Alpha-4L
Direct Thermal Portable Printer
SERVICE
MANUAL
i
Contents
1.
FUNDAMENTAL OF THE SYSTEM
................................ 2
1.1
Overview ......................................................................................................... 2
2.
ELECTRONICS
............................................... 4
2.1
Summary of Board Connectors .................................................................... 4
3.
MECHANISM
............................................... 12
3.1
Replacing the Platen Roller ......................................................................... 12
3.2
Replacing the Print Head Assembly ........................................................... 13
3.3
Replacing the Keys Control Board/ LCD Control Board ........................... 17
3.4
Replacing the Peel-off Sensor Module ....................................................... 18
3.5
Replacing the Bluetooth Module ................................................................. 19
3.6
Replacing the Main Board Assembly .......................................................... 20
3.7
Replacing the Stepping Motor ..................................................................... 21
3.8
Replacing the Gap Sensor Assembly ......................................................... 22
3.9
Replacing the Media Holder Assembly ....................................................... 23
3.10
Replacing the Hand Open Sensor Assemble ............................................. 24
3.11
Replacing the Peel-off Module .................................................................... 25
3.12
Replacing the Black Mark Sensor Assembly ............................................. 26
3.13
Replacing the Charger Board Assembly .................................................... 27
3.14
Replacing the WiFi Module (Option) ........................................................... 28
3.15
Replacing the RTC Battery (Option) ........................................................... 29
4.
TROUBLESHOOTING
......................................... 30
4.1
Common Problems ...................................................................................... 30
5.
MAINTENANCE
............................................. 32
Revise History
................................................ 33
ii
1. FUNDAMENTAL OF THE SYSTEM
1.1 Overview
Front View
1
2
3
P w e r
L
E
9
Lab el roll i i
D n gua
11 a t
Pla o r
5.
6.
7.
8.
1.
2.
3.
4.
Power on/off button
Feed button
Printer status LED indicator
Battery status LED indicator
Media cover release button
Peel-off sensor (Without for linerless model)
Print head
Transmissive sensor
– Gap sensor
9.
Media holder lock switch
10.
Media holder
11.
Media cover
12.
Reflective sensor
– Black mark sensor
4
6
7 in
Plat en
Plate n
13
Plat
15
Plat en
Plat en
13.
Platen roller
14.
Tear/Peeler bar (Without for linerless model)
15.
Peeler module
Note:
* The m edia sensor position is selectable by factory adjustment. Please refer to this figure for default settings. (Default
– center position, black mark in back side)
2
Rear View
2
1
3
4
US
B int erf ac e
5
6
7
US
B int erf ac e
8
1.
Li-ion battery
2.
Belt chip
3.
Battery open clasp
4.
Hanger for shoulder strap
5.
External label entrance chute
6.
USB interface
7.
* MicroSD card socket
8.
Power jack
Note:
* Recommended MicroSD card specification.
SD card spec
SD card capacity
Approved SD card manufacturer
V1.0, V1.1 MicroSD 128 MB Transcend, Panasonic
V1.0, V1.1 MicroSD 256 MB Transcend, Panasonic
V1.0, V1.1 MicroSD 512 MB Transcend, Panasonic
V1.0, V1.1 MicroSD 1 GB Transcend, Panasonic
V2.0 SDHC CLASS
MicroSD 4 GB Transcend
6
- The DOS FAT file system is supported for the SD card.
