User`s Guide For All Series Printers

User`s Guide For All Series Printers
Label Printer
User’s Guide
For All Series Printers
Changing the way the world prints labels…
PROPRIETARY NOTICE AND LIABILITY DISCLAIMER
The information disclosed in this document, including all designs and related materials, is
the valuable property of IntelliTech International Incorporated (IntelliTech) and/or its licensors. IntelliTech and/or its licensors, as appropriate, reserve all patent, copyright and
other proprietary rights to this document, including all design, manufacturing, reproduction, use, and sales rights thereto, except to the extent said rights are expressly granted to
others.
The IntelliTech product(s) discussed in this document are warranted in accordance with the
terms of the Warranty Statement accompanying each product. However, actual
performance of each such product is dependent upon factors such as system configuration,
customer data, and operator control. Since implementation by customers of each product
may vary, the suitability of specific product configurations and applications must be
determined by the customer and is not warranted by IntelliTech.
To allow for design and specification improvements, the information in this document is
subject to change at any time, without notice. Reproduction of this document or portions
thereof without prior written approval of IntelliTech is prohibited.
IntelliBar is a trademark of IntelliTech International, Inc.
Copyright 1998 - 2012
IntelliTech International Inc.
43 Broad Street
Hudson, MA 01749
http://www.intellitech-intl.com
All Rights Reserved
Contents
Preface........................................................................................................................ xi
Abbreviations............................................................................................................. xiii
General Information
Models 48 and 412 ..................................................................................................... 1-2
Model 88..................................................................................................................... 1-3
Hardware Description ............................................................................................... 1-5
Power Supply ...................................................................................................... 1-5
Control Panel ...................................................................................................... 1-5
Main Board ......................................................................................................... 1-5
Ribbon and Label Feed Mechanisms................................................................. 1-7
Print Mechanism................................................................................................. 1-9
Memory Expansion.................................................................................................. 1-10
Options..................................................................................................................... 1-10
User-Installable Options ................................................................................... 1-10
Factory-Installable Options................................................................................. 1-11
Specifications ............................................................................................................. 1-12
Interface ..................................................................................................................... 1-14
Parallel Interface................................................................................................. 1-14
IEEE 1284 Cable Requirements.................................................................. 1-14
Serial Interface.................................................................................................... 1-14
Data Transmission ....................................................................................... 1-15
Section 2
Setup
Unit Setup .................................................................................................................. 2-1
Connecting the Power Cord ............................................................................... 2-5
Connecting the Communications Interface Cables ............................................ 2-6
Label and Ribbon Requirements ........................................................................2-10
IntelliBar Ribbons........................................................................................ 2-12
Ribbon/Label Combination................................................................................ 2-14
Loading Labels.................................................................................................... 2-15
Models 48 and 412 ....................................................................................... 2-15
iv
Contents
Model 88.......................................................................................................
Installing the Thermal Ribbon ...........................................................................
Model 48 or 412 ...........................................................................................
Model 88.......................................................................................................
Print Head Removal and Installation .......................................................................
Print Head Removal ...........................................................................................
Model 48 and Model 412 .............................................................................
Model 88.......................................................................................................
Print Head Installation .......................................................................................
Model 48 and 412.........................................................................................
Model 88.......................................................................................................
Print Head Voltage Adjustment.........................................................................
Section 3
Unit Operation
Controls and Indicators......................................................................................
Self-Test...............................................................................................................
Test Page ......................................................................................................
Bar Code ......................................................................................................
Menu Tree...........................................................................................................
Default Factory Settings ..............................................................................
Changing Settings........................................................................................
Controlling the Printer ................................................................................
LCD Display Messages .......................................................................................
Printing Modes ..........................................................................................................
Standard Mode ...................................................................................................
Peel-Off Mode .....................................................................................................
Tear-Off Mode ....................................................................................................
Cut-Off Mode......................................................................................................
Section 4
2-23
2-26
2-26
2-30
2-34
2-35
2-35
2-38
2-40
2-40
2-41
2-42
3-1
3-4
3-6
3-7
3-7
3-7
3-9
3-20
3-26
3-30
3-30
3-30
3-31
3-31
Options
Memory Expansion....................................................................................................
IntelliTech International Inc. Options ......................................................................
User-Installable Options .....................................................................................
Factory-Installable Options.................................................................................
Memory Expansion Module Installation (All Models) .............................................
Installing SIMMs ................................................................................................
4-1
4-3
4-3
4-3
4-4
4-7
Contents
v
Label Cutter Installation Procedure Overview (Model 48 and 412)......................
A. Remove the Standard Peel-Off Assembly (Model 48 and 412)............
B. Install the Cutter Option (Model 48 and 412)........................................
C. Configure the Printer to Use the Cutter (Model 48 and 412)................
Internal Rewinder (Model 48 and 412).....................................................................
Loading Labels....................................................................................................
Loading Labels in Standard Mode..............................................................
Loading Labels in Peel-Off Mode ...............................................................
4-11
4-12
4-14
4-15
4-16
4-16
4-16
4-19
Section 5
Cleaning and Adjustments
Cleaning ..................................................................................................................... 5-1
External Cleaning ............................................................................................... 5-1
Internal Cleaning ................................................................................................ 5-1
Print Head........................................................................................................... 5-3
Platen Roller........................................................................................................ 5-3
Sensors................................................................................................................. 5-4
Print Position Adjustment......................................................................................... 5-5
Print Head Voltage Adjustment................................................................................ 5-6
Correcting Poor Print Quality................................................................................... 5-6
Print Head Adjustments..................................................................................... 5-7
Media Mismatch ................................................................................................. 5-7
Density................................................................................................................. 5-7
Resistance Value ................................................................................................. 5-7
Print Head Latch ................................................................................................ 5-8
Print Speed.......................................................................................................... 5-8
Ribbon Guide Plate ............................................................................................ 5-8
Bad Print Head ................................................................................................... 5-8
Mechanical Adjustments ........................................................................................... 5-9
Model 48 and 412.............................................................................................. 5-10
Label Width Guides (Model 48 and 412).................................................. 5-10
Horizontal Print Head Alignment (Model 48 and 412) .............................. 5-11
Print Head Pressure Knob for Label Thickness (Model 48 and 412) ........ 5-13
Print Head Balance Lever for Label Width Adjustment (Model 48
and 412) .................................................................................................... 5-14
Print Head Position Dial for Label Thickness Adjustment (Model 48
and 412) .................................................................................................... 5-15
Ribbon Guide Plate (Model 48 and 412)..................................................... 5-18
vi
Contents
Sample Adjustment......................................................................................
Timing Belt Tension Adjustment (Model 48 and 412) ...............................
Model 88..............................................................................................................
Label Width and Pressure Adjustment (Model 88)....................................
Label Thickness Dial (Model 88).................................................................
Ribbon Tension Plate (Model 88)................................................................
Print Density Adjustment..........................................................................................
Section 6
5-19
5-20
5-21
5-21
5-23
5-24
5-26
Troubleshooting
Troubleshooting the Problem....................................................................................
Using LCD Display Error Messages..........................................................................
Correcting Print Quality ...........................................................................................
Top-Level Problem Solving .......................................................................................
Common Questions and Answers.....................................................................
Fax Form.............................................................................................................
Appendix A
Packing
Glossary
Proprietary Notice and Liability Disclaimer
6-1
6-2
6-6
6-8
6-17
6-24
Preface
This IntelliBar User Guide contains the information necessary to set up and maintain the
IntelliBar Models 48, 412, and 88 bar code printers.*
The manual is organized as follows:
A list of the abbreviations used in this manual follows the preface.
Section 1 General Information provides an overview of the IntelliBar printers. This
chapter explains the main features of the printers and their options. This section also lists
printer specifications.
Section 2 Setup describes how to set up the printer.
Section 3 Unit Operation describes control panel buttons, status messages, menus, and
memory settings for the printer.
Section 4 Options provides information on the various IntelliBar user and dealer
installable options, including installation procedures.
Section 5 Cleaning and Adjustments contains instructions for cleaning and adjusting the
printer.
Section 6 Troubleshooting provides troubleshooting aids that include error codes, test
samples, and troubleshooting procedures. This section also contains information on getting
service and support and printer warranty terms and limitations.
Appendix A Packing provides packing information.
The Glossary at the end of this manual provides a list of IntelliBar and bar code printing
terms and briefly defines each one.
NOTE: For updates on IntelliBar printer
specifications and other information about
IntelliTech International, Inc. products, visit our
web site at http://www.intellibar.com.
*
"This information is subject to change without notice. This information is provided "as is" without either express or
implied warranty. IntelliTech International, Inc. disclaims any and all warranties with regard to this information.
IntelliTech shall not be liable in any event for any special, indirect or consequential damages or any damages whatsoever
resulting from loss of data, profits or use, for any reason or in any action, arising out of or in connection with the use or
performance of this information. "
xiii
Abbreviations
A
AC
ACK
ASCII
ampere
alternating current
acknowledge
American Standard Code for
Information Interchange
BIOS
basic input/output system
bit
binary digit
bpi
bits per inch
bps
bits per second
C
centigrade
CD
carrier detect
CLK
clock
cm
centimeter
CMOS
complementary metal oxide
semiconductor
COM
communication
CPU
central processing unit
cpi
characters per inch
CTS
clear to send
DACK
DMA acknowledge
DC
direct current
DIP
dual in-line package
DMA
direct memory access
dpi
dots per inch
DRAM
dynamic RAM
DSR
data set ready
DT
direct thermal application
DTE
data terminal equipment
DTR
data terminal ready
EPROM erasable programmable
read-only memory
EEPROM electrically erasable
programmable read-only
memory
ETX
end-of-text
F
Fahrenheit
FAX
FCC
FG
FRU
GB
GND
HEX
HMI
HP
Hz
IC
ID
in.
IPB
I/O
ips
IRQ
ISO
K
k
KB
kg
kHz
LAN
lb
LCD
LED
lpi
LSB
M
mA
max
MB
MHz
facsimile transmission
Federal Communications
Commission
frame ground
field-replaceable unit
gigabyte
ground
hexadecimal
horizontal motion index
Hewlett Packard
hertz
integrated circuit
identification
inch
illustrated parts breakdown
input/output
inches per second
interrupt request
International Standards
Organization
kilo (1024)
kilo (1000)
kilobyte
kilogram
kilohertz
local area network
pound
liquid crystal display
light-emitting diode
lines per inch
least-significant bit
mega
milliamps
maximum
megabyte
megahertz
xiv
Abbreviations
mm
ms
MSB
NC
NMI
ns
PC
PCB
PCL
PDL
pixel
p-p
PROM
P.S.
RAM
ROM
rpm
R
RD
RTS
R/W
S
SD
SG
SIMM
STB
SW
TD
TG
TSC
TT
TTL
tpi
V
Vdc
VRAM
W
millimeter
millisecond
most-significant bit
not connected
non-maskable interrupt
nanosecond
personal computer
printed circuit board
printer control language
page description language
picture element
peak-to-peak
programmable ROM
power supply
random-access memory
read-only memory
revolutions per minute
read
received data
request to send
read/write
slave
send data
signal ground
single inline memory module
strobe
switch
transmit data
tag stock application
Technical Support Center
thermal transfer application
transistor/transistor logic
tracks per inch
volt
volts, direct current
virtual RAM
watt
W
write
*
*
"This information is subject to change without notice.
This information is provided "as is" without either express or implied warranty. IntelliTech International,
Inc. disclaims any and all warranties with regard to
this information. IntelliTech shall not be liable in any
event for any special, indirect or consequential damages or any damages whatsoever resulting from loss of
data, profits or use, for any reason or in any action,
arising out of or in connection with the use or performance of this information."
Section 1
General Information
The IntelliBar is a thermal label printer that uses industry-standard printer command
languages to produce high-resolution fonts, graphics, and bar codes on thermal transfer or
direct thermal paper or synthetic rolls of labels or tag stock.
The IntelliBar printer family consists of four series differentiated by the printer command
language, emulation, and connectivity as listed in Table 1-1.
Table 1-1 IntelliBar Printer Product Line
Series Name
Printer Command
Language
Emulation
Connectivity
IntelliBar Standard
Series
Hewlett Packard
Printer Control
Language 5
(HP PCL5)
LaserJet III
IEEE 1284 parallel,
RS-232/RS422C serial
IntelliBar AS Series
AFP/IPDS,
HP PCL5
IBM 4028
IEEE 1284 parallel,
RS-232/RS422C serial,
10BaseT Twinax or Coax
IntelliBar ax Series
SCS,
HP PCL5
IBM 5020
10BaseT Twinax or Coax,
IEEE 1284 parallel,
RS-232/RS422C serial
IntelliBar LPR Series
IGP/PGL, IGP/VGL
Magnum Code V,
HP PCL5
Printronix,
Centronics,
QMS
10BaseT Twinax or Coax,
IEEE 1284 parallel,
RS-232/RS422C serial
Each series consists of three models: Model 48, Model 412 and Model 88. All models print
using either the thermal transfer or direct thermal printing method described later in this
section. As standard features, all printers have 300 x 300 dots per inch (dpi) print
resolution, parallel and serial communication ports, and label peel-off capability. The
IntelliBar AS, ax, and LPR Series have the additional standard feature of twinax and coax
connectivity. Each model also features a control panel and LCD display for simple printer
installation and use (see “Control Panel” in this section).
The Model 48 and Model 412 print labels up to a maximum width of 4.37 inches (111 mm).
The Model 88 prints labels up to a maximum width of 8.65 inches (220 mm). Label length is
model and memory dependent. In the Model 48 and Model 412, memory can be expanded
to increase label length, overall printer performance, and data throughput. The IntelliBar
automatically senses label length at power-on and provides a backfeeding capability used
with tear-off, peel-off, or cut-off printing modes.
1-2 General Information
Print output can include text and graphics in addition to high-density bar codes, extending
the IntelliBar printer’s versatility for any label printing need.
Depending on the IntelliBar model and the main board revision, other features include:
an operating speed of up to 8 inches per second (ips) for the Model 48 and Model
88, and 12 ips for the Model 412.
HP PCL 5 compatibility and LaserJet III printer command set emulation with 14
bitmap and eight outline fonts (in addition to specific printer command languages
for the various IntelliBar printer series as described in Table 1-1). Support
includes all PCL 5 commands and functions with several additional command
extensions to deal with special printer features that are not available in the HP
LaserJet (see the IntelliBar Programmer’s Reference Guide for more
information).
a minimum of 2 MB of random-access memory (RAM) expandable (in the Model
48 and Model 412) using SIMM option installation (see “Memory Expansion” in
this section).
MODELS 48 AND 412
Features common to Models 48 and 412 are shown in Figure 1-1 and Figure 1-2 and
described in the following subsections. For printer specifications, see “Specifications” in this
section.
LCD Display
Lamps
Control
Panel
Power Switch
Label Exit
Slot
Access
Handle
Front Panel
Label Release
Paper Slot
Figure 1-1 Model 48 and Model 412 Features (Front and Left Side View)
General Information 1-3
Left Side
Panel
Front Panel
Latch
Print Head
External
Label
Entrance
Slot
Print Head
Release Lever
Serial
Port
Ribbon Takeup
Spindle
Parallel
Port
Ribbon Supply
Spindle
AC Power
Inlet
Power Supply
Label Supply
Spindle
Figure 1-2 Model 48 and Model 412 Features (Rear and Left Side View)
MODEL 88
The features of the Model 88 are shown in Figure 1-3 and Figure 1-4 and described in the
following subsections. For printer specifications, see “Specifications” in this section.
1-4 General Information
Access
Handle
(hidden)
LCD Display
Label Exit
Slot
Front
Panel
Lamps
Control
Panel
Figure 1-3 Model 88 Features (Front and Right Side View)
Ribbon Takeup
Spindle
Print Head
Ribbon Supply
Spindle
External
Label
Entrance
Slot
Print Head
Release Latch
Serial
Port
Parallel
Port
Label Supply
Spindle
AC Power
Inlet
Power Switch
Power Supply
Figure 1-4 Model 88 Features (Rear and Left Side View)
General Information 1-5
HARDWARE DESCRIPTION
Printer operations are coordinated by control panel settings and the main board components
under DC voltage from the power supply. The following subsections describe how printing
is carried out.
power supply
control panel
main board
ribbon and paper feed mechanisms
print mechanism (printer engine)
Power Supply
Alternating current (AC) is fed directly into the power supply and converted into the
various DC voltages that drive and control printer operation (+5 V, +12 V, -12 V, +18 V,
+24 V). The power supply contains one replaceable fuse.
Control Panel
The control panel contains the LCD display, power and alert indicators, and buttons that
allow you to control and monitor printer operation. The 2-line display provides printer
status and error messages and the printer settings menu tree. The power indicator shows
whether the printer is turned on or off, while the alert indicator shows whether the printer
has a fault or error condition that may affect operation. The control panel buttons allow you
to view or change the printer settings (user parameters) via the menu tree.
For more information, see Section 3, “Unit Operation.”
Main Board
The main board (located behind the right side panel) controls communications between the
computer and printer engine and coordinates the printer’s logic and mechanical functions.
The printing process begins when the computer sends data to the main board through either
the serial or parallel interface. The main board receives and interprets the data (HP LaserJet
emulation and HP PCL language), develops the data in RAM, transmits the data to the print
head for thermal transference, and coordinates the paper and ribbon feeding mechanisms.
The main board is functionally divided into two areas: the main or control area for image
(video) processing and the sub area for engine control and print processing.
Figure 1-5 and Figure 1-6 show the locations of the connectors on each main board
revision.
1-6 General Information
CN11 (Power)
6-pin
CN14 (Model 412
Pre-Heater) 2-pin
CN7 (Power)
2-pin
CN6 (Print Head)
14-pin
CN17 (Stepper
Motor) 4-pin
CN8 (Front Panel
Open) 4-pin
CN16 (Stepper
Motor) 6-pin
CN4 (Label Sensor Diode)
2-pin
P2 (Serial)
25-pin
CN3 (Label Sensor LED)
3-pin
CN2 (Label Cutter Option)
5-pin
CN1 (Ribbon Present)
4-pin
CN5 (Print Head Open
/Closed) 4-pin
Figure 1-5
P1 (Parallel)
36-pin
CN12 (Power)
4-pin
P3 (Control Panel)
26-pin
CN13 (Control Panel Print Mode - Peel, Cut,
Rewind) 10-pin
Main Board Revision 12, 13, or 14 Connector Locations
General Information 1-7
C N 1 1 (P o w e r)
6 - p in
C N 7 (P o w e r )
2 - p in
C N 6 ( P r in t H e a d )
1 4 - p in
CN14 (Power for M odel 412 Pre-H eater)
2 - p in
CN17 (Stepper M otor
P o w er ) 4 - p in
C N 1 6 (S te p p er
M o tor) 6 - p in
C N 8 (F ro n t P a n e l
O p e n ) 4 -p in
C N 4 (L ab e l S en s or
D i o d e ) 2 - p in
C N 3 (L ab e l
S ens or L E D )
3 - p in
P 2 ( S e r ia l)
2 5 - p in
C N 2 (L ab e l
C u tt e r O p ti o n )
5 - p in
C N 1 ( R ib b o n
P r e s e n t)
4 - p in
P 1 ( P a r a lle l)
3 6 - p in
C N 5 ( P r in t H e a d
O p e n /C l o s e d
P 3 ( C o n tr o l
P a n e l) 2 6 - p in
C N 1 2 (P o w e r)
4 - p in
P a r a lle l P o r t B u s
C on n ector
C N 1 3 ( C o n tr o l P a n e l P r in t M o d e - P e e l ,
C u t, R e w i n d ) 1 0 - p in
Figure 1-6
Main Board Revision 15 and 16 Connector Locations
Ribbon and Label Feed Mechanisms
This section describes the thermal transfer printing process carried out by the ribbon and
label feed mechanisms.
NOTE: Direct thermal printing, where no
ribbon is required and heat sensitive labels or tag
stock are printed on directly, is not described in
this section.
During the thermal transfer process, the ribbon and label feed mechanisms move the ribbon
and labels between the platen and thermal print head. This confined space causes the ribbon
to press against the label. Ink from the ribbon is applied to the label each time it crosses the
print head by the heating of individual print head elements (resistors). The combination of
heat from the resistors and pressure between the ribbon and label lays down the printed
image.
1-8 General Information
The ribbon is fed by the stepper motor and is controlled by the main board and LED sensor
settings (ribbon end sensor).
During the printing process, the label feed mechanism moves the label from the supply roller
to the thermal print head and platen. Labels are fed by the stepper motor and by friction
with the ribbon. Label feeding is coordinated by the main board, sensor settings (label
sensor), and the control panel (see Section 3 for control panel settings that affect label
feeding).
Figure 1-7 shows a simplified view of how thermal transference works. A cut-away diagram
of the ribbon and label feed mechanism subassemblies for the Model 48 and 412 printers is
provided in Figure 1-8.
NOTE: The ribbon and label feed subassemblies
in the Model 88 printer differ in appearance from
the Model 48 and 412, but the theory of
operation is essentially identical as described
below.
When the label and ribbon are fed between the platen and thermal print head, the label
sensor detects the location of the 0.08-inch (2 mm) minimum gap between the labels on the
paper roll and thus determines the position of the first print line on the label. A print
command is then sent to the thermal print head by the engine control processor on the main
board (see “Print Mechanism”).
Simultaneously, heat builds up in the thermal head heater, which contains a bank of resistors
that selectively heat up, forming a printable image. The heat transfers ink on the ribbon to
areas on the label surface that correspond to the heated resistors. This process fuses the
image to the label.
Thermal Head
Thermal Transfer
Ink
Transferred Ink
Label
Platen
Figure 1-7 Thermal Transference
General Information 1-9
Ribbon Supply
Spindle
Ribbon Take-Up
Spindle
Print Head
(Open)
Stepper
Motor
Label Exit
Slot
Sensor
Plate
Label Supply
Spindle
Label Width
Guide
Figure 1-8 Ribbon and Label Feed Mechanisms (Model 48 and 412)
Print Mechanism
Printer engine functions are controlled by the engine control processor on the main board
sub-area. The engine control processor sends control signals in response to commands and
data received from the computer via the PC/AT core. The control and data signals heat the
thermal print head elements (resistors) as previously described in “Ribbon and Paper Feed
Mechanisms.” Control and data signals from the engine control processor also drive the
stepper motor for feeding the ribbon and labels through the printer. When the label or
ribbon sensors detect that the printer has run out of labels or ribbon (or when label jams
occur), the information is relayed from the engine control processor, and the appropriate
message appears on the control panel LCD (see Section 3 for display messages).
Depending on print speed, a specified “high” or “low” voltage is sent from the power
supply to the heater inside the thermal print head. During normal speed printing (2.4 ips to
12 ips) typically used with wax ribbons, the power supply provides a “high” voltage of
approximately 24V. This voltage can be changed using the control panel menu buttons (see
“Print Head Voltage Adjustment” in Section 5).
During low speed printing (0.6 ips to 1.6 ips) typically used with resin ribbons, a “low”
voltage of approximately 12V is used. This voltage can also be changed using the control
panel menu buttons (see “Print Head Voltage Adjustment” in Section 5).
1-10 General Information
Print speed is controlled by sending the appropriate strobe (STB) pulse (STB1 or STB2
applied pulse) according to the temperature information sent from the print head thermistor.
For high speed printing (10 ips to 12 ips), the print head is pre-heated to an optimum head
temperature of 50o C per resistor. If the head temperature exceeds 70o C, printing stops and
a head temperature message is reported on the control panel (see Section 2 for display
messages).
NOTE: During printing, the actual temperature
of a resistor can exceed 200o C for a few
milliseconds.
MEMORY EXPANSION
Depending on the main board revision installed in the printer, memory expansion can be
done in the IntelliBar Model 48 and 412 through the purchase of industry-standard, userinstallable, SIMM memory modules made for Apple or PC products. SIMM modules are
available from retail or mail order computer hardware suppliers. These modules install in
pairs in two expansion slots on the main board and increase the printer’s standard memory
capacity from the standard 2 MB to a maximum of 10 MB.
NOTE: The Model 88 contains a total of 10 MB
of standard printer memory which is not
expandable.
See Table 4-1 and Table 4-2 in Section 4 for memory installation guidelines and procedures.
OPTIONS
IntelliTech International, Inc. options for the IntelliBar printer are divided into two
categories: user-installable and factory-installable. Each category is described below.
Section 4 provides additional information on IntelliTech International, Inc. printer options
(including installation procedures and dealer order numbers).
User-Installable Options
User installable options for the IntelliBar Models 48 and 412 include the following.
Label Cutter (Model 2401) — Lets you quickly print and process labels for
immediate application. This user-installable option fits in the front panel in place
of the standard peel-off assembly. You must also remove the tear bar from above
the platen roller (see Section 3 for label cutter installation procedures).
General Information 1-11
The cutter is designed for users who require on-demand label printing (usually one
label at a time) and the convenience of a label precut and ready to apply. The
printer can be programmed to print a number of labels (up to 32,767) and then
perform the cut function.
The cutter is designed to cut only paper or synthetic label backing (liner) and can
also cut continuous media that contains no rubber based adhesives.
NOTE: The maximum thickness of labels used
with the cutter option is 0.005 in. (0.127 mm).
External Rewinder (Model 2402) — Mounts in front of the printer and rewinds
labels. Allows you to output labels that can be conveniently spooled for storage or
shipment to another location.
Factory-Installable Options
Factory-installable options for the IntelliBar Models 48 and 412 include the following.
Internal Rewinder (Model 2405) — This option mounts inside the IntelliBar and
can be used to spool printed media (labels and backing paper) for convenient
storage or transportation of labels in volume quantity. You can also use the
rewinder option to spool only the backing paper in peel-off print mode.
Reflective Label Sensor (Model 2404) — This field- or dealer-installable option
replaces the printer’s standard, transmissive (see-through) label sensor. This
option reflects light off the black stripe when tag or ticket stock is fed through the
printer and thereby detects the label’s home position (used for determining the
first print line on the label). This option can also be used on butt-cut or specialty
die-cut labels.
1-12 General Information
SPECIFICATIONS
Table 1-2 lists printer specifications for the IntelliBar Standard series. Specifications for the
IntelliBar AS Series, ax Series, and LPR Series are the same except as differentiated in
Table 1-1 for the printer command language, emulation, and connectivity.
NOTE: For updates on IntelliBar printer
specifications and other information about
IntelliTech International, Inc. products, visit our
Web site at http://www.intellibar.com.
