematics #9)

6 4
U21 AHC245 U1 1 CLOCK DRIVER U43 AHCT541 LVC02
VCC=3.3V;GND=DGND
C955 C963 C971

U22 AHC574
U91 AHC32 U50 EEPROM
D
D
C956 C976 C972
U23 AHC574
U90 LVC02 U5 1 PULL-UP IC
24V_S
C957 C965 C964
U24 AHC574
U60 USB DRIVER U32 LM393
C973
C958 C966 C952 U41 LM358
U25 AHC541
U6 1 RS232 DRIVER U80 AHC86
D D D D
163
15.8 Replacing the CPU board

Replace the CPU board this way:
• Remove any optional interface boards.
• Disconnect all cables from the CPU board.
• Remove the four #T20 Torx screws and the hexagonal spacer that hold
the CPU board to the plate that covers the power supply unit.
• Lift out the CPU board and remove all SIMMs and any real time clock.
Take precautions against electrostatic discharges!
• Fit the SIMMs and possibly the real-time clock on the new board and
install it in reverse order.
The same CPU-board can be used for a range of EasyCoder printers. How-
ever, the firmware can not detect in which type of printer the CPU board
is installed. All replacement CPU boards are preprogrammed for the Easy-
Coder PF2/4i-series printers, which means that replacement CPU boards
always must be reconfigured after being installed in an EasyCoder PX4i or
PX6i printer.
If the printer feeds out labels in a peculiar way, the CPU board may be
configured for the wrong type of printer (there is a difference in the dis-
tance between the dot line and the LSS position). You can easily check if
the CPU board is correctly configured by printing the “Hardware Info” or
“HW” test label in the Setup Mode or sending the Fingerprint instruction
PRINT VERSION$(1).
If the CPU board needs to be reconfigured, do like this:
• Insert a configuration card in the memory card slot.
• Switch on the power.
• Using the same method as in the Setup Mode, select the correct printer
type from the menus shown in the display window.
• Remove the card.
• Switch on the power again and check.

16 Interfaces
This chapter describes the various communication interfaces for the Easy-
Coder PX4i and PX6i printers. However, some interfaces are not sup-
ported by the Intermec Programming Language (IPL) even though the
connectors are present.
The chapter describes three categories:
• Standard built-in interfaces
RS-232 interface
USB interface
Bar code wand interface (Fingerprint only)
• Optional interface boards
Serial/Industrial interface board (Fingerprint only)
Double Serial interface board (Fingerprint only)
IEEE 1284 Parallel interface board
• EasyLAN interface boards
EasyLAN Ethernet interface
EasyLAN Wireless interface
The EasyCoder PX4i and PX6i can—in addition to the standard built-in
interfaces—also be fitted with one or two optional interface boards and
one EasyLAN interface board.
Note: Device designations, such as "uart1:", "usb1:", or "net1:", only
apply to Fingerprint, not to IPL.

Chapter 16 — Interfaces
16.1 Introduction
In Fingerprint, "auto" is by default the standard IN and OUT commu-
nication port, that is, the printer will scan all communication channels
for incoming data. To select a specific communication port as standard
IN and/or standard OUT port, use an Intermec Fingerprint SETSTDIO
statement (see Intermec Fingerprint v8.xx, Programmer’s Reference Manual).
This gives better performance. Note that many application programs, for
example Intermec Shell, contain instructions that select the correct stan-
dard I/O for the application in question. The settings for the selected com-
munication channel will appear in the display window when pressing the
<info> key on the printer’s keyboard.
In IPL, all communication channels are always scanned for incoming data
and the firmware automatically switches to the same channel for output
too. The settings for the active communication channel will appear in the
display window when pressing the <info> key on the printer’s keyboard.
The standard interfaces (RS-232, USB, and Wand) are fitted directly on
the rear of the CPU board with connectors protruding through slots in the
printer’s rear plate. Wand is not supported by IPL.
All optional interface boards, except the EasyLAN boards, are fitted in a
slot on the printer’s standard rear plate and connected to the CPU board
via a flat cable. If no interface board is fitted, the slot is closed by two cover
plates.
The EasyLAN boards are fitted directly to the front of the CPU board and
connected by wire to a connector or antenna. There are provisions for both
the wired EasyLAN connector and the EasyLAN wireless antenna on the
standard rear plate. All rear plates have slots for two interface boards as well
as for the standard interface connectors.

16.2 RS-232 Serial Communication Port ("uart1:")

The EasyCoder PX4i and PX6i printers are always fitted with one RS-
232 communication port. In Intermec Fingerprint, this port is designated
"uart1:" (uart = Universal Asynchronous Receiver and Transmitter.) The
circuitry is fitted on the CPU board (see Chapter 15) and has a fixed set of
signals in a DB-9pin female connector which protrudes through a slot in
the printer’s rear plate.
Protocol
Default setup
Baud rate: 9600
Char length: 8 bits
Parity: None
Stop bits: 1
RTS/CTS: Disabled
ENQ/ACK: Disabled
XON/XOFF: Disabled in both directions
New line: CR/LF
Signals on serial port ("uart1:")
MTG DB-9 socket Signal Meaning

1 External +5VDC max 500 mA (automatic switch-off at
5
overload, short-circuit protected)
9
GND
4 DSR in 2 TXD Transmit data
RTS out 8
3 RXD in 3 RXD Receive data
CTS in 7
2 TXD out 4 DSR Data set ready
DTR out 6
1 +5V DC 5 GND Ground
6 DTR Data terminal ready
MTG 7 CTS Clear to send
8 RTS Request to send
9 – Not used
RS-232 socket
("uart1:")

16.3 USB Interface ("usb1:")

The EasyCoder PX4i and PX6i printers are, as standard, fitted with a USB
(Universal Serial Bus) interface connector on the CPU board.
USB
("usb1:")
The supported USB version is USB 1.1 (also called “USB 2.0 full speed”).
To use the USB interface for printing from a PC, you need a USB-compat-
ible Intermec InterDriver installed in your PC. The printer works only as a
“slave”, that is, the USB interface is not suitable for programming. Unlike
for example RS-232, there is no communication setup in regard of baud
rate, parity, handshaking, etc. Select the USB interface as standard IN/
OUT channel in Intermec Fingerprint, the Intermec Direct Protocol, or
Intermec Shell as device "usb1:" (communication channel 6).
The EasyCoder PX4i and PX6i printers are so called “self-powered
devices.” We recommend that you only connect one printer to each USB
port on the host, either directly or via a hub. Other devices, like a keyboard
and a mouse, can be connected to the same hub. If you need to connect
more than one Intermec USB printer to a host, you should use different
USB ports.
Using a USB Class A/B cable, connect the Class A plug to the PC or hub
and the Class B plug to the printer.
USB Class A connector. USB Class B connector.

Connect to PC or hub. Connect to USB port on
printer’s rear plate.

16.4 Bar Code Wand Interface (wand:) (Fingerprint only)

The printer has a socket (J59) on the CPU board for connecting a bar code
wand or scanner. The socket is accessible through a slot in the printer’s rear
plate. The bar code wand interface is not supported by IPL.
If the Code 128 bar code that contains the character FNC3 is read via this
port, the data will be treated as a setup string and will change the printer’s
setup accordingly. A setup bar code may contain a single parameter or a
combination of up to 3 or 4 setup parameters. Refer to the EasySet Bar
Code Wand Setup manual for more information on how to produce setup
bar codes.
The printer will acknowledge that a bar code has been successfully read by
emitting a short beep signal.
If no FNC3 character is found in the bar code, the data will be stored in a
buffer which could be read by specifying the "wand:" device. The buffer is
small, so it is recommended to use short bar code data (max. 36 characters)
and read the buffer regularly to avoid overflow.
For more demanding applications or for reading bar codes other than
Code 128, choose a regular bar code scanner from Intermec’s wide product
range and connect it to a serial port.
Wand interface
("wand:")

16.5 Installing an Optional Interface Board

To install an optional interface board, proceed according to the step-by-
step instructions below.
Note: This chapter does not apply to installation of any type of EasyLAN
interface board, which instead is described in Chapter 16.9.
• Open the electronics compartment, see Chapter 3.3.

Switch off the power and disconnect the power cord. The electronics
compartment contains high voltage components and wires. Do not open
the electronics compartment before the printer is safely disconnected
from any AC supply.
• Remove the one or two cover plates depending on how many interface
boards you are going to install. Each plate is held by two #T10 Torx
screws. Always start installation at the innermost position.
Spacer and screw
#T10 Torx screws
Cover plates
#T10 Torx screws
• Save the cover plate(s) for possible later use. Keep the screws.
• Remove the #T20 Torx screw fitted on the hexagonal spacer at the
center of the CPU board. Keep the screw.
• If necessary, reconfigure the interface board by fitting or removing cir-
cuits and straps according to the descriptions of each board later in this
chapter.
• Attach the flat cable included in the kit to connector J62 (marked “EXP
BOARD”) on the CPU board (see illustration on the next page).
• Insert the interface board with the component side facing right, as seen
from behind.

#T10 Torx screws
#T20 Torx screw

Inner interface board and spacer(s)
Flat cable (two types)
Component side
Outer interface board
• Installation of one board: Attach the interface board in the innermost

slot in the printer’s rear plate using the two screws left over when you
removed the original cover plate. Using the #T20 Torx screw you previ-
ously removed, attach the interface board to the hexagonal spacer at the
center of the CPU board.
• Installations of two boards: First install the inner board, then the outer
one. Put the hexagonal spacer included in the kit between the inner and
the outer interface board, and finally secure the outer board with the
screw.
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
R54
C24
C23
C22
C21
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3
IC28
IC2
IC22
C36 C34
REL2
IC3 C66
P1
RS232: IC11, J2A
REL1 P35 P1 J62
C33
RS422: IC12, J3, J4
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
R14
C2 C1 C50
UARTA
C32
B A IC13
J2
R5
R13
R15
IC11 IC12
R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
J61
J3 R10
C56
R16
IC4
IC6
R9
C57
J4
C53
C31
R17
R6
R1
R7
IC9
IC5
IC1
C52
C54
C30
R2
R3
C55
P2 J1
R11
R4
EXP BOARD
Hexagonal
Flat cable spacer
(two types)

• The kit contains two flat cables, one with two connectors for use with a
single interface board and one with three connectors for use with double
interface boards. Connect the appropriate flat cable to connector P1 on
the interface board, as illustrated below.
• The flat cable should run as illustrated below.
$16#PBSE
4QBDFS FYJTUJOH
$BCMF
*OOFS*OUFSGBDF#PBSE
4DSFX FYJTUJOH
$16#PBSE
4QBDFS FYJTUJOH
$BCMF
*OOFS*OUFSGBDF#PBSE
4QBDFS GSPNLJU
0VUFS*OUFSGBDF#PBSE
4DSFX FYJTUJOH
• Put back the cover over the electronics compartment.

• Connect the communication cables to the connectors on the printer’s
rear plate.
• Connect the power cord and switch on the power.
• In case the interface board provides additional serial communication
ports, enter the Setup Mode to set the proper communication param-
eters for these ports.

Allowed interface combinations (Fingerprint)
Left-hand slot Ports Right-hand slot Ports

Double Serial uart2: + uart3: – –
Double Serial uart2: + uart3: Double Serial uart4: + uart5:
Double Serial uart2: + uart3: Serial Industrial uart4:
Double Serial uart2: + uart3: IEEE 1284 centronics:
Serial/Industrial uart2: – –
Serial/Industrial uart2: Serial/Industrial uart3:
Serial/Industrial uart2: Double Serial uart3: + uart4:
Serial/Industrial uart2: IEEE 1284 centronics:
IEEE 1284 centronics: – –
IEEE 1284 centronics: Double Serial uart2: + uart3:
IEEE 1284 centronics: Serial/Industrial uart2:
Allowed interface combinations (IPL)

Left-hand slot Ports Right-hand slot Ports
IEEE 1284 parallel – –
Remarks:
• The left-hand slot is the slot closest to the center section.
• Always start by fitting an interface board in the left-hand slot.
• RS-485 is only supported by "uart2:"
When fitting driver circuit and straps before installing the interface
board, make sure that the circuit is not fitted upside down (see front
end markings in the illustrations). Also make sure that the “legs” of the
circuit fit into the slots in the socket and are not bent. Take ample pre-
cautions to protect the board and circuits from electrostatic discharges.

16.6 Serial/Industrial Interface Board (Fingerprint only)

Description
The Serial/Industrial Interface Board is a Fingerprint-only optional device
for EasyCoder PX4i and PX6i. It provides these printers with two extra
interfaces.
The Serial/Industrial Interface kit contains:
• One Industrial Interface Board fitted with straps and circuits for RS-232
• One hexagonal spacer
• Two flat cables
• One Installation Instruction booklet
Serial Interface ("uart2:", "uart3:", or "uart4:")
This interface contains one serial communication port ("uart2:", "uart3:",
or "uart4:") which can be configured for one of the following alternatives:
• RS-232 non-isolated
• RS-422 isolated, full duplex (reconfiguration required)
• RS-485 isolated, half duplex (reconfiguration required, "uart2:" only)
Selection of type of serial interface is decided by fitting various types of
socket-mounted driver circuits and straps.
Industrial Interface
This interface contains eight digital IN and eight digital OUT ports with
optocouplers, plus four OUT ports with relays.
The status of all ports can be read by means of PORTIN functions and
the OUT ports can be set using PORTOUT ON/OFF statements (see
Intermec Fingerprint v8.xx, Programmer's Reference Manual). Thus, it is pos-
sible to design Intermec Fingerprint application programs which control
not only the printer but also various external devices, for example in a
production line. The digital IN ports can read the status of various sensors
and the program can, for example, switch control lamps on or off, open
or close gates, and start or stop conveyor belts accordingly using the relays
and the digital OUT ports.
Industrial Interface
(DB-44pin socket)
Serial Interface
"uart2:"
(DB-9pin socket)

Serial Port Configuration

The serial communication port "uart2:", "uart3:", or "uart4:" are config-
ured for RS-232 as standard but can be reconfigured for two other types
of serial communication by fitting certain driver circuits and straps. The
circuits can be ordered separately from Intermec:
• RS-422 isolated, full duplex
• RS-485 isolated, half duplex ("uart2:" only!)
RS-232 Non-isolated (standard)
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
C24
C23
C22
C21
R54
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3 IC28
IC2
IC22
C36 C34
REL2
IC3 C66
REL1 P1
RS232: IC11, J2A
C33
RS422: IC12, J3, J4
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
R14
C2 C1 C50
UARTA
C32
B A IC13
J2
R5
R13
R15
IC11 IC12
R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
J3 R10
C56
R16
IC4
IC6
R9
C57
J4
C53
C31
Strap fitted on J2 A
R17
R6
R1
R7
IC9
IC5
IC1
RS-232 circuit fitted on

C52
C54
C30
R2
R3
C55
P2
IC11
J1
R11
R4
Connector Configuration (RS-232 on "uart2:", "uart3:", or "uart4:")

DB-9 socket Signal Meaning
MTG
5 GND
9 2 TXD Transmit data
4 DSR in
RTS out 8
3 RXD Receive data
3 RXD in
CTS in 7
DTR out 6
9 – Not used

RS-422 Isolated, Full Duplex (reconfiguration required)
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
C24
C23
C22
C21
R54
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3
IC28
IC2
IC22
C36 C34
REL2
IC3 C66
REL1 P1
RS232: IC11, J2A
C33
RS422: IC12, J3, J4
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
R14
C2 C1 C50
UARTA
C32
B A IC13
J2
R5
R13
IC11 IC12
Remove strap on J2 A
R15
R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
J3 R10
C56
Fit straps on J3 and J4

R16
IC4
IC6
R9
C57
J4
C53
C31
R17
R6
R1
R7
IC9
IC5
IC1
C54 C52
C30
Remove RS-232 circuit

R2
R3
C55
P2 J1
R11
R4
on IC11
Fit RS-422 circuit on IC12
Connector Configuration
(RS-422 Isolated on "uart2:", "uart3:", or "uart4:")
MTG
overload, short-circuit protected) provided strap is fitted
5 GNDE
9 on J2:A which spoils the galvanical isolation
4
-TXD 8 2 +TXD +Transmit data
3 +RXD
-RXD 7
3 +RXD +Receive data
2 +TXD
6
1 +5V DC 4 –
if GND strap
fitted 5 GNDE Ground
MTG 6 -
7 -RXD -Receive data
8 -TXD -Transmit data
9 –

RS-485 Isolated, Half Duplex (reconfiguration required)
P01
C63
C64
R31
C40
R32
IC24
IC23
R33
IC20
R34
R35
R36
1-971643-01
R37
R38
C24
C23
C22
C21
R54
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
IC25
R27
IC26
C62
R26
IC27
R25
R24
R23
R22
R21
P3
REL4
IC21
R28
C61
C51
C67
REL3
IC28
IC2
IC22
C36 C34
REL2
IC3 C66
REL1 P1
Remove strap on J2 A RS232: IC11, J2A

RS422: IC12, J3, J4
C33
C4 C3 C35
IC10
RS485: IC13, J1, J4*
* IF END OF CABLE
Remove RS-232 circuit UARTA

R14
C2 C1 C50
C32
B A IC13
on IC11 J2
R5
R13
R15
IC11 IC12
Fit RS-485 driver circuit

R8
F1 F6 F2 F7 F3 F8 F4 F5
R12 R18
J3 R10
C56
R16
IC4
IC6
R9
Fit strap on J4 J4 C57
C53
C31
if end of cable
R17
R6
(terminator)
R1
R7
IC9
IC5
IC1
C52
C54
C30
Fit strap on J1 R2
R3
C55
P2 J1
R11
R4
(RS-485 Isolated on "uart2:" only)
5 GNDE
4
-DATA 8
2 +DATA
3
7
2 +DATA 3 –
6
1 +5V DC 4 –
if GND
strap fitted 5 GNDE Ground
MTG 6 –
7 –
8 -DATA
9 –
Note: The increased use of LAN networks has made the RS-485 interface
somewhat obsolete, because RS-485 requires a special communication
protocol and a dedicated wiring system limited to 1,200 m (4,000 ft). We
only recommend RS-485 for existing applications and advice the customer
to consider a LAN network solution for new applications.