- Folders/files stored in the SD card should be in the 8.3 filename format
3
2. ELECTRONICS
2.1 Summary of Board Connectors
J101
J401
J404
Main board top
Connector Description
DC Jack
J101
12V DC IN
4
CON101
CON102
CON103
J401
J404
CON101
CON102
CON103
Micro SD connector
Micro USB
Battery
Pin 1
Pin 8
Pin Description
1 SD_Data2
2 SD_Data3
3 SD_CMD
4 3.3V
5 SD_CLK
6 GND
7 SD_Data0
8 SD_Data1
9 GND
10 GND
Pin 1
Pin 10
Pin Description
1 NC
2 VBUS
3 TX
4 D+
5 RX
6 D-
7 RTS
8 GND
9 CTS
10 GND
CON101 pin1~4 & CON102 pin1 for battery positive
CON103 pin1~4 & CON102 pin4 for battery negative
CON102 pin2~3 for NTC
5
Main board bottom
J501
BAT1
J301
J703
J403
S101
S1
J603
J601
Connector Description
For LCD & LED board
J600
J600
Pin 1
J602
6
7
8
9
3
4
5
Pin
1
2
Description
3.3V
PEEL_E
PEEL_R
8V battery
LED_Charging off & low battery
LED_Charging
Power KEY
Feed KEY
GND
6
LCD
J601
Pin 1
13
14
15
16
17
18
19
20
21
8
9
10
11
12
4
5
6
7
Pin
1
2
3
28
29
30
31
32
33
34
22
23
24
25
26
27
CAP1-
CAP3+
NC
VOUT
GND
3.3V
LCM_D7
LCM_D6
LCM_D5
LCM_D4
LCM_D3
LCM_D2
V2
V3
V4
NC
NC
CAP2-
CAP2+
CAP1+
Description
IRS
/HPM
PS
C86
NC
V0
V1
LCM_D1
LCM_D0
LCM_RD
LCM_WR
LCM_A0
/LCM_RST
/LCM_CS
7
For LED Board
J602
Pin
1
2
3
4
5
6
7
Description
3.3V
LED_STATUS
LED_ERROR
LED_FULL
BATTERY
LED_HALF
BATTERY
LED_BT
LED_WIFI
J603
S1
J402
For LCD board
5
6
7
Pin
1
2
3
4
Description
A+
K-
GND
3.3V
LED_ERROR
MANUAL KEY
INFO KEY
Download port
WiFi connector
8
4
5
6
7
8
Pin
1
2
3
Description
3.3V
GND
/RESET
BMS
/CS
MISO
MOSI
CLK
Pin
1
2
3
4
Description
3.3V
/WIFI_RST
WIFI_RXD
WIFI_RST
5
6
7
WIFI_TXD
WIFI_CTS
GND
Bluetooth connector
J403
6
7
8
9
10
3
4
5
Pin
1
2
Description
3.3V
BT_RST
BT_RXD
BT_RTS
BT_TXD
BT_CTS
BT_DISCON
BT_CON
NC
GND
Stepping motor
J501
Pin
1
2
3
4
Description
AOUT1
AOUT2
BOUT1
BOUT2
J701
Black mark sensor
Pin
1
2
3
Description
3.3V
BM_E
BM_R
Gap sensor
J702
Pin
1
2
Description
3.3V
GAP_R
9
J703
Hand open senor
Pin
1
2
Description
HEAD
GND
Print head
J301
STB5
STB6
STB7
DI
VH
VH
VH
GND
GND
GND
GND
GND
GND
GND
GND
GND
STB4
Description
VH
VH
VH
NC
/LAT
TPH_CLK
3.3V_TPH
STB1
STB2
STB3
TM
GND
GND
26
27
28
29
30
22
23
24
25
18
19
20
21
14
15
16
17
10
11
12
13
6
7
8
9
3
4
5
Pin
1
2
10
Charger station
S101
Pin
1
2
3
4
Description
12V_IN
12V_IN
GND
GND
BAT1
RTC battery
Pin
1
2
Description
GND
3V
11
3. MECHANISM
3.1 Replacing the Platen Roller
1. Open the printer cover. Use a tool to take the platen roller off. Replace the platen roller.
2. Reassemble the parts in the reverse procedures.
12
3.2 Replacing the Print Head Assembly
1. Use hex wrench (#2.5)
to remove two screws on lower cover.
2. Open the printer cover. Remove four screws on lower inner cover.
3. Remove the upper cover carefully.
1
13
2
3
4. Remove 2 screws on the each side of lower inner cover to remove the print head spring fixture.
14
5. Loosen the connector lock (black) then disconnect the flat cable from the main board.
Remove the print head assembly.