Table 1-2 IntelliBar Standard Series Specifications
Feature
Model 48, 48E
Print method
Thermal transfer or direct thermal
Resolution
300 x 300 dots per inch (11.81 dots per mm)
Print widths
4.37" (111 mm) maximum)
Print length (standard)*
14 in. (356 mm)
28 in. (711.2 mm)
14 in. (356 mm)
Print length
(maximum)*
99 in. (2,515 mm)
99 in. (2,515 mm)
99 in. (2,515 mm)
Print speed
.6 in. up to 8 in. per
second
.6 in. up to 12 in. per
second
.6 in. up to 8 in. per
second
Memory
2 MB standard, 10 MB
maximum
2 MB standard, 10 MB
maximum
10 MB standard (not
expandable)
Dimensions
Control Panel
Interface
Emulation
Model 412, 412E
Model 88, 88E
8.65 in. (220 mm)
maximum
12.4 in. H x 9.4 in. W x 16 in. D
(315 H mm x 239 mm W x 406 mm D)
13.2 in. H x 14.4 in. W
x 17 in. D (335 mm H x
366 mm W x 432 mm D)
LCD, 16 character, 2 line status and error display
IEEE 1284 (parallel) and RS-232C/RS-422C (serial)
Baud rate:
1200 - 38,400 bps
Hewlett Packard LaserJet III (HP PCL 5, HP GL/2)
Fonts
14 bit map fonts, 8 AGFA IntelliFont scalable typefaces (CG Times, Univers
Bold)
Bar codes
UPC-A, UPC-E, EAN/JAN-13, EAN/JAN-8, UPC/EAN extension (2 of 5 digit
supplemental), 3 of 9 (Code 39), Extended 3 of 9, Interleaved 2 of 5, Code 128,
Codebar, Zip +4, Postnet, MSI Plessey, Code 93, Extended 93, UCC-128,
HIBC, PDF417
Electrical
115 VAC + 10%, 50/60 Hz.
230 VAC + 10% 50/60 Hz
IEEE 1284 compliant cable required
* See Section 2 for print media specifications.
General Information 1-13
Table 1-2 IntelliBar Standard Series Specifications
Feature
Model 48, 48E
Operating environment
41 F – 104 F (5 C – 40 C); below 85%
non-condensing humidity
Agency certifications
UL-1950, C-UL, FCC Class A (115 VAC); TUV EN69050, CE mark (230 VAC)
User-installable options
Label Backing Cutter:
Model No. 2401**
External Label Rewinder: Model No. 2402
Label Cutter: 240X
Factory-installed
options
Reflective Sensor (Model 2404)
Internal Rewinder (Model 2405)
Reflective Sensor 240X
Internal Rewinder 240X
Warranty (U.S)
One-year limited warranty; printhead warranted for 90 days or 500,000 linear
inches, whichever comes first
Media
Die cut and continuous paper stocks, synthetic stocks, tag stock, ticket stock
Label finishing
Standard: Continuous, tear off and on-demand peel off (self strip). Cut off:
optional
Label specifications
Label print width: .75 in. min. to 4.37 in. max.
(19 mm to 111 mm)
o
o
Model 412, 412E
Model 88, 88E
o
4.37 in. minimum to
8.65 in. maximum
(111 mm to 222 mm)
Label print length: .5 in. minimum. to 99 in. maximum*** (13 mm to 2,515 mm)
Minimum. label gap: .125 in. (3.2 mm)
Maximum label thickness: .01 in. (.245 mm)
Maximum roll diameter: 8 in. (203 mm); 7 in.(178
mm) with Internal Rewinder installed
8 in. (203 mm)
Inner core diameter: 3 in. (76.2 mm)
Label web width: .75 in. min. to 4.56 in. max.
(19 mm to 116 mm)
4.56 in. min. to 9.5 in.
max. (116 mm to 241
mm)
Ribbon types
Express Wax for high-speed printing up to 12 inches per second
Dura Wax for economical printing
Rugged Resin for durability and smudge resistance
Dura Resin Plus for chemical, heat and scratch resistance
Dura Wax/Resin for monochromatic color printing
Ribbon length
Wax Ribbons: 1,475 feet (450 meters); Resin Ribbons: 984 feet (300 meters)
Ribbon widths
1.06 in., 2.12 in., 3.27 in., 4.37 in.
(27 mm, 54 mm, 83 mm, 111 mm)
** Not intended for use with rubber-based adhesives.
*** With additional optional memory installed and page protect turned off.
4.37 in., 7 in., 8.65 in.
(111 mm, 178 mm, 222
mm)
1-14 General Information
INTERFACE
This section describes IntelliBar interfaces for communicating with the host computer or
network computer. The printer is equipped with two interface communication ports:
36-pin IEEE 1284 parallel (connector P1)
25-pin RS-232C serial/RS-422 serial (connector P2)
To select the interface, use the control panel menu tree as described in Section 3.
Parallel Interface
This section describes the IntelliBar parallel port interface.
The IEEE 1284 parallel input allows no parameters. It always accepts 8-bit data with no
parity. For communication functions, it reserves the same set of characters reserved by the
serial port, with the exception of X-ON and X-OFF characters.
Note that the IEEE 1284 parallel interface is essentially an input-only channel. The parallel
port communicates in one direction, which is from the host computer to the printer.
IEEE 1284 Cable Requirements
The cable connected to the parallel interface port must be fully shielded and fitted with the
proper connector shell. Keep parallel cables as short as possible (8 ft. maximum) and do not
route or connect them near electrical conduits or high-voltage power lines.
To ensure the cable meets IEEE 1284 specifications, a cable labeled IEEE-1284 compliant
is required and is a simple way to guarantee good cable design. A cable with this label
contains the IEEE 1284-standard of 36 twisted-pair wires and is properly shielded.
Serial Interface
This section describes the IntelliBar serial interface. IntelliBar serial communications meets
the following specifications:
asynchronous
8 data bits per character
no parity
one start bit
one stop bit
Three parameters are used to control serial communication: channel, baud rate, and
options.
General Information 1-15
The baud rate is given as an integer (such as 1200 or 9600), and the maximum supported
baud rate is 38,400 bits per second (bps). Standard baud rates supported by the IntelliBar
are as follows.
300
600
1200
2400
4800
9600
19,200
38,400
Data Transmission
The printer uses Robust X–ON/X–OFF protocol to control transmitted and received
character flow.
At power-on, the serial controller carries out communication as soon as the hardware and
software are initialized. Hence, the first character sent in X-ON/X-OFF mode will be X-ON
(rather than X-OFF).
Available in Menu Mode using the control panel menu buttons, Robust X-ON/X-OFF flow
control determines if additional X-ONs should be transmitted.
If Robust X-ON/X-ON is set to ON (the default), additional X-ONs will be transmitted at
one second intervals until data is received. If it is set to OFF using the control panel (see
Section 3), no additional X-ONs are sent.
NOTE: The information in this section is subject
to change without notice. This information is
provided "as is" without either express or implied
warranty. IntelliTech International, Inc. disclaims
any and all warranties with regard to this
information. IntelliTech shall not be liable in any
event for any special, indirect or consequential
damages or any damages whatsoever resulting
from loss of data, profits or use, for any reason
or in any action, arising out of or in connection
with the use or performance of this information.
Section 2
Setup
This section provides printer setup information, which includes instructions on connecting
power and interface cables, replacing the thermal ribbon, and replacing the label roll. See
Section 3 for instructions on installing memory and printer options.
In addition, this section includes instructions on printing test labels to check printer
operation before performing service or as a check after performing service.
This section also provides information on using the printer’s control panel buttons to affect
operation. Control panel LED indicators, status messages, menu descriptions, and factory
settings of printer operating parameters are described. The 2-line by 16-character liquid
crystal display (LCD) on the control panel shows the printer’s operational status, error
codes, and parameter values. The LCD also displays the menus used to change printer
parameters.
UNIT SETUP
Printer operation and print quality are affected by the environment in which the printer is
placed. When setting up the printer or doing any service procedure, always be sure the
printer meets the environmental specifications listed below and the media specifications in
Section 1 of this manual. If the printer has not yet been unpacked (or to repack it for
shipping), see Appendix A for unpacking/packing procedures.
The IntelliBar is designed to function reliably even under harsh conditions, such as those
that might be present in manufacturing or warehouse environments.
Optimum print quality is achieved under the following conditions:
Temperature: 41° to 104° F (5° to 40° C)
Relative humidity: 15 to 85%
To maintain the best conditions for trouble-free operation, observe the following
environmental standards.
Place the printer in a well-ventilated area. Adequate clearance should be provided
on all sides of the unit to allow heat to dissipate.
A minimum of 14 inches of clearance is needed above the Model 48 and 412
printers to open the hinged access door on the left side of the unit. For the Model
88, a minimum of 11 inches is needed to open the top cover.
2-2 Setup
Note the printer dimensions and the clearance guidelines shown in the following
figures.
With the front panel open on the Model 48 and 412, the distance from the front of
the printer to the back (printer depth) is 24.5 inches
24.50 Inches
Front Panel
Figure 2-1 Printer Depth (Model 48 and 412)
With the left side cover open, the distance from the left side of the Model 48 and
Model 412 to the right side (printer width) is 17 inches.
Setup 2-3
17.00 Inches
Figure 2-2 Printer Width (Model 48 and 412)
With the left side cover completely open, the distance from the bottom of the
Model 48 and Model 412 to the top (printer height) is 24.25 inches.
2-4 Setup
24.25 Inches
Figure 2-3 Printer Height (Model 48 and 412)
The following figure shows the width and height specifications for the Model 88
printer with the top and side covers open.
Setup 2-5
Top Cover
25"
Side Cover
16.5"
30.5"
Figure 2-4 Printer Clearances (Model 88)
Keep the printer away from direct sunlight.
Do not expose the printer to extreme changes in temperature, as might occur near
a heating or air conditioning unit.
Place the printer away from devices that generate strong magnetic fields such as
electric motors or transformers.
Connecting the Power Cord
The power cord supplied with the printer plugs into the ac inlet connector on the back of
the printer. The other (male) end of the power cord plugs into a properly grounded, threeprong wall receptacle or other grounded power outlet. Always ensure the power switch is in
the OFF position before plugging in the cord. Figure 2-5 shows the location of the power
cord inlet connector and power switch and explains the power switch markings.
2-6 Setup
The power source for the IntelliBar is either 110Vac ±10%, 50/60Hz or 220Vac ±10%,
50/60Hz (for “E” Versions). Voltage higher or lower than specified can cause printer
malfunctions.
The electric power line should be free from electric noise caused by other machines. A
dedicated power line for the IntelliBar, separate from noise producing equipment, is
recommended and must be in close proximity to the printer. If a separate line (for example,
a different wall receptacle) is not available, use a noise filter (purchasable from an electrical
supplies dealer).
CAUTION: Turn off the printer before plugging
in the power cord, and always use a properlygrounded power outlet.
Power Switch
0=O ff
1=O n
Figure 2-5 Connecting Power
Connecting the Communications Interface Cables
The following subsections describe how to install the communications interface cable in the
IntelliBar standard, AS Series, and ax Series printers.
Standard IntelliBar Communications Interface
The back of the printer has one RS-232C/RS-422 serial interface port and one Centronics
parallel interface port.
Figure 2-6 identifies the interface ports.
When plugging in the interface cable, observe the alignment shape of the connectors to
ensure proper connection.
CAUTION: Turn off the computer and printer
before installing or removing any interface cable.
Setup 2-7
Rear Interface
Panel
Serial Port
Parallel Port
Figure 2-6 Interface Ports (Standard IntelliBar Series)
Use the correct type of interface cable when connecting the printer to the computer. A
description of each interface type is provided in Section 1 (see “Interface”). Attach the
interface cable as follows.
1. Make sure the power to the printer is turned off.
2. Connect the interface cable to the appropriate standard IntelliBar Series interface
port (see Figure 2-6).
3. Secure the cable with the indicated screws or clips.
For example, the RS-232C serial cable has two screws attached to the cable
connector.
4. If a grounding wire is attached to the interface cable, secure the wire to the one of
the screws on the printer’s rear interface panel (see Figure 2-6).
5. Connect the other end of the interface cable to the computer according to the
manufacturer’s instructions.
2-8 Setup
IntelliBar AS Series and ax Series Communication Interfaces
For IBM AS/400 and System 3X computers, set up the IntelliBar printer to operate in an
AFP/IPDS (AS Series) or SCS/EBCDIC (ax Series) configuration as follows:
1. Attach the twinax or coax cable adapter to the 15-pin port on the interface board
(see Figure 2-7).
2. If connecting to a twinax host, set the I/O address on the four-segment switch
bank to the correct value for your configuration (see Table 2-1). Obtain
information about your configuration’s address from your system administrator.
If connecting to a coax host, set all the switches to OFF.
Table 2-1 IntelliBar AS Series I/O Address
Switch Settings (Twinax Connection)
Twinax
Address
Switch
Segment 1
Switch
Segment 2
Switch
Segment 3
Switch
Segment 4
0
Off
Off
Off
Off
1
On
Off
Off
Off
2
Off
On
Off
Off
3
On
On
Off
Off
4
Off
Off
On
Off
5
On
Off
On
Off
6
Off
On
On
Off
Figure 2-7 shows a close-up view of the rear of the printer with the interface
board installed.
Setup 2-9
Interface
Board
LED
Interface Board
Switch Bank
Interface Board
IEEE 1284 Parallel Port
Main
Board
LED
Main Board RS232C/422
Serial Port
5 mm Hex Nut
Interface Board
RS232C Serial Port
(9-pin)
5 mm Hex Nut
Main Board IEEE 1284
Parallel Port
Interface Board
Twinax/Coax Port (15-pin )
5 mm Hex Nut
Figure 2-7 Interface Board Connector, LED, and Switch Locations
4. Turn on the printer and the host computer. After approximately 8 to 10 seconds,
the LED on the interface board lights green, indicating that the host has
established communication with the printer.
5. Check the status of the printer at the host. The host automatically configures the
printer for AFP/IPDS (AS interface board installed) or SCS (ax interface board
installed).
After auto configuration, the printer is ready to receive print jobs.
2-10 Setup
Label and Ribbon Requirements
Print quality depends on factors such as the type of ribbon and labels being used. Label
thickness and abrasion levels and the resistance of ribbons and labels to extreme
temperatures all play an important role in maintaining the life of the print head and ensuring
print quality.
For best results, use high-quality labels (die-cut, butt-cut, or continuous forms) that meet
the specifications listed in Table 2-2.
Table 2-2 Label Specifications
Measurement
Minimum Specification
Maximum Specification
Model 48, 412: 0.75 in. (19
mm)
Model 48, 412: 4.56 in.
(116 mm) maximum
Model 48, 412: 4.56 in. (116
mm)
Model 88: 9.5 in.
(241 mm) maximum
Length
0.51 in. (13 mm)
99 in. (2.51 m); requires
additional memory
Thickness
0.0025 in. (0.0635 mm)
0.01 in. (0.245 mm)
Gap
0.125 in. (3.2 mm)
1.5 x length of label
*
Width
*Label specifications depend on the label stock. Maximum width of adhesive label stock (including backing
paper) or tag stock is 4.56 in. (116 mm) for the Model 48 and Model 412 and 9.5 in (241 mm) for the Model
88. Figure 2-8 provides label specifications for die-cut labels only. Maximum width of the print line (printable
width) on the label is 4.37 in. (111 mm) for the Model 48 and Model 412 and 8.65 in. (220 mm) for the Model
88.
NOTE: For updates on IntelliBar label
specifications and other information about labels
orderable through IntelliTech International, Inc.,
visit our Web site at http://www.intellibar.com.
Setup 2-11
4.56 inches (116 mm) maximum web
width (Model 48 and 412)
9.5 inches (241 mm) maximum web
width (Model 88)
Printable widths:
4.37 inches
(111 mm) maximum
(Model 48 and 412)
.08 inches (2mm)
Unprintable Area
Top and Bottom
8.65 inches
AAAAAAA.......................................AAAA
(222 mm) maximum
(Model 88)
.125 inches
(3.2 mm) Min.
gap for die-cut
labels
.5 inches (13mm)
Min. Label Length
for die-cut labels
99 inches (2.51m)
Max. Label Length
for die-cut labels
Label Web Width
Figure 2-8 Paper Specifications
2-12 Setup
IntelliBar Ribbons
IntelliTech International, Inc. offers three categories of thermal transfer ribbons:
wax (IntelliTech Express Wax™ and IntelliTech Dura Wax™)
wax/resin (IntelliTech Dura Wax/Resin™
resin (IntelliTech Rugged Resin™ and Dura Resin Plus™).
Each category is manufactured with high quality materials to the following specifications to
fit particular operating conditions and purposes:
thickness – 5 microns
ribbon backing material – polyester film
ink material
— Express Wax, black
— Dura Wax, black
— Dura Wax/Resin, colors (see Table 2-4)
— Rugged Resin, black
— Dura Resin Plus, black
ribbon length – 990 ft. (300 m) for resin type; 1485 ft. (450 mm) for wax type
ribbon widths –
Model 48 and 412
Model 88
1.06 in. (27 mm)
2.13 in. (54 mm)
3.27 in. (83 mm
4.37 in. (111 mm)
6.64 in. (165.0 mm)
8.65 in. (220.0 mm)
The following tables list IntelliTech order numbers for IntelliBar black and color ribbons.
Setup 2-13
Table 2-3
Description
Express Wax
Dura Wax
Rugged Resin
Dura Resin Plus
IntelliBar Black Ribbons∗
∗
Width
Length
Order Number
1.08 inches (27 mm)
450 meters (1,475 feet)
50-101
2.20 inches (54 mm)
450 meters (1,475 feet)
50-102
3.32 inches (83 mm)
450 meters (1,475 feet)
50-103
4.44 inches (111 mm)
450 meters (1,475 feet)
50-104
6.64 inches (165 mm)
450 meters (1475 feet)
50-201
8.88 inches (222 mm)
450 meters (1,475 feet)
50-202
1.08 inches (27 mm)
450 meters (1,475 feet)
50-101
2.20 inches (54 mm)
450 meters (1,475 feet)
50-102
3.32 inches (83 mm)
450 meters (1,475 feet)
50-103
4.44 inches (111 mm)
450 meters (1,475 feet)
50-104
6.64 inches (165 mm)
450 meters (1475 feet)
50-203
8.88 inches (222 mm)
450 meters (1,475 feet)
50-204
1.08 inches (27 mm)
300 meters (990 feet)
50-109
2.20 inches (54 mm)
300 meters (990 feet)
50-110
3.32 inches (83 mm)
300 meters (990 feet)
50-111
4.44 inches (111 mm)
300 meters (990 feet)
50-112
6.64 inches (165 mm)
300 meters (990 feet)
50-205
8.88 inches (222 mm)
300 meters (990 feet)
50-206
1.08 inches (27 mm)
300 meters (990 feet)
50-113
2.20 inches (54 mm)
300 meters (990 feet)
50-114
3.32 inches (83 mm)
300 meters (990 feet)
50-115
4.44 inches (111 mm)
300 meters (990 feet)
50-116
6.64 inches (165 mm)
300 meters (990 feet)
50-207
8.88 inches (222 mm)
300 meters (990 feet)
50-208
∗ This page was prepared September 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at
800-694-3034.
2-14 Setup
Table 2-4 IntelliBar Color Ribbons∗
∗
Description
Color
Width
Length
Order Number
Dura Wax/Resin
White
1.08 inches (27 mm)
300 meters (990 feet)
50-501
White
2.20 inches (54 mm)
300 meters (990 feet)
50-502
White
3.32 inches (83 mm)
300 meters (990 feet)
50-503
White
4.44 inches (111 mm)
300 meters (990 feet)
50-504
White
6.64 inches (165 mm)
300 meters (990 feet)
50-505
White
8.88 inches (222 mm)
300 meters (990 feet)
50-506
Process
cyan
1.08 inches (27 mm)
300 meters (990 feet)
50-508
Process
cyan
2.20 inches (54 mm)
300 meters (990 feet)
50-509
Process
cyan
3.32 inches (83 mm)
300 meters (990 feet)
50-510
Process
cyan
4.44 inches (111 mm)
300 meters (990 feet)
50-511
Process
cyan
6.64 inches (165 mm)
300 meters (990 feet)
50-512
Process
cyan
8.88 inches (222 mm)
300 meters (990 feet)
50-513
Process
magenta
1.08 inches (27 mm)
300 meters (990 feet)
50-515
Process
magenta
2.20 inches (54 mm)
300 meters (990 feet)
50-516
Process
magenta
3.32 inches (83 mm)
300 meters (990 feet)
50-517
Process
magenta
4.44 inches (111 mm)
300 meters (990 feet)
50-518
Process
magenta
6.64 inches (165 mm)
300 meters (990 feet)
50-519
Process
magenta
8.88 inches (222 mm)
300 meters (990 feet)
50-520
Process
yellow
1.08 inches (27 mm)
300 meters (990 feet)
50-522
Process
yellow
2.20 inches (54 mm)
300 meters (990 feet)
50-523
∗ This page was prepared July 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at
800-694-3034.
Setup 2-15
Table 2-4 IntelliBar Color Ribbons∗
∗
Description
Color
Width
Length
Order Number
Dura Wax/Resin
Process
yellow
3.32 inches (83 mm)
300 meters (990 feet)
50-524
Process
yellow
4.44 inches (111 mm)
300 meters (990 feet)
50-525
Process
yellow
6.64 inches (165 mm)
300 meters (990 feet)
50-526
Process
yellow
8.88 inches (222 mm)
300 meters (990 feet)
50-527
Lemon
yellow
1.08 inches (27 mm)
300 meters (990 feet)
50-529
Lemon
yellow
2.20 inches (54 mm)
300 meters (990 feet)
50-530
Lemon
yellow
3.32 inches (83 mm)
300 meters (990 feet)
50-531
Lemon
yellow
4.44 inches (111 mm)
300 meters (990 feet)
50-532
Process
cyan
6.64 inches (165 mm)
300 meters (990 feet)
50-533
Lemon
yellow
8.88 inches (222 mm)
300 meters (990 feet)
50-534
Orange
1.08 inches (27 mm)
300 meters (990 feet)
50-536
Orange
2.20 inches (54 mm)
300 meters (990 feet)
50-537
Orange
3.32 inches (83 mm)
300 meters (990 feet)
50-538
Orange
4.44 inches (111 mm)
300 meters (990 feet)
50-539
Orange
6.64 inches (165 mm)
300 meters (990 feet)
50-540
Orange
8.88 inches (222 mm)
300 meters (990 feet)
50-541
Dark
orange
1.08 inches (27 mm)
300 meters (990 feet)
50-543
Dark
orange
2.20 inches (54 mm)
300 meters (990 feet)
50-544
Dark
orange
3.32 inches (83 mm)
300 meters (990 feet)
50-545
Dark
orange
4.44 inches (111 mm)
300 meters (990 feet)
50-546
∗ This page was prepared July 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at
800-694-3034.
2-16 Setup
Table 2-4 IntelliBar Color Ribbons∗
∗
Description
Color
Width
Length
Order Number
Dura Wax/Resin
Dark
orange
6.64 inches (165 mm)
300 meters (990 feet)
50-547
Dark
orange
8.88 inches (222 mm)
300 meters (990 feet)
50-548
Red
1.08 inches (27 mm)
300 meters (990 feet)
50-550
Red
2.20 inches (54 mm)
300 meters (990 feet)
50-551
Red
3.32 inches (83 mm)
300 meters (990 feet)
50-552
Red
4.44 inches (111 mm)
300 meters (990 feet)
50-553
Red
6.64 inches (165 mm)
300 meters (990 feet)
50-554
Red
8.88 inches (222 mm)
300 meters (990 feet)
50-555
Burgundy
1.08 inches (27 mm)
300 meters (990 feet)
50-557
Burgundy
2.20 inches (54 mm)
300 meters (990 feet)
50-558
Burgundy
3.32 inches (83 mm)
300 meters (990 feet)
50-559
Burgundy
4.44 inches (111 mm)
300 meters (990 feet)
50-560
Burgundy
6.64 inches (165 mm)
300 meters (990 feet)
50-561
Burgundy
8.88 inches (222 mm)
300 meters (990 feet)
50-562
Shamrock
Green
1.08 inches (27 mm)
300 meters (990 feet)
50-564
Shamrock
Green
2.20 inches (54 mm)
300 meters (990 feet)
50-565
Shamrock
Green
3.32 inches (83 mm)
300 meters (990 feet)
50-566
Shamrock
Green
4.44 inches (111 mm)
300 meters (990 feet)
50-567
Shamrock
Green
6.64 inches (165 mm)
300 meters (990 feet)
50-568
Shamrock
Green
8.88 inches (222 mm)
300 meters (990 feet)
50-569
Forrest
Green
1.08 inches (27 mm)
300 meters (990 feet)
50-571
Forrest
Green
2.20 inches (54 mm)
300 meters (990 feet)
50-572
∗ This page was prepared July 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at 800-6943034.
Setup 2-17
Table 2-4 IntelliBar Color Ribbons∗
∗
Description
Color
Width
Length
Order Number
Dura Wax/Resin
Forrest
Green
3.32 inches (83 mm)
300 meters (990 feet)
50-573
Forrest
Green
4.44 inches (111 mm)
300 meters (990 feet)
50-574
Forrest
Green
6.64 inches (165 mm)
300 meters (990 feet)
50-575
Forrest
Green
8.88 inches (222 mm)
300 meters (990 feet)
50-576
Royal Blue
1.08 inches (27 mm)
300 meters (990 feet)
50-578
Royal Blue
2.20 inches (54 mm)
300 meters (990 feet)
50-579
Royal Blue
3.32 inches (83 mm)
300 meters (990 feet)
50-580
Royal Blue
4.44 inches (111 mm)
300 meters (990 feet)
50-581
Royal Blue
6.64 inches (165 mm)
300 meters (990 feet)
50-582
Royal Blue
8.88 inches (222 mm)
300 meters (990 feet)
50-583
Midnight
Blue
1.08 inches (27 mm)
300 meters (990 feet)
50-585
Midnight
Blue
2.20 inches (54 mm)
300 meters (990 feet)
50-586
Midnight
Blue
3.32 inches (83 mm)
300 meters (990 feet)
50-587
Midnight
Blue
4.44 inches (111 mm)
300 meters (990 feet)
50-588
Midnight
Blue
6.64 inches (165 mm)
300 meters (990 feet)
50-589
Midnight
Blue
8.88 inches (222 mm)
300 meters (990 feet)
50-590
Brown
1.08 inches (27 mm)
300 meters (990 feet)
50-592
Brown
2.20 inches (54 mm)
300 meters (990 feet)
50-593
Brown
3.32 inches (83 mm)
300 meters (990 feet)
50-594
Brown
4.44 inches (111 mm)
300 meters (990 feet)
50-595
Brown
6.64 inches (165 mm)
300 meters (990 feet)
50-596
Brown
8.88 inches (222 mm)
300 meters (990 feet)
50-597
∗ This page was prepared July 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at 800-6943034.