Industrial Interface Configuration

The Industrial Interface provides:
• 8 digital IN ports with optocouplers (Opto In)
• 8 digital OUT ports with optocouplers (Opto Out)
• 4 OUT ports with relays (Relay Out)
The Industrial Interface has no straps or circuits to be fitted or removed.
All signals are available on a DB-44pin socket and the various ports are
controlled by the Intermec Fingerprint instructions PORTIN and POR-
TOUT ON/OFF (see Intermec Fingerprint v8.xx, Programmer's Reference
Manual).
Digital Opto In
The status of the digital IN ports can be read using PORTIN functions. If
a current is led through the optocoupler of the port, PORTIN returns the
value -1 (true), else it returns the value 0 (false).
Signal Description Min. Typical Max.
Vin [High] Input Voltage High 10V 24V 40V
Vin [Low] Input Voltage Low -1V 0V 1V
Pin Signal Name Description Fingerprint Ref. No.
10 IN1A Anode Opto In Channel 1 + 101 (301)
40 IN1K Cathode Opto In Channel 1 -
The Fingerprint reference numbers inside the parentheses refer to a second
Serial/Industrial interface board.
INA
INK
GND
Simplified schematics of a digital IN port.

Digital Opto Out

The current to each optocoupler of the digital OUT ports can be turned
on and off using PORTOUT ON/OFF statements.
The status of the ports can be read using PORTIN functions. If a current
is led through the optocoupler of the port, PORTIN returns the value -1
(true), else it returns the value 0 (false).
Signal Description Max.
Vceo Collector-Emitter breakdown voltage 35V
Veco Emitter-Collector breakdown voltage 6V
Collector Current 15 mA
Vog Output to ground (optocoupler) 100V
20 Out1c Collector Opto Out Channel 1 221 (421)
5 Out1e Emitter Opto Out Channel 1
VCC
OUTc
OUTa
Simplified schematics of a digital OUT port.

Relay Out
The relays of the OUT ports can be individually activated using PORT-
OUT ON/OFF statements.
The status of the ports can be read by means of PORTIN functions. If a
relay is activated, PORTIN returns the value -1 (true), else it returns the
value 0 (false).
Max AC Load Breaking Capacity

Signal Description Max.
I Current 1A
Psw AC Switching power 100VA AC
Usw AC Switching voltage 100V AC
Max DC Load Breaking Capacity
b a
1
DC current (A)
0.5
0.1
10 20 30 40 50 100
a: resistive load DC Voltage (VDC)

b: inductive load L/R=20 ms
16 REL1nc Relay 1 Normally Closed 201 (401)
1 REL1no Relay 1 Normally Open
31 REL1com Relay 1 Common
VCC
REL no
REL nc
REL com
Simplified schematics of a relay OUT port.

Components
C40
R31
R32
IC20
C63
C64
R33
IC24 IC23 R34
R35
R36
R37
R38
R54
C24
C23
C22
C21
R44
R53
R43
R52
R42
R51
R41
C28
C27
C26
C25
R58
R48
R57
R47
R56
R46
R55
R45
C65
C60
R27
IC27
C62
R26
IC25 IC26 R25
R24
R23
R22
R21
P3
IC21
REL4
R28
C61
C51
IC28
C67
REL3
IC2
IC22
C36 C34
REL2
C66
IC3
REL1 P1
35
1
C33
RS232: IC11, J2A C35
RS422: IC12, J3, J4

C4 C3
RS485: IC13, J1, J4* C50
*: IF END OF CABLE C2 C1
R5 C32
R14
IC10
UARTA B A
J2 R13
R8
F1 F6 F2 F7 F3 F8 F4 F5
R15 R18
R12 R10
C56
R9
C53
C31
R16
C57 IC6 IC4

J3
IC11
P2
R7
R17
R6
R1
J4
C52
C30
IC9
IC13
IC12
IC5 IC1
C55
34
68
J1
C54
R11
R3
R2
R4
1-971643-26 Serial/Industrial Interface Board; Component side

5V SWITCH FOR
P1
182
EXTERNAL 5V
1 +24VI 5V
35 5V IC9
2 3.3V POWER_SWITCH
1 GND OUT 8 5V_EXT
36 2 7
3 R6 R7 IN OUT
WAIT_N 3 IN OUT 6
37 4 5
4 R5 EN_N OC_N
38 RD_N 5V_EXT_EN_N
5
39 WR_N OVERCURRENT_N
6 R18
40 D<15..0> DCDA_N
7 0
1
4
3
2
1
0
41 VCC=3.3V
8 A<12..1> =1 4 DSRA_N
42 2 6 IC5 5 R8
6
5
4
3
2
1
44
43
41
40
5V
42
9 3 AHC86
43 3.3V VCC=3.3V
RS232
12 CTSA_N C1
10 4 1 IC11 C3
D4
D3
D2
D1
D0
NC
11 IC4 13 +
44 5 MAX238 +
VCC
RI*
AHC32
DCD*
DSR*
CTS*
11 5 7 39 RESET 10 C1+ VCC 9 C4
45 6 D5 MR 12 11
3.3V 6 8 38 C2 C1- V+ +
12 7 D6 OUT1* VCC=5V
7 9 37 1 =1 + 13 15
46 VCC=3.3V 10 D7 DTR* 36 2 IC6 3 C2+ V- F1
13 8 1 =1 RCLK IC10 RTS* 14 C2- GND 8 P2 9PIN DSUB
RESET_N 2 3 RESET 11 35 AHCT86
47 9 IC5 SIN OUT2* 2
12 34 5 T1IN T1OUT F2
14 AHC86 NC NC VCC=5V RS232 RS422 RS485
13 33 INTA 4 =1 DTRA_N 18 T2IN T2OUT 1
48 10 SOUT INTRPT 5 6 RTSA_N 19 24
14 16C550 32 IC6 T3IN T3OUT F3 1 +5V
15 11 VCC=3.3V CS0 RXRDY*
12 1 15 31 1 AHCT86 21 T4IN T4OUT 20 2 TXD +TXD +DATA
49 1 CS1 A0
2 IC4 3 CSA_N 16 30 2 6 R1OUT R1IN 7 F4 3 RXD +RXD
16 12 CS2* A1 29 4 3
AHC32 17 3 R2OUT R2IN 4 DSR
50 13 BAUDOUT* A2 23
22 R3OUT R3IN F5 5 GND GNDE GNDE
17 VCC=3.3V 17 R4OUT R4IN 16 6 DTR
51 14 11 4
1 F6 7 CTS -RXD
18 15 5 IC4 6 CSB_N
8 RTS -TXD -DATA
XIN
XOUT
WR1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
52 AHC32 F7
19 1 3.3V 9
2 MTG1
18
19
21
22
23
25
26
27
28
53 VCC=3.3V
J1 F8 MTG2
20 3 9
1 1
54 4 WR_N 10 IC4 8 WRB_N
21 AHC32 RS485 2 GND-SHIELD
55 5
WR_N 20
RD_N 24
22 6 VCC=3.3V VCC=5V 5V RS422
7
INTA 9 =1 9 =1
1 A J2
56 10 IC5 8 INT_N 10 IC6 8 TXDA IC12 2B C
23 8 MAX1490 3
AHC86 AHCT86 1 VCC1 AC1 24
57 5V 2 VCC2 AC2 23
24 9 VCC=3.3V
=1 12 RXDA 3 D1 IVCC1 22
58 10 11 13 4 21 R16
11 IC5 D2 IRCDRV J3
25 AHC86 5 GND1 A 20 1 TERM.REC.
59 12 R1 R2 R3 3.3V R4 6 19 2
FS B R17
26 7 SD Z 18 J4
4
60 IC3 8 VCC3 Y 17 1
27 R9 9 16 2 TERM.TRA.
SDA VCC DI ICOM1
61 10 VCC4 IDIDRV 15
28 1.8432MHZ 11 RO IVCC2 14
62 SCL 1 CLK 12 13
SA1 NC/EN_N OUT 3 GND2 IRLED
29
63 RESET_N 5V GND
30 CS_N RS485
2
64 INT_N
31 IC1 IC13
MAX1480
65 1 VCC1 AC1 28
32 2 VCC2 AC2 27
66 1 A0 VCC 8 3 D1 IVCC1 26
33 2 A1 WP 7 4 D2 B 25
3 6 5 24 R15
67 A2 SCL GND1 IRCDRV
34 4 GND SDA 5 6 FS A 23
7 22 R12
68 SD IDIIN
5V 8 VCC3 IDEIN 21
Schematics; Serial Port ("uart2:", "uart3:", or "uart4:")
9 DI ICOM1 20
5V 3.3V VCC=5V
12 =1 10 VCC4 IDIDRV 19
R10
1-971643-26 Serial/Industrial Interface Board; Schematics 1

IC2
485_DIR
13 IC6 11 11 DE IVCC2 18
3 2 AHCT86 12 17 R13
VIN VOUT GND2 IDEDRV
C50 + LD1117 13 RO_N ICOM2 16
C51 C52 C53 C54 C55 C56 C57 C30 C31 C32 C33 C34 C35 C36 14 15 R14
GND VCC5 IRLED
R11
1
INTERFACE CONFIGURATION
RS232: IC11, J2A
RS422: IC12, J3, J4
RS485: IC13, J1, J4*
*: IF END OF CABLE

VCC=5V
IC28
5 12
ULN2003A
IC28
IC22 4 13 5V
1 RESET
11 ULN2003A
CLK IC28
AHCT273 3 14
A1
A2
A1
A2
A1
A2
A1
A2
8 3 2
D
A1
A1
A1
A1
9
A2
A2
A2
A2
4 5 ULN2003A
10 7 6 IC28 REL4 REL3 REL2 REL1 DSUB44
11 8 9 2 15 NO 14 NO 14 NO 14 NO 14 P3
13 12 COM 11 COM 11 COM 11 COM 11 SIGNALS
ULN2003A
5V
14 15 IC26 NC 12 NC 12 NC 12 NC 12 16 REL1NC
17 16 OPTO_COUPLER 1 REL1NO
18 19 1 16 31 REL1COM
VCC=5V IC28 17 REL2NC
1 16 R28 2 15 2 REL2NO
3 14 32 REL2COM
ULN2003A
IC27 18 REL3NC
7 10 R27 4 13 3 REL3NO
33 REL3COM
ULN2003A
5 12 19 REL4NC
IC21 IC27 4 REL4NO
RESET_N 1 6 11 R26 6 11 34 REL4COM
RESET 20 OUT1C
WRB_N 11 CLK ULN2003A
7 10
IC27 5 OUT1E
7 3 AHCT273 2 5 12 R25 8 9 35 OUT2C
6 D 21 OUT2E
4 5
5 7 6 ULN2003A 6 OUT3C
4 8 9 IC25 36 OUT3E
3 13 12 OPTO_COUPLER 22 OUT4C
2 14 15 VCC=5V 1 16 7 OUT4E
1 17 16 IC27 37 OUT5C
0 18 19 4 13 R24 2 15 23 OUT5E
VCC=5V 3 14 8 OUT6C
ULN2003A
IC27 38 OUT6E
3 14 R23 4 13 24 OUT7C
9 OUT7E

ULN2003A
5 12 39 OUT8C
IC27 25 OUT8E
2 15 R22 6 11 30 IN8A
Schematics; Industrial Interface
7 10 15 IN8K
ULN2003A
IC27 14 IN7A
D<15..0> 1 16 R21 8 9 44 IN7K
43 IN6A
ULN2003A 29 IN6K
IC24 28 IN5A
OPTO_COUPLER R48 R58 13 IN5K
CSB_N 16 1 12 IN4A
C28 42 IN4K
RD_N 15 2 41 IN3A
IC20 R38 14 3 R47 R57 27 IN3K
1 26 IN2A
EN & 19 C27 11 IN2K
13 4
AHC541 R37 R46 R56 10 IN1A
7 11 9 12 5 40 IN1K
6 12 8 MTG1
5 13 7 11 6 C26
MTG2
4 14 6 R36 R45 R55
3 15 5 10 7
2 16 4 C25
1 17 3 9 8
0 R35 C
18 2
VCC=3.3V IC23
OPTO_COUPLER R44 R54
16 1
3.3V
C24
1-971643-26 Serial/Industrial Interface Board; Schematics 2

IC28 15 2
7 10 R34 14 3 R43 R53
C40
ULN2003A
13 4 C23
IC28
6 11 R33 12 5 R42 R52
ULN2003A
11 6 C22
5V
R32 10 7 R41 R51
C60 C61 C62 C63 C64 C65 C66 C67 9 8 C21

R31
183
16.7 Double Serial Interface Board (Fingerprint only)

Description
The Double Serial Interface Board (DUART) is a Fingerprint-only
optional device for EasyCoder PX4i and PX6i printers. It provides these
printers with two extra serial interfaces.
"uart2:", "uart3:", or "uart4:"
This interface (marked “UART A” on the interface board) can be fitted
with straps and circuits for one of the following alternatives:
• RS-485 isolated, half duplex ("uart2:" only)
"uart3:", "uart4;", or "uart5:"
This interface (marked “UART B” on the interface board) can be fitted
with straps and circuits for one of the following alternatives:
• RS-422 non isolated, full duplex
• 20 mA Current Loop.
The Double Serial Interface Kit contains:
• One interface board fitted for RS-232 on both ports.
• Two flat cables
Circuits for modifying the board for RS-422 non-isolated, RS-422 iso-
lated, RS-485 isolated, or 20 mA current loop can be bought separately
from Intermec.
"uart3:"
(DB-9pin socket)
"uart2:"
(DB-9pin socket)

"uart2:", "uart3:" & "uart4" Configuration (connector UART A)

The serial communication ports "uart2:", "uart3:", and "uart4:" can be
configured for up to three different types of serial communication respec-
tively by fitting or removing certain driver circuits and straps:
• RS-485 isolated, half duplex ("uart2:" only!)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12
J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
*: TRANSM.=J9, RECEIV.=J10
C41
PASSIVE=B, ACTIVE=A+C
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 P1
IC2
IC3
RS485: IC13, J1, J4*
C35
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
Strap fitted on J2 A
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
RS-232 circuit fitted on

R2
C54
C55
P2
R11
J1
IC11

MTG
5 GND
9 2 TXD Transmit data
4 DSR in
RTS out 8
3 RXD Receive data
3 RXD in
CTS in 7
DTR out 6
9 – Not used

RS-422 Isolated, Full Duplex (reconfiguration required)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
C41
Remove RS-232 circuit on
IC11 C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 P1
IC2
IC3
Remove strap on J2 A RS485: IC13, J1, J4*
C35
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
Fit straps on J3 and J4
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
Fit RS-422 circuit on IC12

R4
R3
R2
C54
C55
P2
R11
J1
Connector Configuration (RS-422 Isolated on "uart2:", "uart3:", or

"uart4:")
5
GNDE
4
3 +RXD
-RXD 7
2 +TXD 3 +RXD +Receive data
6
1 +5V (0.5 A) 4 –
if GND strap
6 -
9 –

RS-485 Isolated, Half Duplex (reconfiguration required)
IC23 C11 IC21

C10 C12
1-971642-01 P01
UARTB B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
Remove RS-232 circuit on 20MACL: IC23, IC24, J5 J9*, J10*
IC11
C41
C34 C42
RS232: IC11, J2A
Remove strap on J2 A RS422: IC12, J3, J4 P1
IC2
IC3
RS485: IC13, J1, J4*
C35
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
Fit RS-485 driver
IC11 IC12
J2 R13
R8
R15
circuit on IC13
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
Fit strap on J4
J4
R6
R17
if end of cable
R1
R7
IC5
IC1
(terminator)
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1
Fit strap on J1
Connector Configuration (RS-485 Isolated on "uart2:" only)

5 GNDE overload, short-circuit protected) provided strap is fitted
4
-DATA 8
3 2 +DATA
7
2 +DATA 3 –
6
1 +5V (0.5 A)
if GND strap 4 –
6 –
7 –
8 -DATA
9 –
Note: The increased use of LAN networks has made the RS-485 interface
somewhat obsolete, because RS-485 requires a special communication
protocol and a dedicated wiring system limited to 1,200 m (4,000 ft). We
only recommend RS-485 for existing applications and advice the customer
to consider a LAN network solution for new applications.