2
1
6. Replace the print head assembly.
15
Print head ass’y
Print head spring fixture
7. Reassemble the parts in the reverse procedures.
16
3.3 Replacing the Keys Control Board/ LCD Control Board
1. Refer to section 3.2 to remove the upper cover.
Disconnect the cables from the main board.
Note:
For the flat cable (LCD control board), please loosen the connector lock (brown) then disconnect the cable.
Keys control board cable LCD control board cable
2. Remove 4 screws on the keys control board/ LCD control board and disconnect the peel-off sensor connector by loosen the connector lock (brown).
Keys control board LCD control board
3. Replace the keys control board/ LCD control board assembly.
4. Reassemble the parts in the reverse procedures.
17
3.4 Replacing the Peel-off Sensor Module
1.
Refer to section 3.2 to remove the upper cover.
2.
Disconnect the peel-off sensor connector by loosen the connector lock for panel board.
Remove 1 screw.
3.
Replace the peel-off sensor module.
4.
Reassemble the parts in the reverse procedures.
18
3.5 Replacing the Bluetooth Module
1. Refer to section 3.2 to remove the upper cover.
2. Remove 2 screws on the Bluetooth control board. Use a tool to remove the spacer support on the Bluetooth control board.
3. Disconnect the connector on the board. Replace the Bluetooth module.
4. Reassemble the parts in the reverse procedures.
19
3.6 Replacing the Main Board Assembly
1.
Refer to section 3.5 to remove the upper cover and Bluetooth control board.
2.
Remove 2 screws on the main board. Disconnect all the connectors on the main board.
Replace the main board.
3. Reassemble the parts in the reverse procedures.
20
3.7 Replacing the Stepping Motor
1. Refer to section 3.2 to remove the upper cover.
2. Remove 5 screws. Disconnect the connectors on main board to take out the internal mechanism.
3. Remove 2 screws to replace the stepping motor.
4. Reassemble the parts in the reverse procedures.
21
3.8 Replacing the Gap Sensor Assembly
1. Refer to section 3.7 to take out the internal mechanism.
2. Loosen 2 springs.
3. Remove 4 screws on the internal mechanism.
4. Replace the gap sensor assembly.
5. Reassemble the parts in the reverse procedures.
22
3.9 Replacing the Media Holder Assembly
1. Refer to section 3.8 to remove the gap sensor assembly.
2. Replace the media holder assembly.
3. Reassemble the parts in the reverse procedures.
23
3.10 Replacing the Hand Open Sensor Assemble
1.
Refer to section 3.7 to take out the internal mechanism.
2.
Remove 1 screw to replace the hand open sensor assembly.
3.
Reassemble the parts in the reverse procedures.
24
3.11 Replacing the Peel-off Module
1. Refer to sections 3.1 and 3.7 to remove the platen roller and take out the internal mechanism.
2. Remove the black mark sensor cover.
3. Remove 4 screws on upper cover to take out the black mark sensor module.
4. Replacing the Peel-off cover.
5. Reassemble the parts in the reverse procedures.
25
3.12 Replacing the Black Mark Sensor Assembly
1. Refer to sections 3.11 to take out the black mark sensor assembly. Disconnect the black mark sensor connector from main board.
2. Reassemble the parts in the reverse procedures.
26
3.13 Replacing the Charger Board Assembly
1. Refer to the section 3.7 to take out the internal mechanism.
2. Disconnect the connector on the main board. Remove 2 screws to replacing the charger board assembly.
3. Reassemble the parts in the reverse procedures.
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3.14 Replacing the WiFi Module (Option)
1. Refer to section 3.2 to remove the upper cover.
2. Remove 1 screw on the WiFi module. Disconnect the connector and the antenna.
Note: Please keep the antenna connector horizontal when disconnect the antenna.
Keep the antenna connector horizontal to disconnect.
3. Replace the WiFi control board.
4. Reassemble the parts in the reverse procedures.
28
3.15 Replacing the RTC Battery (Option)
1. Refer to section 3.14 to remove the WiFi module.
2. Disconnect the connector on the main board.
3. Replace the RTC battery.
4. Reassemble the parts in the reverse procedures.
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4.