2-18 Setup
Ribbon/Label Combination
Refer to Table 2-5 for general guidelines in selecting the ribbon/label combination best
suited for the application and environmental variables that affect print quality.
Table 2-5 Ribbon/Label Selection Matrix
Application
Ribbon
Description
Label Description
For economical high to medium speed
printing.
Express Wax
Coated or uncoated paper
stock only.
For economical yet more durable
medium speed printing. Used in
environments that require some
smudge and scratch resistant capability.
Dura Wax
Coated label and tag stock
only. Also for use with smooth
uncoated stocks. Economical
labels for many applications.
Used in harsh environments needing
smudge and scratch resistant materials.
For medium speeds.
Rugged Resin
Excellent on synthetic label
stock and coated paper. Not
recommended for uncoated
paper stock.
For low speed printing. Permanent bar
codes. Suitable for harsh environments.
Smudge and super scratch proof.
Solvent, heat, and wash proof.
Dura Resin Plus
Excellent on synthetic label
stock. Not recommended for
coated or uncoated paper
stock.
For color printing.
Dura Wax Resin
Good all around, versatile use on
many paper and synthetic stocks.
To help you further identify the ribbon/label combination that meets your needs, Table 2-6
provides information about average ink-to-label transfer and smudge characteristics. This
information should only be used as a guideline, since ribbon/label performance is also
dependent on print speeds, print head energy levels, print head position, and other factors.
CAUTION: To avoid undue wear on the print
head and reduce repair costs, use ribbons that are
the same width or slightly wider than the
labels.
Setup 2-19
Table 2-6 Ribbon and Label Type Performance Guidelines
Uncoated Paper
Print
Quality
Express Wax
Dura Wax
Rugged
Resin
Dura Resin
Plus
Dura
Wax/Resin
Rating
NR
Smudge &
Scratch
Resistance
NR
NR
Print Quality
Excellent
Good
Fair
Marginal
Not recommended
Coated Paper
Print
Quality
Smudge &
Scratch
Resistance
Polypropylene
Print
Quality
Smudge &
Scratch
Resistance
Polyester
Print
Quality
Smudge &
Scratch
Resistance
NR
Smudge & Scratch Resistance
No change to printed image
Slight effect to printed image
Some effect to printed image
Noticeable effect to printed image
Not recommended
Loading Labels
To load a label roll, proceed as follows depending on your IntelliBar model and whether
you are operating the printer in standard, tear-off, cut-off, or peel-off print modes. For
information on selecting the print mode for your printer through the control panel menu
button, see Section 3, “Unit Operation.”
Models 48 and 412
The following subsection describes how to load labels for the IntelliBar Models 48 and 412.
See “Model 88” later in this section to load labels in the IntelliBar Model 88 printer.
Standard Mode, Tear-Off Mode, Cut-Off Mode (Models 48 and 412)
If the printer is operating in standard, tear-off, or cut-off mode, follow these steps to load
labels.
1. Open the printer’s left side cover. Open and lower the front panel by pressing the
front panel release latch (see Figure 2-9).
2. Place the label roll on the label supply spindle, label side up, so the roll unwinds in
the clockwise direction.
3. Pull up the print head release latch and raise the print head.
2-20 Setup
Raise print head.
Mount label
media roll.
Pull blue handle
to open front
panel.
Pull up blue
print head
release latch.
Figure 2-9 Mounting the Label Roll (Model 48 and 412)
4. Raise the label sensor plate and gently route the label backing paper (liner)
between the white teflon label width guides, under the label sensor plate, and over
the platen roller (see Figure 2-10).
Setup 2-21
Lift label sensor
plate and pull
labels through.
Adjust label width guide
to label edge.
Platen Roller
Center label
sensor over
label.
Figure 2-10 Installing Labels (Model 48 and 412)
NOTE: Make sure the label sensor mounted on
the sensor plate is positioned in the center of the
label and is not over a label gap. If it is not
centered, slide the sensor assembly to the left or
right as required (see Figure 2-11).
2-22 Setup
Sensor Plate
Label Sensor
Label
Figure 2-11 Label Sensor Location (Model 48 and 412)
5. Route the label liner through the exit slot in the front panel.
6. Close and latch the print head assembly, making sure the print head is securely
latched.
7. Make sure the inside edge of the label backing paper is touching the inside label
width guide (see Figure 2-12). (If it is not, open the print head, realign the label
media, and close the print head). Slide the outside label width guide up to the
edge of the label backing paper to prevent liner mistracking (skew).
Setup 2-23
Inside Label Width
Guide
Label Sensor Plate
Label Media
Outside Label Width
Guide
Figure 2-12 Label Width Guides (Model 48 and 412)
8. Close the front panel and left side cover.
9. Turn on the printer and wait for it to initialize (“OFFLINE, INITIALIZE”
appears in the 2-line control panel LCD display). During initialization, several
labels will feed consecutively and exit the label exit slot as the printer
automatically measures the label gap and label length.
After the printer has measured the label gap and label length, feeding stops.
“ONLINE, READY” appears in the 2-line control panel LCD display.
10. From the control panel, select the desired “PRINT MENU, PRINT MODE,”
parameter (see Section 3 for information on using the control panel menu button
and menu tree to set the standard, tear-off, or cut-off print mode parameter).
NOTE: If you want to operate in standard
mode, you do not need to set the print mode
parameter if you are loading labels for the first
time after taking the printer out of the box. The
“STANDARD” print mode parameter is the
default that is set at the factory.
2-24 Setup
Peel-Off Mode (Models 48 and 412)
If the printer operates in peel-off mode (with no cutter option installed), follow these steps
to load labels.
1. Load labels as described in steps 1 through 9 in the previous subsection.
2. From the control panel, select the “LABEL MENU, LABEL MEASURE,
FIXED” parameter as follows (see also “Menu Tree” later in this section).
Press the Menu button (“MAIN MENU”, “PRINT MENU” appears in the
LCD display).
Press Next (“MAIN MENU”, “LABEL MENU” appears in the LCD display).
Press Select (“LABEL MENU”, “LABEL TYPE” appears in the LCD
display).
Press Next (“LABEL MENU”, “MEASURE LABEL” appears in the LCD
display).
Press Select (“MEASURE LABEL”, “AUTOMATIC” appears in the LCD
display).
Press Next (“MEASURE LABEL”, “FIXED” appears in the LCD display).
Press Select (“MEASURE LABEL, “FIXED” appears with an asterisk).
Press the Online button (“ONLINE, READY” appears in the control panel
LCD).
This setting ensures that no more than one label advances during subsequent
power-on initialization routines, avoiding possible label jams at the label exit slot.
3. From the control panel, select the “PRINT MENU, PRINT MODE, PEEL-OFF”
parameter as follows (see also “Menu Tree” later in this section).
Press the Online button (OFF LINE, PAUSE appears in the 2-line control
panel LCD display).
Press the Menu button (“MAIN MENU”, “PRINT MENU” appears in the
LCD display).
Press Select (“PRINT MENU”, “PRINT METHOD” appears in the LCD
display.
Press Next (“PRINT MENU”, “PRINT MODE” appears in the LCD display.
Press Select. One of the print modes other than peel off appears in the LCD
display (“STANDARD”, “TEAR OFF”, or “CUT OFF”) depending on the
print mode that you previously selected (“STANDARD” is the factory
default).
Setup 2-25
Press Next until “PEEL OFF” appears.
Press Select (“PRINT MODE , “PEEL OFF” appears with an asterisk).
4. Open the front panel and print head.
5. Reroute the label strip downward past the peel-off roller and through the label
release paper slot (see Figure 2-13).
Platen Roller
Peel-off/Tear Bar
Peel-off
Roller
Label Release
Paper Slot
Figure 2-13 Peel-Off Mode Label Routing (Model 48 and 412)
6. While gently pulling the liner downward, close and latch the print head assembly,
making sure the print head is securely latched. Then close and latch the front
panel.
Figure 2-14 shows a cut-away view of the label routing path for peel-off mode.
2-26 Setup
Peel-off/Tear Bar
Label Media
Label
Platen Roller
Backing
Paper
Peel-Off
Roller
Label Release
Paper Slot
Figure 2-14 Model 48 and 412 Peel-Off Mode Label Routing – Cut-Away View
7. Press Online. Two labels will feed consecutively. The first label will feed and
separate (peel) from the backing paper (liner) and exit the label exit slot. (The
liner exits through the label release paper slot.) After the first label feeds, manually
remove this label from the label exit slot and then wait for the second label to
finish feeding.
When the second label has fed, the printer pauses. “PEEL OFF LABEL” appears
in the control panel LCD display.
8. Remove the label from the exit slot. When you have removed the label, the label
roll will automatically back up so that the next label is in position for printing.
“ONLINE, READY” will appear in the control panel LCD.
Setup 2-27
Model 88
The following subsection describes how to load labels for the IntelliBar Model 88. See
“Models 48 and 412” earlier in this section to load labels in the IntelliBar Model 48 and 412
printers.
Standard Mode, Tear-Off Mode, Cut-Off Mode (Models 88)
If the printer is operating in standard, tear-off, or cut-off mode, follow these steps to load
labels.
1. Open the printer’s left side cover and top cover.
2. Place the label roll on the label supply spindle, label side up, so the roll unwinds in
the clockwise direction (see the following figure).
3. Pull up the print head release latch and raise the print head (see Figure 2-15).
Figure 2-15 Mounting the Label Roll (Model 88)
4. Grasp the locking rod firmly with two fingers and push the rod toward the inside
of the printer. Lift up the label sensor plate when the rod slips out of the retaining
hole (see the following figure).
2-28 Setup
5. Carefully route the label backing paper (liner) between the metal label width
guides, under the label sensor plate, and over the platen roller (see Figure 2-16).
Locking Rod
Platen Roll
Label Width Guides
Label Sensor Plate
Picture shown without
front bezel or covers
installed.
Figure 2-16 Installing Labels (Model 88)
6. Lower the label sensor plate and slide the locking rod toward the left side of the
printer so the rod fits into the hole and secures the sensor plate.
7. Close and securely lock the print head with the latch lever.
Setup 2-29
Figure 2-17 Locking the Print Head (Model 88)
8. Close the top cover and left side cover.
Peel-Off Mode (Model 88)
If the printer operates in peel-off mode, follow these steps to load labels.
1. From the control panel, select the “LABEL MENU, LABEL MEASURE,
FIXED” parameter as follows (see also “Menu Tree” later in this section).
Press the Menu button (“MAIN MENU”, “PRINT MENU” appears in the
LCD display).
Press Next (“MAIN MENU”, “LABEL MENU” appears in the LCD display).
Press Select (“LABEL MENU”, “LABEL TYPE” appears in the LCD
display).
Press Next (“LABEL MENU”, “MEASURE LABEL” appears in the LCD
display).
Press Select (“MEASURE LABEL”, “AUTOMATIC” appears in the LCD
display).
Press Next (“MEASURE LABEL”, “FIXED” appears in the LCD display).
Press Select (“MEASURE LABEL, “FIXED” appears with an asterisk).
2-30 Setup
Press the Online button (“ONLINE, READY” appears in the control panel
LCD).
This setting ensures that no more than one label advances during subsequent
power-on initialization routines, avoiding possible label jams at the label exit slot.
2. From the control panel, select the “PRINT MENU, PRINT MODE, PEEL-OFF”
parameter as follows (see also “Menu Tree” later in this section).
Press the Online button (OFF LINE, PAUSE appears in the 2-line control
panel LCD display).
Press the Menu button (“MAIN MENU”, “PRINT MENU” appears in the
LCD display).
Press Select (“PRINT MENU”, “PRINT METHOD” appears in the LCD
display.
Press Next (“PRINT MENU”, “PRINT MODE” appears in the LCD display.
Press Select. One of the print modes other than peel off appears in the LCD
display (“STANDARD”, “TEAR OFF”, or “CUT OFF”) depending on the
print mode that you previously selected (“STANDARD” is the factory
default).
Press Next until “PEEL OFF” appears.
Press Select (“PRINT MODE , “PEEL OFF” appears with an asterisk).
3. Load labels as described in steps 1 through 5 in the previous subsection.
4. Thread approximately two feet of media through the print head to the front of the
printer.
5. Lower the label sensor plate and slide the locking rod toward the left side of the
printer so the rod fits into the hole and secures the sensor plate.
6. Close and securely lock the print head with the latch lever.
7. Lift up the peel-of roller latch rod and route the label media around the back of
the peel-off roller and out the front of the printer (see Figure 2-18). Make sure
the media exits the printer under the peel off roller and above the media exit
guide plate.
8. Firmly push the peel off roller latch rod down to engage the peel-off roller.
Setup 2-31
Peel-off Roller
Latch Rod (Up
Position)
Latch Rod
(Down Position)
Figure 2-18 Model 88 Peel-Off Mode Label Routing – Cut-Away View
9. Press Online. Two labels will feed consecutively. The first label will feed and
separate (peel) from the backing paper (liner) and exit the label exit slot. (The
liner exits through the label release paper slot.) After the first label feeds,
manually remove this label from the label exit slot and then wait for the second
label to finish feeding.
When the second label has fed, the printer pauses. “PEEL OFF LABEL” appears
in the control panel LCD display.
10. Remove the label from the exit slot. When you have removed the label, the label
roll will automatically back up so that the next label is in position for printing.
“ONLINE, READY” will appear in the control panel LCD.
2-32 Setup
Installing the Thermal Ribbon
The printer comes with a start-up thermal ribbon roll that is approximately 50 meters long.
An unopened ribbon roll package has a shelf life of about 2 1/2 years.
NOTE: Open ribbon roll wrappers carefully to
prevent the ribbon material from ripping.
For best results, store ribbons in an environment that meets the following conditions.
Temperature:
4° F to 86° F (-20° C to 30° C)
Humidity:
20 to 80% (non-condensing)
Model 48 or 412
To install a ribbon in the Model 48 or 412 printer, proceed as follows. If you are installing a
ribbon in the Model 88, see “Model 88” later in this section.
NOTE: IntelliTech International Inc.
recommends that you use a ribbon that is the
same width or slightly wider than the label liner
(backing paper) to protect the print head from
unnecessary wear.
1. Open the printer’s left side cover. Open the front panel by pressing the front panel
release latch (see Figure 2-19).
2. Remove the ribbon and take-up spool from the shipping bag.
NOTE: The take-up spool is mounted inside the
ribbon spool. Grasp both ends of the ribbon
spool and gently pull them apart to separate the
take-up spool from the ribbon roll.
3. Holding the black plastic flange away from you, align and slide the ribbon roll
onto the supply spindle so the ribbon unwinds in the counterclockwise direction
from the bottom of the spool.
4. Holding the black plastic flange away from you, align and slide the take-up spool
onto the take-up spindle, being careful to align the notches.
Setup 2-33
Mount ribbon
roll.
Line up notch
to mount
take-up spool.
Pull blue handle
to open front
panel.
Take-up
spool
Ribbon
Figure 2-19 Mounting the Ribbon Supply and Take-up Spools (Model 48 and 412)
5. Open the print head assembly by pulling up the print head latch lever. Raise the
print head and gently thread the ribbon over the white teflon guides and under the
print head (see Figure 2-20).
NOTE: Be careful to remove any wrinkles or
creases while threading ribbon under the print
head.
2-34 Setup
Raise print head.
Pull through
about 12" to 18"
of ribbon.
Thread ribbon
under print head.
Pull up blue
print head
release latch.
Figure 2-20 Threading the Ribbon (Model 48 and 412)
6. Guide the ribbon over the ribbon guide plate and then back toward the take-up
spool (see Figure 2-21).
7. Attach the ribbon to the take-up spool with the adhesive patch on the ribbon
leader and turn the spool several turns in the counterclockwise direction to take
up any slack in the ribbon (see Figure 2-21).
Setup 2-35
Attach adhesive patch on ribbon leader
to take-up spool and wind spool
several turns counterclockwise.
Guide ribbon over ribbon guide
plate.
Figure 2-21 Attaching the Ribbon (Model 48 and 412)
8. Close and securely latch the print head (see Figure 2-22). Close and securely latch
the front panel. Then lower the left side cover.
2-36 Setup
Close front
panel and latch
securely.
Gently lower print head and
latch securely.
Figure 2-22 Securing the Print Head and Front Panel (Model 48 and 412)
Model 88
To install a ribbon the Model 88 printer, proceed as follows. If you are installing a ribbon in
the Model 48 or 412, see “Model 48 or 412” earlier in this section.
1. Open the printer’s left side cover and top cover.
2. Remove the ribbon and the two take-up cores from the shipping bag as shown in
Figure 2-23, step A.
3. Remove the ribbon supply and take-up spindles from the printer by lifting the
spindles out of the mounting slots on the outside of the printer and sliding the
spindles out of the holes on the side of the printer frame (see Figure 2-24).
4. Align the key inside take-up core 1 with the slot on the take-up spindle. Leading
with the plastic flange, slide core 1 onto the take-up spindle (see Figure 2-23,
step B).
5. Align the key inside take-up core 2 with the key on core 1. With the plastic flange
trailing, slide take-up core 2 onto the take-up spindle (see Figure 2-23, step C).
Both cores should lock firmly in place on the take-up spindle.
Setup 2-37
Take-up Core
Take-up Core
Slot
A
Flange
B
Take-up Core 1
Key
Take-up Spindle
C
Key
Supply Spindle
Take-up Core 2
D
Removal Tape
Ribbon Leader
Figure 2-23 Assembling the Ribbon Supply and Take-up Cores (Model 88)
6. With the take-up cores in place, fit the rectangular shaft of the take-up spindle
into the rectangular hole in the side of the center printer frame (see Figure 2-24).
7. Lower the rounded shaft of the take-up spindle into the plastic mounting block on
the outer printer frame as shown in Figure 2-24.
8. Slide the ribbon roll onto the supply ribbon spindle (see Figure 2-23, step D) and
fit the rounded end of the supply ribbon spindle into the round hole on the side of
the center printer frame (see Figure 2-24).
2-38 Setup
9. Lower the rectangular shaft of the ribbon supply spindle into the metal mounting
bracket on the printer frame as shown in Figure 2-24.
Rectangular
Take-Up Spindle
Shaft End
Take-Up
Spindle Drive
Hole
Round Supply
Shaft End
Printer Center
Frame
Supply Ribbon
Spindle Holder
Printer Outer
Frame
Take-up Spindle
Plastic Mounting
Block
Supply Spindle
Rectangular Shaft
End
Metal Mounting
Bracket
Take-Up Spindle
Round Shaft End
Figure 2-24 Mounting the Ribbon Supply and Take-up Cores (Model 88)
NOTE: When properly installed, the ribbon
should unwind in a counterclockwise direction.
10. Open the print head assembly by pulling up the print head latch lever. Raise the
print head and gently thread the ribbon under the print head (see Figure 2-25).
NOTE: Be careful to remove any wrinkles or
creases while threading ribbon under the print
head.
11. Guide the ribbon over the ribbon guide plate and then back toward the take-up
spool (see Figure 2-25). Pull through at least 18 inches of ribbon. The ribbon
leader (see Figure 2-23, step D) must clear the print head.
Setup 2-39
Ribbon Guide
Plate
Take-Up Spool
Figure 2-25 Threading the Ribbon (Model 88)
12. Attach the ribbon to the take-up spool with the adhesive tape on the ribbon
leader (see Figure 2-23, step D) and turn the spool several turns in the
counterclockwise direction to take up any slack in the ribbon (see Figure 2-26).
13. Close and securely latch the print head (see Figure 2-26). Then close the top
cover and left side panel.
2-40 Setup
Take-up Spool
Figure 2-26 Securing the Print Head (Model 88)
PRINT HEAD REMOVAL AND INSTALLATION
This section provides procedures for removing a print head from inside the IntelliBar printer
and installing a new one.
If you have a problem removing or installing the IntelliBar print head or need answers to
technical questions, call 800-694-3034 (or 978-568-0370 for international calls).
CAUTION: Turn off and unplug the printer
before removing or installing the print head or
any other IntelliBar hardware. Voltage is present
inside the printer even when the power is turned
off. All voltage is removed only when the printer
is unplugged.
Setup 2-41
Print Head Removal
To remove the print head, proceed as follows depending on the IntelliBar printer model.
NOTE: To install the print head, reverse the
removal procedures (except where indicated
below).
Model 48 and Model 412
To remove the print head in the Model 48 or 412 printer, proceed as follows. If you are
removing the print head in the Model 88, see “Model 88” later in this subsection.
1. Turn off and unplug the printer.
2. Raise the left side cover and lower the front panel by pressing the front panel
release latch (see Figure 2-27).
3. Open the print head assembly by pulling the print head latch lever (see Figure
2-27).
Left Side Cover
Front Panel
Release Latch
Print Head Latch Lever
Figure 2-27
Left Side Cover, Front Panel, and Print Head Release Latches
(Model 48 and 412)
2-42 Setup
4. Loosen (completely) the two front thumb screws on the print head assembly top
cover (see Figure 2-28).
5. Loosen or remove the two rear thumb screws.
6. Raise the print head assembly.
Print Head Assembly
Top Cover
NARROW
Rear
Thumb
Screws
(Loosen or
Remove)
02
Front
Thumb
Screws
01
THIN
1
2
WIDE
3
THICK
(Loosen)
4
THICKNESS ADJ.
5
6
WIDTH ADJ.
Print Head Assembly
Bottom Cover
Figure 2-28
Print Head Top Cover (Model 48 and 412)
7. Pull back and remove the print head assembly bottom cover. As shown in
Figure 2-29, free the print head from under the top cover. Figure 2-29 shows the
print head for the Model 48. The Model 412 print head contains one additional
connector described in the next step.
Setup 2-43
Model 48 Print Head
Shown
Bottom
Cover
Figure 2-29
Print Head Removal (Model 48 and 412)
8. Turn over the print head and disconnect the data and power connectors (see
Figure 2-30). In addition, for the Model 412 only, disconnect the pre-heat
connector from the print head.
2-44 Setup
Print Head Data Connector
Power Connector
Pre-Heat Connector
(Model 412 Only)
Print Head
Resistance and
Serial Number (see
Reverse Side of Print
Head)
XXXX
Print Head
4-Digit Resistance
Value
Figure 2-30
Print Head Cable Connectors (Model 48 and 412)
9. Remove the print head.
Model 88
To remove the print head in the Model 88 printer, proceed as follows. If you are removing
the print head in the Model 48 or Model 412, see “Model 48 and 412” earlier in this
subsection.
1. Turn off and unplug the printer.
2. Open the left side cover and top cover.
3. Pull the print head latch lever (see Figure 2-31) and raise the print head (see
Figure 2-32).
4. Loosen the two thumb screws on the front of the print head adjustment assembly
(see Figure 2-33).
The print head will drop down out of the print head adjustment assembly.
5. Disconnect the two wiring connectors from the print head (see Figure 2-34).
Setup 2-45
Print Head Adjustment Assembly
Latch
Figure 2-31 Print Head Release Latch (Model 88)
Wiring
Print Head Adjustment
Assembly
Print Head
Figure 2-32 Print Head Adjustment Assembly (Model 88)
Thumb Screws
Figure 2-33 Print Head Thumb Screws (Model 88)
2-46 Setup
Wire Connectors
KJT-220-12MPL4-AT R=2028
59-00227
MADE IN JAPAN
Print Head
Figure 2-34 Print Head Connectors (Model 88)
Print Head Installation
To install a new print head after removing the old one, proceed as follows, depending on
your IntelliBar printer model.
Model 48 and 412
To install the print head in the Model 48 or 412 printer, proceed as follows. If you are
installing the print head in the Model 88, see “Model 88” later in this subsection.
1. Locate the 4-digit resistance tag on the new print head (see Figure 2-30). Record
the resistance value.
NOTE: Both the resistance value and print head
serial number are located on the print head heat
sink (located on the reverse side of the print
head). This information should be written down
for reference when adjusting the print head
voltage as described in the next section.
2. Connect the power and data cables to the new print head (see Figure 2-30). In
addition, for the Model 412 only, connect the pre-heat cable to the pre-heat
connector on the print head (see Figure 2-30).
3. Align the two dimples in the print head top cover with the holes in the print head.
4. Finger tighten the two front thumb screws (see Figure 2-28).
5. Align the bottom cover in the top cover slots (see Figure 2-35), and finger tighten
the two rear thumb screws (see Figure 2-28).
Setup 2-47
NOTE: The four thumb screws should be
moderately tightened. Do not overtighten.
Make sure to align the bottom cover as shown
below. Misalignment of the bottom cover (see
detail) results in impaired printer output.
Print Head Top
Cover (Side View)
Correctly aligned
Slot
Bottom Cover
(Side View)
Misaligned
Figure 2-35
Print Head Bottom Cover Replacement – Side View
6. Close and securely latch the print head assembly.
NOTE: After replacing the print head, see
“Print Head Voltage Adjustment” for information
about adjusting the print head voltage.
7. Close and securely latch the front panel.
8. Close the left side cover.
Model 88
To install the print head in the Model 88 printer, proceed as follows. If you are installing the
print head in the Model 48 or Model 412, see “Model 48 and Model 412” earlier in this
subsection.
1. Locate the 4-digit resistance tag on the new print head (see Figure 2-36). Record
the resistance value.
2-48 Setup
NOTE: Both the resistance value and print head
serial number are located on the print head heat
sink (located on the reverse side of the print
head). This information should be written down
for reference when adjusting the print head
voltage as described in the next section.
4 Digit Number
KJT-220-12MPL4-AT R=2028
59-00227
MADE IN JAPAN
7 Digit Number
Figure 2-36 Model 88 Print Head Serial Number and Resistance Values
2. Connect the two print head wire connectors (see Figure 2-34).
3. Install the print head in the print head adjustment assembly.
4. Tighten the two thumb screws.
5. Close and securely latch the print head adjustment assembly.
NOTE: After replacing the print head, see
“Print Head Voltage Adjustment” for information
about adjusting the print head voltage.
6. Close the top cover and left side cover.
Print Head Voltage Adjustment
After you have installed the new print head, you must set the print head voltage and/or enter
the print head serial number using the following procedure and the flowcharts in Figure 237 through Figure 2-39.
1. Turn on the printer. When the words “ONLINE” and “INITIALIZING” appear in
the LCD display, press and hold down the Menu button.
Setup 2-49
The words “MAINTENANCE MENU” and “DISPLAY COUNTERS” appear.