"uart3:" , "uart4:", and "uart5:" Configuration (connector UART B)

The serial communication ports "uart3:", "uart4:", and "uart5:" can be
configured for three different types of serial communication by fitting or
removing certain driver circuits and straps:
• RS-422 non-isolated, full duplex
• 20 mA Current Loop
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12
J7
R24
R23
C63
C
C61
A
Z2
B
K
NC
IC8
C13
A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
C41
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 IC3
IC2 P1
RS485: IC13, J1, J4*
*: IF END OF CABLE C35
Strap fitted on J6 A C4 C3
C33
IC10 C51
C2 C1 C50
C32
RS-232 driver circuit

R14
IC13
UARTA B A
R5
IC11 IC12
fitted on IC21
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1

5 GND
9
4 DSR in 2 TXD Transmit data
RTS out 8
3 RXD in 3 RXD Receive data
CTS in 7
2 TXD out
DTR out 6 4 DSR Data set ready
1 +5V DC
5 GND Ground
MTG
7 CTS Clear to send
9 – Not used

RS-422 Non Isolated, full duplex (reconfiguration required)
IC23 C11 IC21 1-971642-01 P01

UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
Move strap from
C63
C
C61
A
Z2
B
K
NC
IC8
C13
J6 A to J6 B A
R33 R34
IC22
R31
C60
C C62
R22
R21
A
Z1
K
B
NC
R25 R28 R29
IC7
J8 A
R26
A
Fit straps on
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
J7 and J8
R20
P3 IC24 C36
RS232: IC21, J6A IC20

RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
C41
Fit RS-422 driver

circuit on IC22 C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 P1
IC2
IC3
Remove RS-232 driver RS485: IC13, J1, J4*

circuit from IC21 C4 C3
C33
IC10 C51
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1
(RS-422 Non-isolated on "uart3:", "uart4:", or "uart5: )
overload, short-circuit protected) if strap is moved from
5 GND
9 J6 B to J6 A.
4
3 +RXD
-RXD 7 3 +RXD +Receive data
2 +TXD
6
1 +5V (0.5 A) 4 –
5 GNDE Ground
6 -
9 –

20 mA Current Loop (reconfiguration required)

Remove strap from J6 A
IC23 C11 IC21 1-971642-01 P01
UARTB C10 C12
B A
J6
F13 R27
J10 R35 R30
F14 F10 F15 F11 F16 F12

J7
R24
R23
C63
C
C61
A
Z2
B
K
Fit strap on J10
NC
IC8
C13
A
R33 R34
IC22
R31
if printer is receiver:
C60
C
A + C = active
C62
R22
R21
A
Z1
K
B
NC
R25
B = passive
R28 R29
IC7
J8 A
R26
D1
J9 R19
K
F9
NC
C64
R32
J5
C40
Fit strap on J9
R20
P3 IC24 C36
RS232: IC21, J6A IC20

if printer is transmitter: RS422: IC22, J6B, J7, J8
A + C = active 20MACL: IC23, IC24, J5 J9*, J10*
B = passive
C41
Fit optocouplers
on IC23 and IC24 C34 C42
RS232: IC11, J2A

Remove RS-232 driver RS422: IC12, J3, J4 P1
IC2
IC3
circuit from IC21 RS485: IC13, J1, J4*

C4 C3
C33
IC10 C51
Fit strap on J5
C2 C1 C50
C32
R14
IC13
UARTA B A
R5
IC11 IC12
J2 R13
R8
R15
R18
F1 F6 F2 F7 F3 F8 F4 F5
R12 R10
C56
J3
IC4
IC6
R9
R16
C57
C53
C31
J4
R6
R17
R1
R7
IC5
IC1
IC9
C52
C30
R4
R3
R2
C54
C55
P2
R11
J1
(20 mA Current Loop on "uart3:", "uart4:", or "uart5:")
MTG
5 1 External +5VDC max 500 mA (automatic switch-off
9 at overload, short-circuit protected) provided a strap is
4
-TXD 8 fitted on J6 A which spoils the galvanic isolation.
3 +RXD
-RXD 7 2 +TXD +Transmit data
2 +TXD
6
1 +5V DC 3 +RXD +Receive data
if GND strap 4 –
fitted
MTG 5 GNDE Ground
6 -
9 –
Note: Max. recommended baud rate 9600.

Components
UARTB B A
J6 C11
C10 C12
R27
F13 R30 IC23
R35
R24
R23
C C13
F12
C61
C63
J10
J7
A
F16
Z2
B
K
NC
A
F11 R34 IC21 IC8
P3 IC22
R31
C60
F15
R33 C62
F10 C
J8
R22
A
R21
J9
Z1
B K
NC
F14
R25 R28 R29

A
F9 R19
IC24 IC7
D1
R26
R32
K
NC
C64
J5
C40
R20
C36
RS232: IC21, J6A
RS422: IC22, J6B, J7, J8
20MACL: IC23, IC24, J5 J9*, J10*
*: TRANSM.=J9, RECEIV.=J10 IC20
C41
C34 C42
RS232: IC11, J2A

RS422: IC12, J3, J4 IC2
P1
RS485: IC13, J1, J4*
35
C33
C51
IC3
C4 C3
C50
C2 C1
IC10
C32
R14
UARTA B A
R5
J2 R13
R15 R8
R18
F5
R12 R10
F4
C56
R9
F8
R16
C57 IC6 IC4

J3
F3
P2
C31
C53
IC11
F7
R6
R17
F2
J4
R7
R1
F6
C30
F1
IC9 IC5 IC1

C52
IC13
IC12
J1
34
68
R4
R3
C55
R2
R11
C54
1-971642-26 Double Serial Interface Board; Component side

5V SWITCH FOR
P1
192
5V EXTERNAL 5V
1 +24VI
35 5V IC9
2 3.3V POWER_SWITCH
1 GND OUT 8 5V_EXT
36 2 7
3 R6 R7 IN OUT
WAIT_N 3 IN OUT 6
37 4 5
4 R5 EN_N OC_N
38 RD_N 5V_EXT_EN_N
5
39 WR_N OVERCURRENT_N
6 R18
40 D<15..0> DCDA_N
7 0
1
4
3
2
1
0
41 VCC=3.3V
8 A<12..1> =1 4 DSRA_N
42 2 65 IC5 R8
5V
6
5
4
3
2
1
44
43
42
41
40
9 3 AHC86
43 3.3V VCC=3.3V
RS232
12 CTSA_N C1
10 4 1 IC11 C3
D4
D3
D2
D1
D0
NC
5
11 IC4 13 +
44 MAX238 +
VCC
RI*
AHC32
DCD*
DSR*
CTS*
11 5 7 39 RESET 10 C1+ VCC 9 C4
45 6 D5 MR
Schematics UART A
3.3V 6 8 C2 12 C1- V+ 11 +
12 7 D6 OUT1* 38 VCC=5V
7 9 37 1 =1 + 13 C2+ 15
46 VCC=3.3V 10 D7 DTR* 36 2 IC6 3 V- F1
13 8 1 =1 RCLK IC10 RTS* 14 C2- GND 8 P2 9PIN DSUB
RESET_N 2 3 RESET 11 AHCT86
47 9 IC5 SIN OUT2* 35 2 F2
14 AHC86
12 NC 34 VCC=5V
5 T1IN T1OUT RS232 RS422 RS485
10 13 NC 33 INTA 4 =1 DTRA_N 18 T2IN T2OUT 1
48 14 SOUT 16C550 INTRPT 32 5 IC6 6 RTSA_N 19 T3IN T3OUT 24 F3 1 +5V
15 11 VCC=3.3V CS0
12 1 15 RXRDY* 31 1 AHCT86 21 T4IN T4OUT 20 2 TXD +TXD +DATA
49 1 CS1
2 IC4 3 CSA_N 16 A0 30 2 67 R1OUT R1IN F4 3 RXD +RXD
16 12 CS2* A1 29
AHC32 17 3 43 R2OUT R2IN 4 DSR
50 13 BAUDOUT* A2 22 R3OUT R3IN 23 F5 5 GND GNDE GNDE
17 VCC=3.3V 17 R4OUT R4IN 16 6 DTR
51 14 11 4
1 F6 7 CTS -RXD
18 15 5 IC4 6 CSB_N
8 RTS -TXD -DATA
XIN
XOUT
WR1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
52 AHC32 F7
19 1 3.3V 9
2 VCC=3.3V
MTG1
18
19
21
22
23
25
26
27
28
53 INTA 9 J1 F8 MTG2
20 3 1
4
INTB 10 IC4 8 1
54 AHC32 RS485
21 2 GND-SHIELD
55 5
WR_N 20
RD_N 24
22 6 VCC=3.3V VCC=5V 5V RS422
7
9 =1 9 =1
1 A J2
56 10 IC5 8 INT_N 10 IC6 8 TXDA IC12 2B C
23 8 MAX1490 3
AHC86 AHCT86 1 VCC1 AC1 24
57 5V 2 VCC2 AC2 23
24 9 VCC=3.3V
=1 12 RXDA 3 D1 IVCC1 22
58 10 11 13 4 21 R16
11 IC5 D2 IRCDRV J3
25 AHC86 5 GND1 A 20 1 TERM.REC.
59 12 R1 R2 R3 3.3V R4 6 19 2
FS B R17
26 7 SD Z 18 J4
60 IC3 8 VCC3 Y 17 1
4
27 R9 9 16 2 TERM.TRA.
SDA VCC DI ICOM1
61 10 VCC4 IDIDRV 15
28 1.8432MHZ 11 RO IVCC2 14
62 SCL CLK 12 13
SA1 1 NC/EN_N OUT 3 GND2 IRLED
29
63 RESET_N 5V GND
2
30 CS_N RS485
64 INT_N
31 IC1 IC13
MAX1480
65 1 VCC1 AC1 28
32 2 VCC2 AC2 27
66 1 A0 VCC 8 3 D1 IVCC1 26
33 2 A1 WP 7 4 D2 B 25
3 6 5 24 R15
67 A2 SCL GND1 IRCDRV
34 4 GND SDA 5 6 FS A 23
7 22 R12
68 SD IDIIN
5V 8 VCC3 IDEIN 21
9 DI ICOM1 20
VCC=5V
1-971642-26 Double Serial Interface Board; Schematics 1

5V 3.3V 12 =1 10 VCC4 IDIDRV 19
IC2 R10
485_DIR
13 IC6 11 11 DE IVCC2 18
3 2 AHCT86 12 17 R13
VIN VOUT GND2 IDEDRV
C50 + 3.3V 13 RO_N ICOM2 16
C51 C52 C53 C54 C55 C56 C57 C30 C31 C32 C33 C34 C35 C36 14 15 R14
GND VCC5 IRLED
R11
1
UARTA CONFIGURATION
RS232: IC11, J2A
RS422: IC12, J3, J4
RS485: IC13, J1, J4*
*: IF END OF CABLE

5V
R21 R22
3.3V
D<15..0> DCDB_N R24
4
3
2
1
0
A<12..1> VCC=3.3V
=1 1 DSRB_N
32 IC7 R23
5V
6
5
4
3
2
1
44
43
42
41
40
AHC86
3.3V VCC=3.3V
RS232
=1 4 CTSB_N C10
IC21 C12
D4
D3
D2
D1
D0
NC
65 IC7 +
MAX238 +
VCC
RI*
AHC86
DCD*
DSR*
CTS*
5 7 39 10 C1+ VCC 9 C13 5V_EXT
6 8 D5 MR 38 C11 12 C1- V+ 11 +
D6 OUT1* VCC=5V
7 9 37 1 +
D7 DTR* 1 13 C2+ V- 15
10 36 2 IC8 3 8 F9
RCLK IC20 RTS* 14 C2- GND P3 9PIN DSUB
11 35 AHCT32
12 SIN OUT2* 34 5 T1IN T1OUT 2 F10
Schematics UART B
NC NC VCC=5V RS232 RS422 20MACL

13 33 4 DTRB_N 18 T2IN T2OUT 1
SOUT INTRPT 1
14 16C550 32 5 IC8 6 RTSB_N 19 T3IN T3OUT 24 F11 1 +5V
15 CS0 RXRDY* 31 1 AHCT32 21 T4IN T4OUT 20 2 TXD +TXD TXDIN
CSB_N 16 CS1 A0 30 2 67 R1OUT R1IN F12 3 RXD +RXD RXDIN
17 CS2* A1 29 3 43 R2OUT R2IN 4 DSR
BAUDOUT* A2 22 R3OUT R3IN 23 F13 5 GND GNDE
17 R4OUT R4IN 16 6 DTR
F14 7 CTS -RXD RXDOUT
8 RTS -TXD TXDOUT
XIN
XOUT
WR1*
WR2
VSS
NC
RD1*
RD2
DDIS
TXRDY*
ADS*
F15 9
3.3V RS422 MTG1
18
19
20
21
22
23
24
25
26
27
28
CLK 20MACL 5V F16 MTG2
IC22
WR_N J5 1 DS2981
2 1 5 GND-SHIELD
VCC DO-

RD_N 2 RO DO+
6
VCC=3.3V
=1 9 RXDB 3 7 1 A J6
CL_EN_N
DI RI-
8 IC7 10 4 GND RI+
8 2B C
AHC86 3
INTB
RESET R31
5V 1 J7
2 TERM.REC.
VCC=3.3V R32
12 =1 J8
VCC=5V R27 1
13 IC7 11 9 20MACL
1 2 TERM.TRA.
AHC86 10 IC8 8
AHCT32 IC23
8
VCC=5V
12 2 J9
1 R30
13 IC8 11 TXDB 7
5V 3.3V AHCT32 1 A CURR-FEED
3 6 TRANSM.
R20
2 B
6N139
5 3 C
C60 C61 C62 C63 C64 C40 C41 C42 5V 4
IC24 J10
R25 8 CURR-FEED
2 R29 1 A
2 B RECEIVER
7
R28
3 C
6 D1 4
3
1-971642-26 Double Serial Interface Board; Schematics 2

R26 5 6N139
UARTB CONFIGURATION
+24VI R19
C
RS232: IC21, J6A

RS422: IC22, J6B, J7, J8 Z1
R33 10V
A
20MACL: IC23, IC24, J5, J9*, J10*

R34
C
Z2
PASSIVE=B, ACTIVE=A+C R35 10V
A
193
16.8 IEEE 1284 Parallel Interface Board

Description
The IEEE 1284 Parallel Interface Board is an optional device for Easy-
Coder PX4i and PX6i printers. It provides these printers with one parallel
interface port and is supported by both Fingerprint and IPL.
The parallel communication port is addressed in Intermec Fingerprint as
device centronics: (communication channel 4). The board is IEEE1284-I
compatible. Nibble Mode and device ID is supported. Byte, ECP, and EPP
modes from printer to host are presently not supported.
The IEEE 1284 Parallel Interface kit contains:
• One Parallel Interface Board
• Two flat cables
• One Installations Instructions booklet.
There are neither any straps nor any other types of physical configuration
on this interface board, nor any options in the Setup Mode.
IEEE 1284 interface

("centronics:")

The IEEE 1284 board has a standard 36pin IEEE 1284 B socket with the
following configuration:
Pin Signal Remark

1 DSTROBE
2 DATA 0
3 DATA 1
4 DATA 2
5 DATA 3
6 DATA 4
7 DATA 5
8 DATA 6
9 DATA 7
10 ACK
11 BUSY
12 PE
13 SELECT
14 AF
15 N/C
16 GND
17 SCREEN
18 External +5VDC max 500 mA (automatic switch-
off at overload, short-circuit protected)
19 GND
20 GND
20 GND
21 GND
22 GND
23 GND
24 GND
25 GND
26 GND
27 GND
28 GND
29 GND
30 GND
31 INIT
32 ERROR
33 N/C
34 N/C
35 N/C
36 SELECTIN

Components
1-971641-02 P01
F18
F17
R17
F16
R16
F15
R11
F14
R10
F13
R15
F12
R14
F11
R13
F10
R12
F8
R8
F7
R7
F6
R6
R18
F5
R5
F4
IC5
R4
C1 C2
F3
R3
F2
R19
R2
C13
F1 P1
IC3
R1
P3 F9
R9 D1
C9 C3
F19 C11
IC1
C8
IC4
C14
C10
C5
IC6
C6 C7
C4
R20
IC2
C12
R22
R21
1-971641-27 IEEE 1284 Parallel Interface Board; Component side

CABLE ASSEMBLY
D1 40-PIN RIBBON CABLE
3.3V CONNECTOR -> 36-PIN
5V CENTRONICS CONN.
P1 R9 R1 R2 R3 R4 R5 R6 R7 R8 R12 R13 R14 R15 R10 R11 R16 R17 40-PIN - 36-PIN
1 IC4 3.3V
35 VCC P3
2 OSC. F9 1 STROBE 1
36 1 3 2 GND 19
3 NC/EN_N OUT
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
F1 3 DATA0 2
37 WAIT_N GND
4 4 GND 20
F2 5 DATA1 3
24
38 RD_N
5 6 GND 21
F3 7 DATA2 4
DONE
GND6
IO47
IO46
IO45
IO44
IO43
IO42
IO41
IO40
IO39
GND5
VCC5
IO37
IO36
IO35
IO34
IO33
IO32
IO31
IO30
Schematics
39 WR_N
6 8 GND 22
D<15..0> F4 9 DATA3 5
40 51 25
PWRDWN_N
0 VCC6 VCC4 10 GND 23
GCK4/IO48
GCK3/IO29
7 RESET_N 52 PROG_N M0 24 F5 11 DATA4 6
41 1 53 23
INIT_N/IO38
8 IO49 GND4 12 GND 24
54 IO50/GCK5 M1 22 F6 13 DATA5 7
42 2 55 21 STROBE
3 INT_N IO51 GCK2/IO28 14 GND 25
9 CS_N 56 IO52 IO27 20 CD0 F7 15 DATA6 8
43 A<12..1> 57 IO53 IO26 19 CD1 16 GND 26
10 4 58 18 CD2
12 IO54 IO25 F8 17 DATA7 9
44 5 59 17 CD3
11 IO55 IO24 18 GND 27
11 10 60 IO56 IO23 16 CD4 F10 19 ACK 10
45 6 61 15 CD5
9 IO57 IO22 20 GND 28
12 7
8 62 IO58 IO21 14 CD6 F11 21 BUSY 11
46 63 VCC7 XCS05XL-4 IO20 13 CD7 22 GND 29
13 8 64 GND7 VCC3 12 F12 23 PERROR 12
47 9 65 11
7 IO59 IC1 GND3 24 GND 30
14 6 66 IO60 IO19 10 ACK F13 25 SELECT 13
48 10 67 9 BUSY
5 IO61 IO18 26 INIT 31
15 11
4 68 IO62 IO17 8 PERROR F14 27 AFEED 14
49 3 69 IO63 IO16 7 SELECT 28 ERROR 32
16 12 70 6 AFEED
2 IO64 TMS/IO15 F15 29 15
50 13 71 5 INIT
1 IO65 TCK/IO14 30 33
17 0 72 IO66/DIN TDI/IO13 4 ERROR F16 31 GND 16
51 14 VCC=3.3V
CS_N 2 73 IO67/DOUT IO12 3 SELIN 32 34
18 15 1
F17