TROUBLESHOOTING
4.1 Common Problems
The following guide lists the most common problems that may be encountered when operating this bar code printer. If the printer still does not function after all suggested solutions have been invoked, please contact the Customer Service Department of your purchased reseller or distributor for assistance.
Problem
Power indicator does not illuminate
Possible Cause
* The battery is not properly installed.
* The battery is dead.
Recovery Procedure
* Reinstall the battery.
* Switch the printer on.
* Charge the battery.
- The printer status from
DiagTool shows
“Head
Open
”.
* The printer carriage is open. * Please close the print carriage.
- The printer status from
DiagTool shows
Paper
”..
“Out of
* Running out of media roll.
* The media is installed incorrectly.
* Black mark sensor is not calibrated.
* Supply a new media roll.
* Please refer to the steps on section 3.4 to reinstall the media roll.
* Calibrate the black mark sensor.
* Black mark sensor is not set properly.
- The printer status from
* Make sure media size is set
DiagTool shows
“Paper Jam”. properly.
* Media may be stuck inside the printer mechanism.
* Calibrate the black mark sensor.
* Set media size correctly.
Memory full
( FLASH / DRAM )
Poor Print Quality
* The space of FLASH/DRAM is full.
* Media is loaded incorrectly
* Dust or adhesive accumulation on the print head.
* Print density is not set properly.
* Printhead element is damaged.
* Delete unused files in the FLASH/DRAM.
* The max. numbers of DRAM is 256 files.
* The max. user addressable memory space of DRAM is 256KB.
* The max. numbers of file of FLASH is 256 files.
* The max. user addressable memory space of FLASH is 2560KB.
* Reload the supply.
* Clean the print head.
* Clean the platen roller.
* Adjust the print density and print speed.
* Run printer self-test and check the print head test pattern if there is dot missing in the pattern.
* Change proper media roll.
Missing printing on the left or
* Wrong label size setup.
right side of label
Gray line on the blank label
* The print head is dirty.
* The platen roller is dirty.
30
* Set the correct label size.
* Clean the print head.
* Clean the platen roller.
Irregular printing
* The printer is in Hex Dump mode.
* The RS-232 setting is incorrect.
* Turn off and on the printer to skip the dump mode.
* Re-set the Rs-232 setting.
31
5.
MAINTENANCE
This session presents the clean tools and methods to maintain your printer.
1. Please use one of following material to clean the printer.
Cotton swab
Lint-free cloth
Vacuum / Blower brush
100% ethanol
2. The cleaning process is described as following,
Printer Part Method
1. Always turn off the printer before cleaning the print head.
2. Allow the print head to cool for a minimum of one minute.
3. Use a cotton swab and 100% ethanol to clean the print head surface.
Interval
Clean the print head when changing a new label roll
Print Head
Platen Roller
1. Turn the power off. Clean the platen roller when changing a
2. Rotate the platen roller and wipe it new label roll thoroughly with 100% ethanol and a cotton swab, or lint-free cloth.
Tear Bar/Peel Bar
Use the lint-free cloth with 100% ethanol to wipe it.
As needed
Sensor
Exterior
Compressed air or vacuum
Wipe it with water-dampened cloth
Monthly
As needed
Interior
Brush or vacuum As needed
Note:
Do not touch printer head by hand. If you touch it careless, please use ethanol to clean it.
Please use 100% Ethenol. DO NOT use medical alcohol, which may damage the printer head.
Regularly clean the print head and supply sensors once change a new ribbon to keep printer performance and extend printer life.
32
Revise History
Date Content
33
Editor
TSC Auto ID Technology Co., Ltd.
Corporate Headquarters
9F., No.95, Minquan Rd., Xindian Dist.,
Li Ze Plant
No.35, Sec. 2, Ligong 1st Rd., Wujie Township,
New Taipei City 23141, Taiwan (R.O.C.) Yilan County 26841, Taiwan (R.O.C.)
TEL: +886-2-2218-6789
FAX: +886-2-2218-5678
Web site: www.tscprinters.com
TEL: +886-3-990-6677
FAX: +886-3-990-5577
E-mail: [email protected] [email protected]
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