2. Press the Next button once.
3. Press the Next button again.
The words “MAINTENANCE MENU” and “HEAD VOLTAGE
ADJUSTMENT” appear in the LCD display.
4. Press the Select button once.
“REPLACING HEAD?” and “NO” appear.
5. Press the Previous button to choose “YES.”
6. Press the Select button once.
“ENTER HEAD S/N” appears.
7. Enter the first two characters of the head serial number by pressing the Next
button until you get to the first two digits of the serial number.
8. Press the Select button once to enter the characters in printer memory.
9. Repeat the procedure in steps 6 through 8 to enter the second half of the serial
number.
10. Press Select to enter the digits in printer memory and move you to the next
selection.
The words “ENTER HEAD OHMS” appear in the LCD display.
11. Enter the number for the print head by pressing the Previous or Next buttons
until the correct ohms value appears.
12. Press the Select button to save the setting.
The printer automatically configures the correct voltage settings for the print
head.
13. Turn off the printer to exit the Maintenance Menu.
14. Turn the printer on to resume normal operation.
The following menus show the procedure described in steps 1 through 14 above.
2-50 Setup
MAINTENANCE MENU
PRESS SELECT
M A I N T E N A N CE ME NU
D I S P L A Y COUN T E R S
PRESS
NEXT TO
ADVANCE
DI S P L A Y
T H E RMA L
C OU N T E R =
TR A N S F ER
T R A N S F E R C OU N T =
X X X XX X X X X *
D I S P L A Y C OU N T E R =
T H E RMA L D I R E C T
D I R E C T C OU N T =
X X X X X X X X X
D I S P L A Y C OU N T E R =
P R I N T E R
P R I N T ER C OU N T =
X X X X X X X X X
PRESS SELECT
M A I N T E N A N CE ME NU
D I S P L A Y VO L T A G E
PRESS
NEXT TO
ADVANCE
V O L T AG E =
X X . Y
D I S P L A Y V O L T AG E =
L OW
L OW
D I S P L A Y V O L T AG E =
H I G H
H I G H
D I S P L A Y V O L T AG E =
P R E H E A T
P R EH E AT V O L T AG E =
X X . Y
V O L T AG E =
X X . Y
PRESS SELECT
M A I N T E N A N CE ME NU
H E A D VO L T A G E A D J
RE PL AC I NG
NO *
H E A D ?
RE PL AC I NG
Y E S
H E A D ?
(A)
SEE SETTING LOW/HIGH
HEAD VOLTAGE
(B)
SEE ENTERING PRINT
HEAD SERIAL NUMBER
* DEFAULT SETTI NG
NOTE: TO EXIT THE MAINTENANCE MENU, TURN
OFF THE PRINTER, THEN TURN IT BACK ON.
Figure 2-37
Maintenance Menu Tree
Setup 2-51
ENTERING PRINT HEAD SERIAL NUMBER
FROM MAINTENANCE MENU
(B) YES E N T E R H E A D S / N
0 0 - 0 0 0 0 0
1. SERVICE PERSON PRESSES “NEXT” OR “PREVIOUS” WHICH CHANGES THE VALUE OF THE FIRST TWO POSITIONS
(0 THROUGH 9 ARE VALID FOR THE FIRST POSITION)
(0 THROUGH 9 AND XYZ ARE VALID FOR THE SECOND POSITION)
2. PRESS “SELECT” TO ENTER THE FIRST TWO ALPHA- NUMERIC VALUES
E N T E R H E A D
S / N
3 Y - 0 0 0 0 0
1. SERVICE PERSON PRESSES “NEXT” OR “PREVIOUS” WHICH CHANGES THE VALUE OF THE RIGHT MOST FIVE POSITIONS
(0 THROUGH
THROUGH 999
ARE VALID)
(0
99999
ARE VALID)
2. PRESS “SELECT” TO ENTER THE FIVE DIGIT NUMERIC VALUE
E N T E R H E A D
S / N
3 Y - 6 3 7 9 2
THE
PROCESS
ON TO IS
THE
ENTER PRESS
HEAD ''OHMS
DISPLAY
WHEN
CORRECTMOVES
SERIAL NUMBER
IN DISPLAY,
SELECT.
THE PROCESS MOVES ON TO THE ENTER HEAD OHMS DISPLAY
TO ABORT OR RESTART AT THE BEGINNING, PRESS “MENU”
E N T E R
H E A D
X X X X
OH MS
Figure 2-38
(A)
SEE SETTING LOW/HIGH
HEAD VOLTAGE
Print Head Serial Number Menu Tree
2-52 Setup
SETTING LOW/HIGH HEAD VOLTAGE
FROM MAINTENANCE MENU
(A) NO
E N T E R
H E A D
X X X X
O H M S
SERVICE PERSON ENTERS PRINTHEAD RESISTANCE
USE "NEXT" AND "PREVIOUS" BUTTONS WITH FAST SCROLL CAPABILITY
ALLOWABLE RANGE EQUALS 1100 TO 1400
E N T E R
H E A D
1 2 0 0
O H M S
WHEN CORRECT RESISTANCE VALUE IS IN DISPLAY, PRESS "SELECT"
MAIN BOARD CALCULATES PRINTHEAD VOLTAGE AND DISPLAYS SETTING VOLTAGE VALUE TO (1) DECIMAL PLACE
OR
L O W
S E T T I N G
T O = X X . Y
V O L T A G E
S E T T I N G
H I G H
T O = X X . Y
V O L T A G E
MAIN AREA OF BOARD SENDS NEW VOLTAGE SETTING INFORMATION TO SUB AREA OF BOARD
MAIN AREA REQUESTS VOLTAGE INFORMATION FROM SUB AREA AFTER SETTING NEW VALUE
AFTER 5 SECONDS (APPROX) DISPLAY SHOWS ACTUAL HEAD VOLTAGE
M A I N T E N A N C E
M E N U
V O L T A G E
D I S P L A Y
DISPLAY
SHOWS
THE
ACTUAL
HEAD VOLTAGE
DISPLAY
SHOWS
THE
SET VOLTAGE
AND THE ACTUAL HEAD VOLTAGE.
ACTUAL
VOLTAGE
UPDATED
EVERY
THREE
SECONDS
ACTUALHEAD
HEAD
VOLTAGE
UPDATED
EVERY
THREE
SECONDS
Figure 2-39
Print Head Voltage Menu
NOTE: Turn off the printer to exit the
maintenance menu. Turn the printer on to resume
normal operation.
Setup 2-53
NOTE: The information in this section is
subject to change without notice. This
information is provided "as is" without either
express or implied warranty. IntelliTech
International, Inc. disclaims any and all
warranties with regard to this information.
IntelliTech shall not be liable in any event for any
special, indirect or consequential damages or any
damages whatsoever resulting from loss of data,
profits or use, for any reason or in any action,
arising out of or in connection with the use or
performance of this information.
Section 3
Unit Operation
The following subsections provide operating procedures for the printer, including
information on using the printer’s control panel menu to configure parameters.
Controls and Indicators
Figure 3-1 shows the control panel for the Model 48 and 412 printer. Figure 3-2 shows the
control panel for the Model 88 printer. The control panel contains the LCD display, power
and alert indicators, and buttons that allow you to control and monitor printer operation.
Explanations for each button and indicator are listed in Table 3-1. The subsections that
follow provide printer default settings configured using the control panel, menu button
explanations, and control panel status messages that indicate the operating condition of the
printer.
LCD Display
Power Indicator
Alert Indicator
Online Button
Feed Button
Cancel Button
Menu/Select Button
Previous/Next Button
Figure 3-1
Control Panel (Model 48 and 412)
3-2
Unit Operation
LCD Display
Status LED's
Online Button
Feed Button
Cancel Button
Select Button
Next Button
Previous Button
Menu Button
Figure 3-2 Control Panel (Model 88)
NOTE: With the exception of the Feed button,
the control panel buttons will not work unless the
printer is offline. The Feed button works in both
offline and online modes. The printer must be
online before it will print any data.
Table 3-1
Control Panel Explanations
Buttons/Indicators
Explanation
Power indicator
Lit whenever printer power is ON.
Alert indicator
Lit when the printer has a problem needing
attention, such as replacing ribbons or labels.
The lamp blinks if a service related error
occurs.
Online button
The Online button switches the printer between
online mode when it can receive data and
offline mode when operation pauses so you can
change menu items or cancel an operation.
Feed button
Advances labels through the print head. One
label at a time is fed each time the button is
pushed. Works in both offline and online
modes.
Unit Operation
Table 3-1
3-3
Control Panel Explanations
Buttons/Indicators
Explanation
Cancel button
Performs the following functions:
• Quits the current job.
• Resets the printer parameters to the default
settings (when Cancel is pressed and held for
at least five seconds while the printer is in
offline mode).
• Clears all data in the print buffer.
• Resets printer engine errors.
• Cancels the alarm sound.
• Cancels the pre-heating sequence for the
Model 412 when “OPEN PRINT HEAD”
appears in the control panel LCD.
• Cancels the “LABEL SENSOR ADJ”
parameter setting when the control panel
LCD displays “SET LABEL, NOT GAP,
UNDER HEAD”.
Menu/Select button
Used when the printer is in offline mode.
Pressing the button to the right selects the
menu item and category displayed on the LCD.
Pressing the button to the left enters the menu
listings.
Previous/Next button
Moves you forward and backwards through the
menu categories and selections.
Display
Allows you to monitor the current state of printer
by providing a two-line screen for messages.
Messages include
• operator messages requiring you to perform a task such as replacing the label
supply or ribbon so the printer can resume
printing.
• status messages that let you know the
printer’s current condition. The standard
status message reads “READY”, meaning
the printer is online and ready for use.
• error messages that let you know when the
printer has a problem that needs service.
• menu selections for printer configuration.
3-4
Unit Operation
Self-Test
Follow the printer self-test procedure in this subsection to verify that the printer is set up
correctly. The three self-tests exercise all the print head elements so you can also verify that
the print head is adjusted correctly.
Before running the self-test, load the label and ribbon rolls (see “Installing the Thermal
Ribbon” and “Installing Labels” in Section 2). Do not run the self-test without properly
installing a label and ribbon. The ribbon and label must be a minimum of 4.25 in. (108 mm)
wide. Running the self-test with narrower ribbons or labels can damage the print head or
platen roller.
NOTE: Check that the label sensor is centered
over the label and is not over the label gap. When
you turn on the printer as described below, the
label sensor automatically detects the label gap.
To run the self-test, proceed as follows.
1. Turn on the printer and wait for it to initialize.
NOTE: At power-on, the green power and red
alert LEDs light and an audible alarm sounds.
Then “OFF LINE, INITIALIZE” appears in the
2-line, control panel LCD, followed by
“ONLINE, READY.”
The printer feeds several labels under the print head and out the label exit slot as it
automatically measures label length.
2. Press the Online button to take the printer offline (“OFF LINE, PAUSE” appears
in the 2-line LCD).
3. Press the Menu button to access the printer menu listings (“MAIN MENU,
PRINT MENU” appears).
4. Press Next four times to advance to the Configuration submenu (“MAIN MENU,
CONFIGURE MENU” appears).
5. Press Select to access the available selections (“TEST PAGE, BAR CODE,
FONT LIST”).
Unit Operation
3-5
TEST PAGE — Prints a preformatted test label listing the standard default
settings (see Figure 3-3).
NOTE: TEST PAGE output includes the label
count used for determining print head life. The
label count is measured in linear inches.
BAR CODE — Prints a preformatted bar code label used for adjusting print
quality (see Figure 3-4).
FONT LIST — Lists the resident fonts and their assigned number.
6. Press Next to advance to the desired self-test selection. (If running TEST
PAGE, you do not have to press Next).
7. Press Select to select the self-test.
8. Press Select again to start the test.
The printer will run the self-test and output a label. The examples in Figures 3-3
and 3-4 show the TEST PAGE and BAR CODE self-tests. To stop the test,
press the Online button.
9. Examine the printout carefully for signs of uneven print quality between the left
and right sides of the label (or the top and bottom). Examine the top and bottom
edges of the label to make sure the horizontal print line is straight. In addition,
look carefully for blank areas in the label.
If print quality is uneven, not straight, or if blank areas appear, these are signs
that the print head pressure, position, and/or alignment need adjustment (see
“Mechanical Adjustments” in Section 5) or that the ribbon is wrinkled as it
passes under the print head.
10. Examine the print sample for overall print quality, making sure the output is crisp
and sharp with optimum black and white contrast between text and graphics and
the label surface.
If the printed image is too light, or if the image is too dark, use the control panel
menu to adjust the print density and head voltage so that the desired print
quality is obtained (see “Menu Tree” in the next subsection).
3-6
Unit Operation
Test Page
Figure 3-3
Self-Test Sample Printout (All Models)
Unit Operation
3-7
Bar Code
Figure 3-4 Bar Code Sample Printout (All Models)
Menu Tree
You can control the operation of the printer through software commands from the host
computer or through the printer’s control panel menu button. Information on software
commands is provided in the Programmer’s Reference Guide. To configure the printer to
meet unique job requirements, use the control panel menu tree described below to select
new default parameters.
The menu consists of parameter listings with a variety of setting selections. These listings
control printer features and configurations. For nearly all printing jobs, the default factory
settings do not have to be changed.
Default Factory Settings
Table 3-2 lists the default printer settings.
3-8
Unit Operation
Table 3-2
IntelliBar Default Printer Settings
Main Menu
PRINT MENU
Print method
Print mode
Ribbon type
Print speed
Printer Default
Thermal transfer
Standard
Express wax
4, 8, or 12 in. per second (ips) maximum
(depending on model)
LABEL MENU
Label type
Measure label
Set label length*
Set gap length*
Die cut
Automatic
—
—
ADJUSTMENTS MENU
Print density
Print position
Cut position
Label sensor adj**
0
0
0
—
LJIII SETUP MENU
Font source
Font number
Point size
Symbol set
Number of copies
Page rotation
Line spacing
Top/bottom margin
Internal
6 (Courier 10)
xx
Roman-8
Copies=1
0
1/48
Ignore
CONFIGURATION MENU
Test print
Hex dump
Page protect
Panel language
Interface
Test page
Off
Yes
English
Parallel
MAINTENANCE MENU***
Display counters
Display head voltage
Adj head voltage
xxxx
xx.xxxx
xxxx
*Does not appear when “Measure Label” is set.
**Sensor adjusts automatically to liner opacity.
*** Not available from main menu. Accessed by turning the printer off and then on again. When “Initialize”
appears in the LCD display, push and hold down the Menu button until “Maintenance Menu” appears in
the LCD display.
Unit Operation
3-9
Changing Settings
To configure the printer to meet unique job requirements, refer to the detailed menu tree in
Figure 3-5. Change the printer’s default settings from the control panel as follows.
1. Turn the printer ON.
2. Press Online to take the printer offline. The 2-line display will read “OFF LINE,
PAUSE.”
3. Press Menu. The 2-line display will change to “MAIN MENU, PRINT MENU.”
Press Prev to go to the previous item in the menu structure.
Press Next to go to the next item in the menu structure.
Press Select to choose the displayed setting.
NOTE: Once the selections have been made,
press Online to exit the menu, save the
selections, and put the printer online (“READY”
appears in the display). The selections are not
lost when you turn the printer off.
You can restore the factory default setting with the following steps.
1. Press Online to take the printer offline. The 2-line display will read “OFF LINE,
PAUSE.”
2. Press and hold down Select for at least 5 seconds.
The printer parameters will reset to their factory default settings except for:
Page protect
Panel language
Interface
Unit of measure
3-10
Unit Operation
MAIN MENU
M A I N
M E N U
P R I N T
M E N U
SELECT
TO PRINT MENU
NEXT
M A I N
M E N U
L A B E L
M E N U
TO LABEL MENU
M A I N
M E N U
A D J U S T M E N T S
TO ADJUSTMENTS MENU
M A I N
L J 3
M E N U
M E N U
S E T U P
M E N U
M A I N
M E N U
C O N F I G U R E
M E N U
TO LASERJET 3 SETUP MENU
TO CONFIGURATION MENU
M A I N
M E N U
P R I N T
M E N U
NOT AVAILABLE FROM
MENU.FROM
ACCESSED
AT POWER-ON. HOLD
NOT MAIN
AVAILABLE
MAIN MENU
DOWN
MENU BUTTON
WHEN “INITIALIZE”
APPEARS
ONMENU
LCD DISPLAY
ACCESSED
AT POWER-ON
WHILE HOLDING
DOWN
SWITCH
M A I N T E N A N C E
M E N U
D I S P L A Y
C O U N T E R S
Figure 3-5
Menu Tree
TO MAINTENANCE MENU
Unit Operation
3-11
PRINT MENU
PRESS SELECT
M E N U
P R I N T
P R I N T
M E T H O D
P R I N T
M E T H O D =
T R A N S F E R *
PRESS
NEXT TO
ADVANCE
P R I N T
M E T H O D =
D I R E C T
PRESS SELECT
P R I N T M O D E =
S T A N D A R D *
P R I N T
M E N U
P R I N T
M O D E
PRESS
NEXT TO
ADVANCE
P R I N T
M E N U
R I B B O N
T Y P E
PRESS
NEXT TO
ADVANCE
P R I N T M O D E =
O F F
P E E L
R I B B O N
T Y P E =
E X P R E S S W A X *
P R I N T M O D E =
O F F
T E A R
R I B B O N
T Y P E =
D U R A
W A X
P R I N T M O D E =
O F F
C U T
R I B B O N
T Y P E =
D U R A
R E S I N
W A X
R I B B O N
T Y P E =
R U G G E D
R E S I N
R I B B O N
T Y P E =
R E S I N
P L U S
D U R A
P R I N T
M E N U
P R I N T
S P E E D
PRESS SELECT
P R I N T
P R I N T
S P E E D =
X X X
I P S
P R I N T
* DEFAULT SETTING
Figure 3-5
Menu Tree (cont’d)
S P E E D =
I P S
0 . 6
S P E E D =
1 2
I P S
3-12
Unit Operation
LABEL MENU
PRESS SELECT
L A B E L
T Y P E =
D I E
C U T *
M E N U
L A B E L
L A B E L
T Y P E
PRESS
NEXT TO
ADVANCE
L A B E L
T Y P E =
C O N T I N U O U S
PRESS SELECT
M E A S U R E
L A B E L =
A U T O M A T I C *
L A B E L
M E N U
L A B E L
M E A S U R E
M E A S U R E
L A B E L =
F I X E D
PRESS
NEXT TO
ADVANCE
M E A S U R E
L A B E L =
O P E R A T O R
P A N E L
ONLY AVAILABLE WHEN CONTINUOUS OR OPERATOR PANEL IS SELECTED
S E T
L E N G T H =
6
0 / 1 6
I N C H E S
L A B E L
M E N U
L A B E L
S E T
L E N G T H
*
OR
S E T
L A B E L
M E N U
S E T
L E N G T H
G A P
L E N G T H =
1 5 2
m m
S E T
G A P
2 / 1 6
S E T
G A P
L E N G T H =
I N C H E S
OR
3
* DEFAULT SETTING.
Figure 3-5
Menu Tree (cont’d)
L E N G T H =
m m
Unit Operation
ADJUSTMENTS MENU
P R I N T
D E N S I T Y =
- 1 5
P R I N T
D E N S I T Y =
0 *
P R I N T
D E N S I T Y =
+ 1 5
P R I N T
P O S I T I O N =
- 3 0
P R I N T
P O S I T I O N =
0 *
P R I N T
P O S I T I O N =
+ 3 0
PRESS SELECT
M E N U
A D J U S T M E N T S
P R I N T
D E N S I T Y
PRESS
NEXT TO
ADVANCE
PRESS SELECT
M E N U
A D J U S T M E N T S
P O S I T I O N
P R I N T
PRESS
NEXT TO
ADVANCE
PRESS SELECT
M E N U
A D J U S T M E N T S
P O S I T I O N
C U T
PRESS
NEXT TO
ADVANCE
C U T
P O S I T I O N =
- 3 0
C U T
P O S I T I O N =
0 *
C U T
P O S I T I O N =
+ 3 0
PRESS SELECT
M E N U
A D J U S T M E N T S
L A B E L
S E N S O R
A D J
S E T
G A P ,
P A P E R ,
N O T
U N D E R
H E A D
A D J U S T I N G
P L E A S E W A I T
THIS MESSAGE LASTS FOR
APPROXIMATELY 5 SECONDS
AND THEN RETURNS TO THE
ADJUSTMENTS MENU
* DEFAULT SETTING.
Figure 3-5
Menu Tree (cont’d)
3-13
3-14
Unit Operation
LJ3 SETUP MENU
L J 3
S E T UP M E N U
F O N T
S O U R C E
F O N T
S O U R C E =
I N T E R N A L *
F O N T
S O U R C E =
SO F T
F O N T
L J 3
S E T U P M E N U
N U M B E R
F O N T
L J 3
S E T U P M E N U
PO I N T
S I Z E
SOFT FONT CAN ONLY BE SELECTED WHEN
A SOFT FONT HAS BEEN DOWNLOADED.
P O I N T
S I Z E =
X X
POINT SIZE CAN ONLY BE SELECTED WHEN AN OUTLINE FONT HAS BEEN SELECTED.
S Y M B O L
S E T =
L J 3
S E T U P M E N U
R OM A N - 8 *
S Y M B O L S E T
L J 3
S E T U P
N U M B E R O F
M E N U
C O P I E S
F O N T N U M B E R =
C O U R I E R
1 0
O
1 6
6
*
F O N T N U M B E R =
1 2
C O U R I E R
1 0 I T A L
F O N T N U M B E R =
1 8
C O U R I E R
1 0
B O L D
F O N T N U M B E R =
C O U R I E R
1 2
2 4
F O N T N U M B E R =
3 0
C O U R I E R
1 2
I T A L
#
O F
C O P I E S =
1 *
3 6
F O N T N U M B E R =
C O U R I E R 1 2
B O L D
#
O F
C O P I E S =
X X X X
F O N T N U M B E R =
U N I V E R S
B O L D
#
O F
C O P I E S =
9 9 9 9
L I N E
L I N E
L I N E
L J 3
S E T U P ME N U
T O P / B O T MA R G I N
N U M B E R =
PR I N T E R
=
S Y M B O L
S E T
X X X X X X X X
MODELS 48 AND 412 HAVE 7 ADDITIONAL
OUTLINE FONTS.
R O T A T I O N =
0 *
P A G E
R O T A T I O N =
9 0
S P A C I N G =
1 / 4 8
P A G E
R O T A T I O N =
1 8 0
S P A C I N G =
8 / 4 8 *
P A G E
R O T A T I O N =
2 7 0
S P A C I N G =
4 8 / 4 8
T O P / B O T
M A R G I N =
I GN O R E *
T O P / B O T
M A R G I N =
A C C E P T
* DEFAULT SETTING
Figure 3-5
4 2
P A G E
L J 3
S E T U P M E N U
P A G E R O T A T I O N
L J 3
S E T U P M E N U
L I N E S P A C I N G
F O N T
L I N E
Menu Tree (cont’d)
Unit Operation
3-15
CONFIGURATION MENU
PRESS SELECT
C O N F I GU R E ME N U
T E S T
P R I N T
PRESS
NEXT TO
ADVANCE
T E S T
P R I N T =
P A G E *
T E S T
T E S T
P R I N T =
C OD E
B A R
T E S T
P R I N T =
F O N T
L I S T
C O N F I GU R E ME N U
H E X D U M P
H E X
D U M P =
O F F *
H E X
D U M P =
O N
P A G E
P R O T E C T
N O
P A G E
P R O T E C T
Y E S *
P A N E L
L A N G U A G E =
E N G L I S H *
U N I T
O F M E A S U R E =
I N C H E S *
P A N E L
L A N G U A G E =
G E R M A N
U N I T
O F M E A S U R E =
M E T R I C
P A N E L
L A N G U A G E =
F R E N C H
C O N F I GU R E ME N U
P A G E
P R OT E C T
C O N F I GU R E ME N U
P A N E L
L A N G U A G E
PRESS
NEXT TO
ADVANCE
P A N E L
L A N G U A G E =
S P A N I S H
P A N E L
L A N G U A G E =
I T A L I A N
I N T E R F A CE M E N U
HO T PO R T S *
C O N F I GU R E ME N U
I N T E R F A C E
I N T E R F A C E ME N U =
P A R A L L E L *
I N T E R F A C E ME N U =
R S - 2 3 2 - C
I N T E R F A C E ME N U =
R S - 4 2 2 A
* DEFAULT SETTING
Figure 3-5
Menu Tree (cont’d)
SERIAL
SUBMENU
3-16
Unit Operation
SERIAL SUBMENU
PRESS SELECT
R S - 2 3 2 - C
B A U D R A T E
R S - 2 3 2 - C
B I T S
D A T A
B I T S =
8 *
B A U D
R AT E =
1 9 2 0 0
D A T A
B I T S
7
B A U D
R A T E =
3 8 4 0 0
B A U D
R A T E =
3 0 0
B A U D
R A T E =
6 0 0
PRESS SELECT
R S - 2 3 2 - C
R O B U S T
F L O W
C O N T R O L =
X O N
X O F F *
B A U D
R A T E =
1 2 0 0
F L OW
C O N T R O L =
D T R
D S R
B A U D
R A T E =
2 4 0 0
B A U D
R A T E =
4 8 0 0
R O B U S T
X O N
O N *
R O B U S T
X O N
O F F
X O N
R S - 2 3 2 - C
D T R
P O L A R I T Y
R S - 2 3 2 - C
P A R I T Y
R AT E =
9 6 0 0 *
D A T A
PRESS
NEXT TO
ADVANCE
R S - 2 3 2 - C
F L OW C O N T RO L
B A U D
D T R
P O L A R I T Y =
H I G H *
D T R
P O L A R I T Y =
L O W
P AR I T Y =
N O N E *
P AR I T Y =
OD D
P AR I T Y =
E V E N
* DEFAULT SETTING
Figure 3-5
Menu Tree (cont’d)
Unit Operation
3-17
MAINTENANCE MENU
PRESS SELECT
M E N U
M A I N T E N A N C E
D I S P L A Y
C O U N T E R S
PRESS
NEXT TO
ADVANCE
D I S P L A Y
T H E R M A L
C O U N T E R =
T R A N S F E R
C O U N T =
T R A N S F E R
X X X X X X X X X *
D I S P L A Y
C O U N T E R =
T H E R M A L
D I R E C T
D I R E C T
C O U N T =
X X X X X X X X X
D I S P L A Y
C O U N T E R =
P R I N T E R
P R I N T E R
C O U N T =
X X X X X X X X X
PRESS SELECT
M A I N T E N A N C E
M E N U
D I S P L A Y
V O L T A G E
PRESS
NEXT TO
ADVANCE
V O L T A G E =
X X . Y
D I S P L A Y
V O L T A G E =
L O W
L OW
D I S P L A Y
V O L T A G E =
H I G H
H I G H
D I S P L A Y
V O L T A G E =
P R E H E A T
V O L T A G E =
P R E H E A T
X X . Y
V O L T A G E =
X X . Y
PRESS SELECT
M A I N T E N A N C E
M E N U
H E A D
V O L T A G E
A D J
R E P L A C I N G
N O *
H E A D ?