WR_N 14 74 CCLK GCK1/IO11 2 33 SCREEN 17
52 IC6 75 VCC8 GND2 1 5V 34 35
19 1 IC5 F18
2 AHC1G32 35 EXT-5V 18
53 POWER_SWITCH 36 SELIN 36
20 3 1 GND OUT 8 F19
54 4 2 7 3.3V 37
IN OUT 38
21 3 IN OUT 6
R19 R18 39
O/TDO
GND8
IO68
IO69/GCK7
IO70/CS1
IO71
IO72
IO73
IO74
IO75
IO76
IO77
GND1
VCC1
IO1
IO2
IO3
IO4
IO5
IO6
IO7
IO8
IO9
IO10/GCK8
VCC2
55 5 4 EN_N OC_N 5
22 6 40
56 7 MAX1607
8 5V_EXT_EN_N C
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
23
100
57 5V BR1
MTG1
24 9
MTG2
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
58 10
25 11
59 12 R20 R21 R22 BR2
WR_N
26 MTG1
RD_N OVERCURRENT_N
60 MTG2
27 WAIT_N
61 SDA
28 BR3
SCL MTG1
62 MTG2
29 SA1
63 RESET_N 5V
30 CS_N
64 INT_N
1-971641-27 IEEE 1284 Parallel Interface Board; Schematics

31 IC2
65
32 5V IC3 3.3V
66 1 A0 VCC 8
33 2 A1 WP 7 32 VIN
67 3 A2 SCL 6 + C14 3.3V
4 5 C11 C12 C13 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10
34 GND SDA GND
68
197
16.9 EasyLAN Ethernet Interface Board

Description
This section describes how to install an EasyLAN Ethernet network inter-
face in an EasyCoder PX4i and PX6i printer and how to connect it to a
100base TX Fast LAN, WAN, Intranet, or Internet network via a wired
connection.
The installation instructions describes how to physically install the inter-
face board in a printer. Configuration and setup are described in the
EasyLAN Interface Kit, Installation Instructions and the Intermec EasyLAN,
User’s Guide on the attached CD-ROM.
This interface kit must only be physically installed by an authorized
service technician.
Printer Firmware
The printer must either be fitted with Intermec Fingerprint v8.30 (or
later) or IPL v2.30 (or later). In Intermec Fingerprint, the network port is
addressed as device "net1:" (communication channel #5).
Installation Kit
The EasyLAN Interface Kit contains:
• One EasyLAN interface board
• One light guide
• One hexagonal threaded spacer
• One network extension cable
• One cable tie
• One serial number label
• One CD-ROM with software and manuals
The only tool required for the installation is a #T20 Torx screwdriver.

Installation Instructions
Also see illustration on the next page.
• Switch off the printer and disconnect the power cord.
• Disconnect all communication cables.
• Remove the LAN connector plug, which is snap-locked at the top of the
rear plate.
• Remove the #T20 Torx screw that holds the upper/front part of the
CPU board to the power supply unit and replace it with the hexagonal
LAN connector plug spacer included in the kit. Keep the screw.
• Connect the EasyLAN board to the PCI connector (J84) on the CPU
board so the hole in the interface board becomes aligned with the spacer.
• Secure the EasyLAN board with the #T20 Torx screw you previously
removed.
• From the inside of the electronics compartment, press the metal socket
of the network extension cable into the square hole in the rear plate
(where you removed the LAN plug) until it is held by its snap-lock.
• Route the extension cable over the SIMMs on the CPU board and con-
nect it to the RJ-45 socket on the EasyLAN interface board (J2).
• From the outside, insert the thin end of the light guide through the
small hole next to the RJ-45 socket on the rear plate. Press the clear plas-
tic “lamp” in place. Connect the other end to the black plastic socket
(D1) on the EasyLAN interface board.
• Pull the cable tie through the hole in the upper edge of the CPU board
between the SIMMs and the RTC socket. Secure both the extension
cable and the light guide with the cable tie.
• Fit the serial number label on the rear plate to the left of the RJ-45
socket.
• Put back the left-hand cover. Route the cable from the display unit
above the ribbon motor. Connect the cable to connector J50 at the
upper front corner of the CPU board.
• Enter the Setup Mode and print the test label “Hardware Info” in Fin-
gerprint or “HW” in IPL to see if the printer detects the EasyLAN Eth-
ernet interface board. For information on how to enter the Setup Mode
and print test labels, refer to the User’s Guide for the printer in question.
• After startup, enter the Setup Mode to set up the network parameters.
See Appendix A. Setting the network parameters in IPL, when the server
does not support DHCP or BOOTP, is described in EasyLAN Interface
kit, Installation Instructions.

Network extension cable Cable tie Light guide #T20 Torx screw
and spacer
RJ-45 Ethernet
connector
EasyLAN Ethernet
interface board
RJ-45 Ethernet connector

("net1:")
Serial number label (MAC address)

Components
J2
C33
C39
Y2
C25
L2
L3
R12 C7 C4
D1
C27
R13 C28
C34
M1
R1
C26
C17 C6 C15 C5 C14 R9
C23
R4
IC2
R11
C29 R7
C22
C31
R6 R8
R5 C30
C24
C20
L1
IC1
C21
C10
C11
C3
C18
IC3
Y1
C13
C1
C32
C2
C38
C37
C36
R3
R2
C19 C35 C16

C12
1-971645-26 EasyLAN Interface Board; Component side
J1
1-971645-26 EasyLAN Interface Board; Soldering side

L2+C17 ONLY POPULATED Y2
3.3V C27 C28
FOR DP83815
202
PCI_AD(31..0) L2 L3 25MHZ 3.3V
C17
5V
PIN19
1
2
D1
0 1 PCI_AD0 SCA80 PCI_AD1 41 1
36
35
34
33
32
27
26
21
20
19
18
17
16
9
8
7
6
5
4
3
2
1
31
30
29
28
25
24
23
22
15
14
13
12
11
10
2 VSS1 PCI_AD2 42 2 R4=9K31 FOR
3
4
3 3 PCI_AD3 VCC1 43 DP83815 AND
4 4 PCI_AD4 PCI_AD5 44 5 R4=10K FOR
C1
X2
X1
6 5 PCI_AD6 7 PCI_AD7 45 DP83816
CRS
MDC
MA5
6 46 PCI_CBE0_N 37 144 R9
Schematics
VSS2 PCI_CBE_N0 SUBGND1/NC83816 MA2/LED100_N
TXEN
RXOE
MDIO
NC_34
TXCLK
VSS_8
RXCLK
8 7 PCI_AD8 VCC2 47 38 VSS_38 MA1/LED10_N 143
VSS_35
VSS_32
VSS_26
VSS_20
VSS_16
9 8 48 10 RXAVDD 39 142 R11
PCI_AD9 PCI_AD10 AUXVDD_39 MA0/LEDACT_N
COL/MA16
RXD3/MA9
RXD2/MA8
RXD1/MA7
AUXVDD_9
RXD0/MA6
MA3/EEDI
11 9 PCI_AD11 PCI_AD12 49 12 40 VREF MD7 141
AUXVDD_33
AUXVDD_27
TXD3/MA15
TXD2/MA14
TXD1/MA13
TXD0/MA12
AUXVDD_21
RXDV/MA11
RXER/MA10
MA4/EECLK
10 VSS3 PCI_AD13 50 13 41 RESERVED_41 MD6 140
14 11 PCI_AD14 VCC3 51 42 NC_42 MD5 139
15 12 52 PCI_CBE1_N R4 43 138
PCI_AD15 PCI_CBE_N1 NC_43 MD4/EEDO
FXVDD/NC83816
PCI_PAR 13 PCI_PAR PCI_SERR_N 53 PCI_SERR_N 44 VSS_44 AUXVDD_137 137
14 VSS4 PCI_PERR_N 54 PCI_PERR_N TPRDM 45 TPRDM VSS_136 136
15 PCI_LOCK_N VCC4 55 TPRDP 46 TPRDP MD3 135
PCI_STOP_N 16 PCI_STOP_N PCI_DEVSEL_N 56 PCI_DEVS_N RXAVDD 47 AUXVDD_47 MD2 134

PCI_TRDY_N 17 PCI_TRDY_N PCI_IRDY_N 57 PCI_IRDY_N REGEN 48 REGEN DP83815/6 MD1/CFGDIS_N 133
18 VSS5 PCI_FRAME_N 58 PCI_FRAME_N 49 VSS_49 MD0 132 3.3V
PCI_CBE2_N 19 PCI_CBE_N2 VCC5 59 50 RESERVED_50 TQFP144 MWR_N 131
16 20 PCI_AD16
J1 PCI_AD17 60 17 51 VSS_51 MRD_N 130 IC2
18 21 PCI_AD18 PCI_AD19 61 19 52 VSS_52 MCS_N 129 VCC 8
22 VSS6 PCI_AD20 62 20 TPTDM 53 TPTDM EESEL 128 1 CS EEPROM
21 23 PCI_AD21 VCC6 63 TPTDP 54 TPTDP RESERVED_127 127 2 SK
22 24 PCI_AD22 PCI_AD23 64 23 55 VSS_55 IC1 SUBGND3/NC83816 126 3 DI DO 4
PCI_CBE3_N 25 PCI_CBE_N3 PCI_AD24 65 24 56 AUXVDD_56 MACVDD2/NC83816 125 6 ORG/NC
26 VSS7 PCI_AD25 66 25 57 VSS_57 MACVSS2/NC83816 124 7 NC
26 27 PCI_AD26 VCC7 67 58 AUXVDD_58 PWRGOOD 123 GND 5
27 28 PCI_AD27 PCI_AD28 68 28 59 PMEN/CLKRUN_N 3VAUX 122
29 29 PCI_AD29 PCI_AD30 69 30 PCI_CLK2 60 PCICLK AD0 121 0
30 VSS8 PCI_AD31 70 31 PCI_INT_N 61 INTA_N AD1 120 1
PCI_REQ_N 31 PCI_REQ_N0 VCC8 71 PCI_RST_N 62 RST_N AD2 119 2
PCI_GNT_N 32 PCI_GNT_N0 PCI_CLK 72 PCI_CLK1 PCI_GNT_N 63 GNT_N AD3 118 3
PCI_INT_N 33 PCI_INT_N PCI_REQ_N2 73 PCI_REQ_N 64 REQ_N PCIVDD_117 117
34 VSS9 PCI_RST_N 74 PCI_RST_N 65 VSS_65 AD4 116 4
35 TCK VCC9 75 31 66 AD31 AD5 115 5
36 TMS NC1 76 + C12 30 67 AD30 VSS_114 114
37 TDO SCL 77 29 68 AD29 AD6 113 6
38 VSS10 SDA 78 69 PCIVDD_69 AD7 112 7 C39 ONLY POPULATED
39 TDI PCI_DET_N 79 28 70 AD28 CBEN0 111 PCI_CBE0_N FOR DP83816
40 TRST_N 24V 80 27 71 AD27 AD8 110 8
26 72 AD26 AD9 109 9 3.3V
C39
REGEN +
AD12
AD11
AD25
AD24
CBEN3
IDSEL
VSS_77
AD23
AD22
PCIVDD_80
AD21
AD20
AD19
VSSIO4/NC83816
VDDIO4/NC83816
AD18
AD17
AD16
CBEN2
VSS_90
FRAME_N
IRDY_N
TRDY_N
PCIVDD_94
DEVSEL_N
STOP_N
PERR_N
SERR_N
PAR
CBEN1
AD15
AD14
VSS_103
AD13
PCIVDD_107
AD10
84
90
91
73
74
75
76
77
78
79
80
81
82
83
85
86
87
88
89
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
3.3V
NORMALLY UNPOPULATED
C34
4
Y1
VCC R2 PCI_CLK1
32.768MHZ
1 EN/NC OUT 3 C
GND R3
PCI_CBE3_N
PCI_CBE2_N
PCI_FRAME_N
PCI_IRDY_N
PCI_TRDY_N
PCI_DEVS_N
PCI_STOP_N
PCI_PERR_N
PCI_SERR_N
PCI_PAR
PCI_CBE1_N
PCI_CLK2
25
24
11
23
22
21
20
19
18
17
16
15
14
13
12
11
10
2
M1
1 TD- TX- 16 TX-
5V 3.3V R5 J2
TPTDM 2 TDCT TXCT 15 R12
C35 1 TX+
RXAVDD 2 TX-
C36 AC RETURN PATHS 3 TD+ TX+ 14 TX+ 3 RX+
1-971645-26 EasyLAN Interface Board; Schematics

FOR PCI SIGNALS 4 NC1 NC4 13 4
CROSSING 5V TO 3.3V TPTDP R6 5 12
C37 NC2 NC3 5
BOUNDARY 6 RD- 1CT:1CT RX- 11 RX- 6 RX-
C38
BYPASS CAPACITORS 7
IC1 R7 8
TPRDM 7 RDCT RXCT 10 R13 MTG1
RX+ MTG2
3.3V PINS
C33 MTG3
8 RD+ RX+ 9 MTG4
3.3V 69/80 94/107 117 IC2 Y1
IC1 3.3V 3.3V TPRDP R8 C29 C30 C31 RJ45
PINS C13 C16 C18 C20 C32 NORMALLY
5V 3.3V UNPOPULATED
C4 C5
21 R1
IC3 L1 R1=0OHM C
3 2 ONLY POPULATED
VIN VOUT IC1 FOR DP83815
C1 C2 + C3
GND C6 C7 RXAVDD PIN19
33 3.3V PINS
C23 C24 C25 + C26
1
9 27 85 125 137
C10 C11 C14 C15 C19 C21 C22

56/58

16.10 EasyLAN Wireless Interface Board

Description
This section describes how to install an EasyLAN Wireless network inter-
face in an EasyCoder PX4i and PX6i printer and how to connect it to a
LAN, WAN, Intranet, or Internet network via a wireless connection.
The installation instructions describes how to physically install the inter-
face board in a printer. Configuration and setup are described in the
EasyLAN Wireless Kit, Installation Instructions and the Intermec EasyLAN,
User’s Guide on the attached CD-ROM.
This interface kit must only be physically installed by an authorized
service technician. The device is country/region specific and must be
ordered for the correct country/region. Use of this device in other region
than shown on the device home page/test label may violate applicable
law.
Printer Firmware
The printer must either be fitted with Intermec Fingerprint v8.30 (or
later) or IPL v2.30 (or later). In Intermec Fingerprint, the network port is
addressed as device "net1:" (communication channel #5).
Installation Kit
The EasyLAN Interface Kit contains:
• One EasyLAN adapter board complete with radio module fitted
• Rear plate (for EasyCoder PF2/4i-series printers only)
• RJ-45 plug (for EasyCoder PM4i, PX4i, and PX6i only)
• One light guide
• One hexagonal threaded spacer
• One antenna extension cable
• One antenna
• One cable clip
• One cable tie
• One CD-ROM with software and manuals
The only tools required for the installation are #T10 and #T20 Torx screw-
drivers and a small wrench.

Installation Instructions
• Switch off the printer and disconnect the power cord.
• Disconnect all communication cables.
• Remove any present EasyLAN Ethernet interface including cables etc.
Fit the RJ-45 plug included in the kit into the square hole left by the
RJ-45 Ethernet connector.
• Remove the antenna plug, which is snap-locked into the rear plate.
• Connect the antenna cable to the radio module, which is factory-fitted

on the EasyLAN adapter board, as illustrated below. Support the upper
edge of the radio module with a finger while connecting the cable.
Adapter board
Connect antenna
cable here
Radio module
• Remove the #T20 Torx screw that holds the upper/front part of the
CPU board to the power supply unit and replace it with the hexagonal
spacer included in the kit. Keep the screw.
• Connect the EasyLAN adapter board to the PCI connector (J84) on the
CPU board so the hole in the board becomes aligned with the spacer
and secure the board with the #T20 Torx screw.
• Route the antenna cable over the SIMMs on the CPU board towards
the rear plate and secure it using the cable clips included in the kit.
One clip is factory-fitted on the EasyLAN adapter board and the other
should be fitted in the small hole at the top of the CPU board immedi-
ately to the rear of the memory SIMM sockets.
• From the inside of the electronics compartment, insert the antenna
connector through the round hole in the rear plate and lock it with the
washer and nut on the outside.

• Fit the antenna to the connector of the antenna cable and bend the
hinge so the antenna points straight up.
• From the outside, insert the thin end of the light guide through the
small hole next to the antenna on the rear plate. Press the clear plastic
“lamp” in place. Connect the other end to the black plastic socket (D1)
at the top of the EasyLAN adapter board. Secure it with the cable tie
through the hole at the upper edge of the CPU board.
• Put back the left-hand cover. Route the cable from the display unit
above the ribbon motor. Connect the cable to connector J50 at the
upper front corner of the CPU board.
• Enter the Setup Mode and print the test label “Hardware Info” in
Fingerprint or “HW” in IPL to see if the printer detects the EasyLAN
Wireless interface board. For information on how to enter the Setup
Mode and print test labels, refer to the User’s Guide for the printer in
question.
• Set up the network parameters. There are several methods:
- Connect the printer and a PC and run the EasyLAN Network Setup
wizard, which can be found on the attached CD-ROM. Requires a
PC running Windows 98 or later.
- Insert a CompactFlash Card containing a configuration file in the
printer and start it up. Configuration Compact Flash cards can be
created using the EasyLAN Network Setup wizard on the attached
CD-ROM.
- Fingerprint:
Establish an RS-232 communication with the printer and set it up
using Fingerprint setup strings or setup files. IP address, netmask,
default router, and name server can also be set using the printer’s
built-in keyboard. Only requirement on the PC side is a terminal pro-
gram that can transmit and receive ASCII characters on an RS-232
line. See EasyLAN Wireless Kit, Installation Instructions.
- IPL:
Establish an RS-232 communication with the printer and set it up
using IPL commands. Only requirement on the PC side is a terminal
program that can transmit and receive ASCII characters on an RS-
232 line. Select the method of obtaining IP address, netmask, default
router, and name server automatically from the server using the print-
er’s built-in keyboard. This requires a server that supports DHCP
and/or BOOTP. See EasyLAN Wireless Kit, Installation Instructions.

Cable tie Cable clips Light guide #T20 Torx screw

and spacer
Antenna cable
Antenna
EasyLAN
adapter board
Antenna
(packed separately when the EasyLAN Wireless
interface is factory-installed)

Components
D1 C11
C11
R28
R28
C12
C12
R7
R6
R5
R9
R4
R8
R7
R6
R5
R9
R4
R8
R29
R29
IC2
IC2
R30
R30
R27
R27 R26
R26 C5
C5
C1
C1
R19
R18
R20
R21
R22
R23
R25
R24
R19
R18
R20
R21
R22
R23
R25
R24
C2
C2
C9
C9 C6
C6
J1
C10
C10
IC1
IC1
Y1
Y1
R1
R1
R2
R2
C7
C7
C3
C3
C4
C4
C8
C8
R12
R12 R17
R17
R15
R15 R11
R11
1
R13
R13 R14
R14 R16
R16
2 4 124
J2
J2
1 3 123
L1
Primary Side Secondary Side
1-971646-26 Adapter Board

Schematics
PRINTER PCI INTERFACE MINI-PCI INTERFACE
PCI_AD(31..0)
5V
0 1 PCI_AD0 PCI_AD1 41 1 3.3V 3.3V

2 VSS1 PCI_AD2 42 2
3 3 PCI_AD3 VCC1 43
4
6
4
5
6
PCI_AD4
PCI_AD6
PCI_AD5
PCI_AD7
44
45
46
5
7
CBE0_N
J2
VSS2 PCI_CBE_N0 1 2
8 7 PCI_AD8 VCC2 47 3 4
9 8 PCI_AD9 PCI_AD10 48 10 5 6
11 9 PCI_AD11 PCI_AD12 49 12 7 8
10 VSS3 PCI_AD13 50 13 9 10
14 11 PCI_AD14 VCC3 51 LED1_GRNP 11 12 LED2_YELP 5V
15 12 PCI_AD15 PCI_CBE_N1 52 CBE1_N LED1_GRNN 13 14 LED2_YELN
PAR 13 PCI_PAR PCI_SERR_N 53 SERR_N 15 16
14 VSS4 PCI_PERR_N 54 PERR_N 17 18
15 PCI_LOCK_N VCC4 55 19 20 INT_N
STOP_N 16 PCI_STOP_N PCI_DEVSEL_N 56 DEVSEL_N 21 22
TRDY_N 17 PCI_TRDY_N PCI_IRDY_N 57 IRDY_N C 23 24
18 VSS5 PCI_FRAME_N 58 FRAME_N CLK2 25 26 RST_N
CBE2_N
16
19
20
PCI_CBE_N2
PCI_AD16
J1 VCC5
PCI_AD17
59
60 17 REQ_N
27
29
28
30 GNT_N
18 21 PCI_AD18 PCI_AD19 61 19 31 32
22 VSS6 PCI_AD20 62 20 31 33 34
21 23 PCI_AD21 VCC6 63 29 35 36
22 24 PCI_AD22 PCI_AD23 64 23 37 38 30
CBE3_N 25 PCI_CBE_N3 PCI_AD24 65 24 27 39 40
26 VSS7 PCI_AD25 66 25 25 41 42 28
26 27 PCI_AD26 VCC7 67 43 44 26
27 28 PCI_AD27 PCI_AD28 68 28 CBE3_N 45 46 24
29 29 PCI_AD29 PCI_AD30 69 30 23 47 48 11
30 VSS8 PCI_AD31 70 31 49 50
REQ_N 31 PCI_REQ_N0 VCC8 71 21 51 52 22
GNT_N 32 PCI_GNT_N0 PCI_CLK 72 CLK1 19 53 54 20
INT_N 33 PCI_INT_N PCI_REQ_N2 73 55 56 PAR
34 VSS9 PCI_RST_N 74 RST_N 17 57 58 18
35 TCK VCC9 75 CBE2_N 59 60 16
36 TMS NC1 76 IRDY_N 61 62
37 TDO SCL 77 63 64 FRAME_N
38 VSS10 SDA 78 CLKRUN_N 65 66 TRDY_N
39 TDI PCI_DET_N 79 SERR_N 67 68 STOP_N
40 TRST_N 24V 80 69 70
PERR_N 71 72 DEVSEL_N
CBE1_N 73 74
14 75 76 15
77 78 13
12 79 80 11
10 81 82
83 84 9
8 85 86 CBE0_N
5V 3.3V 7 87 88
89 90 6
IC1 5V 5 4
91 92
3 2 93 94 2
VIN VOUT
+ C1 C2 C3 + C4 3 95 96 0
GND 97 98
1 99 100
101 102
1
AC_SYNC 103 104

AC RETURN PATHS 105 106 AC_SDATA_OUT
FOR PCI SIGNALS AC_BIT_CLK 107 108 AC_CODEC_ID0_N
CROSSING 5V TO 3.3V AC_CODEC_ID1_N 109 110 AC_RESET_N
BOUNDARY 111 112
113 114
115 116
5V 3.3V 117 118
3.3V
C5 119 120
121 122
123 124
C6
4
Y1 MTG1
VCC R1 MTG2
CLK1
C9 C10 C7
32.768MHZ
1 EN/NC OUT 3
GND R2 CLK2 C8 C
2
LED BLINK ONE-SHOT CIRCUIT
LED_LINKP
3.3V
COLOR SWITCH
RESISTORS R29 LED_ACTP LED_LINKP R7
SOURCE SIDE
LED_ACTP R4 R8
5V
R18
IC2
LED2_YELP
2
1
C11 AHCT123
R19 + 14 D1
R26 GREEN/YELLOW
CEXT
R20 R28 15
REXT/CEXT
3
4
LED1_GRNP R21 1 13
A Q R9 R5
LED_ACTN
2
B 4 LED_LINKN R6
Q
3
CLR
LED1_GRNN R22
VCC=5V;GND=GND
R23 R27
R24 R26 OR R27

ONLY
R25 POPULATED ONLY IC2 OR
LED2_YELN IF IC2 R29 OR R30
POPULATED POPULATED
R30 LED_ACTN
COLOR SWITCH
RESISTORS
SINK SIDE
LED_LINKN
TERMINATION OF UNUSED
MINI-PCI SIGNALS
DECOUPLING IC2
3.3V
R11 UNUSED PART
AC_CODEC_ID0_N 5V
R12 C12
AC_CODEC_ID1_N IC2
CLKRUN_N R13 AHCT123
6
AC_SYNC R14 CEXT
7
AC_BIT_CLK R15 REXT/CEXT
9 5
R16 A Q
AC_SDATA_OUT DO NOT POPULATE
10
AC_RESET_N R17 L1 B 12
Q
11
CLR
VCC=5V;GND=GND
C
1-971646-26 Adapter Board

17 Troubleshooting
This chapter explains how to diagnose and fix troubles that may occur in
an EasyCoder PX4i or PX6i printer, even if great effort has been made to
safeguard troublefree printing. Some parts are, however, subject to wear
and may need periodical replacement, such as the printhead.
Please note that replacement parts are generally only available as complete
modules (see the Spare Parts Catalog or Spare Parts List).
This chapter is supplemented by the Technical Bulletins that are distrib-
uted as soon as any new problem has been reported and a remedy has been
found.
EasyCoder PX4i and PX6 Service Manual 209

Chapter 17 — Troubleshooting
17.1 Diagnosing
To diagnose the printer for faults, take steps in the following order:
• In case the printer is running the Intermec Fingerprint firmware, use
Intermec Shell to check printer’s setup and functions. Intermec Shell
can be accessed regardless of any running autoexec.bat files as described
below.
• Browse through the remainder of this chapter to find symptoms that
apply to the faulty printer.
• Refer to the Printer Technical Bulletins for updated information.
Fingerprint only
The keyboard, display messages, sounds, and other functions will be
custom-configured, if a custom-made program is running in the printer.
Normally, such a program is started at power-on using an autoexec.bat file.
The procedure of starting up Intermec Shell, bypassing any other auto-
exec.bat files the printer’s memory, is called the Test Mode. In fact, the
Test Mode is just a convenient way of accessing Intermec Shell and, via
Intermec Shell, also the Setup Mode.
Note: Any changes done in the Test Mode will remain after leaving the
Test Mode.
Entering Intermec Shell in the Test Mode

• Raise the printhead.
• Press any key on the printer’s built-in keyboard, with the exception of
<Shift>, and keep on pressing it.
• Switch on the power.
• The printer will start the initialization procedure.
• Release the key.
• The printer will start up Intermec Shell.
• Press <Enter> before the 5 sec. countdown is completed.
Inside Intermec Shell you have a variety of options, for example:
• Enter the Setup Mode to check or change the setup. Before changing
the setup, you should print out or write down the settings so you can
restore them before returning the printer.
• Make a printout of the present setup values.
• Perform testfeed operations.
• Print test labels to check the printout quality.
• Reset all setup values to default. Before resetting the setup, you should
print out or write down the settings so you can restore them before
returning the printer.
• Enter Intermec Fingerprint, for example to check what files the printer’s
memory contains or to list files.

• Restart the printer and leave the Test Mode.

Refer to the Intermec Shell Overview in Appendix 1 or in the User’s
Guide.
If the printer works normally in the Test Mode, it is likely that the mal-
function is either due to communication problems, abnormal conditions at
the site of operation, or a custom-made program.
Returning to Factory Default Setup ( Fingerprint and IPL)
There are four ways to return to the factory default setup of the printer:
A Insert a special CompactFlash memory card and restart the printer.
B Use the Default Setup option in Intermec Shell (Fingerprint only).
C Use the Memory Reset option in the Test/Service part of the Setup
Mode (IPL only).
D Use the printer’s built-in keyboard as described below:
1 Lift the printhead.
2 Switch on the power to the printer and press the key and wait until
the printer beeps.
3 Swiftly press the following keys:
<d> t <c/Esc> t <c/Esc> t <e>
4 The following message will be displayed:
Factory Default?
Enter=Yes ESC=No
5 Within 10 seconds, press <Enter> to reset the printer to factory default.
The parameters will be reset and the printer will continue the normal
startup.
If you press <c/Esc> or wait until the 10 seconds time-out has passed,
the normal startup will continue without any reset being performed.
Note: The factory default will remove all files used to store settings. It will
not reset settings that already has been read when the files are removed.
This means that EasyLAN Wireless settings (SSID, keys, etc.) will retain
their values from the previous start. However, the next reboot will reset
them to factory default.

Troubleshooting short-list (Fingerprint and IPL)

Use this short-list to find the symptom that applies to the printer:
Symptom See
• No reaction at power up 17.2
• Printer stops working after startup 17.3
• CPU board failures 17.4
• Power supply unit failures 17.5
• Driver board failures 17.6
• Console errors 17.7
• Error messages 17.8
• No communication (general) 17.9
• No serial communication 17.10
• Sensor malfunctions 17.11
- Label stop sensor
- Headlift sensor
- Label taken sensor
- Ribbon end sensor
• Printing troubles 17.12
- No printout at all
- Overall weak printout
- Weaker printout on either inner or other part of label
- Overall dark printout (bleeding)
- Weak or missing printout of some dots
- Unexpected black printout (completely or partially)
- Only first part of label printed
- Media feed does not work properly
• Ribbon troubles 17.13
- Transfer ribbon breaks
- Transfer ribbon wrinkles
- No transfer printout
• Liner takeup troubles 17.14
• Memory card troubles 17.15
• Paper cutter troubles 17.16

17.2 No Reaction at Power Up

Description:
There is no visible reaction when the power to the printer is switched on.
• The Power LED does not light up.
• There is no text in the display window.
Possible Causes and Suggested Remedies:
• No power in AC wall socket.
- Check with some other electrical device or a voltage meter.
• Power cord connectors not completely inserted in printer’s power cord
receptacle or in wall socket.
- Disconnect and firmly connect both ends of power cord. Try again.
• Faulty power cord.
- Replace and try again.
• Cables between power supply, driver board and CPU board not prop-
erly connected.
- Test as described in Chapter 17.5 using test points on CPU board
(see Chapter 15.5).
• Power Supply overload.
- Too high a temperature in the power supply unit. Leave the power
on and wait for the power supply to cool off (may take up to half
an hour). When the temperature returns to normal, the printer will
automatically restart. If the error persists, examine the power supply
as described in Chapter 17.5.
• Faulty power supply unit.
- Refer to Chapter 17.5.
• Faulty driver board.
• Faulty console unit.

17.3 Printer Stops Working after Startup

Description:
The printer stops working after a successful startup.
• The Power LED is lit.
• The <Feed>, <Setup>, and <Print> keys, work properly.
• Communication problems?
- Refer to Chapters 17.9-17.11.
• Printer malfunction?
- Check if the printer can print test labels in the Setup Mode.
Description:
• The Power LED is lit.
• There is no reaction on software commands.
• There is no reaction on any keys on the printer’s keyboard.
• The printer’s main program has halted due to high external disturbances
from other electrical sources.
- Restart the printer and find out if there are disturbances coming via
the AC supply, via a communication channel, or from other electrical
appliances.
• CPU board failures.
• Power Supply Unit failures.
• Driver board failures.
• Console errors.

Description:
• The Power LED is not lit.
• Error in the supply of AC power to the printer.
• Faulty console, faulty power LED, or faulty cabling between CPU
board and console.

17.4 CPU Board Failures

Description:
The power LED is lit, but the printer has one of the following faults:
• The printer refuses to start.
• The program execution is halted.
• The stepper motor does not work.
• At startup, the message “Starting” is displayed followed by the message
“Timed Out.”
• Flash or SDRAM SIMMs not properly fitted.
- A SIMM is not fully inserted in its socket. Remove all SIMMs and fit
them back again, making sure they are being firmly held by the snap-
locks.
• No Boot Flash SIMM in socket J20.
- A Flash SIMM containing a boot sector must be fitted in socket J20,
or the printer will not start.
• Fluttering voltages.
- Check voltages on the CPU board test points, see Chapter 13.4.
If a voltage flutters with an interval of approximately one second,
there may be a short-circuit on the CPU board. If a voltage is miss-
ing, there is probably an error in the power supply unit or the driver
board, see Chapters 17.5 and 17.6.
• Startup error.
- Execution of the initial boot sequence can be checked as described in
Chapter 15.5. If the execution stops prematurely, try changing to a
Flash SIMM that works in another printer. If that does not help, note
where the startup sequence is halted and contact Intermec’s Printer
Product Support dept.
- If there is no reaction neither on the display nor on the serial channel,
there is a major error on the CPU board. Check the Flash and
SDRAM SIMMs by installing them in another printer. Inspect the
CPU board visually in the area of the processor (U13) and the sup-
port chip (U30). If no obvious fault is detected, replace the CPU
board.

Description:
The power LED does not become lit when the power is switched on.
• Blown fuse.
- First check that the fault is not caused by an interruption of the 90-
265 VAC input voltage, a faulty power cord, or a disconnected power
cord.
- Inspect the fuse F70. If the fuse has blown and you are positively sure
that the fuse has blown because of a short-circuit of your own doing,
you can cut off the legs of the fuse and solder a new fuse in its place.
If the fuses blows again, replace the CPU board.

17.5 Power Supply Unit Failures

Description:
The printer refuses to print.
• The message “Temperature high please wait" (FP) or “Printhead hot”
(IPL) appears in the display window.
The power supply unit contains wires and circuits with dangerous
voltages. For safety reasons, it is strictly forbidden to try to repair a
power supply unit or to replace a blown fuse. Generally, in a primary-
switched power supply, a blown fuse is an indication that components
in the power supply has been damaged or degraded. Even if you could
get the power supply working by replacing a fuse, there is a risk that it
soon will fail again and more components will be damaged. Therefore,
whenever a fuse blows, always replace the entire power supply unit.
• Power Failure Interrupt signal activated because of a Power Supply
overload.
- Too high a temperature in the power supply unit, for example caused
by extreme ambient temperatures (possibly in connection with large
black areas in the print image, high speed printing, and media that
require a high energy level), triggers the automatic overheating pro-
tection switch.
Leave the power on and wait for the power supply to cool down (may
take up to half an hour). When the temperature returns to normal,
the printer will automatically restart. If the error persists, examine the
power supply (also see Chapter 13).
Description:
The printer stops working or functions are unstable.
• The power LED is unstable, weak or not lit..
• Wrong or missing 24 VDC voltage from power supply.
- Check the 24 VDC output on connector P2.
- Check the cables between the power supply unit, the driver board,
and the CPU board. If the cables are OK, try to find out whether
the power supply or driver board is faulty (also see Chapter 17.6).
Replace the faulty unit.
- If there is no 24 VDC and you can rule out that the PSU has been
shut down because of overheating (see above), check for a blown fuse
in power supply. If any of the fuses F1 or F2 has blown, replace the
entire power supply unit. Do not replace a blown fuse and do not
attempt to repair the power supply unit (see “Warning” notice above).