R E P L A C I N G
Y E S
H E A D ?
* DEFAULT SETTI NG
NOTE: TO EXIT THE MAINTENANCE MENU, TURN
OFF THE PRINTER, THEN TURN IT BACK ON.
Figure 3-5
(A)
SEE SETTING LOW/HIGH
HEAD VOLTAGE
Menu Tree (cont’d)
(B)
SEE ENTERING PRINT
HEAD SERIAL NUMBER
3-18
Unit Operation
SETTING LOW/HIGH HEAD VOLTAGE
FROM MAINTENANCE MENU
(A) NO
E N T E R
H E A D
X X X X
O H M S
SERVICE PERSON ENTERS PRINTHEAD RESISTANCE
USE "NEXT" AND "PREVIOUS" BUTTONS WITH FAST SCROLL CAPABILITY
ALLOWABLE RANGE EQUALS 1100 TO 1400
E N T E R
H E A D
1 2 0 0
O H M S
WHEN CORRECT RESISTANCE VALUE IS IN DISPLAY, PRESS "SELECT"
MAIN BOARD CALCULATES PRINTHEAD VOLTAGE AND DISPLAYS SETTING VOLTAGE VALUE TO (1) DECIMAL PLACE
OR
L O W
S E T T I N G
T O = X X . Y
V O L T A G E
S E T T I N G
H I G H
T O = X X . Y
V O L T A G E
MAIN AREA OF BOARD SENDS NEW VOLTAGE SETTING INFORMATION TO SUB AREA OF BOARD
MAIN AREA REQUESTS VOLTAGE INFORMATION FROM SUB AREA AFTER SETTING NEW VALUE
AFTER 5 SECONDS (APPROX) DISPLAY SHOWS ACTUAL HEAD VOLTAGE
M A I N T E N A N C E
M E N U
V O L T A G E
D I S P L A Y
DISPLAY
SHOWSTHE
THE
ACTUAL
HEAD
DISPLAY SHOWS
SET
VOLTAGE
ANDVOLTAGE
THE ACTUAL HEAD VOLTAGE.
ACTUAL HEAD
UPDATED
EVERY
THREE
SECONDS
ACTUAL
HEADVOLTAGE
VOLTAGE
UPDATED
EVERY
THREE
SECONDS
Figure 3-5
Menu Tree (cont’d)
Unit Operation
3-19
ENTERING PRINT HEAD SERIAL NUMBER
FROM MAINTENANCE MENU
(B) YES E N T E R H E A D S / N
0 0 - 0 0 0 0 0
1. SERVICE PERSON PRESSES “NEXT” OR “PREVIOUS” WHICH CHANGES THE VALUE OF THE FIRST TWO POSITIONS
(0 THROUGH 9 ARE VALID FOR THE FIRST POSITION)
(0 THROUGH 9 AND XYZ ARE VALID FOR THE SECOND POSITION)
2. PRESS “SELECT” TO ENTER THE FIRST TWO ALPHA- NUMERIC VALUES
E N T E R H E A D
S / N
3 Y - 0 0 0 0 0
1. SERVICE PERSON PRESSES “NEXT” OR “PREVIOUS” WHICH CHANGES THE VALUE OF THE RIGHT MOST FIVE POSITIONS
(0 THROUGH
99999999
ARE VALID)
(0
THROUGH
ARE VALID)
2. PRESS “SELECT” TO ENTER THE FIVE DIGIT NUMERIC VALUE
E N T E R H E A D
S / N
3 Y - 6 3 7 9 2
THE
PROCESS
ON TO IS
THE
ENTER PRESS
HEAD ''OHMS
DISPLAY
WHEN
CORRECT MOVES
SERIAL NUMBER
IN DISPLAY,
SELECT.
THE PROCESS MOVES ON TO THE ENTER HEAD OHMS DISPLAY
TO ABORT OR RESTART AT THE BEGINNING, PRESS “MENU”
E N T E R
H E A D
X X X X
OH MS
(A)
SEE SETTING LOW/HIGH
HEAD VOLTAGE
Figure 3-5
Menu Tree (cont’d)
3-20
Unit Operation
Controlling the Printer
Table 3-3 explains the settings and functions of menu choices.
Table 3-3
Menu Selection
Controlling the Printer
Description
Print Menu
PRINT METHOD
Transfer
Direct
PRINT MODE
Standard
Selects thermal transfer printing and enables
the ribbon sensor. Thermal transfer printing
requires less print head energy and therefore
increases print head life.
Selects direct thermal printing (no ribbon
required). Disables the ribbon sensor and
automatically increases print head energy.
Higher energy requirements and direct contact
between the print head and label surface
shortens print head life.
Printing is continuous. Normally selected when
using either the internal or external rewinder or
when printing long strips of labels.
Peel off
Use for printing one label at a time while
automatically separating the label from the liner
(backing paper).
Tear off
Use for printing one label at a time and
positioning for easy tear-off.
Cut off
When the optional Label Cutter is installed,
allows automatic cut-after-print of die cut labels.
Intended for cutting backing paper.
RIBBON TYPE
PRINT SPEED
Use to match ribbon type with label application.
Not all ribbons perform equally at the same
print speed and print density settings. By
selecting the correct ribbon for the application,
the printer automatically adjusts the print speed
and print density to predetermined average
values.
Use to match the print speed with the
application. The type of ribbon and label media
(along with the level of print quality desired) are
also critical factors when choosing the correct
print speed.
NOTE: Peel-off, Tear-off, and Cut-off modes feature automatic backup prior to printing the next label so
that printing begins at the beginning of the label.
Unit Operation
Table 3-3
Menu Selection
3-21
Controlling the Printer (cont’d)
Description
Label Menu
LABEL TYPE
Die cut
Continuous
MEASURE LABEL
Automatic
Use to select die-cut labels and enable the
printer’s label sensor, which detects the
beginning of a label. Die-cut labels must have a
minimum label gap of 0.125 in. (3 mm).
Use to select continuous media (labels with no
gaps) and disable the label sensor. Requires
setting of label and gap length (see “Operator
Panel” below).
Automatically measures die-cut label length at
power on by advancing a predetermined
number of blank labels.
Fixed
Disables automatic label measurement. The
last label length measured during automatic
measuring is stored in memory, and this value
is used at power on. Use this feature when the
label media remains constant (no change in
size).
Operator panel
Select this feature to print on continuous labels
or die-cut labels that are less than 0.95 in. (24
mm) long. You must set label length and gap
length. Minimum label length is 0.51 in. (13
mm) and minimum gap length is 0.125 in.
(3 mm).
Set label length
Used to enter label length information when
continuous media is selected or operator panel
is selected. Length can be set in increments of
1/16 in (1.6 mm).
Set gap length
Used to enter gap length information when
continuous media is selected or operator panel
is selected. Length can be set in increments of
1/16 in (1.6 mm).
3-22
Unit Operation
Table 3-3
Menu Selection
Controlling the Printer (cont’d)
Description
Adjustment Menu
PRINT DENSITY
Used to increase or decrease print head
temperature resulting in darker or lighter print.
Allowable range is +15 to -15. Increasing the
number by pressing the NEXT button causes
the printed areas to get darker; decreasing the
number by pressing PREVIOUS causes the
printed areas to get lighter.
PRINT POSITION
Used to establish the first print line relative to
the leading edge of the label. Adjustable range
is 0.12 in. (3 mm) forward or backward in 0.004
in. (0.1 mm) steps. Increasing the number by
pressing the NEXT button moves the first line of
print back on the label; decreasing the number
by pressing PREVIOUS moves the first print
line closer to the front edge of the label.
For details, see “Print Position Adjustment” in
Section 4.
CUT POSITION
Adjusts the cut or tear position when advancing
labels using tear-off and cut-off print modes.
For tear-off mode, use this adjustment to
ensure that the label perforations or the center
of the label gap is directly above the edge of
the tear bar. For cut-off mode, use this
adjustment to ensure that cutting occurs in the
center of the label gap. Allowable range is +30
to -30. Adjustable range is 0.12 in. (3 mm)
forward or backward in 0.004 in. (0.1 mm)
steps. Increasing the number by pressing the
NEXT button causes the cut position to move
forward; decreasing the number by pressing
PREVIOUS moves the position backward.
LABEL SENSOR ADJ
Automatically calibrates sensitivity of label
sensor to the opaqueness level of the label and
liner.
Unit Operation
Table 3-3
Menu Selection
3-23
Controlling the Printer (cont’d)
Description
LJIII Setup
FONT SOURCE
Internal
Soft font
Selects the printer’s internal resident fonts.
Selects the downloaded (soft) fonts as default
fonts. Not selectable if soft font is not loaded.
FONT NUMBER
Used to select the type face. Every font
(resident or soft) is assigned a font number that
is used to select a specific type face. See TEST
PRINT below for information on printing out a
font list, which lists the resident fonts and their
numbers.
POINT SIZE
Used to select a specific size for outline fonts.
One point equals 1/72 in. Not selectable if
selected font is not an outline font.
SYMBOL SET
Used to select a specific character set for
international use.
NUMBER OF COPIES
Used to print from 1 to 9999 copies of the same
label.
PAGE ROTATION
Used to rotate the contents of the label in four
different orientations:
0 = portrait
90 = landscape
180 = reverse portrait
270 = reverse landscape
LINE SPACING
Used to set the line spacing in 1/48 in.
increments.
TOP/BOTTOM MARGIN
Ignore
Accept
Activates an additional 35 scan lines of print
area on each of the top and bottom page
margins compared to standard PCL. The result
is an unprintable area of 15 scan lines top and
bottom (1/20-in). 1 scan line equals 1/300 in.
Accepts standard PCL unprintable page
margins of 50 scan lines top and bottom.
3-24
Unit Operation
Table 3-3
Menu Selection
Controlling the Printer (cont’d)
Description
Configuration
TEST PRINT
Test page
Prints a preformatted test label listing the
standard default settings.
Bar code
Prints a preformatted bar code used for
adjusting print quality.
Font list
Lists the resident fonts and their assigned
number.
HEX DUMP
Used for problem isolation. Causes the printer
to print out host data in hexadecimal format.
PAGE PROTECT
On
Reserves enough memory to image an entire
label to prevent possible loss of data (default
setting for Models 48 and 412).
Off
Selects banded printing.
PANEL LANGUAGE
INTERFACE
Parallel
Selects 1 of 5 languages for use in the
32-character LCD display. Also allows selection
of metric measurement when English is
selected.
Selects the Centronics parallel port for
communications.
RS-232C
Selects asynchronous serial port for
communications.
RS-422A
Selects RS-422A as serial communications
interface.
Baud rate
Selects communication speed in bits per
second.
Data bits
Selects either 7 or 8 data bits.
Unit Operation
Table 3-3
Menu Selection
Flow control
DTR
X-ON
3-25
Controlling the Printer (cont’d
Description
Selects Data Terminal Ready (DTR) to control
communications from the host to the printer.
Selects X-ON or X-OFF to control
communications from the host to the printer.
The printer sends an X-ON character to the host
when it is ready to receive data.
Robust X-ON
Same as X-ON except that the printer sends
multiple X-ON characters to the host when it is
ready to receive data.
DTR polarity
Can be set either high or low depending on the
host’s requirements.
Parity
Selects whether the parity bit is used or unused,
depending on the host’s requirements.
3-26
Unit Operation
LCD Display Messages
Table 3-4 lists in alphabetical order the error messages that appear on the control panel
LCD. Table 3-5 lists the control panel LCD status messages that indicate the operating
condition of the printer.
Table 3-4
Error Messages
Error Message
Definition
BREAK INTERRUPT
Host system has broken or is holding
communications open. Check the host protocol.
CUTTER ERROR
Cutter option failed to cut or blade is jammed.
Clear the jam or replace the cutter option.
ENGINECOMM ERROR
Image processor (main) side of main board
receives status or command that it cannot
interpret.
FATAL ERROR
No fonts on main board or PCL failure.
(Replace main board.)
FRAMING ERROR
Printer received an invalid stop bit for a
character. Check the host protocol or the serial
cable connections.
FRONT DOOR OPEN
Front panel is not fully closed and latched.
HEAD OVERHEAT
Print head has overheated. The printer stops
printing. It will resume printing when the print
head cools down. Reset the printer.
HEAD POWER LOAD
Print head and/or power supply problem.
Drawing too much current. Reset the printer by
turning it off and then on.
INSUF. MEMORY FOR PAGE
PROTECT
Add additional SIMM memory to enable page
protection (see Section 4 for SIMM memory
installation procedures).
LABEL OUT
Label sensor detects no label.
•
•
•
•
A new label roll needs to be installed.
See “Loading Labels” in Section 2 for label
installation procedures.
Label media improperly loaded (the
label media should be under the label
sensor).
Label sensor needs adjusting (call
IntelliTech for service information at
800-694-3034).
More than one label missing from
release paper (liner).
Unit Operation
Table 3-4
3-27
Error Messages (cont’d)
Status Message
Definition
MEDIA JAM
IntelliBar cannot measure label length or gap.
•
•
•
•
Sensitivity of label sensor needs adjustment
(call IntelliTech for service information at
800-694-3034).
Wrong media in use; change to label type
that matches sensitivity setting of label
sensor.
If the “MEASURE LABEL, FIXED”
parameter is set from the control panel and
the value is 6 in. (for example), a media
jam occurs if you load labels of another
size.
If “MEASURE LABEL, AUTOMATIC” is set
from the control panel with 6 in. labels
loaded (for example), a media jam will
occur if you load labels of another size. You
must do another auto measure, i.e., turn
printer off and then on.
Mechanical interference:
Label sticking or slipping due to improper label
installation or the build up of label residue, dirt,
or foreign material under the print head or on
the platen roller. See “Loading Labels” in
Section 2 for label installation procedures; see
Section 5 for cleaning procedures.
Mechanical failure (call IntelliTech for service
information at 800-694-3034).
•
•
•
Bad stepper motor (replace)
Bad driver (replace)
Bad sensor (replace)
OUT OF MEMORY
Print job requires more memory than is
available. Add additional SIMM memory (see
Section 4 for SIMM memory installation
procedures).
OVERRUN ERROR
Printer could not keep up with host. Use a lower
baud rate.
3-28
Unit Operation
Table 3-4
Error Messages (cont’d)
Status Message
Definition
PARITY ERROR
Printer received the wrong parity bit from the
host. Check the host protocol or the serial cable
connections.
PRINT HEAD OPEN
Appears when printer is online or offline and the
print head is not closed and latched. When it
occurs, printer automatically goes offline. Close
and latch print head, and press Online button.
“READY” appears in control panel display.
RIBBON OUT
Ribbon sensor detects no ribbon.
•
•
•
•
A new ribbon roll needs to be installed.
See “Installing the Thermal Ribbon” in
Section 2 for ribbon installation
procedures.
The label roll is not installed correctly
under the print head, blocking ribbon
detection. Install the label roll properly,
making sure to feed the label liner
under the label sensor plate. See
“Loading Labels” in Section 2 for label
installation procedures.
Ribbon sensor needs adjustment or
replacement (call IntelliTech for service
information at 800-694-3034).
Ribbon leader is under ribbon sensor.
SERIAL OVERFLOW
Host system continues to send data after the
printer has signaled that it cannot accept more
data. Check the host protocol.
SUB RAM ERROR
Main board controller requires service (call
IntelliTech for service information at
800-694-3034).
Unit Operation
Table 3-5
3-29
Status Messages
Status Message
Definition
BUFFER CLEAR
The print buffer contains no data.
DATA IN BUFFER
Data remains in the print buffer. Press Feed to
print the last label.
CANCEL=NOREPRINT
If a recoverable error occurs, press Cancel
and the last label will not reprint.
INITIALIZE
Operating parameters are loading into the
printer’s memory, making it ready to print.
OFFLINE PAUSE
Printer is not ready to accept computer data.
ONLINE READY
Printer is ready to accept data from the
computer.
ONLINE=REPRINT
If a recoverable error occurs, press Online to
reprint the last label.
PEEL OFF LABEL
Tells you when to peel off the label.
PRESS SELECT
Press Select button.
PREHEATING
Model 412 print head is pre-heating for highspeed printing.
CLOSE HEAD
LIFT HEAD
TEAR OFF LABEL
When pre-heating completes, close the print
head (Model 412 only).
During pre-heating (Model 412 only), open the
print head.
Tells you when to tear off the label.
3-30
Unit Operation
PRINTING MODES
The IntelliBar can operate in any of the following modes: Standard, Peel-off, Tear-off, and
Cut-off.
NOTE: Peel-off, Tear-off, and Cut-off modes
are intended for print speeds of 6 ips or less.
Standard Mode
Standard Mode, sometimes called strip printing, is recommended for higher speed printing
applications, such as normal batch or volume printing.
In Standard mode, the application prints one label after another, and the print head
maintains a relatively constant temperature. When the last label is printed, the label gap is
positioned behind the tearbar, making it difficult to remove the last label unless you advance
one label using the FEED button.
Standard Mode is the only selection possible when winding printed labels on the internal or
external rewinder option.
NOTE: When printing at high speeds (10 ips or
higher), Express Wax ribbons are recommended.
For the best print quality at print speeds of 10 ips
or higher, media specially formulated for highspeed thermal transfer printing is recommended.
Peel-Off Mode
Peel-off Mode is intended for on-demand applications, where you print and take off one
label at a time and set the printer to automatically strip the label from the backing material
(liner). The internal rewinder option can be used to rewind the backing material. When peeloff mode is set through the Print Menu, the printer
receives data from the host
prints the label
instructs you (through the LCD display) to remove the label. After you remove
the label, the liner backs up and printing resumes at the beginning of the next
label.
Since Peel-off Mode automatically strips the label from the liner, change the MEASURE
LABEL selection in the Label Menu from automatic (the default) to fixed. This ensures that
no more than one label advances during power-on initialization. If left in the Automatic
mode, more than one label advances, which may result in a media jam at the label exit slot.
Unit Operation
3-31
Tear-Off Mode
Like Peel-off Mode, Tear-off Mode is commonly used in on-demand, one-label-at-a-time
printing applications. The printer instructs you to tear off the label after automatically
positioning the label stock so that the label gap is above the tear bar, making the tearing
operation easier.
After you tear off the label, the label automatically backs up so that printing resumes at the
beginning of the next label. While this eliminates waste, printing is discontinuous, and it is
therefore recommended that Tear-off Mode be used at slower print speeds (less than 6 ips).
Cut-Off Mode
Cut-off Mode is available when you install the Cutter option (Model 2401) as described in
Section 3. Designed for on-demand, one-label-at-a-time printing, Cut-off Mode provides
the convenience of a label that is automatically cut and ready to apply. The printer can also
be programmed to print a number of labels (up to 32,767) and then perform the cut
function. The cutter is designed to cut paper or synthetic liners, and can also cut continuous
label media that does not contain rubber-based adhesives..
NOTE: If Cut-off Mode is used to cut through
the entire label material, frequent cleaning of the
cutter blade may be required to remove adhesive
residue that could adversely affect the operation
of the device.
NOTE: The information in this section is subject
to change without notice. This information is
provided "as is" without either express or implied
warranty. IntelliTech International, Inc. disclaims
any and all warranties with regard to this
information. IntelliTech shall not be liable in any
event for any special, indirect or consequential
damages or any damages whatsoever resulting
from loss of data, profits or use, for any reason
or in any action, arising out of or in connection
with the use or performance of this information.
Section 4
Options
This section provides an overview, specifications, settings, and installation information on
the IntelliBar Model 48 and 412 options. This section also lists IntelliTech International,
Inc. and dealer order numbers for the available options.
Users can purchase and install industry-standard memory expansion SIMM modules to
improve data throughput and overall performance for the IntelliBar Model 48, Model 412,
and Model 88 printers.
In addition, IntelliTech options for the Model 48 and 412 printers are listed below.
User-installable options:
Label Cutter (Model 2401)
External rewinder (Model 2402)
Factory-installable options:
Internal rewinder (Model 2405)
Reflective label sensor (Model 2404)
MEMORY EXPANSION
Depending on the main board, IntelliBar memory expansion can be done in the IntelliBar
Model 48 and 412 through the purchase of industry-standard, user-installable, SIMM
memory modules made for Apple or PC products and available from retail or mail order
computer hardware suppliers. These modules install in pairs in two slots on the main board
and increase the printer’s standard memory capacity as shown in Table 4-1 and Table 4-2.
NOTE: 70 SIMMs are required or printers with
Revision 12, 13, or 14 main boards, while 60 ns,
9-chip SIMMs are required for printers with Rev.
15 or 16 main boards.
4-2 Options
Table 4-1 Memory Expansion Upgrade Path, Main Board Rev. 12, 13, or 14
Expansion RAM
Model
Standard
RAM
1 MB
2.5 MB
4 MB
8.5 MB
Socket 1 Socket 2
Socket 1 Socket 2
Socket 1
Not supported
4MB** 4MB**
Not supported
Socket 1
Socket 2
Socket 1
Socket 2
48
1 MB*
—
—
1MB**
88
2 MB***
—
—
Not supported
Not supported
Not supported
4MB
4MB
412
2 MB***
—
—
Not supported
1MB
Not supported
4MB
4MB
*=
1MB**
Socket 2
10 MB
1MB
The Model 48 contains 1 MB of standard RAM in total: 512 KB of RAM soldered on the main board and two 256-KB
SIMMs pre-installed in the memory expansion slots.
** = Requires removal of SIMMs already installed.
*** = The Model 412 and Model 88 contain 2 MB of standard RAM soldered on the main board. The Model 88 comes with 10 MB
of standard memory and no expandability.
NOTE: Revision 12, 13, and 14 main boards require 70 ns SIMMs.
Table 4-2 Memory Expansion Upgrade Path, Main Board
Rev. 15 or 16 (for All Models and Series)
Soldered on Main
Board
1
2
SIMM Slot
3
Total RAM
4
2 MB
1 MB
1 MB
None
None
4 MB
2 MB
4 MB
4 MB
None
None
10 MB
NOTE: Revision 15 and 16 main boards require 60 ns SIMMs.
Adding memory to the IntelliBar increases the length of labels that can be output and
improves the printer’s overall performance.
To avoid corrosion between different metals, use only tin-plated SIMM modules. For
memory module installation instructions, see “Memory Expansion Module Installation (All
Models)” later in this section.
Options 4-3
INTELLIBAR OPTIONS
IntelliBar options are divided into two categories: user-installable and factory-installable.
The following subsection describes these options.
User-Installable Options
Label Cutter (Model 2401) — Lets you quickly print and process labels for
immediate application. This user-installable option fits in the front panel in place
of the standard peel-off assembly. You must also remove the tear bar from above
the platen roller (see “Label Cutter Installation Procedure Overview (Model 48
and 412)” later in this section for installation procedures).
The cutter is designed for users who require on-demand label printing (usually one
label at a time) and the convenience of a label precut and ready to apply. The
printer can be programmed to print a number of labels (up to 32,767) and then
perform the cut function.
The cutter is designed to cut paper or synthetic label backing (liner) and can also
cut continuous media.
External rewinder (Model 2402) — Mounts on front of printer and rewinds paper
through the front slot. Allows you to prepare labels that can be conveniently
spooled for storage or shipment to another location.
Factory-Installable Options
Internal rewinder (Model 2405) — This option mounts inside the IntelliBar and
can be used to spool printed media (labels and backing paper) for convenient
storage or transportation of labels in volume quantity. You can also use the
rewinder option to spool only the backing paper in peel-off print mode. For label
loading instructions, see “Internal Rewinder (Model 48 and 412)” later in this
section.
Reflective label sensor (Model 2404) — This option replaces the printer’s
standard, transmissive (see-through) label sensor. This option reflects light off the
black stripe when tag or ticket stock is fed through the printer and thereby detects
the label’s home position (used for determining the first print line on the label).
Can also be used on butt-cut or specialty die-cut labels.
4-4 Options
MEMORY EXPANSION MODULE INSTALLATION (ALL MODELS)
This subsection describes how to install industry-standard SIMM memory modules for
increasing printer random access memory.
NOTE: The SIMM modules must have a speed
of 70 ns or faster on Rev. 12, 13, or 14 main
boards; for Rev. 15 or 16 main boards, the
SIMM modules must have a speed of 60 ns or
faster. Slower SIMMs are not supported. To
avoid corrosion between different metals, use
only tin-plated SIMM modules.
The two memory modules must be installed in tandem (both SIMM expansion sockets must
be populated with the SIMMs for the printer to operate properly). To install the modules,
proceed as follows:
CAUTION: Before handling a SIMM, discharge
any static electricity by touching a grounded
metal object, such as the metal frame inside the
printer.
Always hold a SIMM by its edges. Avoid
touching the components on the SIMM.
1. Turn off and unplug the printer.
2. Open the left side cover.
3. Loosen the four cover screws (two on the inside and two on the outside) holding
the right side cover in place (see Figure 4-1).
4. Close the left side cover.
Options 4-5
Screws
Screws
(Hidden)
Note: Model 48
shown
Figure 4-1 Right Side Cover Screws
5. Lift the right side cover up and away from the printer (see Figure 4-2).
4-6 Options
Right Side Cover
Note: Model 48
shown
Figure 4-2 Right Side Cover Removal
6. Depending on the main board installed in the printer, locate the two SIMM
sockets on the main board (see Figure 4-3 or Figure 4-4).
SIMM Sockets
Figure 4-3 SIMM Sockets (Rev. 12, 13, or 14 Main Board)
Options 4-7
SIMM Sockets
Figure 4-4 SIMM Sockets (Rev. 15 or Rev. 16 Main Board)
Adding Expanded Memory
Use the following procedure to install SIMM modules in the main board SIMM sockets.
Removing an Installed SIMM
If you need to replace a SIMM that is presently installed with a different SIMM
configuration, remove the installed SIMM as follows (see Figure 4-5).
1. Press the plastic clips at the outer edges of the socket away from the SIMM.
2. Push the SIMM away from the locking tabs and remove it from the socket.
4-8 Options
Clips
Figure 4-5 Removing a SIMM
Installing a SIMM
Install a SIMM as follows.
1. Align the notched end of the SIMM (see Figure 4-6) with the bottom end of the
left or right SIMM socket (see Figure 4-7).