17.6 Driver Board Failures

Description:
• Some or all of the following functions do not work properly.
- Console
- Printhead
- Platen roller/ribbon rewind stepper motor
- Liner rewind stepper motor
- Cutter
• Faulty driver board.
- Check voltages using the test points on the CPU board, see Chapter
15.4. If all voltages are missing, check the 24 VDC output from the
CPU board and the cable between the power supply and the driver
board. If the 24 VDC input to the driver board is OK, the trouble is
likely to be in the driver board.
- Check the 24 VDC to the CPU board on connector P1, pin 1.
- Check the 24 VDC to the printhead on connector P5 while perform-
ing a print operation.
- Check the 33 VDC to the platen roller/ribbon rewinder stepper
motor on connector P10 while performing a feed or print opera-
tion. The stepper motor driver may be damaged because the platen
roller has been manually rotated while power was on, unintentionally
making the stepper motor work as a generator.
- Check the 33 VDC to the platen roller/ribbon rewinder stepper
motor on connector P11 while performing a feed or print operation.
- Check the 24 VDC to the cutter on connector P12 while performing
a cut operation.
If the any of the voltages are missing or are wrong, replace the driver
board without attempting to repair it. The only exception is if you are
positively sure that the fuse F1 has blown because of a short-circuit of
your own doing. In that case, you can cut off the legs of the fuse and
solder a new 4A fuse in its place.

17.7 Console Errors

Description:
The complete console is “dead”.
• Power LED is not lit.
• Green background lighting in display window is not lit.
• The 5V on the CPU board is OK (see Chapter 15.4).
• Defective cable.
- The cable between the CPU board and the console pcb. may be
defective or not properly connected. Check cable and connector J50
on CPU board.
• Defective console pcb.
- Replace. Do not attempt to repair.
Description:
No keys on the keyboard seem to be working or no keybeep.
• Power LED is lit.
• Green background lighting in display window is lit.
• Bad connection between keypad and console pcb.
- Check connections on the two flat cables between the keypad and con-
nectors P2 and P3 on console pcb.
• Keys disabled or keyboard remapped by a custom-made program (Fin-
gerprint only).
- If the printer does not respond to any keys in the Test Mode, the
keyboard is defective and needs to be replaced.
• Keybeep disabled by a custom-made program (Fingerprint only).
- If no beep is heard when the keys are pressed in the Test Mode, but
the printer nevertheless responds to the keys, the beeper is out of
order.
• Keyboard damaged by moisture.
- Soaking the keyboard with, for example, water or cleaning fluids, may
cause short-circuits. Let it dry, replace if necessary.

Description:
No messages appear in the display window after power-up.
• Power LED is lit.
• Green background lighting in display window is lit.
• Display not utilized by custom-made program (Fingerprint only).
- If there is no display function in the Test Mode, the display is out of
order and the console unit needs to be replaced. Else, check out the
custom-made program.

17.8 Error Messages

Description:
An error message appears in the display window or is returned via a serial
port.
• The printer stops functioning.
• The Error LED is usually lit.
• Consult the Intermec Fingerprint v8.xx, Programmer’s Reference Manual
or IPL Programming, Reference Manual for the meaning of the different
error codes and use that information to correct the error.
Depending on the firmware, printer’s mode, or running program, there are
different ways of giving the error message.
Immediate Mode (Fingerprint only)
• The firmware can detect and return three error conditions, provided the
printhead is lowered and a media feed is executed.
- Error 1005 (“Out of paper”)
- Error 1027 (“Out of transfer ribbon”)
- Error 1031 (“Next label not found”)
Programming Mode (Fingerprint only)
• At every erroneous instruction during programming, the printer trans-
mits an error code on the selected standard OUT channel (serial com-
munication only), provided the verbosity is not disabled. The same
applies if programming errors are detected when the program is run.
• When a program is executed, the same errors as in the Immediate Mode
will be detected. The execution stops and an error message is transmit-
ted. It is recommended to included some kind of error handler in any
custom-made application program, for example ERRHAND.PRG.
Intermec Direct Protocol (Fingerprint only)
• Eleven error conditions can be detected. Note that by default verbosity
is off in the Intermec Direct Protocol.
- Error 15 ("Font not found")
- Error 18 ("Disc full")
- Error 37 ("Cutter device not found")
- Error 43 ("Memory overflow")
- Error 1003 ("Field out of label")
- Error 1005 (“Out of paper”)
- Error 1006 (“No field to print”)
- Error 1022 (“Head lifted”)
- Error 1027 (“Out of transfer ribbon”)
- Error 1031 (“Next label not found”)
- Error 1606 (“Testfeed not done”)
The Intermec Direct Protocol has a programmable error-handler. Refer
to the Intermec Direct Protocol v8.xx, Programmer’s Reference Manual.

IPL only
• Ten possible errors are indicated by messages in the display window:
Error Displayed message
Empty/Paused PAUSE
Out of media PAPER OUT
Out of ribbon RIBBON OUT
Printhead lifted PRINT HEAD UP/PRESS FEED
Cutter error OPEN&SHUT CUTTER
Ribbon fitted RIBBON FITTED
Paper fault PAPER FAULT
Power supply error PSU ERROR
Power supply too hot PSU OVER TEMP
Printhead too hot PRINTHEAD HOT
Some additional errors can be returned to the host as an ASCII number
by the <BEL> command, see IPL Programming, Reference Manual.
Firmware Error
• In case the CPU is unable to access data on a given address, the internal
program will light up the red error LED regardless of any error-handling
program.

17.9 No Communication (general)

Description:
The following actions are valid for all communication interfaces installed
in the printer.
• Defective cable between printer and host.
- Check that the communication cable is correctly inserted and that it
is of the correct type and is correctly configured.
- Check that any clips or ground screws are properly engaged.
- Inspect cable for physical damage.
- Disconnect and connect the cable a few times to rub off possible
oxide from the connectors.
- Try using another identical cable.
• Defective cable between interface board and CPU board. This does not
apply to the serial port ("uart1:"), the USB port, or any EasyLAN board
which all are fitted directly on the CPU board.
- Check that the cable is connected correctly.
- Inspect cable for physical damage.
- Disconnect and connect the cable a few times to rub off possible
oxide from the connectors.
- Replace the cable.
• Error in host.
- Try connecting the printer to another host computer.
• Erroneous data.
- If using Fingerprint, check if the data string contains the correct char-
acters using the Line Analyzer program included in Intermec Shell
(see the User’s Guide).

17.10 No Serial Communication

Description:
The following actions are valid for the standard RS-232 serial interface
("uart1:" in Fingerprint) fitted on the CPU board and to some extent also
to any other serial interfaces on optional interface boards. Also see Chapter
17.8.
• Communication setup mismatch.
- Press the key or enter the Setup Mode to check that the printer
and host are set for the same communication parameters, such as
baud rate, parity, character length, stopbits, new line and handshak-
ing. It is strongly recommended to use some kind of handshaking, for
example XON/XOFF or RTS/CTS.
• Damaged RS-232 driver circuit.
- With the aid of an oscilloscope, or some kind of line analyzer (“break-
out box”), verify that the interface signals to and from the CPU board
are correct. The RS-232 driver (U61) could have been damaged as a
result of voltage transients from the interface, necessitating the CPU
board to be replaced. Repeated damage is an indication of insufficient
cable screening, or the electrical environment being too noisy.
• Circuits or straps on an optional interface board missing or fitted
incorrectly.
- See configuration instructions in Chapter 16.
• No supply voltage.
- Verify that the +3.3 VDC and +5 VDC voltages are present (see
Chapter 15.4).
• No external +5 VDC.
- The printer supplies max. 500 mA. The current is automatically
switched off at higher loads. Check the consumption of the con-
nected device.
- The switch (RP60 on the CPU board; IC9 on the Industrial Interface
Board and the Double Serial Interface Board) may be out of range
and need to be replaced.
• Too long communication cables.
- RS-232 max. 10-17 m (33-49 ft).
- RS-422 max. 1,200 m (4,000 ft).
- RS-485 max. 1,200 m (4,000 ft).
- Current Loop max. 500 m (1,500 ft).

• Input buffer on host overflow.

- The input buffer should normally be handled by the software of the
host. Increase the receive buffer in the printer to a large value, restart
the host to empty its input buffer and try again.
• No response from printer a custom-made program is run (Fingerprint
only).
- The verbosity can be controlled using the Fingerprint instructions
VERBON/VERBOFF and SYSVAR(18). In the Intermec Direct Pro-
tocol, verbosity is disabled by default. Check the program for instruc-
tions that affect the verbosity.
- Verify that the correct communication port is selected as standard
IN/OUT channel.
• Interface type mismatch (Fingerprint only).
- A communication cable is connected to a port configured for another
type of serial interface; for example an RS-232 cable is connected to
an RS-422 port. In the Setup Mode, the type of interface for which
the interface board is configured is indicated for each communication
port ("uart2:" to "uart5:"), see Appendix A.

17.11 Network Communication Troubles

This section applies both to EasyLAN Ethernet and EasyLAN Wireless
communication between a printer and a local area network. It does not
cover general network troubles in other types of equipment, such as wiring,
access points, routers, switches, servers, etc. It is assumed that the network
is in good working order, that is, other devices connected to the network
works well and the trouble can be pinpointed to the printer.
Description:
The printer cannot communicate with the network after the network
interface has been installed.
• Defect interface board or bad connection between interface board and
CPU board.
- Print a Hardware test label in the Setup Mode to see if the printer
recognizes the interface board. Also check if the Network node is
shown in the Setup Mode. If not, switch off the power, disconnect
the interface board, clean the connectors, and connect the interface
again. Switch on the power. Print a new Hardware test label. If the
troubles remains, replace the interface board.
Wireless only: Also check visually that the radio module is properly
connected to the adapter board. If the radio module is not connected
properly, the Network node will be displayed in the Setup Mode
but the wireless interface will not be recognized on the hardware test
label.
• Bad internal cabling.
- Ethernet only: Check that the network extension cable is properly
connected to the interface board. Visually check the cable for breaks
or shavings.
- Wireless only: Check that the antenna cable is properly connected to
the connection point marked “MAIN” on the radio module. Visually
check the cable for breaks or shavings.
Check that the antenna is properly connected and is pointing straight
up.
• Bad connection between printer and an Ethernet network
- Check the network LED indicator at the back of the printer. There
should be a green light flashing occasionally showing network activ-
ity or a solid yellow background light if connected to a 100 Mbps
network. Note that there is no background light indication provided
for 10 Mbps wired networks.
- Check that the network cable is connected correctly to the network
wall socket, hub, or similar and to the RJ-45 socket on the printer’s
rear plate.

- Check that the cable connecting to the network is not of "crossover"

type. Use a straight "pin to pin" cable to connect to a LAN, but use a
crossover cable to connect directly to a PC.
If you are trying to connect the printer directly to a PC via a crossover
network cable, you may need to disable the web browser’s proxy set-
tings on your computer to get in contact with the printer’s web pages.
• Bad communication between printer and a Wireless network
- Check the network LED indicator at the back of the printer. There
should be a green light flashing occasionally showing network activ-
ity, or a solid yellow background light if the network card is associated
with an access point, or flashing yellow light if the network card is
searching for an access point.
- Press the key on the printer’s front panel and browse to the net-
work information. There you can see the present signal strength and
channel. If both are 0, the network card is not associated with any
access point and/or the WLAN settings are wrong.
- Check if the access point is on.
- Check if the access point lists the MAC address of the network card.
- Check if other devices associated with this access point are working.
- Inspect the location and see if there is any reason why the radio trans-
mission between printer and access point is prevented, such as shield-
ing objects like walls, shelves, fork lifts, metal grids, etc. Sometimes,
just moving the printer around a little may help.
For demanding applications, Intermec offers a series of high gain
antennas that can replace the standard antenna.
- Check SSID settings.
- Check WEP settings. Note that you must have the same WEP key
settings in both the printer and the access point in regard of both the
content of the WEP keys and the order of the WEP keys. However,
you can have one active WEP key selected in the printer and another
in the access point.
- Check the region setting, which can be found on the Network Info
test label.
Description:
The printer seems to be physically connected to the network but cannot
communicate.
• Bad IP Settings in printer
- Use a PC connected to the same network as the printer. First of all
verify the network configuration of the printer as described in the
Installation Instructions provided with the kit.

PC Settings
You should verify that the PC has a working connection to the net-
work. Do this by opening a Command Prompt and type the com-
mand that corresponds to your operating system:
- For Windows 95, 98 and ME, use the command WINIPCFG.
- For Windows NT4, 2000 and XP, use the command IPCONFIG.
The PC will show a table with its configuration containing the set-
tings for IP-address, Subnet Mask and Default Gateway. Verify these
settings to be sure that the computer is correctly configured to access
your network.
Printer Settings
Check the IP address of the printer. Press the key on the printer’s
keyboard and use the <W> and <X> keys to browse to the IP address.
In Fingerprint, a prerequisite is that the standard IN port is set either
to "auto" or "net1:", which can be done using Intermec Shell.
Another method is using the Setup Mode:
Press the <Setup> key, on the printer’s internal keyboard, and step
your way to “NETWORK” using the <X> key.
By pressing <Enter> on the printer, you can step through the configu-
ration to verify the settings.
Press <Setup> to exit the Setup Mode.
More information about configuration settings can be obtained by
printing a test label.
Also check on the printer’s home page (Configuration [TCP/IP]) that
the net1 TCP Port Number is correct (default 9100).
Verifying IP Address
In the User’s Guide of the printer, you will find information on how
to print test labels in the chapter “Setting Up the Printer”. Print the
network test label and find the IP Address field. If the IP address is set
to 0.0.0.0, the network card has not received a IP address. Verify the
IP SELECTION setting under the NETWORK menu in the Setup
Mode. See the Installation Instructions for information on various
methods for setting the IP address automatically or manually.
Verifying Subnet Mask
Check subnet mask of PC and printer and make sure they belong to
the same segment. For example:
If they have the subnet mask The numbers in the PC and Printer IP
addresses have to be
255.255.255.0 <Same>.<Same >.<Same >.<Any >
255.255.0.0 <Same>.<Same >.<Any >.<Any >
255.0.0.0 <Same>.<Any >.<Any >.<Any >
Other subnet masks Contact the network administrator

In case the addresses are not in the same network segment, the
printer may not be reachable from the LAN side. Check the configu-
ration with the administrator.
Pinging the Printer
Start the Command Prompt. In the Command Prompt, type Ping
<printer IP-Address> and then click OK.
This command sends an echo command to the EasyLAN to check
if the PC and the printer can reach each other through the network.
The following figure shows a correct response to the Ping command.
The first reply to the first Ping command often takes more time than
the following. This is a normal behavior. The first time the Ping
command is executed, the PC needs some extra time to perform a
“discovery” of the network address (ARP request). The Ping com-
mand makes the printer’s network LED flash green.
If you have completed the test procedure and all the conditions are
met, but you do not get any answer to the Ping command, then you
probably have a hardware problem.
Description:
The performance of a Wireless network connection ceases to work or the
performance deteriorates after having worked properly for some time after
installation.
• Bad radio connection between printer and access point.
- Either the printer or the access point has been moved after instal-
lation or some kind of obstruction has come between printer and
access point. In principle, there should be a free line-of sight between
the access point and the antenna. There is also a distance limit.
Check the signal strength.
- Check network test label for statistics.
- Try moving either the printer or the access point (or both) or con-
sider fitting a higher gain antenna.
• Slow response.
- Too many devices associated with the same access point.

17.12 Sensor Malfunctions

Label Stop Sensor (LSS)
Description:
Label (ticket) gap or black mark not detected by the label stop sensor (LSS)
or wrong amount of media feed.
• Lost or obsolete media feed data, for example after a headlift, change
of media, or replacement of the sensor.
- In Fingerprint, perform a TESTFEED operation, for example by
simultaneously pressing <Shift> and <Feed> or selecting the Testfeed
option in the Setup Mode.
- In IPL, adjust the media feed by pressing the Feed/Pause button.
• Bad LSS lateral alignment.
- Check that the gaps or marks actually pass between the upper and
lower parts the label stop sensor (lateral alignment), see Chapter 7.5.
- Check that both parts of the LSS are adjusted to the same lateral posi-
tion, see Chapter 7.5.
• Light path obstructed.
- Check that both the upper and lower sensors are free from dust and
the slots in the upper and lower guide plates are free from stuck
labels, or other matters that may interfere with the path of light.
• Printer set for wrong media type.
- Set up the printer for the correct media type.
• Media feed detection using PRSTAT (Fingerprint only).
- PRSTAT AND 8 only checks for out-of-media conditions once as
opposed to the normal error checking (errors 1005 and 1031) that
checks for out-of-media conditions almost continuously. Thus, when
using PRSTAT, a dark spot or a bad media angle can give an incorrect
out-of-media indication, especially when using tickets (w. mark).
• Bad connection
- Check the LSS cables and make sure that they are correctly connected
to J54 and J55 on the CPU board, see Chapter 13.3.
• Faulty sensor or diode.
- Replace LSS as described in Chapter 7.5.
• CPU board not configured for the right type of printer.
- Reconfigure the CPU board as described in Chapter 15.8.
Note: The LSS Test option in the Setup Mode is useful for identifying LSS
troubles. Refer to Chapter 8.5.

Headlift Sensor
Description:
• The printer does not work, although the printhead is lowered.
• Error condition 1022 “Head lifted” (FP) or “Print Head UP/Press Feed”
(IPL) is indicated at any attempt of printing a label.
• Headlift sensor blocked.
- Check the sensor for dust or foreign objects.
• Bad connection.
- Check that the sensor’s cable is connected to J58 on the CPU board.
Inspect cable for damage.
• Faulty sensor.
- Replace as described in Chapter 7.8.
Label Taken Sensor (LTS)
Description:
The label taken sensor (LTS) is not working properly.
• Intermec Fingerprint instruction missing.
- The LTS must either be enabled using an LTS& ON statement, or
the status of the LTS must be polled using a PRSTAT function in the
current Intermec Fingerprint program.
• IPL instruction missing.
- The self-strip mode must be enabled using the commands
<STX>R<ETX> and <STX><SI>t1<ETX>.
• Bad connection.
- Check that the LTS is correctly connected to J53 on the CPU board.
- Check that the cable between CPU board and sensor is not damaged.
• Dirty sensor.
- Make sure that the active parts of the sensor are not obstructed by
dust or foreign objects.
• Wrong LTS sensitivity.
- The sensitivity of the sensor’s receiver and the light intensity of the
sensor’s emitter are adjustable, see Chapter 10.4.
• Interference from sunlight or lamps.
- Shield the sensor from interfering light source.
• Defective sensor.
- If still no reaction, the sensor is probably defective. Replace.

Ribbon Sensor
Description:
The ribbon sensor is not working properly.
• Bad sensor adjustment (Fingerprint only).
- Adjust the sensor in the Setup Mode as described in Chapter 6.4.
• Bad connection or faulty sensor.
- Cable between the ribbon sensor and J56 on the CPU board dam-
aged or not correctly connected?
- Sensor blocked by dust or foreign matters? Clean.
- Faulty ribbon sensor? Replace.
• Bad detection pattern inside ribbon supply bobbin.
- Check the black and silvery sector pattern at the inner end of the
ribbon supply bobbin for scratches or dust.
Paper Sensor
Description:
The ribbon sensor is not working properly.
• Bad sensor adjustment.
- Adjust the sensor in the Setup Mode.
• Bad connection or faulty sensor.
- Cable between the paper sensor and J57 on the CPU board damaged
or not correctly connected?
- Sensor blocked by dust or foreign matters? Clean.
- Faulty paper sensor? Replace.
• Bad detection pattern inside media supply bobbin.
- Check the black and silvery sector pattern at the inner end of the
media supply bobbin for scratches or dust.

17.13 Printing Troubles

The best way to start is to get an overall check of the printout quality by
printing a series of test labels in the Test Mode.
If you suspect a defective printhead, you can check it out using the fol-
lowing Intermec Fingerprint instructions (see Intermec Fingerprint v8.xx,
Programmer’s Reference Manual):
• FUNCTEST$ ("HEAD")
• HEAD
• SYSVAR(21)
• SYSVAR(22)
Description:
No printout at all.
• Bad connection.
- Is the cable between the printhead and P5 on the driver board fitted
correctly and not broken or otherwise damaged?
- Is the cable between the printhead and J40 on the CPU board fitted
correctly and not broken or otherwise damaged?
• Dirty printhead.
- Is the printhead clean? Residue from label adhesive, thermal paper
topcoating, or preprint ink prevents the printhead from functioning
correctly. Clean the printhead as described in the User’s Guide.
• Wrong type of direct thermal media.
- In case of direct thermal printing, verify that the media is intended
for direct thermal printing (not thermal transfer!) and of an approved
quality.
• Wrong type of thermal transfer ribbon.
- In case of thermal transfer printing, verify that the stock of ribbon is
of an approved quality.
• Transfer ribbon loaded incorrectly.
- Verify if the ribbon is loaded with the ink-coated side facing the
receiving face material. If not, reload the ribbon as described in the
User’s Guide.
• Transfer ribbon mechanism failure.
- See Chapter 17.14
• Wrong printhead voltage.
- Check the printhead voltage +24 VDC ±2V (see Chapter 15.4). If the
power on the CPU board is OK, but the trouble remains, disconnect
the power cable on the inner side of the printhead and use probes to
measure the voltage during printing between two adjacent lines in the
socket. If wrong voltage, check driver board and cables.

• Wrong printhead pressure.

- Check the printhead pressure, see Chapter 8.8.
• Headlift sensor out of order.
- Check the headlift sensor as described in Chapter 17.11.
Description:
Overall weak printout.
• Various reasons.
- Check as for “No printout at all”.
• Wrong Contrast/Darkness setup.
- Check setup for extremely low value.
• Wrong Paper Type/Media Sensitivity setup.
- Verify that setup matches the direct thermal media or the combina-
tion of transfer ribbon and media.
- Measure the +24 VDC on the CPU board, see Chapter 17.3 “No
printout at all.”
• Printhead pressure too low.
- Adjust as described in Chapter 8.8.
Description:
Weaker printout on either inner or outer part of label.
• Bad printhead pressure alignment.
- Adjust the position of the headlift arm as described in Chapter 8.8.
Description:
Overall too dark printout (bleeding). Too dark a printout is particularly
troublesome when printing compact bar codes, in which case spaces
between the bars become less distinctive, and consequently less readable.
• Wrong Contrast/Darkness setup.
- Check Contrast/Darkness setup for extremely high value.
• Wrong Paper Type/Media Sensitivity setup.
- Verify that setup matches the direct thermal media or the combi-
nation of transfer ribbon and media.
- Measure the +24 VDC on the CPU board, see Chapter 17.3 “No
printout at all.”

Description:
Weak or missing printout of some dots.
• Dirty printhead or platen roller.
- Examine the printhead and the platen roller for dust, adhesive resi-
due, or visible damage.
- Clean or replace.
• One or two missing dots.
- May be due to mechanical damage to the printhead. Try to establish
why such damage have occurred in order to prevent future failures of
this kind. (Hard foreign particles, electrostatic discharge?)
- If the printer has been used for printing on less than full width labels
for some time, the platen roller and possibly also the printhead may
have become worn from the outer edge of the media. This will show
up when reverting to wider labels. Change the platen roller and pos-
sibly also the printhead.
• Preprinted ink has got stuck to the dot line.
- Avoid preprinted labels with ink that has a low melting point (less
than +225°C/+437°F).
• Many dots, or a block of dots, are missing.
- The internal IC circuit of the printhead is probably damaged. Replace
the printhead.
Description:
Unexpected black printout (completely or partially).
- If the printer unexpectedly produces completely or partially black
printout, or prints a black line across the media at startup (regard-
less of label layout), check the printhead voltage +24 VDC ±2V
(see Chapter 15.4). If the power on the CPU board is OK, but the
trouble remains, disconnect the power cable on the inner side of the
printhead and use probes to measure the voltage during printing
between two adjacent lines in the socket. If too high, in the range of
40 to 50V during printing, replace the power supply unit.
- The printhead is most certainly damaged too and will also need to be
replaced.

Description:
Media feed does not work properly.
• Faulty stepper motor.
- Connect a replacement stepper motor to P10 on the driver board
(see Chapter 14) and perform a print or feed operation. If this motor
runs, the original stepper motor is probably damaged and needs to be
replaced (see Chapter 7.3).
• Dirty or worn platen roller.
- Inspect the platen roller for visible wear. Replace if necessary (see
Chapter 8.2).
- Clean the platen roller using a cleaning card or a soft cloth moistened
with isopropyl alcohol. Paper dust or adhesive residue can deteriorate
the media feed function or make the media slip.
• Intermec Fingerprint instruction missing.
- Verify that a print command is actually issued in the current Intermec
Fingerprint program.
• Power Supply Unit malfunction or bad connection.
- The stepper motor could be incorrectly connected to P10 on the
driver board, or its drive circuit (U3) on the driver board could be
damaged.
- Check that all pins in the connector of the stepper motor’s cable are
fully inserted.
- Measure the +24 VDC on the driver board, see Chapter 14. If there
is no power, when an attempt to print is made, the power supply unit
or driver board is probably faulty.
• CPU board configured for wrong printer model.
- A replacement CPU board must be configured for the correct printer
model after installation. Refer to Chapter 15.8.
Description:
Excessive wear of printhead.
• Various reasons.
- Refer to Chapter 8.6 “Printhead/Precautions” for advices on how to
reduce the wear of the printhead.

17.14 Transfer Ribbon Troubles

Description:
The thermal transfer ribbon breaks.
• Wrong brand of ribbon.
- Check if the transfer ribbon is of an approved brand. If not, recom-
mend the customer to use approved brands only.
• Bad ribbon load.
- Check that the ribbon is routed so it runs above upper guide (that is,
the one where the upper part of the LSS is fitted).
• Wrong paper type setup.
- Check that the printer is set up correctly for the type of thermal
transfer ribbon in use, see the User’s Guide.
- Check printhead voltage, see Chapter 15.4.
Description:
The thermal transfer ribbon wrinkles.
• Media misalignment.
- Are the edge guides positioned so as to guide the media closely along
the printer’s center section?
- Is the media supply roll as far in on the hub as possible?
• Ribbon misalignment.
- Are both the ribbon supply roll and the ribbon rewind core pressed as
far in on their hubs as possible?
• Ribbon path obstructed.
- Check that nothing obstructs the path of the transfer ribbon.
• Wrong or uneven printhead pressure.
- Check that the pressure arm is center-aligned in the relation to the
width of the media, see Chapter 8.8.
- Check the printhead pressure, see Chapter 8.8. Decrease the pressure
somewhat and test for both wrinkles and printout contrast. You may
need to feed out 25-50 cm of ribbon (1-2 ft.) before you can see any
effect.
• Bad ribbon break shaft adjustment.
- Check the adjustment of the ribbon assist roller, see Chapter 8.9.
Do not change the adjustment before you have performed all other
checks mentioned above.

Description:
No transfer printout.
• Refer to Chapter 17.13 for general printout troubles.
• Bad ribbon load.
- Transfer ribbon loaded incorrectly so the ink-coated side does not face
the receiving face material. Reload ribbon.
Description:
Ribbon fed out in front of printer.
• Printer is set up for direct thermal printing, but a ribbon is loaded.
- Remove ribbon or change the paper type setup to thermal transfer.
• Ribbon rewinder belt broken.
- Replace as described in Chapter 8.4.

17.15 Liner Takeup Troubles

Description:
The internal liner takeup unit does not work properly.
• Bad liner takeup or bad separation of labels from liner at the tear bar.
- Check that the media is routed correctly as described in the User’s
Guide.
- Check that the liner is securely locked to the takeup hub by the brace,
so it cannot slip.
- Check the setup for incorrect media type and feed adjust settings.
• Takeup unit slips.
- Spring clutch inside the takeup hub is broken.
- Either the outside of the pulley or the inside of the hub has become
worn.
• Either the liner drive roller in the print mechanism or the takeup hub
is not driven by the stepper motor.
- Check if any of the belts from the stepper motor is broken or has
come off the pulleys, see Chapter 9.2.
• Neither the liner drive roller in the print mechanism nor the takeup
hub is driven by the stepper motor.
- Check if the stepper motor runs. If not, check as for “Media feed does
not work” in Chapter 17.13.
- Check if both the belts from the stepper motor are broken or have
come off the pulleys, see Chapter 9.2.

17.16 Memory Card Troubles

Description:
The printer cannot read a memory card. Note that in IPL, memory cards
are not used to expand the printer’s memory.
• Memory card not inserted at startup.
- The card must be inserted before the power is switched on or the
printer is rebooted.
• Memory card incorrectly inserted.
- Check that the card is inserted as far as it goes.
• Bad contact between card and adapter.
- Switch off the printer. Pull out and insert the card a few times to rub
off any oxide on the connectors.
• Wrong type of memory card.
- The memory cards must be Type I CompactFlash cards (thickness 3.3
mm/0.13 in.) commonly used with digital cameras. PCMCIA-cards
or Type II CompactFlash cards (thickness 5 mm/0.20 in.) cannot
be used. If a CompactFlash card is marked CF+, it is probably not a
regular memory card and cannot be used.
• Error in content of the card.
- If you have access to a PC equipped with a CompactFlash card reader,
list the memory content of the PC memory card to see if it is correct.
- If you can communicate with the printer via a PC, you could see
what files are stored in the memory card and their sizes with the aid
of Intermec Fingerprint command FILES "card1:".
- The memory card must be formated for FAT12 or FAT16
- If the memory card is formated for FAT32, an "ERROR 41" message
will occur.
- Try to format the card in the printer using the Fingerprint instruction
FORMAT "card1:",A. Also see Intermec Fingerprint v8.xx, Program-
mer’s Reference Manual.
• Hardware error.
- Inspect the memory card for mechanical damage.
- Examine the memory card adapter on the CPU board for damaged
card mating pins, breakage, or bad soldering.

17.17 Paper Cutter Troubles

Description:
The printer cannot detect the cutter.
• In Fingerprint, error 37, “Cutter device not found” or Error 1059, “Cutter
does not respond” occurs.
Possible Causes and Sugged Remedies:
• No reboot has been performed after installation.
- Cycle the power to the printer.
• Cable between cutter pcb and CPU board is not fitted properly.
- Check that the cable has not come loose from the cutter interface
connector, see Chapter 11.2.
- Check that the cable from the cutter interface connector is properly
connected to P12 on the driver board.
• Faulty cable, driver board, or CPU board.
- Replace one at the time, reboot, and check.
Description:
The cutter does not cut.
• Error 1704, “Cutter open” occurs in Fingerprint.
- Check that the cutter is positively in closed position.
- The home position microswitch in the cutter assy may be defect.
Replace the cutter assy.
- Faulty cable, driver board, or CPU board. Replace one at the time,
reboot, and check.
• Errors 1701-1703 occurs in Fingerprint.
- Check the cutting shears and cutter mechanism for adhesive residue,
label shavings, stuck labels, or other things that may prevent the
cutter from operating mechanically. Clean if necessary, but do not use
any solvent that can dissolve the grease.
- Replace the cutter assy or cutter pcb, one at the time.
• No error occurs but cutter does still not cut.
- If using Fingerprint, check that the application program utilizes the
Fingerprint statements CUT or CUT ON/OFF correctly. See the
Intermec Fingerprint v8.xx, Programmer’s Reference Manual.
- If using IPL, check that the cutter has been enabled in the Setup
Mode.

Description:
The cutter cuts at the wrong place.
• Faulty LSS or bad Feedadjust setup.
- In Fingerprint, perform a Testfeed to adjust the LSS.
- In IPL, adjust the media feed by pressing the Feed/Pause button.
- Check Start- and Stopadjust setup values (Fingerprint only).
- Check application for FORMFEED<nnn> instructions (Fingerprint
only).


A Program Overviews
This appendix shows overviews of the Intermec Shell and the Intermec
Fingerprint Setup Mode followed by overviews of the IPL Setup Mode.
Refer to the User’s Guides for information on the various parameters and
instructions for navigation.

Appendix A — Program Overviews
Intermec Shell v8.2 Overview

POWER ON ENTER=SHELL SHELL SEL. APPLICATION
5 sec. v.8.2 SEL. APPLICATION CURRENT APPL.
Last selected application is started
ENTER=SHELL
SEL. APPLICATION
4 sec. v.8.2 Note: Dotted channels are only shown if
Fingerprint 8.30 the corresponding optional interface pcb
is fitted.
ENTER=SHELL STD I/O CHANNEL
SEL. APPLICATION
3 sec. v.8.2 auto
Direct Protocol

Optional application
2 sec. v.8.2 uart1:
programs
The selected application is started

1 sec. v.8.2 uart2:
Last selected STD I/O CHANNEL

application is started uart3:
Default:
Fingerprint 8.30 w. std I/O = "auto"
STD I/O CHANNEL
centronics:
Legend:
STD I/O CHANNEL
net1:
Return to previous menu.
STD I/O CHANNEL
Proceed to next menu. usb1:
STD I/O CHANNEL

Accept displayed option
and proceed, or uart4:
execute displayed option.
STD I/O CHANNEL
uart5:
Perform a Testfeed
anywhere in Intermec Shell.
SEL.APPL rom:
LINE_AXP.PRG
Enter the Setup Mode
from anywhere SHELL SETUP:
in Intermec Shell. SETUP SER-COM,UART1
See the chapter “Setup Mode”
SHELL
PRINT SETUP
Prints a list of current setup values (test label “Setup Info”).
SHELL Performs a Testfeed (feeds out a number of blank copies

TESTFEED while autoadjusting the label stop sensor).
SHELL Prints test labels “Diamonds”, “Chess”, “Bar Codes #1”, and “Bar Codes #2” in a loop
TEST LABEL Press Enter for each new label.
SHELL ARE YOU SURE? DEFAULT SETUP

DEFAULT SETUP YES=ENTER/NO=ESC PERFORMED
SHELL UPDATE: TRANSFER FILE

SOFTWARE UPDATE COMPACT FLASH? USING ZMODEM
TRANSFER
COMPLETED
SHELL UPDATE: TRANSFER FILE

REBOOT FIRMWARE? USING ZMODEM
Printer rebooted
Restarts the printer (same as power off/on) automatically.
Note: To enter Intermec Shell if an autoexec-file prevents access, lift the

printhead and press any key (except the <Shift> key), then turn on the
power while continuing to press the key. When the Shell countdown
begins, release the key and press <Enter> to start Shell. Do not forget to
lower the printhead if you, for example, want to print test labels.