Options 4-9
Notch
Figure 4-6 Notched End of SIMM
Notche d End of SIMM
Figure 4-7 Aligning the SIMM
2. Insert the SIMM at an angle into the left or right socket.
3. Carefully tilt the SIMM toward the locking tabs (see Figure 4-8).
4-10 Options
Figure 4-8 Inserting the SIMM
4. Using equal pressure at the ends of the SIMM, push the SIMM until it locks into
the locking tabs on the ends of the socket (see Figure 4-9).
5. Repeat the installation procedure for the other SIMM.
NOTE: Be careful when handling the SIMM; the
SIMM and socket tabs are fragile.
Options 4-11
Clips
Figure 4-9 Securing the SIMM
LABEL CUTTER INSTALLATION PROCEDURE OVERVIEW (MODEL 48
AND 412)
To install the Model 2401 Label Cutter option, you must do the following:
A. remove the standard peel-off assembly from the printer.
B. install the cutter option.
C. configure the printer to use the cutter option using the control panel menu
buttons.
4-12 Options
A. Remove the Standard Peel-Off Assembly (Model 48 and 412)
To remove the peel-off assembly from the printer, proceed as follows.
1. Turn off and unplug the printer.
2. Open the left side cover (see Figure 4-10).
3. Press the front panel release latch and gently lower the front panel.
The peel-off assembly is located on the inside of the front panel.
NOTE: By lifting up the front panel stopper, you
can lower the front panel so it is flat on the work
table, allowing better access. Figure 4-11 in this
section shows the location of the stopper.
Left Side Cover
Front Panel
Release Latch
Peel-off Assembly
(Hidden)
Figure 4-10 Left Side Cover and Front Panel Release Latch
4. Loosen the peel-off assembly thumb screw by turning it counterclockwise (see
Figure 4-11).
Options 4-13
5. Slide the peel-off assembly upward and out of the notches in the front panel and
lift off the assembly.
6. Disconnect the peel-off assembly cable connector from the control panel board.
Cable
Connector
(Color-Coded)
Front Panel
Release Latch
Control Panel
Board (Hidden)
Thumb Screw
Peel-Off
Assembly
Stopper
Figure 4-11 Model 48 and 412 Peel-Off Assembly Removal
(Inside Front Panel View)
7. Remove the peel-off/tear bar from the printer by sliding it out of the slots (see
Figure 4-12).
4-14 Options
Peel-off/Tear Bar
Front Panel
Stopper
Figure 4-12 Peel-off/Tear Bar Removal (Model 48 and 412)
B. Install the Cutter Option (Model 48 and 412)
To install the label cutter, follow the removal procedure for the peel-off assembly in reverse
order.
NOTE: Do not reinstall the peel-off/tear bar.
1. Connect the label cutter cable connector to the lower, six-pin control panel board
connector.
2. Slide the label cutter option into the notches on the front panel.
3. Secure the label cutter option to the front panel by turning the thumb screw
clockwise (see Figure 4-13).
4. Close and securely latch the front panel.
Options 4-15
Cable Connector
(Color-Coded)
Front Panel
Release Latch
Control Panel
Board (Hidden)
Label Cutter
Option
Thumb Screw
Figure 4-13 Label Cutter Installation (Model 48 and 412)
C. Configure the Printer to Use the Cutter (Model 48 and 412)
After you have installed the label cutter, use the control panel menu buttons to configure the
print mode parameter for operating the label cutter option. See “Controls and Indicators” in
Section 2 for information on the following set up procedure.
1. Plug in and turn on the printer. Wait for “READY” to appear in the 2-line LCD
display.
2. Press Online to take the printer off line. The 2-line display will read “OFF LINE,
PAUSE.”
3. Press Menu. The 2-line display will change to “MAIN MENU, PRINT MENU.”
4. Press Select. The 2-line display will change to “PRINT MENU, PRINT
METHOD.”
5. Press Next. The 2-line display will change to “PRINT MENU, PRINT MODE.”
6. Press Select. The 2-line display will change to “PRINT MODE=, STANDARD.”
7. Press Next until “PRINT MODE=, CUT OFF” appears in the display.
8. Press Select.
4-16 Options
9. Press Online. This saves your menu selections, puts the printer online (“READY”
appears in the control panel display) and sets up the printer to operate the label
cutter after every label.
INTERNAL REWINDER (MODEL 48 AND 412)
This subsection describes how to load labels for the Model 2405 Internal Rewinder option.
NOTE: This option must be installed by
IntelliTech International, Inc. service
representatives and authorized dealers.
Loading Labels
The internal rewinder can operate in one of two ways. You can rewind labels and backing
paper (liner) onto the take-up spindle when the printer is in standard print mode.
Alternatively, you can rewind only the backing paper when the printer is set to peel-off
mode using the control panel menu buttons (see Section 3 for instructions on using the
control panel to put the printer in peel-off mode).
The rewinding method you use determines the remaining parts removal and installation
procedures for the internal rewinder option.
To load labels, proceed as follows, depending on how you are using the internal rewinder to
rewind the label media.
Loading Labels in Standard Mode
To rewind both labels and liner with the printer in standard mode, follow the steps below.
(If you are rewinding only the backing paper, see the following subsection, “Loading Labels
in Peel-Off Mode.”)
1. With the front panel open, remove the peel-off assembly as follows. (The peel-off
assembly is located on the inside of the front panel.)
NOTE: By lifting up the front panel stopper, you
can lower the front panel so it is flat on the work
table, allowing better access. Figure 4-14 in this
section shows the location of the stopper.
Loosen the peel-off assembly thumb screw by turning it counterclockwise (see
Figure 4-14).
Slide the peel-off assembly upward and out of the notches in the front panel
and lift off the assembly.
Options 4-17
Disconnect the peel-off assembly cable connector from the control panel
board.
Front Panel
Release Latch
Cable
Connector
(Color-Coded)
Control Panel
Board (Hidden)
Thumb Screw
Peel-Off
Assembly
Figure 4-14 Model 48 and 412 Peel-Off Assembly Removal
(Inside Front Panel View)
2. Remove the peel-off/tear bar by sliding it out of the notches (see Figure 4-15).
3. Mount the front panel inside cover supplied with the internal rewinder option kit
onto the front panel. To install the inside cover, reverse the peel-off assembly
removal procedure described in step 1.
Slide the inside cover into the notches on the front panel.
Secure the inside cover to the front panel by turning the thumb screw
clockwise.
NOTE: No cable connection is required for the
front panel inside cover.
4-18 Options
4. Insert the front panel label guide supplied with the internal rewinder option kit so
that the dimples on the guide’s top lip lock in place in the label exit slot on the
front panel (see Figure 4-15). Be sure the bottom lip on the label guide is
positioned in the label release paper slot as shown in Figure 4-15.
NOTE: When properly positioned, the top lip of
the label guide plate should fit into the cut-out on
the front panel inside cover (with the dimples
secured in the label exit slot).
Cut-out
(Hidden)
Peel-off/Tear Bar
Dimples
Front Panel
Stopper
Front Panel Label Guide
Label Release
Paper Slot
Front Panel Inside
Cover
Figure 4-15 Front Panel Label Guide and Inside Cover
5. Follow the label loading instructions in Section 2 (see “Standard Mode, Tear-Off
Mode, Cut-Off Mode), and, in addition, proceed as follows to load labels for the
internal rewinder option.
Options 4-19
Route the leading edge of the label strip downward from the label exit slot,
past the front panel label guide, into the label release paper slot (see
Figure 4-16), and between the bar and plate in the lower media guide.
Guide the label strip away from the lower media guide and thread it onto the
internal rewinder take-up spindle.
Wind the spindle several turns in the clockwise direction to take up any slack
in the label roll.
Adjust the white teflon guides on the lower media guide for the label width.
Close and securely latch the front panel.
Labels and Liner
Internal Rewinder Take-up
Spindle
Figure 4-16 Loading Labels for the Internal Rewinder in Standard Print Mode
Loading Labels in Peel-Off Mode
To rewind only the liner with the printer set to peel-off mode, proceed as follows. (If you
are rewinding both the labels and liner, see the previous subsection, “Loading Labels in
Standard Mode.”)
NOTE: The peel-off assembly and peel-off/tear
bar must be installed to use peel-off mode.
1. Follow the label loading instructions in Section 2 (see “Peel-Off Mode”), and, in
addition, proceed as follows to load labels for the internal rewinder option.
4-20 Options
Route the label strip downward from the tear bar, around the platen roller, and
through the slot in the backing paper guide (see Figure 4-17).
Guide the label strip from the slot in the backing paper guide onto the take-up
spindle (see Figure 4-17).
Wind the spindle several turns in the clockwise direction to take up any slack
in the label roll.
2. Close and securely latch the front panel.
Internal Rewinder Take-up Spindle
Liner (Peel-Off Mode Only)
Figure 4-17 Loading Labels for the Internal Rewinder in Peel-Off Print Mode
NOTE: The information in this section is subject
to change without notice. This information is
provided "as is" without either express or implied
warranty. IntelliTech International, Inc. disclaims
any and all warranties with regard to this
information. IntelliTech shall not be liable in any
event for any special, indirect or consequential
damages or any damages whatsoever resulting
from loss of data, profits or use, for any reason
or in any action, arising out of or in connection
with the use or performance of this information.
Section 5
Cleaning and Adjustments
This section contains information for maintaining the printer in top condition for
continuous, error-free, high-quality performance. Included in this section are procedures for
external and internal cleaning and printer adjustments.
After completing any procedure in this section, print out a test label as outlined in Section 2
to verify operation.
CLEANING
Printer cleaning materials include a cotton-tipped applicator or cotton swabs dipped in
isopropyl alcohol (90%), and a soft, lint free cloth. Clean the printer’s external and internal
surfaces as follows.
CAUTION: Before starting any cleaning
procedure, turn OFF and unplug the printer. Do
not use benzine, paint thinner, or other chemicals
or abrasives to clean the printer’s plastic
surfaces. Such cleaning materials may dissolve
the plastic or cause discoloration.
Do not use water to clean the print head.
External Cleaning
Whenever necessary, clean the printer’s plastic front panel and the metal side and rear
covers with a soft cloth dampened in water and a mild detergent.
Internal Cleaning
To clean the inside of the printer, follow these preliminary steps (see Figure 5-1 or 5-2).
o
1. Pull the front panel latch release lever and gently lower the front panel to a 45
angle (Model 48 and 412 only).
2. Push the print head latch release lever and gently raise the print head all the way
up.
3. Remove the ribbon and paper from under the print head.
4. Clean the print head, platen roller, and sensors as described in the following
subsections.
5-2 Cleaning and Adjustments
Print Head
(Hidden)
Front Panel Latch
Release Lever
Ribbon Tension
Plate
Platen Roller
Print Head
Assembly
Print Head
Latch Release
Lever
Figure 5-1 Printer Interior (Model 48 and 412)
Print Head
(hidden)
Ribbon Tension
Plate
Platen Roller
Print Head
Assembly
Print Head
Latch Release
Lever
Figure 5-2 Printer Interior (Model 88)
Troubleshooting and Repair 5-3
Print Head
Clean the print head after every ribbon change or when inconsistent print quality (such as
faded or broken lines or blank areas) appears on labels. To clean the print head (see
Figure 5-3), gently wipe the bank of print head resistors with a cotton swab dipped in 90%
isopropyl alcohol.
Print Head Life
The print head service life is dependent on printing materials, operating environment, and
duty cycle (the amount of time the printer is in operation). Print quality deteriorates when
the print head wears out.
Observe the following guidelines to prolong print head life.
Do not rotate the platen roller without having ribbon and label media loaded in the
printer and passing under the printer head.
Clean the print head whenever you replace the ribbon.
Use only specified, IntelliTech ribbons and labels to maintain long print head life
and ensure premium print quality (see Section 2 for information about IntelliTech
labels and ribbons).
Keep dust and dirt from getting inside the printer.
Keep the print head surface clear of debris such as plastic or metal shavings.
Other Parts
Operating environment and duty cycle also affect other parts such as the platen roller and
peel-off roller. These parts require service by a qualified service representative.
NOTE: See “Getting Service and Support” in
Section 6 for information about the service and
support options for your printer.
Platen Roller
The platen roller presses the paper and ribbon against the print head. It also guides the
paper and ribbon away from the print head and therefore picks up ink and paper residue
during operation. To clean the platen roller (see Figure 5-3), proceed as follows.
1. Manually remove any label or foreign material from the platen roller.
2. Gently wipe the platen roller with a lint-free cloth dipped in 90% isopropyl
alcohol. This should be done every three months or when the need arises.
5-4 Cleaning and Adjustments
Sensors
Once a month (or whenever dust or dirt has accumulated and affected operation), the head
open, ribbon end, and label sensors should be wiped with a cotton-tipped applicator dipped
in 90% isopropyl alcohol. See Figure 5-3 for the location of the sensors.
Print Head
Resistors
Label Sensor
Ribbon
Sensor
Head Open
Sensor
Platen Roller
Figure 5-3 Cleaning the Print Head, Rollers, and Sensors
Troubleshooting and Repair 5-5
NOTE: Raise the label sensor plate to clean the
LEDs on the underside of the sensor assembly
(see Figure 5-4).
Label
Sensor
LEDs
Label Sensor Plate
(Raised)
Figure 5-4 Label Sensor LED Location
PRINT POSITION ADJUSTMENT
Using the control panel, you can select the desired “ADJUSTMENT MENU, PRINT
POSITION” parameter (see “Controls and Indicators” in Section 2 for information on using
the control panel).
This setting adjusts the position of the first print line relative to the leading edge of the label.
The adjustable range is .12 in. (3 mm) forward or backward in 0.004 in. (1.0 mm) steps (see
Figure 5-5). Using the control panel display, the allowable range is +30 to -30.
In Figure 5-5, the print head is positioned at the front edge of the label (1 mm from the
perforation) and the first possible print line is 2 mm from the edge of the label (ramp up
area).
If you set the range to -30 steps (3 mm), the print head is positioned in front of the edge of
the label (2 mm in front of the perforation) and the first possible print line is 1 mm in front
of the edge of the label. In this case, you would clip the first 1 mm of the character.
5-6 Cleaning and Adjustments
3 MM
+30
2 MM
0
1 MM
ABC
ABC
ABC
-30
Label
Feeding Direction
Head of Label
Figure 5-5 Print Position
PRINT HEAD VOLTAGE ADJUSTMENT
If you have replaced the print head, you must set the print head voltage and/or enter the
print head serial number.
For print head removal and installation procedures, see “Print Head Removal and
Installation” in Section 2.
NOTE: Be sure to see the print head removal
and installation procedure appropriate for your
IntelliBar printer model.
For instructions on setting the print head voltage and/or entering the print head serial
number, see “Print Head Voltage Adjustment” in Section 2.
CORRECTING POOR PRINT QUALITY
This subsection describes common printer problems that affect print quality. Knowing the
causes of poor print quality can help you to avoid potential problems (and solve problems
when they arise). See “Mechanical Adjustments” later in this section for adjustment
procedures that prevent or fix common problems.
Troubleshooting and Repair 5-7
Some contributing factors to poor print quality are:
Print head not properly adjusted to label width
Mismatch or improper media being used
Density setting is too high or low for media type
Print head resistance not properly set
Print head latch is too loose or tight
Print speed too fast or slow
Improperly adjusted ribbon guide plate
Bad print head
Any one or combination of the above could produce poor print quality. Below is a brief
explanation why this can occur.
Print Head Adjustments
When the print head is not adjusted properly, wrinkling, light or faded print, skewing of the
ribbon or label, or missing print can occur. Print head adjustments will be described in more
detail later on in this section (see “Mechanical Adjustments”).
Media Mismatch
A mismatch of media occurs when a ribbon that is designed for fast application is used with
a coated label stock that requires slower print speeds. An example of this would be if you
used an Express Wax ribbon with a polyester label stock. This combination would produce
poor print quality, a resin based ribbon at slower speeds would perform better in this case.
Density
Density settings are important to overall print quality as well. In instances where you are
using a material such as polyester, the print head may have to burn hotter to imprint the
image onto the material. In most applications the default setting of “0” is sufficient.
Resistance Value
When the firmware, main board, or print head is replaced you must reset the print head
resistance value. Each print head has its own resistance value and must be matched with the
other components of the printer. This is done through the control panels maintenance menu.
If this is not done, the printer defaults to “1000” Ohms and the correct voltage will not be
set for use with the print head causing less than perfect print quality.
5-8 Cleaning and Adjustments
Print Head Latch
When the print head latch is too loose it produces a very light or no print. A simple test to
tell if your latch may be the cause of your problem is to press down on the print head with
your hand while printing. If your print improves dramatically, this may be the source of the
problem. If the print head latch is too tight, it may cause wrinkling of the ribbon.
WARNING: Do not wear loose clothing, long
sleeves, or loose jewelry when doing this test.
Print Speed
Print speed is very important to perfecting the quality of your print. Although some models
of IntelliBar printers can reach speeds of up to 12 inches per second (ips), you may have to
lower the speed of the printer to produce good quality on the media you have chosen to
use. Some ribbon and label combinations perform better under slower speeds, and some
perform better at faster speeds. At slower speeds, the print head will have more time to
transfer the ribbon onto the media.
Ribbon Guide Plate
The ribbon guide plate (also referred to as the ribbon tension plate) is used to adjust ribon
tracking to correct ribbon wrinkling. The guide plate is located on the front of the print
head housing and is connected by two Phillips head screws. This plate provides tensioning
to the ribbon to keep it from wrinkling under the print head. Once the ribbon has passed the
print head, you may see some wrinkling at the take up spool, which is normal. Printing an
all black page will show the wrinkle area clearer and help you adjust it properly.
Bad Print Head
Generally a print head will not produce fading when it fails. Print heads that fail will
produce missing text, clipped characters, or straight white lines across the page.
When a print head fails, one or more elements (resistors) can fail and produce the white
lines.
Troubleshooting and Repair 5-9
MECHANICAL ADJUSTMENTS
To maintain normal operation, the following conditions must be met.
labels must feed straight under the print head without skewing to the left or right
(label alignment)
the ribbon must be free of wrinkles or creases as it passes under the print head
resistors
the printer must be able to sense the presence or absence of labels and ribbon
the print head must be aligned horizontally so that the print line outputs straight
across the width of the label (horizontal print head alignment)
the print head must be set according to label width and thickness so that ink
transfers properly from the ribbon to the label (print head balance and pressure)
the print head elements (resistors) must be positioned over the platen roller to
ensure the highest print quality (print head position)
the stepper motor belt tension must be maintained so that ribbons and labels feed
properly
To meet the above conditions, the following subsections describe routine mechanical
adjustments that will keep your printer operating normally. These adjustments should be
done whenever necessary to maintain normal operation.
NOTE: If a problem occurs and you cannot
restore normal operation by following these
procedures, a service call may be needed. For
more information, call IntelliTech International,
Inc. at 800-694-3034.
You may also fill out and fax the service request
form provided at the end of Section 6.
5-10 Cleaning and Adjustments
Model 48 and 412
The following mechanical adjustments to the Model 48 and 412 must be done periodically:
label width guide adjustment
horizontal print head alignment
print head pressure knob adjustment for label thickness
print head balance lever adjustment for label width
print head postion dial adjustment for label thickness
ribbon guide plate tension adjustment for wrinkling
timing belt tension adjustment
Label Width Guides (Model 48 and 412)
The two white teflon label width guides are located under the print head cover (see
Figure 5-6). The guides align the paper so it feeds straight under the print head and onto the
platen roller.
In addition, the inside guide lines up the inside edge of the label with the first print element
on the print head. As viewed from the front panel, the specification is to set the outside
edge of this guide 0.16 in. (4 mm) from the first print element.
When the inside label width guide is within specification, slide the outside label width guide
up to the edge of the backing paper (liner).
Inside Label Width Guide
Label Sensor Plate
Label Media
Outside Label Width
Guide
Figure 5-6 Label Width Guides (Model 48 and 412)
Troubleshooting and Repair 5-11
Horizontal Print Head Alignment (Model 48 and 412)
The print head alignment adjustment (print head skew) should be done to adjust the label’s
horizontal print line and to help prevent the ribbon from wrinkling as it feeds under the print
head resistors.
1. Load ribbon at least 4.25-in. (108.9 mm) wide. Load labels at least 4.25-in. (108.9
mm) wide and 1.5-in. (38.1 mm) long. This is necessary to adjust the full
horizontal position of the print head elements so they are parallel with the label
edge.
2. Output a self-test bar code label from the control panel to see if the bottom line of
print on the left side of the label is exactly the same distance from the label top as
it is on the right side of the label (see Figure 5-7).
NOTE: See Section 3 for information on the bar
code self-test procedure.
Verify the alignment by using a ruler to measure the distance, on both sides, from
the bottom line of the bar code label to the leading edge (top) of the label. The
distance on each side should be equal, ensuring a full horizontal print line and
minimizing the chance of the ribbon skewing and wrinkling as it feeds under the
print head.
Figure 5-7 Bar Code Self-Test
If the bottom line of print on the left side of the label is not exactly the same
distance from the label top as it is on the right side of the label, proceed as
follows.
3. Open the left side cover and front panel.
5-12 Cleaning and Adjustments
4. Check that the perforation on the label liner (backing paper tear line) lines up with
the peel-off/tear bar, using the bar as a straight edge. If the perforation does not
align, unlatch and open the print head and reload the labels (at least 4.25-in.
(108.9 mm) wide and 1.5-in. (38.1 mm) long).
5. With the print head closed and securely latched, locate the Phillips head screw
under the print head position dial (see Figure 5-8).
o
6. Turn the Phillips head screw 45 (1/8 of a complete revolution) in either direction.
7. Run the self-test again (see “Self-Test” Section 3), printing a minimum of three
bar code labels.
8. Verify the measurement on the third label to make sure the proper alignment has
been achieved. If it has not, repeat step 4, readjusting the Phillips head screw as
required to obtain the proper alignment.
Print Head
Alignment Screw
(Hidden Under
Dial)
NARROW
02
THIN
01
1
2
3
THICK NES S
A DJ.
W IDE
4
THICK
5
6
W IDTH A DJ.
Figure 5-8 Print Head Alignment Screw (Model 48 and 412)
Troubleshooting and Repair 5-13
Print Head Pressure Knob for Label Thickness (Model 48 and 412)
The print head pressure knob is factory set to off (turned completely counterclockwise),
which works for most label thicknesses (such as the sample labels supplied with the printer).
However, thicker labels may be less pliable and require increased pressure. To improve print
quality, turn the print head pressure knob clockwise to increase pressure and better mold
thick labels around the print head elements (resistors).
CAUTION: In thermal transfer applications, too
much pressure can result in reduced print quality
(a “ghosting” affect).
This adjustment is best made prior to loading ribbon. Turn the knob clockwise (see
Figure 5-9) for thick, spongy, or stiff paper (increasing head pressure), allowing thicker
print media such as tag stock to feed through the print head mechanism without causing
undue wear on the print head elements. For thinner or more flexible media, turn the knob
counterclockwise (lighter head pressure).
This adjustment must be made on a trial-and-error basis using the control panel to print out
self-test samples and readjusting the knob as necessary until the correct print quality is
obtained. The test sample should exhibit optimum print density (black/white contrast), with
output that is neither too dark or muddy in appearance nor too light or faded.
NARROW
THIN
02
01
1
2
3
THICKNESS
ADJ.
4
THICK
5
6
WIDE
Print Head
Pressure Knob
for Label
Thickness
WIDTH ADJ.
Figure 5-9 Print Head Pressure Knob (Model 48 and 412)
5-14 Cleaning and Adjustments
Print Head Balance Lever for Label Width Adjustment (Model 48 and 412)
This lever (see Figure 5-10) balances the print head so there is equal pressure along the
label stock calibrated to the label width. This ensures that the label feeds straight through
the print head mechanism without skewing to the left (which may cause the rightmost
printing on the label to be lost and possibly cause the label liner to creep over the label
width guides, eventually leading to paper jams).
NARROW
THIN
02
01
1
2
3
THICKNESS
ADJ.
WIDE
4
THICK
5
6
Print Head
Balance
Lever
for Label
Width
WIDTH ADJ.
Figure 5-10 Print Head Balance Lever (Model 48 and 412)
Print head balance is factory set all the way to left (to Wide), which is the setting for the
sample labels supplied with the printer.
This adjustment also reduces wear on the print head, since less pressure is put on the platen
roller when the head is properly balanced according to label width. For narrower labels, this
adjustment puts force on the top of the label rather than the platen (see below).
Figure 5-11 Print Head Balance Adjustment for Narrow Label Stock
Troubleshooting and Repair 5-15
Slide the print head balance lever all the way to the left (as viewed from the front panel) for
maximum-width labels (4.25 inches or 108 mm). To adjust for narrower labels, slide the
lever to the right. Each division on the scale in front of the lever represents a label width
increment of approximately 0.75 in (19 mm).
This adjustment must be made on a trial-and-error basis using the control panel to print out
self-test samples and readjusting the lever as necessary until the correct print quality is
obtained.
If the print head balance adjustment is set too narrow, the output will resemble the sample
in Figure 5-12.
Figure 5-12 Sample of Incorrect Print Head Balance
The test sample should exhibit the same uniform print quality on the left and right sides of
the label as it does in the middle. See Section 3 for self-test procedures.
Print Head Position Dial for Label Thickness Adjustment (Model 48 and 412)
The print head position dial is factory set to 0, which works well for most labels (including
the sample labels supplied with the printer).
This adjustment positions the print head elements (resistors) over the platen roller. At the 0
setting, the elements are over or just slightly in front of the top-center of the platen (see the
following figure).
5-16 Cleaning and Adjustments
Figure 5-13 Print Head Movement for Label Thickness Adjustment
Turning the head position lever (see Figure 5-14) clockwise (to increment 1, 2, 3, etc.)
brings the print head forward (for printing on thicker labels, such as those used in the
thermal transfer printing method). Turning the head position lever counterclockwise (to
increment 01, 02) moves the print head back (for thinner labels, such as those used in the
direct thermal printing method). The print head moves backwards to maximize the heat and
pressure on the label media.
Print Head
Position Dial
NARROW
THIN
02
01
1
2
3
THICKNESS
THICK
ADJ.
6
WIDE
4
5
WIDTH ADJ.
Figure 5-14 Print Head Position Dial for Label Thickness Adjustment
Troubleshooting and Repair 5-17
Do this adjustment and then run the self-test (see Section 3 for self-test procedures).
If the print head position dial is incorrectly set, output may resemble the sample in
Figure 5-15.