Setup Mode Overview (FP v8.30) Ser-Com, uart1:

Setup Mode Overview (FP v8.30) Feed Adjust

Setup Mode Overview (FP v8.30) Media

Setup Mode Overview (FP v8.30) Print Defs

Setup Mode Overview (FP v8.30) Ser-Com, uart2

3%4503%450
3%2 #/- 5!24
3%2 #/- 5!24

"!5$2!4%
"!5$2!4%

"!5$2!4%

"!5$2!4%

"!5$2!4%

"!5$2!4%

"!5$2!4%

"!5$2!4%

"!5$2!4%

"!5$2!4%

"!5$2!4%





Setup Mode Overview (FP v8.30) Network Communication

Setup Mode Overview (IPL v2.30) Serial Communication

SETUP: Continued on
SER-COM the next page
SER-COM: SER-COM: SER-COM: SER-COM: SER-COM:

BAUDRATE DATA BITS PARITY STOP BITS PROTOCOL
BAUDRATE: DATA BITS: PARITY: STOP BITS: PROTOCOL:

9600
BAUDRATE; 8 CHAR LENGTH NONE
PARITY: 1 STOP BITS: XON/XOFF
ENQ/ACK:
19200
BAUDRATE; 7 EVEN
PARITY: 2 STANDARD
38400
BAUDRATE; ODD
PARITY:
57500
BAUDRATE; Scroll forward Scroll forward
SPACE Scroll back Scroll back
115200
BAUDRATE;
1200
BAUDRATE; Scroll forward
2400
BAUDRATE; Scroll back
4800
Scroll forward
Scroll back

Setup Mode Overview (IPL v2.30) Network (option)

SETUP:
NETWORK These menus will only be displayed when an optional EasyLAN interface board is installed.
NETWORK: NETWORK: NETWORK: NETWORK: NETWORK: NETWORK:

IP SELECTION IP ADDRESS NETMASK DEFAULT ROUTER NAMESERVER MAC ADDRESS
IP SELECTION: IP ADDRESS: NETMASK: DEFAULT ROUTER: NAMESERVER: MAC ADDRESS:

DHCP+BOOTP
PARITY: 0.0.0.0 0.0.0.0 0.0.0.0 0.0.0.0 nnnnnnnnnnnn
MANUAL
PARITY: Read-only Read-only Read-only Read-only Read-only
DHCP
PARITY:
BOOTP

Setup Mode Overview (IPL v2.30) Test/Service

Continued from SETUP: Continued on
the previous page TEST/SERVICE the next page
TEST/SERVICE:
TESTPRINT
TESTPRINT: TESTPRINT: TESTPRINT: TESTPRINT:

CONFIG TEST LABELS FORMAT PAGE
CONFIG: TEST LABELS: FORMAT: PAGE:

SW
CONFIG: PITCH
TEST LABELS: ALL ALL
HW
CONFIG: PRINT QUALITY
NETWORK
ALL: ALL:
Scroll forward Scroll forward PRINT FORMATS PRINT PAGES
Scroll back Scroll back
TESTPRINT: TESTPRINT:
UDC FONT
UDC:
ALL
ALL:
PRINT UDC
TEST/SERVICE: TEST/SERVICE: TEST/SERVICE:

DATA DUMP MEMORY RESET LSS TEST
DATA DUMP: MEMORY RESET: LSS TEST:

NO
CONFIG: ALL
CONFIG: LSS AUTO
YES CONFIGURATION
Scroll forward Scroll forward LSS AUTO:

Setup Mode Overview (IPL v2.30) Media

Continued from SETUP: Continued on
the previous page MEDIA the next page
MEDIA : MEDIA : MEDIA : MEDIA : MEDIA :

MEDIA TYPE PAPER TYPE LBL LENGTH DOTS SENSITIVITY DARKNESS
MEDIA TYPE: PAPER TYPE: LBL LENGTH DOTS: SENSITIVITY: DARKNESS:

GAP
CONFIG: DT
CONFIG: 1200 420 0
MARK
CONFIG: TTR 100/200/400/800/ 120/130/140/160/170/ 0/1/2/3/4/5/6/7/8/
CONTINUOUS Scroll forward 1200/1600/2000/ 180/222/226/236/238/ 9/10/-10/-9/-8/-7/
Scroll forward Scroll back 2500/3000/3600/ 366/369/420/440/450/ -6/-5/-4/-3/-2/-1
Scroll back 4200/4800 460/470/480/513/527/
533/563/565/567/623/
Scroll forward 627/633/647/673/677/ Scroll forward
Scroll back 687/720/854/864 Scroll back
Scroll forward
Scroll back
MEDIA : MEDIA : MEDIA : MEDIA : MEDIA :

LBL REST POINT FORM ADJ DOTS X FORM ADJ DOTS Y RIBBON LOW PAPER LOW
LBL REST POINT: FORM ADJ DOTS X: FORM ADJ DOTS Y: RIBBON LOW: PAPER LOW:
0 0 0 0 0
0/2/4/6/8/10/15/20/25/ 0/2/4/6/8/10/15/20/25/ 0/2/4/6/8/10/15/20/25/ 0/5/10/15/20/25/30/35/ 0/10/20/30/40/50/60/70/
30/-30/-25/-20/-15/-10/ 30/-30/-25/-20/-15/-10/ 30/-30/-25/-20/-15/-10/ 40/45/50/55/60/65/70/ 80/90/100/110/120/130/
-8/-6/-4/-2 -8/-6/-4/-2 -8/-6/-4/-2 75/80 140/150
Scroll forward Scroll forward Scroll forward Scroll forward Scroll forward
Scroll back Scroll back Scroll back Scroll back Scroll back

Setup Mode Overview (IPL v2.30) Configuration

Continued from SETUP: Return to
the previous page CONFIGURATION the start of
the loop
CONFIGURATION: CONFIGURATION: CONFIGURATION: CONFIGURATION:
PWRUP EMULATION PRINT SPEED CUTTER LTS CALIBRATION
PWRUP EMULATION: PRINT SPEED: CUTTER: LTS CALIBRATION:

NONE
CONFIG: 4PRINT
IN/SECSPPED: NOT INSTALLED
CONFIG: PRESS <ENTER>
86XX-10MIL
CONFIG: 5PRINT
IN/SECSPPED: ENABLE
CONFIG: Labels are fed out
86XX-15MIL 6PRINT
IN/SECSPPED: DISABLE
7PRINT
IN/SECSPPED: REMOVE LABEL AND
Scroll forward Scroll forward PRESS ENTER
8PRINT
IN/SECSPPED:
9PRINT
IN/SECSPPED: <Enter>
10 IN/SEC
PRINT SPPED:
11 IN/SEC
PRINT SPPED: SENSITIVITY 9
12 IN/SEC OUT OF 8-14
Read only,
Scroll forward press<Enter>
Scroll back

B Firmware Upgrading
This appendix describes various methods for upgrading the printer’s firm-
ware and for switching from Intermec Fingerprint to IPL or vice versa.

Appendix B — Firmware Upgrading
Introduction
All EasyCoder PX4i and PX6i printers can use both Fingerprint v8.xx and
IPL v2.xx firmware. There are many ways to upgrade or exchange printer’s
firmware. Use the most convenient way. You can either do it from host by
sending the file to the printer or by inserting a CompactFlash card in the
memory card slot at the printer’s rear plate. There are 3 different file types
containing the firmware. The file types are related to the way of upgrade
procedure. The files can be obtained from Intermec.
File Description
File name Type of file
1-972020-xx.bin (for FP) These .bin files contain the firmware kernel file only. To
1-972105-xx.bin (for IPL) be sent on serial port to printer using a communication
program, for example HyperTerminal or Printset, or via
FTP. Can also be stored on a CompactFlash card.
1-972021-xx.bin (for FP) These .bin files contain the firmware kernel file and the
1-972106-xx.bin (for IPL) factory default setup parameter values. To be stored on a
CompactFlash card.
Note: These files remove all files except the firmware
files, so it is advised to make a backup before running
such a file. They are primarily intended to allow restor-
ing forgotten passwords.
Another format is .uff files, which are created by, for instance, NetPrintSet.
They contain the kernel and optional instructions (if necessary), images,
fonts, etc. To be stored in CompactFlash memory cards.
General Principles
• During upgrading, do not switch off the printer. Wait and follow the
prompts in the printer’s display.
• If changing firmware from IPL to Fingerprint, we recommend to erase
memory to factory setup setting [FORMAT "/c",A] after the upgrade
procedure is completed.
• Some update of Fingerprint may show the error “mcs: Error during
setup” at host terminal. This just means that there was an instruction
that erased "/c" [FORMAT "/c",A]. This is a normal condition! The
error shows that no setup file [.setup.saved] is detected on "/c". The
"/rom" setup file is copied automatically into "/c" which gives printer a
factory setup setting.
• If an EasyLAN interface board is installed, by default only admin is
allowed to upgrade. See EasyLAN User's Guide for more information.

Upgrading From a Memory Card

This chapter describes how to upgrade the printer from a CompactFlash
card.
1 Insert the card and switch on the printer. The printer’s display will auto-
matically show ongoing steps. The procedure ends with a normal startup
of the printer.
2 Switch off the printer and remove the card. Printer is ready for use.
CompactFlash cards with firmware (Fingerprint or IPL) can be ordered
from Intermec. Empty CompactFlash cards can be ordered from Intermec
or procured locally.
If there are more than one firmware files on the memory card, it is not
foreseeable which one will be selected. However, by renaming the desired
file to FIRMWARE.BIN, you can make sure that the file will be selected.
How to make an upgrading card
There are two possible places to program a CompactFlash card. One is
your PC CompactFlash card slot, another is the printer’s card slot.
At the PC-side
1 Use a computer fitted with a PCMCIA slot and a CompactFlash adapter
and insert the CompactFlash card.
2 Copy the upgrade .bin or .uff file to the CompactFlash card.
At the printer side (Fingerprint only)
1 Insert the CompactFlash card in the slot at the printer’s rear plate.
2 Start up the printer and select Intermec Shell.
3 Press <Enter> to go to the “Sel. Application” menu.
4 Press <⇒> repeatedly to browse to ”SOFTWARE UPDATE”.
5 Press <Enter> to go to ”UPDATE: COMPACT FLASH?”
6 Press <Enter>.
7 Start sending the file using a communication program, for example
HyperTerminal. The communication program must use zmodem.
(There is a one-minute time-out on the printer side.) Shell will auto-
matically rename the file to FIRMWARE.BIN to make sure that this file
will upgrade the printer.
8 Switch off the printer and remove the card.

Note: A special case is if the CompactFlash card already has a Fingerprint

firmware. Inserting such card will always install firmware in the printer
according to CompactFlash card. However, perhaps you like to install a
later firmware version picked from the web. If so, proceed like this:
1 Insert the CompactFlash card with a upgrade firmware on. Switch on
and wait for a completed upgrade and the normal startup of the printer
so you are in Fingerprint mode.
2 Activate the Shell program from "/rom" like this:
LOAD "/rom/SHELLXP.PRG"
MERGE "/rom/ERRHAND.PRG"
RUN
3 In Shell, select the option “UPDATE: COMPACT FLASH?” and press
<Enter>.
4 Send the .bin or .uff file from the host using zmodem.

Upgrading From the Host

Software Suggestions
1. Intermec PrintSet (IPL and Fingerprint)
Install Intermec Printset software and a serial cable. Intermec PrintSet is
included in the printer companion CD. It can also be obtained from the
Intermec Printer Support Web.
2. Terminal program (Fingerprint only)
Use Terminal program included in Windows (95/98/Me or NT/2000/XP)
and a serial cable. At serial communication, the software has to be prepared
by a protocol Zmodem and have same communication settings on both
side. We recommend hardware handshaking (RTS/CTS).
3. Command prompt with FTP
Use command prompt in Windows (95/98/Me or NT/2000/XP) and an
Ethernet network.
4. Intermec NetPrintSet (Fingerprint only)
Use Intermec NetPrintSet software and a serial cable. Intermec NetPrintSet
can be obtained from the Intermec Printer Support Web.
Cable Suggestions
RS-232 Serial Cable
DB-9pin female -> DB-9pin male (see Spare Parts Catalog)
Ethernet Cable
Intermec does not provide any Ethernet cable. The cables are normally
provided locally. At a straight connection between a host and printer, a
cross RJ-45 cable is needed.
Parallel Cable
(see Spare Parts Catalog)
How to use Intermec PrintSet and serial cable.
1 Connect a serial cable between host and printer
2 Start up the printer and select Fingerprint via Shell and to listen on
serial port "uart1:" on for example baud rate 115,200.
3 Start PrintSet. The program will automatically set the communication
parameters and is ready for use.
4 Select ”DataXfer\Change firmware”. Depending on settings, PrintSet
may ask for the admin password.
5 Send one of the following files:
1-972020-xx.bin (Fingerprint)
1-972105-xx.bin (IPL)
6 After file is received in printer, it will automatically replace the firmware
and boot up with the new one.
7 The printer’s display will automatically show ongoing steps. The proce-
dure ends with a normal startup of the printer.

How to use MS HyperTerminal and a serial cable (Fingerprint only)

1 Connect a serial cable between host and printer.
2 Start the HyperTerminal or a similar terminal program. Select port
com1. Use a high communication speed (115,200 baud).
3 Start up the printer and select Fingerprint via Intermec Shell1 to listen
on serial port "uart1:".
4 Make sure that your are in contact with printer by typing for example
FONTS and the printer will respond showing fonts.
5 Type a download command2 so printer is ready for receiving data:
RUN "dlk"
Select .bin upgrade file. Now printer waits for about 1 minute to get the
file sent using zmodem as protocol.
6 Go to “Send file” and send it.
and the printer will boot up with the new one.
1
/. In Intermec Shell it is also possible to select printer to be in the receiving mode. Start
up Intermec Shell and use <⇒> to browse to “Software Update\Update:Firmware”. (You
have one minute to send the file.) Also check the printer’s baud rate in the Setup Mode.
Continue with items 6-8. If the printer is fitted with an EasyLAN board, user must be
allowed to upgrade.
2
/. dlk only works if the current user is allowed to update. RUN "su admin" could be
required.

How to use command prompt FTP and Ethernet

1 Connect a printer on Ethernet LAN or by a cross cable between host
and printer
2 Open an FTP session to the printer typing this command from your
Windows command prompt: FTP <ip address of the printer>
3 You will get a prompt asking you for User: type admin or user. You
may get a prompt for a Password: type pass (default; case sensitive).
Note: The user you log in as must be allowed to upgrade.
4 After some answers on your screen you will see the prompt FTP>. At
this point type bin + <Enter>, then type hash + <Enter>.
5 Now send the firmware to the printer with the command:
put <filename.bin> FLASH
6 Some ###### will appear on your screen showing the ongoing transfer.
8 Close FTP session typing bye + <Enter>.
9 After file is received in printer it will automatically replace the firmware
and the printer will boot up with the new one. The printer’s display will
automatically show ongoing steps and the procedure ends with a normal
startup of the printer.
How to use Intermec NetPrintSet and serial cable (Fingerprint only)
What is NetPrintSet
NetPrintSet is a printer configuration utility for Intermec printers that
allows you to upgrade or configure the printer. Makes font upgrades and
other maintenance a child’s play. Available both as Netscape plugin and
standalone executable.
• NetPrintSet can merge printer’s necessary file to one file either using a
CompactFlash card or download direct to printer. Necessary files are for
example Images, Fonts, Firmware, or other custom-made files.
• How to use? Please refer to the Help included in the software.
If upgrading directly via NetPrintSet and printer
1 Start up the printer and select Shell. Press <Enter> to go to the “SEL.
APPLICATION” menu. Use <⇒> to browse to “SOFTWARE
UPDATE”. Press <Enter> to go to the “UPDATE: COMPACT
FLASH?” menu. Use <⇒> to go to “UPDATE: FIRMWARE?”. Finally,
press <Enter>.
User might not be allowed to update.
2 Start to send the file from the software. (There is a one-minute time-out
before the printer exits the receive mode.)
and the printer will boot up with the new one.


C Measuring the Brake Torque
This appendix describes a simple way to measure the brake torque when
advanced tools are not available.

Appendix C — Measuring the Break Torque
Measuring the Brake Torque

If you do not have access to a torque-measuring instrument, you could
easily make a provisional instrument using a roll of spent transfer ribbon, a
simple dynamometer and a ruler:
• Fit the ribbon roll on the spool you want to check. The larger roll, the
better accuracy.
• Measure the radius from the center of the spool to the edge of the
ribbon roll.
• Fit the end of the ribbon to the dynamometer and pull.
• Read the dynamometer.
• Calculate the torque using the formula:
Torque (Nmm) = Radius (mm) × Force (N)
Dynamometer
Force
Formula:
Torque = Force x Radius
ius
Rad

Intermec Technologies Corporation
Corporate Headquarters
6001 36th Avenue West
Everett, WA 98203
U.S.A.
tel 425.348.2600
fax 425.355.9551
www.intermec.com
EasyCoder PX4i & PX6i Service Manual
*1-960624-00*
*1-960624-00*

1 960624 00 20SM 20PX4i 20 20PX6i1403955131998

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Service Manual

EasyCoder PX4i and

1 Models and Options

2 Front and Keyboard

3 Covers and Doors

6 Label Slack Absorber

EasyCoder PX4i and PX6i Service Manual iii

7 Transfer Ribbon Mechanism

9 Liner Takeup Kit

10 Label Taken Sensor

iv EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual v

C Measuring the Break Torque

vi EasyCoder PX4i and PX6i Service Manual

Before You Begin

EasyCoder PX4i and PX6i Service Manual vii

Global Services and Support

viii EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual ix

x EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual 1

EasyCoder PX4i EasyCoder PX4i

EasyCoder PX6i EasyCoder PX6i

Note: Unless otherwise stated, illustrations in this manual show an Easy-

2 EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual 3

Options for EasyCoder PX4i

Alphanumeric Fan-fold guide

Liner/batch takeup unit

4 EasyCoder PX4i and PX6i Service Manual

Options for EasyCoder PX6i

Label taken sensor

Liner takeup unit

EasyCoder PX4i and PX6i Service Manual 5

Provision for Easy-

Serial Port (RS-232)

6 EasyCoder PX4i and PX6i Service Manual

Checking Hardware and Firmware

In the electronics compartment, check:

EasyCoder PX4i and PX6i Service Manual 7

1.2 EasyCoder PX4i Specifications

8 EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual 9

1.3 EasyCoder PX6i Specifications

10 EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual 11

1.4 Measures EasyCoder PX4i

 MM   MM 

12 EasyCoder PX4i and PX6i Service Manual

1.5 Measures EasyCoder PX6i

 MM   MM 

EasyCoder PX4i and PX6i Service Manual 13

14 EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual 15

Provision for cutter

16 EasyCoder PX4i and PX6i Service Manual

EasyCoder PX4i and PX6i Service Manual 17

EasyCoder PX4i Fingerprint version

EasyCoder PX4i Fingerprint version, Alphanumeric keyboard (option)

EasyCoder PX4i IPL version

18 EasyCoder PX4i and PX6i Service Manual

EasyCoder PX6i Fingerprint version

EasyCoder PX6i Fingerprint version, Alphanumeric keyboard (option)

MM MM

MM MM

2 # 2

2 # 2

2 # 2

+ # )# 2 2

2 2 2 2