Figure 5-15 Samples of Incorrect Print Head Position Setting
The print head elements are properly positioned when optimum print density is obtained and
bar code lines are crisp and sharp. The default is to set the lever on the third notch (0
position) for normal or thinner label stock.
5-18 Cleaning and Adjustments
Ribbon Guide Plate (Model 48 and 412)
The ribbon guide plate must be properly adjusted to keep the ribbon flat on the label and
prevent ribbon mistracking (wrinkling or tearing). Ribbon wrinkling is indicated by white
space and voids on printed labels (see Figure 5-16) and can be eliminated by increasing the
tension exerted on the ribbon by the plate. Decrease the tension to eliminate ribbon tearing.
Figure 5-16 Sample of Ribbon Wrinkling
To stop ribbon wrinkling or tearing, proceed as follows.
1. Feed a fresh section of ribbon under the print head and wind it onto the ribbon
take-up spool. Make sure the ribbon feeds straight under the print head and is
properly positioned over the label with no folds or creases.
2. Loosen the two ribbon guide plate screws (see Figure 5-17) and move the ribbon
guide plate toward the front panel to increase tension on the ribbon or toward the
rear panel to decrease tension (whichever is needed).
Troubleshooting and Repair 5-19
Ribbon Guide Plate
Sc rew
N AR R OW
T H IN
02
01
1
2
3
T H IC KN ESS
AD J .
W ID
Ribbon Guide
Plate
4
T H IC K
6
5
W ID T H AD J .
Ribbon Guide Plate
Sc rew
Figure 5-17 Ribbon Guide Plate
Sample Adjustment
To adjust the print when using standard, smooth, thermal transfer printing labels, use the
following sample procedure.
1. Turn the print head pressure knob fully counterclockwise (see Figure 5-9).
2. Turn the print head position dial to the “0” position (see Figure 5-14).
3. Set the printer to print at 4 ips.
4. Set the print density to -15 (see “Print Density Adjustment”).
5. Output several labels using the self test (see Section 3).
6. Look for uniform print quality across the width of the label.
7. If the print quality appears normal, turn the print head position dial to the “1”
position (see Figure 5-14) and run the self test again.
8. As print quality declines (breaks up), turn the print head pressure knob clockwise
until the broken characters have the same density across the width of the label (as
seen on the self-test). This ensures that the print head is properly balanced over
the entire label. Verify by watching the label move straight through the label
feeding path without skewing.
5-20 Cleaning and Adjustments
9. Readjust the print head pressure to obtain the best possible print quality within
its range.
10. Readjust the print density to obtain the best print quality within its range.
NOTE: If you change the print speed, you may
need to readjust the print density.
To adjust the print head for thick or stiff labels, turn the pressure knob clockwise to
increase pressure and then follows steps 1 through 10.
Timing Belt Tension Adjustment (Model 48 and 412)
During normal printer operation, the timing belt tension gradually loosens over time and
affects ribbon feeding. As the belt wears and stretches, it causes the ribbon to be wound
more and more loosely onto the ribbon take-up roller, and you end up with a larger than
necessary, cumbersome take-up roll that occupies space inside the printer and may interfere
with operation. Finally, when the timing belt becomes too loose, the ribbon feeds out the
label exit slot along with the label (instead of being wound onto the ribbon take-up roller).
To adjust the timing belt so there is enough tension to drive the ribbon correctly and wind it
more tightly onto the spool (or if you replace the belt during maintenance), proceed as
follows.
1. Open the left side cover and remove the label roll.
2. Locate the belt tension pulley screw next to the label supply spindle (see
Figure 5-18).
3. To increase belt tension, loosen the tension screw and move it downward in the
slot (Model 48 and 412 only).
To decrease tension, loosen the tension screw and move it up in the slot.
Troubleshooting and Repair 5-21
Belt Tension Screw
(slide down and left to
increase tension;
slide up and right to
decrease tension)
Figure 5-18 Timing Belt Tension Screw
Model 88
The following mechanical adjustments to the Model 88 may have to be done periodically.
label width and pressure adjustment
print head position dial for label thickness
ribbon guide plate adjustment
Label Width and Pressure Adjustment (Model 88)
The label width adjustment and label pressure adjustment are dual functions of the same
print head mechanism. To adjust the label width for a size less than eight inches, slide the
circular knob (see Figure 5-19) toward the inside of the printer.
5-22 Cleaning and Adjustments
Screws
Label
Width and
Pressure
Adjustment
Knob
Figure 5-19 Label Width and Pressure Adjustment (Model 88)
When adjusted at the factory, the print head is set for the widest possible position (toward
“WIDE”). Incorrect print head adjustment can cause problems such as ribbon wrinkling,
poor quality, and media jam errors.
NARROW
WIDE
Figure 5-20 Label Width Knob (Model 88)
The label pressure is adjustable for use with thicker media such as polyester or card stock
materials. These materials are less pliable and may require additional pressure to mold them
around the print head.
The label pressure is set at the factory to work with most media materials. To adjust for
thicker materials, turn the circular knob clockwise (this increases the amount of pressure) or
counterclockwise (to decrease pressure). See the following figure.
Troubleshooting and Repair 5-23
Figure 5-21 Label Pressure Adjustment Knob (Model 88)
CAUTION: Too much pressure can cause poor
print quality.
Label Thickness Dial (Model 88)
The label thickness dial (see Figure 5-22) moves the print head forward or backward
relative to the center of the platen. The label thickness is set at the factory for the best
possible adjustment for label stock. At the factory setting, the print head elements are
positioned over or slightly in front of the top center of the platen.
Screws
Label
Thickness
Dial
Figure 5-22 Label Thickness Dial (Model 88)
5-24 Cleaning and Adjustments
The label thickness dial is conveniently marked for adjustment (see Figure 5-23). The single
blue dot on top of the dial indicates the starting position. To adjust, turn the dial toward the
desired setting.
NOTE: Before moving the dial, loosen the 2
mm hex screw located next to the dial. Tighten
the hex screw after making the necessary
adjustment.
Turning the dial 180o displays the two red dots that indicate that you have reached the full
adjustment for that direction, and the adjustment will reverse direction from that point on.
T
H
I
C
K
T
H
I
N
Blue Dot
(Start)
Figure 5-23 Label Thickness Dial Adjustment (Model 88)
Ribbon Tension Plate (Model 88)
Adjust the ribbon tension plate to eliminate ribbon wrinkling. To adjust the plate (see the
following figure), loosen one (or both) screws as shown in Figure 5-25. Position the plate
so that the ribbon is tight across the length of the guide plate. Rotate the ribbon take-up
spool a few turns (while the printer is turned off) to make sure the ribbon is tight across the
guide plate. Then tighten the screw(s).
Troubleshooting and Repair 5-25
Print Head
(hidden)
Ribbon Tension
Plate
Platen Roller
Print Head
Assembly
Print Head
Latch Release
Lever
Figure 5-24 Ribbon Tension Plate (Model 88)
Screws
Screws
Figure 5-25 Ribbon Tension Plate Screws (Model 88)
5-26 Cleaning and Adjustments
PRINT DENSITY ADJUSTMENT
The print density adjustment (from the control panel) is used to fine tune print quality. If all
your prior adjustments have not produced the quality of output you require, try adjusting
the print density. See Section 3 for instructions on using the control panel.
NOTE: Print density and print speed go hand in
hand and should be adjusted together from the
control panel.
CAUTION: Print density can adversely affect
rotated (vertical bar codes).
If printed output is too dense or filling in, try reducing print density. If that doesn’t help, try
increasing the print speed. If output is too light or breaking up, try increasing print density
and/or reducing print speed.
Print density can be adjusted from -15 to +15 with “0” as the default setting. The following
examples show the differences in that range.
NOTE: The actual size of the printouts is
smaller than shown.
Troubleshooting and Repair 5-27
-15
0
+15
Figure 5-26 Print Density Samples
5-28 Cleaning and Adjustments
Table 5-1 lists the print speeds supported for each IntelliBar model. Use this list as a
reference when adjusting the print speed and density from the control panel.
Table 5-1 IntelliBar Print Speeds
Print Speed
(in./sec. (mm/sec.))
Model 88
Model 48
Model 412
0.6 (15)
X
X
X
0.8 (20)
X
X
X
1.2 (30)
X
X
X
1.6 (40)
X
X
X
2.4 (60)
X
X
X
3 (80)
X
X
X
4 (100)
X
X
X
5 (120)
X
X
X
6 (150)
X
X
X
7 (200)
X
X
X
8 (250)
X
X
X
12 (300)
X
NOTE: The information in this section is subject
to change without notice. This information is
provided "as is" without either express or implied
warranty. IntelliTech International, Inc. disclaims
any and all warranties with regard to this
information. IntelliTech shall not be liable in any
event for any special, indirect or consequential
damages or any damages whatsoever resulting
from loss of data, profits or use, for any reason
or in any action, arising out of or in connection
with the use or performance of this information.
Section 6
Troubleshooting
Jump to Section 5
This section contains troubleshooting information for isolating problems in the printer to a fieldreplaceable consumable item (paper and ribbon) or printer assembly.
Primary troubleshooting aids include the alert LED on the control panel and control panel LCD
display messages. Troubleshooting procedures include eliminating paper jams and diagnosing
mechanical and electrical malfunctions.
TROUBLESHOOTING THE PROBLEM
Diagnosing a print quality problem can sometimes be difficult and time consuming, especially if
you are doing it over the phone. Here are some tips to determining the origin of the problem. A
sample question form is available later in this section.
1. Gather as much information as you can on what type of media (ribbon and label
material) is being used. This information should include:
n
Size of label material.
n
Material type (i.e. polyester, paper, card stock).
n
Size of ribbon and type of ribbon.
n
Whether the label is die-cut or continuous stock.
2. Gather information on the printer setup. This information should include:
n
Print speed used.
n
Density settings.
n
Print head settings.
See “Menu Tree” in Section 3 for information on how to use the control panel to
determine the printer setup.
3. Print a copy of all test pages and examine them closely. See “Self-Test” in
Section 3 for a description of the available test pages for the printer.
6-2
Troubleshooting
NOTE: Always perform the self tests to ensure
that the machine is operating correctly.
4. Make sure the media is within specification and that the print head settings are correct
for the media. See “Label and Ribbon Requirements” in Section 2 for media
specifications.
5. Check the print speed to see if an adjustment is needed in speed to correct the
problem. Table 5-1 in Section 5 lists IntelliBar print speeds.
6. Make sure the print head is securely mounted to the housing.
7. Enter the maintenance menu and check that the print head resistance value matches
the print head. See “Menu Tree” in Section 3 for information on how to use the
control panel to enter the maintenance menu.
8. If the print output exhibits light or dark print, check the print density level. See “Print
Density Adjustment” in Section 5 for more information.
9. Examine the ribbon for wrinkle during printer operation. If wrinkling occurs, adjust the
ribbon guide plate (see “Mechanical Adjustments” in Section 5 for information on
how to adjust the guide plate for your printer).
10. Place pressure on the print head housing and look for dramatic improvement in print
quality.
11. Reset to the factory defaults. See “Menu Tree” in Section 3 for information on how to
use the control panel to restore the printer default settings.
USING LCD DISPLAY ERROR MESSAGES
Table 6-1 lists simple troubleshooting procedures for the LCD display error messages.
Table 6-1 LCD Display Error Messages
Status Message
Corrective Action
Engine Errors
RIBBON OUT
Ribbon sensor detects no ribbon.
•
•
A new ribbon roll needs to be installed.
See Section 2 for installation steps.
The label roll is not installed correctly
under the print head, blocking ribbon
detection. Install the label roll properly,
making sure to feed the label liner under
the label sensor plate. See Section 2 for
installation procedures.
Troubleshooting
•
•
6-3
Ribbon leader is under ribbon sensor,
blocking ribbon detection. Rotate take-up
spindle to move leader away from sensor.
Replace faulty ribbon sensor (for more
information, call IntelliTech International,
Inc. at 800-694-3034).
Table 6-1 LCD Display Error Messages (cont’d)
Status Message
Corrective Action
Engine Errors (cont’d)
CUTTER ERROR
The controller senses an error in cutter operation.
•
•
•
LABEL OUT
Label sensor detects no label.
•
•
•
•
MEDIA JAM
The printer is configured in “Cut-Off” mode
without having the cutter option installed.
The cutter cable is not properly connected
to the control panel board.
The cutter blade is jammed or the cutter is
faulty. Clear the jam or replace the cutter
(for more information, call IntelliTech
International, Inc. at 800-694-3034).
A new label roll needs to be installed (see
Section 2).
Label media improperly loaded (the label
media should be under label sensor).
Label sensor needs adjusting (for more
information, call IntelliTech International,
Inc. at 800-694-3034).
More than one label missing from
release paper (liner).
IntelliBar cannot measure label length or gap.
•
•
•
•
Sensitivity of label sensor needs adjustment
(for more information, call IntelliTech
International, Inc. at 800-694-3034).
Wrong media in use; change to label type
that matches sensitivity setting of label
sensor.
If the “MEASURE LABEL, FIXED”
parameter is set from the control panel and
the value is set for a specified length, a
media jam occurs if you load labels of a
different length.
If “MEASURE LABEL, AUTOMATIC” is set
from the control panel with 6 in. labels
loaded (for example), a media jam will
occur if you load labels of another size. You
must do another auto measure, i.e., turn
6-4
Troubleshooting
printer off and then on.
Table 6-1 LCD Display Error Messages (cont’d)
Status Message
Corrective Action
Engine Errors (cont’d)
MEDIA JAM (cont’d)
Label sticking or slipping due to improper label
installation or the build up of label residue, dirt, or
foreign material under the print head or on the
platen roller. See “Loading Labels” in Section 2
for label installation procedures; see “Cleaning” in
Section 5 for cleaning procedures.
Mechanical failure:
•
•
•
Replace stepper motor (for more
information, call IntelliTech International,
Inc. at 800-694-3034).
Bad driver
Bad label sensor
PRINT HEAD OPEN
Appears when printer is online or offline and the
print head is not closed and latched. When it
occurs, printer automatically goes offline. Close
and latch print head, and press Online button.
“READY” appears in the control panel display.
SUB RAM ERROR
Cutter option failed to cut or blade is jammed.
Clear the jam or replace the cutter option.
HEAD POWER LOAD
Main board controller requires service (for more
information, call IntelliTech International, Inc. at
800-694-3034).
Print head and/or power supply problem. Drawing
too much current. Reset the printer by turning it
off and then on.
HEAD OVERHEAT
Print head has overheated. The printer stops
printing. It will resume printing when the print
head cools down. Reset the printer.
FRONT DOOR OPEN
Front panel is not fully closed and latched.
Troubleshooting
6-5
Table 6-1 LCD Display Error Messages (cont’d)
Status Message
Corrective Action
Engine Errors (cont’d)
PCL Errors
FATAL ERROR
No fonts on main board or PCL failure. Replace
main board (call IntelliTech International, Inc. at
800-694-3034 for more information).
OUT OF MEMORY
Job requires more memory than is available.
ENGINECOMM ERROR
Image processor (main) side of main board
receives status or command that it cannot
interpret. Replace main board (call IntelliTech
International, Inc. at 800-694-3034 for more
information).
INSUF. MEMORY FOR PAGE
PROTECT
Add additional SIMM memory to enable page
protection (see Section 4 for SIMM memory
installation procedures).
Serial Interface Errors
OVERRUN ERROR
Printer could not keep up with host. Use a lower
baud rate.
PARITY ERROR
Printer received the wrong parity bit from the
host. Check the host protocol or the serial cable
connections.
FRAMING ERROR
Printer received an invalid stop bit for a character.
Check the host protocol or the serial cable
connections.
BREAK INTERRUPT
Host system has broken or is holding
communications open. Check the host protocol.
SERIAL OVERFLOW
Host system continues to send data after the
printer has signaled that it cannot accept more
data. Check the host protocol.
6-6
Troubleshooting
CORRECTING PRINT QUALITY
Table 6-2 lists print quality troubleshooting procedures.
Table 6-2 Print Quality Problem Solving
Problem
Corrective Action
Print quality too light
•
Wrong ink on media; for example, wax ribbon
on synthetic label stock. Ensure that you
have the correct combination of ribbon and
label material (see Section 2).
If necessary, use a different ribbon or label
stock.
•
Adjust the print head balance lever and/or
pressure knob, depending on the label
material being used (see “Print Head Balance
Lever for Label Width” and “Print Head
Pressure Knob for Label Thickness” in
Section 5).
See also “Sample Adjustment” in Section 5.
•
Increase print density using control panel
menu until quality is acceptable (see “Print
Density Adjustment” in Section 5).
The factory default level is 0. If application
software controls print density, the LCD
display will not change from the factory
default. If this is the case, use the software
command (as described in the Programmer’s
Reference Guide) and run the self-test to
check print density.
•
Use different ribbon or paper stock.
Troubleshooting
6-7
Table 6-2 Print Quality Problem Solving (cont’d)
Problem
Corrective Action
Dark print
Too much print head energy can cause printed
characters (especially serifs) to spread or
blossom (character fill-in).
Uneven density (light or dark print only on one
side or in middle of label)
Label mistracking (label rides over the label
guides)
•
Reduce print density using the control panel
(see “Print Density Adjustment” in Section 5)
or software (see the Programmer’s Reference
Guide).
•
Increase the print speed using the control
panel or software and recheck print density
(see “Print Density Adjustment” in Section
5).
•
Adjust print head balance (see “Print Head
Balance Lever for Label Width” in
Section 5 ).
•
A label or foreign material may be wrapped
around platen roller. Check platen roller,
remove foreign material, and clean platen as
necessary (see “Cleaning” in Section 5).
•
Check the position of the label width guides
(see “Label Width Guides” in Section 5).
•
Adjust print head balance lever for print head
balance across width of label (see “Print
Head Balance Lever for Label Width” in
Section 5).
6-8
Troubleshooting
Table 6-2 Print Quality Problem Solving (cont’d)
Problem
Corrective Action
Ribbon wrinkle
Reload the ribbon (see Section 2). Ensure that
the supply ribbon spool is firmly seated to the
ribbon supply spindle. Check that the ribbon film
is tracking squarely through the print head with
no creases or wrinkles.
Reduce the print density using the control panel
menu (see “Print Density Adjustment” in Section
5) or software (see the IntelliBar Programmer’s
Reference Guide). Excessive print density
causes the ribbon to stick to the label facestock
during printing, adversely affecting ribbon
tracking.
Adjust ribbon tension plate (see “Ribbon Guide
Plate” or “Ribbon Tension Plate” in Section 5).
Adjust print head balance lever for print head
balance across width of label (see “Print Head
Balance Lever for Label Width” in Section 5).
Turn the print head position dial clockwise (see
“Print Head Position Dial for Label Thickness” in
Section 5); also, decrease the print head
pressure by turning the print head pressure knob
counterclockwise (see “Print Head Pressure
Knob for Label Thickness” in
Section 5).
Print too dark; bar codes bleed together
Reduce print density using the control panel
menu (see Section 3).
Poor match between label and ribbon media.
Decrease the print head pressure by turning the
print head pressure knob counterclockwise (see
“Print Head Pressure Knob for Label Thickness”).
Data sent to printer, but no label prints
•
Check data cable for loose connection to
interface port (see Section 2) or defect.
•
Reboot computer and printer.
TOP-LEVEL PROBLEM SOLVING
Table 6-3 lists top-level troubleshooting procedures for isolating a problem to a
field-replaceable printer assembly.
Troubleshooting
6-9
NOTE: To have a printer repaired, place a service
call to IntelliTech International, Inc. at 800-6943034.
You will be required to fill out and fax the service
request form provided at the end of this section.
Table 6-3 Top-Level Problem Solving
Problem
Corrective Action
Control panel POWER indicator OFF.
•
Verify that the power cord is connected to a
live, properly grounded AC power outlet.
•
Check that the power switch is turned on.
•
Check cable connections from power supply
to main board.
•
Check that power supply jumper is set to
match 110 volt or 220 volt power source (call
800-694-3034 for service).
•
Check power supply fuse and replace as
necessary (call 800-694-3034 for service).
•
Replace power supply (call for service).
•
Is printer online? Press Online button.
•
Is Alert LED on and does message appear in
control panel LCD? See Table 6-1 and take
corrective action.
•
Check cable connections between main
board and ribbon and paper empty sensors.
•
Check cable connections between stepper
motor and main board.
•
Check cable connections between print head
and power supply.
•
Check cable connections between power
supply and main board.
•
Replace stepper motor (call for service).
•
Replace main board (call for service).
Ribbon and paper do not feed. Control panel
POWER indicator ON.
6-10
Troubleshooting
GETTING SERVICE AND SUPPORT
This section provides information on getting service and support for your IntelliBar printer. In
addition, this section contains warranty information that you should read.
If you have a problem with your printer, first review Section 5, Cleaning and Adjustments. If you
still have a problem, continue with the suggestions that follow.
Maintenance Programs
IntelliTech International, Inc. offers three maintenance choices in addition to standard printer
warranties: on-site service, extended factory warranty, and factory repair.
On-Site Service
On-site printer service for IntelliBar printers is provided by the IBM Printing System Company.
IBM Printing Systems services printers exclusively. As a result, they deliver an unequaled degree
of expertise and skill in printer technical knowledge and repair. IntelliTech’s on-site program
offers prompt and professional printer repair service at your location in the United States, Canada
and Puerto Rico.
On-site service provides Monday through Friday, 8:00 AM to 5:00 PM, coverage. Response
time from your call to arrival of an IBM customer engineer is four hours within a fifty mile radius
of an IBM Printing System office. On-site service costs $468 per printer, per year (U.S. and
Puerto Rico only, Canada slightly higher).
Extended Factory Warranty
IntelliTech offers a return direct to factory, extended warranty program for our printers. The
extended warranty lengthens IntelliTech's standard warranty in yearly increments. IntelliTech will
repair your printer at our depot within two business days of our receipt and ship it back to you via
UPS ground delivery service. Federal Express, next day air, is also available for an additional
charge. (Customers are responsible for freight in and insurance costs.) The IntelliTech extended
warranty cost is $350 per year, per printer, payable in advance.
Post Warranty Factory Repair Program
IntelliTech offers factory depot repair for out of warranty printers. Post-warranty repair service
is charged on a time and material basis. Labor is currently charged at $75/hour. Materials are
charged at the prevailing rate of the IntelliBar Repair Components Price List. Estimates are
available, if requested in advance and incur a minimum of an one hour labor charge if repairs are
not performed. After receipt of your printer, IntelliTech will ship the repaired printer back to you
within five business days via UPS ground.
For additional information on the above programs, or to purchase an extended factory warranty
or an on-site service program, please call IntelliTech at 1-800-694-3034.
Troubleshooting
6-11
NOTE: All pricing is subject to change without
notice. If an IntelliTech Customer Care Service
representative determines that a technical problem
cannot be resolved via telephone, a product return
authorization will be issued. The customer is
responsible for proper packaging of the product for
shipment, freight costs, and insurance costs.
WARRANTY AND SERVICE PROGRAMS
The following IntelliTech International, Inc. Limited Warranty policy and procedures are
described in this subsection:
n
IntelliBar Printer Warranty
n
IntelliBar Printer Option Warranty
n
IntelliBar Printer Ribbon Warranty
n
IntelliBar Replacement Parts
n
Non-Warranty Service and Repair
IntelliTech International, Inc. products are warranted in accordance with the terms of this
LIMITED WARRANTY. Users are cautioned that product performance is affected by system
configuration, software, the application, customer data, and operator control of the system,
among other factors. Products are considered to be compatible with many systems; the specific
functional implementation by the consumer of the Product may vary; therefore, the suitability of a
product for a specific purpose or application must be determined by the consumer and is not
warranted by IntelliTech International, Inc.
NOTE: Warranty varies from product to product
for all IntelliTech International, Inc. products.
Please contact IntelliTech International, Inc. to
receive warranty information on any products in
question.
6-12
Troubleshooting
IntelliBar Printer Warranties
IntelliBar printers are warranted to be free from defects in material and workmanship, and
IntelliTech International, Inc. agrees to repair or replace any part of the unit which proves
defective under these terms and conditions:
n
Warranty period
n
Who is protected
n
What is not covered
n
What IntelliTech will pay for and what we will not pay for
n
How to get Warranty Service
n
Warranty Return Procedure
n
Limitation of Damages and Implied Warranties
Warranty Period
Printer Parts and Labor are warranted for one (1) year from the date of the first consumer
purchase provided the customer can show proof of purchase. The print head is a consumable
item and is warranted for ninety (90) days from date of the first consumer purchase or 500,000
linear printed inches, whichever occurs first.
Who is Protected
This warranty may be enforced only by the first end-user-purchaser, and it is not transferable.
Who is Not Covered
The above warranty is contingent upon the proper use of the Products and will not apply to
Products on which the original identification marks have been removed or altered. In addition, this
warranty shall not apply to defects or failures due to:
1. Accident, neglect or misuse, fire, water, lightning or other acts of nature, improper
storage, unauthorized modification, or failure to follow instructions supplied with the
Printer.
2. Failure or defect of electrical power, external electrical circuitry, air-conditioning or
humidity control.
3. The use of items not provided by IntelliTech International, Inc.
4. Unusual stress.
Troubleshooting
6-13
5. Modification or alteration of the printer by any party other than IntelliTech
International, Inc.
6. Misadjustment, repair or attempted repair or service of the printer by any party other
than IntelliTech International or an authorized representative.
7. Damage caused by shipment of the printer (claims must be submitted to the carrier).
8. Installation or removal of the Printer.
9. Any other cause which does not relate to a printer defect. Cartons or any accessories
used in conjunction with the Printer.
10.Cartons or any accessories used in conjunction with the Printer.
What IntelliTech International, Inc. Will Pay for and What We Will Not Pay For
IntelliTech International, Inc. will pay labor and material expenses for covered items. Also we
will cover the cost of prepaid return freight to the end user. But we will not pay for the following:
1. Removal or installation charges.
2. Costs of initial technical adjustments (setups) including adjustment of user controls.
Shipping insurance charges.
3. Insurance is the responsibility of the end user. IntelliTech International will prepay
insurance and bill the end user for return shipment of repaired printers at the end
user's request.
4. Freight costs to return the printer to IntelliTech International, Inc. for repair.
How to Get Warranty Service
Customers should call the IntelliTech International Customer Service and Support line at 800694-3034. Please have the following information ready for the Customer Service Representative:
n
Model number
n
Serial number
n
Date of purchase
To obtain a warranty repair Return Material Authorization (RMA) number, a Service Request
Form (SRF) must be filled out and returned to IntelliTech International. See “Fax Form” later in
this section for a copy of the Service Request Form (or you may obtain an SRF from IntelliTech
International by calling our technical support staff at (800) 694-3034. The customer MUST
submit a completed SRF along with a dated copy of the sales receipt or other dated proof of
purchase in order to receive IntelliTech International's warranty repair service.
6-14
Troubleshooting
Warranty Return Procedure
Printers returned under warranty must follow IntelliTech International's RMA procedures.
Printers must be returned directly to an IntelliTech International repair depot for warranty
service. IntelliTech International, Inc. will either repair your printer or replace it with a printer that
will be, at IntelliTech International's option, new or like new, and meets all of the specifications of
the replaced printer. The repaired or replaced printer will be shipped to you at IntelliTech
International's expense within the United States or Canada.
NOTE: All Products returned for service MUST
be issued an RMA # from IntelliTech International
prior to return shipment. An RMA may be obtained
by calling the IntelliTech International Customer
Service department. Products returned to
IntelliTech International without an RMA Number
will be refused and returned to the sender at the
sender's expense. To receive the warranty services,
it is the sender’s obligation and expense to ship the
Product, freight prepaid, or to deliver it to the
IntelliTech International repair depot in either the
original package or a similar package affording an
equal degree of protection. Ribbon and Label Stock
must be removed from the printer prior to shipment
and removable spindles must be properly packaged
and secured or the printer will suffer shipping
damage.
Product damage suffered during shipment is the responsibility of the sender. Obtaining freight
insurance and payment for insurance charges are the responsibility of the Customer.
Limitation of Damages and Implied Warranties
IntelliTech International's sole liability for any defective Product is limited to the repair or
replacement of the Product at our option. IntelliTech International, Inc. shall not be liable for:
1. Damage to other property caused by any defects in this Product, damages based upon
inconvenience, loss of use of the Product, loss of time or data, commercial loss.
2. Any other damages, whether incidental, consequential or otherwise.
Troubleshooting
6-15
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EITHER EXPRESSED
OR IMPLIED. INTELLITECH INTERNATIONAL, INC. MAKES NO OTHER
WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
INTELLITECH INTERNATIONAL, INC., SHALL NOT BE LIABLE FOR ANY
DAMAGES, WHETHER INCIDENTAL, CONSEQUENTIAL OR OTHERWISE
RESULTING FROM DEFECTIVE PRODUCTS. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES,
SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. This
warranty gives you specific legal rights, and you may also have other rights that vary from state to
state.
IntelliBar Printer Option Warranty
IntelliTech International, Inc. warrants its IntelliBar printer options to be free from manufacturing
defects in materials and workmanship for a period of ninety (90) days after date of purchase by
the ultimate end user. Any defective Product will be replaced at no charge if it is returned to the
authorized IntelliTech Reseller from which it was purchased within the warranty period.
(Authorized IntelliTech International Resellers must follow the IntelliTech International, Inc.
RMA policy when returning defective options when they are under warranty.)
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EITHER EXPRESSED
OR IMPLIED. INTELLITECH INTERNATIONAL, INC. MAKES NO OTHER
WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
INTELLITECH INTERNATIONAL, INC. SHALL NOT BE LIABLE FOR ANY
DAMAGES, WHETHER INCIDENTAL, CONSEQUENTIAL OR OTHERWISE,
RESULTING FROM DEFECTIVE PRODUCTS. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES,
SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. This
warranty gives you specific legal rights, and you may also have other rights that vary from state to
state.
IntelliBar Printer Ribbon Warranty
IntelliTech International, Inc. warrants its IntelliBar ribbons to be free from manufacturing defects
in materials and workmanship for a period of one (1) year after date of purchase by the ultimate
consumer. Any defective Product will be replaced at no charge if it is returned to the IntelliTech
Reseller from which it was purchased within the warranty period. (Authorized IntelliTech
International Resellers must follow the IntelliTech International, Inc. RMA policy when returning
defective ribbons when they are under warranty.)
6-16
Troubleshooting
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EITHER EXPRESSED
OR IMPLIED. INTELLITECH INTERNATIONAL, INC. MAKES NO OTHER
WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
INTELLITECH INTERNATIONAL, INC. SHALL NOT BE LIABLE FOR ANY
DAMAGES, WHETHER INCIDENTAL, CONSEQUENTIAL OR OTHERWISE,
RESULTING FROM DEFECTIVE PRODUCTS. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES,
SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. This
warranty gives you specific legal rights, and you may also have other rights that vary from state to
state.
IntelliBar Replacement Parts Warranty
IntelliTech International, Inc. warrants its IntelliBar replacement parts to be free from
manufacturing defects in materials and workmanship for a period of ninety (90) days after date of
purchase by the ultimate consumer. Any defective Product will be replaced at no charge if it is
returned to the IntelliTech reseller from which it was purchased within the warranty period.
(Authorized IntelliTech International Resellers must follow the IntelliTech International, Inc.
MRA policy when returning defective replacement parts when they are under warranty.)
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EITHER EXPRESSED
OR IMPLIED. INTELLITECH INTERNATIONAL, INC. MAKES NO OTHER
WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
INTELLITECH INTERNATIONAL, INC. SHALL NOT BE LIABLE FOR ANY
DAMAGES, WHETHER INCIDENTAL, CONSEQUENTIAL OR OTHERWISE,
RESULTING FROM DEFECTIVE PRODUCTS. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES,
SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. This
warranty gives you specific legal rights, and you may also have other rights that vary from state to
state.
Non-Warranty Service and Repair
Non-warranty service and repair will be performed by IntelliTech International, Inc. at the
prevailing factory repair rate for IntelliBar printers. Post warranty repair service is charged on a
time and material basis. Labor is charged at the prevailing rate. Materials are charged at the
prevailing rate of the IntelliBar Repair Components Price List. Estimates are available, if
requested in advance and incur a minimum of one-hour labor charge if repairs are not performed.
After receipt of the printer, IntelliTech International, Inc. will ship the repaired printer back to
you within five business days via UPS ground.
Troubleshooting
6-17
Repairs performed under this policy are warranted for parts and labor for 90 days. Print heads
are warranted for 270 days with no limited mileage.
NOTE: All Products returned for service MUST
be issued an RMA # from IntelliTech International
prior to return shipment. An RMA may be obtained
by calling the IntelliTech International Customer
Service department. Products returned to
IntelliTech International without an RMA Number
will be refused and returned to the sender at the
sender's expense. To receive the warranty services,
it is the sender’s obligation and expense to ship the
Product, freight prepaid, or to deliver it to the
IntelliTech International repair depot in either the
original package or a similar package affording an
equal degree of protection. Ribbon and Label Stock
must be removed from the printer prior to shipment
and removable spindles must be properly packaged
and secured or the printer will suffer possible
shipping damage.
Product damage suffered during shipment is the responsibility of the sender. Insurance charges
are the responsibility of the Customer.
COMMON QUESTIONS AND ANSWERS
Some of the most commonly asked questions about the IntelliBar printers are listed below. You
will also find this information helpful when troubleshooting a particular problem.
Q. What number do I call for IntelliBar Support ?
A. The following numbers should be used for IntelliBar support:
For technical questions, problems, or service calls, dial 800-694-3034 x209.
NOTE: When calling in a problem, it is very
important that you fill out all the required information
on the fax form (see “Fax Form” in the next
subsection).
6-18
Troubleshooting
The IntelliTech International, Inc. Web site is located at http://www.intellitech-intl.com.
Q. When I change my label stock from a smaller to a larger length I get a media jam
error.
A. When you change lengths or widths of label stock you must do the following two things.
n
Make sure the label present sensor is over the label.
n
Reinitialize the printer as follows so the sensor will automatically adjust for label length.
1. Take the printer off line by pressing the Online button
2. Hold down the Cancel button for five seconds until the LCD display reads
“INITIALIZE”. After initialization completes, place the printer on line by pressing
the Online button.
Q. Can I connect an IntelliBar printer to an AS/400 ?
A. Yes, by using IntelliBar AS series printers. The IntelliBar AS Series provides an
AFP/IPDS logical controller and twinax or coax connectivity, in addition to RS232
and Centronics interfaces.
For non-IPDS systems, third party connectivity products may be required to connect
standard IntelliBar series printers to an AS/400 system. There are several manufacturers of
products that allow you to connect the IntelliBar printer to the AS/400. Depending on the
specific system network configuration and the printing language used in the system, different
connectivity products may be needed.
To connect a standard IntelliBar printer to an AS/400 system, see “Connecting the
Communications Interface Cables” in Section 2 and call IntelliTech technical support at
800-694-3034.
Q. Can I connect my IntelliBar to a network ?
A. There are different third party manufacturers of after-market network connectivity devices
that allow you to connect the IntelliBar printer to a network.
Troubleshooting
6-19
These network connectivity products are widely available from vendors of personal
computer (PC) products.
Q. What Windows driver do I use for the IntelliBar printer ?
A. IntelliTech’s Windows driver disk includes the drivers for all three IntelliBar models and
allows you to address certain functions of the printer through software.
If you do not have the driver disk or you are not using Windows, you can use the
HP LJIII driver for the Model 48 and Model 412.
Q. How do I print multiple copies of the same label ?
A. You can print multiple copies of the same label by utilizing the PCL command for multiple
copies. A typical PCL driver may not always send a copy command to the printer when
multiple copies are requested. In this case, multiple copies can be selected through the
printer’s Menu mode.
Q. My printout is shifting the data sideways.
A. Turn Page Protect on (found in the Configuration menu ) and add additional memory.
Q. What is an error 7 ?
A. There are certain circumstances where the imaging of data and the printing cycle
become unsynchronized. This situation only occurs when Page Protect is OFF. The
error can be cleared by turning the printer off and then on again. Turning Page Protect
ON from the Configuration menu and adding additional memory should solve the problem.
Q. My ribbon is moving and wrinkling.
6-20
Troubleshooting
A. Make sure you have the correct print head settings for your application. If this does not
solve the problem, adjust the ribbon tension plate.
Q. When I turned on my printer, the display went blank or the Power and Alert lights
flash.
A. Check the revision level of your U1 chip on the main board. If it is below revision 2.10, you
need to upgrade. A free upgrade chip will be sent out to you as soon as you call the technical
support line and give the required information.
Q. Does the IntelliBar have internal bar code generation capability ?
A. The IntelliBar Models 48, 412, and 88 have internal bar code generation capability.
Bar codes and fonts are created by ESC codes that are provided in the IntelliBar
Programmer’s Reference Guide.
IntelliTech can provide you with a chip set and ESC codes for your printer if you do not
have the current firmware.
IntelliTech recommends that you be familiar with PCL programming before
attempting to access the printers commands. Call 800-694-3034 to request this chip
set.
Q. I am using the HP LJ drivers and cannot get close to the edge of the
label.
A. All HP LaserJet drivers have a default top and bottom, left and right edge margin of
approximately 1/4-inch. This default margin is a result of mechanical considerations
for the
LaserJet printers. The IntelliBar has a 2 mm (.078 in.) top and bottom margin and can print
closer to the edge of the label by using the IntelliTech Windows drivers.
Troubleshooting
6-21
When using a standard LaserJet driver, the first print position will be 2 mm plus 1/4”
from the top edge of the label. In order to override the default Laserjet 1/4” margin, the
driver must be modified. Customers using the IntelliBar Windows driver can print within 2
mm of the top edge. By using the Print Position function in the Adjustments
Menu, the first
print line can be further adjusted by plus or minus 3 mm (refer to “Print Position Adjustment”).
Q. When I set the printer for page rotation, it doesn’t work right.
A. The software overrides the printer’s control panel settings. The printer control panel
commands will only work for host based machines, not for application driven print jobs.
Q. I get a constant media jam error upon initialization and can’t find a jam.
A. The Label Sensor may be dirty or out of calibration. Clean the label sensors by
the procedure on page 5-3 of this guide.
following
If you still have media jam problems after cleaning the sensor, call the IntelliTech technical
support line at 800-694-3034 for assistance.
Q. Can I use the IntelliBar with a Macintosh PC ?
A. Yes. There are several applications that will provide you with the necessary connectivity and
label design and print capability (see Table 6-4 and Table 6-5).
Table 6-4 Macintosh Connectivity Products
Connectivity Products
Contact Information
Power Print Networks
IntelliTech International, Inc.
800-694-3034 x202, x207
Comments
Power Print Pro provides a
complete solution that lets your
Macintosh use virtually any PCcompatible printer. Using the HP
Laser Jet II driver allows
Macintosh users to print to
IntelliBar HP PCL5 printers via
ethernet.
6-22
Troubleshooting
T-Script
TeleTypesetting
311 Harvard Street
Brokline, MA 02146
T-Script for the Macintosh is a
postscript to HP PCL protocol
translation application that
enables IntelliBar printers to
interpret Postscript.
800-717-4478
[email protected]
Table 6-5 Macintosh Label Design and Print Products
Label Design and Print
Products
Contact Information
Comments
Bar Code Pro Filemaster
SNX
Bar Code Pro Filemaster for the
Macintosh allows users to
customize their own database,
add bar codes, graphics, video
images, text or numbers and
print any sort of label imaginable
on IntelliBar printers.
692 10th Street
Brooklyn, NY 11215
718-499-6293
Q. I am using PowerPrint with a Macintosh, and when I print I get white spaces
where data should be.
A. This combination of application packages requires you to add more memory to your
IntelliBar. IntelliTech recommends increasing your memory to a minimum of
2 MB.
Q. Where can I purchase supplies for my IntelliBar printer?
A. The dealer where you purchased your IntelliTech IntelliBar printer can provide you with the
necessary supplies. You may also call 800-694-3034 for availability information.
Q. Where do I buy memory for my IntelliBar?
Troubleshooting
6-23
A. You can use 8- or 9-bit, 30-pin, 70-nanosecond (ns) or faster SIMMs with tin connectors
on Rev. 12, 13, or 14 main boards. You can use 8- or 9-bit, 30-pin, 60-ns or faster
SIMMs on Rev. 15 or Rev. 16 main boards. These are industry-standard memory packages
that are widely available from PC vendors.
NOTE: SIMMs must be installed in pairs of the
same value. These SIMMs can be found in most PC
stores that sell Macintosh computers. See “Memory
Expansion” in Section 4 for suggested SIMM
upgrades.
CAUTION: Illegal combinations of SIMMs
(SIMM stick size not listed for Model type) will
cause failures or error messages.
Q. Where do I buy spare parts such as print heads?
A. Your dealer will be able to provide you with the necessary parts or you can call
IntelliTech at 800-694-3034.
Q. Why does the printer feed four labels on initialization?
A. If the Label Measure mode is set to Automatic (found in the Label Menu), the printer
advances a preset number of labels in order to accurately measure the length of the label and
gap. This function sets the label length so that the controller can format data for the label. If
the same length label will always be used, the Label Measure mode can be set to Fixed. This
will eliminate the automatic advancing of labels at power on. If the label length changes while
in the Fixed mode, a Media Jam will occur and either Automatic or Operator Panel will have
to be selected from the menu in order to enter the new label length.
Q. My label seems to be missing data, like it has been clipped off.
6-24
Troubleshooting
A. HP PCL printers perform pixel-level clipping. When printing characters or graphics,
if any portion of the character cell or graphic is outside the printable area, only that portion
outside the printable area is clipped. The fix is to make sure you are within the printable area of
your application.
Q. My label stock gets pulled backwards into the printer. Why?
A. In non-peel-off or tear-off mode, this can occur if the label stock has been changed
without a re-measure of the new stock. To create a re-measure of the label stock, you
must turn the power off, load the new label stock, and then turn the power back on.
The printer, if set for automatic mode, will do an automatic measure of the stock.
If tear-off or peel-off mode is used, check the Label Present Sensor adjustment (VR5).
Q. My Model 412 feeds the label and then retracts it approximately ¼ inch. Why?
A. Due to the speed at which the Model 412 prints, it cannot stop within the normal label gap
range, so it must stop and then retract the label stock to the first print position of the next
label. If you are using a larger label gap, you may not experience this occurrence.
NOTE: The information in this section is subject to
change without notice. This information is provided
"as is" without either express or implied warranty.
IntelliTech International, Inc. disclaims any and all
warranties with regard to this information.
IntelliTech shall not be liable in any event for any
special, indirect or consequential damages or any
damages whatsoever resulting from loss of data,
profits or use, for any reason or in any action, arising
out of or in connection with the use or performance
of this information.
Troubleshooting
6-25
Fax Form
When calling in a problem or requesting service, please fill out all the required information on the
following fax form or fill out your request online at IntelliTech International - Online Service
Request Form
6-26
Troubleshooting
IntelliTech International, Inc.
RMA#_____
577 Main Street
Hudson, MA 01749
Tel: 800-694-3034 (or 978 568-0370) x209 or x213
FAX: 978-568-9591
Web: www.intellitech-intl.com
Email: [email protected]
Advancing the way the world prints labels…
Service Request Form
In order for us to better fulfill your request for service, we ask that the following questions be answered.
Please complete all questions to the best of your knowledge and fax the completed form to the fax number
listed above. Service cannot be started until this information is returned to IntelliTech. Once the information
is received, you will be contacted with a return material authorization (RMA) number. You must ship the
products back to IntelliTech in their original packaging or equivalent, prepay shipping charges, and you
must insure the shipment or accept the risk of loss or damage during shipment. IntelliTech pays freight
charges on warranty units only when shipping directly back to you, the customer. (Note*: if you wish to
insure return shipment, you must request in writing and you will also be responsible for the return charge.)
Do not ship the printer back with labels and ribbons loaded on printer. Doing so will cause damage to the
printer that you will be held responsible for. Please package labels and ribbons separately if you need to send
them.
Estimates are available, if requested in advance, and incur a minimum one-hour labor charge of $75.00 if repairs
are not performed.
Company Information:
Company Name:
_________________________________________________________________________
Shipping Address (no P.O. Box please):
______________________________________________________
___________________________________________________________________________________
___
Telephone:_____________________ Fax:______________________
*I authorize IntelliTech to insure the shipment of my repaired property upon its return to my location. ____
(If blank is left unchecked, the property will not insured.
Who should we contact regarding the problem:
________________________________________________
Contact Tel: _________________________ Contact Fax: __________________________
Contact e-mail address: ___________________________
Troubleshooting
Who sold you the printer? __________________________
6-27
6-28
Troubleshooting
Printer Information:
Model No. (on back of printer):___________________________ Serial No.:_________________________
Error Message on display:
_________________________________________________________________
Type of Ribbon (Express Wax, Dura Wax, Dura Wax/Resin, Rugged Resin, Dura Resin Plus): ___________
Width of ribbon stock being used (1 inch, 2 inch, etc.):______________________________
Type of label stock (thermal paper, polyester, tag,
other):_________________________________________
Is label stock continuous or die cut:
__________________________________________________________
Are any options installed (cutter, internal rewinder, reflective sensor): ______________________________
If so, which: __________________________ Who installed it:
____________________________________
Are you using the printer with a PC, Mac, AS400, or other network: _______________________________
What software are you using: _________________________________________ Rev: _____________
What drivers are you using:
________________________________________________________________
If you are using a PC, are you using DOS or WINDOWS: ________________________________________
*If under warranty, please provide a copy of bill of sale.
Problem Information:
Please provide a detailed description of your problem:
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Troubleshooting
6-29
___________________________________________________________________________________
___________________________________________________________________________________
If the printer is operational, please provide a copy of the test page from the configuration menu and place it on
a separate piece of paper.
Appendix A
Packing
When packing the IntelliBar printer for shipping or moving, reuse the original shipping
carton and packing materials. Reverse the unpacking instructions found in the carton. *
Repack as follows.
1. Remove the label and ribbon rolls from the printer.
2. Make sure the print head is closed and securely latched.
3. Tape the front and left side panels so they stay securely shut during shipment.
4. Pack the printer using the shipping carton and packing material. Figure A-1 and
Figure A-2 show the configurations for repacking the Model 48, Model 412, and
Model 88 printers in the carton.
Corner Inserts
Starter Ribbon
(taped inside the printer)
Polybag
CD ROM
Set-Up Sheet
IntelliBar Box
Power Cord
(115V only)
Figure A-1 Packing Configuration (Model 48 and Model 412)
A-2
Packing
Take Up Spools
M88 Starter Ribbon
Top Insert
CD ROM
Polybag
Set-Up Sheet
Bottom Insert
Power Cord
(115V only)
Figure A-2
*
Packing Configuration (Model 88)
"This information is subject to change without notice. This information is provided "as is" without either express or
implied warranty. IntelliTech International, Inc. disclaims any and all warranties with regard to this information.
IntelliTech shall not be liable in any event for any special, indirect or consequential damages or any damages
whatsoever resulting from loss of data, profits or use, for any reason or in any action, arising out of or in connection
with the use or performance of this information. "
Glossary G
abrasion -- a scraped spot or area. The result of rubbing or scraping.
abrasion resistant -- the ability to withstand scrapes.
adhesion -- the bond established on contact between two surfaces.
adhesive -- a substance capable of holding materials together by surface attachment.
aggressive adhesive -- a tenacious adhesive.
application temperature -- the environmental temperature at which the label will be applied.
backing -- the liner of pressure-sensitive label stock. Functions as a carrier.
bar code -- a binary coding system consisting of vertical marks or bars that, when read by
an optical scanner, can be converted into machine language. An automatic identification
technology that encodes information into an array of adjacent varying width parallel rectangular bars and spaces.
bar code character -- a single group of bars and spaces that represent a specific number,
letter, punctuation mark or other symbol. This is the smallest subset of a bar code symbol
that contains data.
bar code density -- the number of data characters that can be represented in a linear unit of
measure. Bar code density is often expressed in characters per inch.
bar code reader -- a device used to read a bar code symbol, usually connected to a CRT or
personal computer.
butt cut labels -- rectangular labels in continuous form, separated by a horizontal face cut.
coated paper/tag -- paper or tag stock which has one or both surfaces covered with a substance to produce certain desired properties for use in specific printing processes.
coatings -- a layer of material covering the facestock usually to provide a smoother finish.
continuous -- labels feeding directly one after another in quantity rather than one at a time.
deposit buildup -- the residue accumulated from constant activity in a certain spot.
die cut -- the severance line between a pressure-sensitive label and its matrix or adjoining
label, made by the cutting edge of a die.
direct thermal -- a printing system using heat sensitive paper. Heated areas of the paper
turn dark.
environment -- the combination of external physical conditions that affect and influence
an object.
Glossary-2
facestock -- any paper, film or foil material that can be converted into labels. Retains the
printed image.
fanfold -- labels with perforations in the release liner so they can be folded into stacks.
font -- the appearance (typeface, style, pitch, etc.) of printed characters on a page.
general purpose permanents -- permanent adhesives for a wide variety of surfaces and
environments.
high tack -- a high degree of stickiness to the adhesive.
infrared -- the band of light wavelengths too long to be seen by the human eye. Represented by waves that are between 750 and 4 million nanometers.
ladder -- vertical bar code -- a bar code or symbol presented in such a manner that its
overall length dimension is perpendicular to the horizon. The bars are presented in an array
which look like a ladder.
laminate -- web of material formed by bonding two or more materials together. In labels,
the liner, adhesive and facestock.
laser scanner -- an optical bar code reading device using a low energy laser light beam as
its source of illumination.
light pen -- in a bar code system, a hand held scanning wand that is used as a contact bar
code reader held in the hand (wand scanner).
liner -- material used as a label carrier which enables the labels to be released.
media -- the label or tag stock used as the receptor for the printed image.
perforations -- a series of holes used to separate labels on a roll for easy tear off.
permanent adhesive -- adhesive capable of long-lasting bond strength to a wide variety of
surfaces.
picket fence -- horizontal bar code -- a bar code or symbol presented in such a manner that
its overall length dimension is parallel to the horizon. The bars are presented in an array
which look like a picket fence.
pin feed -- round holes in label stock that help maintain the labels proper alignment during
printing.
polyesters -- strong film that resists moisture, oils and many chemical solvents.
polymids -- a synthetic polymeric resin resistant to high temperatures, wear and corrosion.
polypropylenes -- any of a group of durable, thermoplastic resins.
preprinted -- printed in advance of use.
Glossary-3
pressure sensitive label -- label material with adhesive backing and protective siliconecoated release liner to permit it to adhere instantly to most surfaces with the application of
slight pressure.
print head energy levels -- the amount of energy (heat) at the point of contact on the print
head.
print quality -- the measure of compliance of a bar code symbol to the requirements of
dimensional tolerance, edge roughness, spots, voids, reflectance, print contrast, quiet zone,
and encodation.
processing temperature -- the temperature a label would be expected to withstand as its
normal environment.
quiet zone -- a clear space, containing no machine readable marks, which precedes the
start character of a bar code symbol and follows the stop characters.
reflectance -- the light which is reflected back from the white spaces of a bar code during
scanning. This light is converted to an electrical signal, amplified and transmitted to a data
entry terminal.
removable adhesives -- pressure sensitive adhesive that offers low ultimate adhesion to a
variety of surfaces for easy removal.
repositionable adhesive -- pressure sensitive adhesive that can be removed cleanly and
repositioned on a variety of surfaces.
resolution -- in a bar code system, the narrowest element dimension which can be distinguished by a particular reading device or printed with a particular device or method.
ribbon leader -- paper strip that attaches to the beginning of a new ribbon and whose other
end has an adhesive patch used to attach the ribbon to the take-up spindle.
scanner -- an electronic device that electro-optically converts optical information into
electrical signals.
scratch resistant -- the ability of an image to withstand abrasion.
smudge -- the tendency of an image to smear or streak onto an adjacent area when rubbed.
involves the redisposition of abraded material.
smudge resistant -- the ability of an image to withstand smudging.
static -- electrostatic discharge caused by two surfaces coming together.
substrate -- the surface on which a bar code symbol is printed.
synthetic label -- a manmade compound or material, usually a plastic film.
tack -- the amount of stickiness of an adhesive.
tag -- a paperboard card or synthetic material considerably stiffer and heavier than label
facestock.
Glossary-4
thermal transfer -- a printing system where dots are selectively heated against a ribbon
and common paper is used as a substrate. Usually produces the highest print quality and
eliminates the problems of fading or changing color inherent in direct thermal.
UL recognized label -- Underwriters Laboratory tested and approved device rating labels.
UPC -- Universal Product Code -- the standard bar code symbol for retail food packages in
the United States.
ultraviolet -- high frequency light present in sunlight, which causes fading of printed characters especially direct thermal images.
UV varnish -- ultraviolet light-cured coating applied to label surfaces for a protective finish.
visible light -- used in some hand laser scanners to project a beam of light visible to the
human eye, simplifying the scanning process.
wand scanner -- in a bar code system, a wand that is used to scan bar codes.
*
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resulting from loss of data, profits or use, for any reason or in any action, arising out of or in connection with the use or
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