Service Manual Edition 12/07
Brady IP Series Printer Service manual for the following products PRODUCT NUMBER CATALOG NUMBER PRODUCT DESCRIPTION 103957 BP-IP300 BRADY IP PRINTER - 300DPI STANDARD 103958 BP-IP600 BRADY IP PRINTER - 600DPI STANDARD 103959 BP-IP300-C BRADY IP PRINTER - 300DPI W/CUTTER 103960 BP-IP600-C BRADY IP PRINTER - 600DPI W/CUTTER 103961 BP-IP300-P BRADY IP PRINTER - 300DPI PEEL/PRESENT 103962 BP-IP600-P BRADY IP PRINTER - 600DPI PEEL/PRESENT 103963 BPA-IP-C-FI BRADY IP PRINTER CUTTER FIELD I
Brady IP Series Printer Table of Contents Table of Contents 1 1.1 1.2 1.3 1.4 Important Information ....................................................................................................... 4 General safety instructions .................................................................................................. 4 Protective devices ............................................................................................................... 4 Handling electricity......................
Brady IP Series Printer Important Information 1 Important Information 1.1 General safety instructions This service manual is intended for use by qualified service and maintenance personnel. For more operation and configuration information, refer to the user or configuration manual. Follow the general safety rules below: • • • • Keep the area around the device clean at all times! Work with safety in mind. Parts of device that are removed during the maintenance work must be put in a safe place.
Brady IP Series Printer Important Information 1.3 Handling electricity The following work may only be done by trained and qualified electricians: • Work on electrical components. • Work on an open device still connected to the mains supply. General precautions before starting maintenance work: • Find out where the emergency and power switches are so that they can be quickly thrown in an emergency.
Brady IP Series Printer Replacing assembly units 2 Replacing assembly units 2.1 Device overview View A 1 2 3 4 5 6 7 8 9 10 11 12 13 A 14 15 16 Fig. 1: 1 2 3 4 5 6 7 8 6 Overview RS-232 serial interface USB 2.
Brady IP Series Printer Replacing assembly units 2.2 Tools • Do not use any worn of damaged tools. • Only use tools and testing devices that are suitable for the task at hand. cab special tools: • Clutch mounting tool (part no. 5541180) • Service key (part no. 5540301) Standard tools: • • • • • Edition 12/07 Screw driver Torx, size TX 10/200 Hex screwdriver, straight, size 2.
Brady IP Series Printer Replacing assembly units 2.3 Replacing the control panel 1 Fig. 2: 2 3 4 2 5 3 1 2 3 4 5 Control panel Lug Bearing Plug connector Axle Replacing the control panel NOTE! To convert the printer from the standard or peel/present version to the cutter version by replacing the control panel the peel-off edge must be removed. To convert the printer in the opposite direction the peel-off edge must be inserted (see section 2.8, item 5). 1. Hinge down the control panel (1). 2.
Brady IP Series Printer Replacing assembly units 2.4 Replacing the cover 1 Fig. 3: 1 2 3 4 2 3 5 4 6 7 4 Replacing the cover 5 6 7 Toothed lug Damping wheel Hinged aperture cover Axle Cover Locking ring Guide for outer casing 1. Open the cover (5), remove the media hub and label stock. 2. Disconnect the damping mechanism by pressing both toothed lugs (1) towards the center of the device. 3. Press the cover further back until the axles (4) come out of the guide (7). 4.
Brady IP Series Printer Replacing assembly units 2.5 Replacing the outer casing DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply before opening the outer casing. 1 2 3 4 5 paus menu e feed canc el 6 Fig.
Brady IP Series Printer Replacing assembly units The outer casing can be removed complete with the cover. 1. Open the cover (4), remove the media hub and material. 2. Unscrew 2 screws (1) from the front of the casing. 3. Unscrew 2 screws (2) from the inside of the bottom. 4. Remove the outer casing (3) together with the cover (4) and place it beside the printer. 5. Remount the print mechanism (5) (see section 2.6, item 4) and hinge it up. 6.
Brady IP Series Printer Replacing assembly units 2.6 Replacing the print mechanism DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply before opening the outer casing. 4 5 6 7 1 8 2 9 3 10 11 12 Fig. 5: 1 2 3 4 5 6 7 8 9 10 11 12 Lug Elongated hole Bottom guide Print mechanism Cable Cable Ferrite Two screws BDC PCB CPU PCB Grounding cable Screw Replacing the print mechanism 1. Remove the outer casing together with the cover (see section 2.
Brady IP Series Printer Replacing assembly units 2.7 Replacing the printhead DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply. 1 Fig.
Brady IP Series Printer Replacing assembly units 2.8 Replacing the print roller DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply. 50 40 30 20 10 0 10 50 1 Fig. 7: 1 2 3 2 3 4 5 6 Replacing the print roller 4 5 6 Apertures Holding lugs Print roller unit Roller holder Peel-off edge Print roller 1. Open the cover and hinge down the control panel, press the release button and hinge up the print module. 2.
Brady IP Series Printer Replacing assembly units 5 7 6 Replacing the brake of the ribbon supply hub 4 2.9 3 1 2 6 5 5 4 7 6 4 3 3 1 2 6 5 4 7 1 3 5 6 3 1 1 1 2 2 2 7 4 3 4 5 5 4 1 2 3 4 3 6 Fig. 8: 2 4 6 5 7 1 3 6 5 7 2 4 3 6 7 Replacing the brake of the ribbon supply hub Tape holder of the ribbon supply hub Cover Three screws Brake 5 6 7 Clutch mounting tool Holder Lock washer 1.
Brady IP Series Printer Replacing assembly units 2.10 Replacing the drive of the cutting unit Fig. 9: 1 2 3 4 5 Replacing the drive of the cutting unit 6 7 8 9 10 Control panel Two plastic latches Cutting unit Clock wheel Shaft Two eccentrics Two screws Two connectors Base plate Drive 1. Turn the control panel (1) down, unlock the cutting unit (3) at the both plastic latches (2) and lift it. 2. Loosen the nuts (9). 3.
Brady IP Series Printer Replacing assembly units 2.11 Replacing the blades of the cutting unit Fig. 10: Replacing the blades of the cutting unit 1 2 3 4 5 6 7 8 9 10 11 Control panel Two plastic latches Cutting unit Base plate Screw Three screws Clamp Lower blade Paper guide Upper blade Three screws 1. Turn the control panel (1) down and hinge it up. 2. Unlock the cutting unit (3) at the both plastic latches (2) and lift it. 3. Turn the screw (5) clockwise using a 2.
Brady IP Series Printer Replacing assembly units 2.12 Replacing the CPU PCB DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply before opening the outer casing. 1 2 10 3 11 4 5 6 7 12 8 9 Fig.
Brady IP Series Printer Replacing assembly units 2.13 Replacing the BDC PCB DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply before opening the outer casing. paus menu e feed canc el 1 4 2 3 4 5 Fig. 12: Replacing the BDC PCB 1 2 3 4 5 Three cables BDC main cable Cover 4 screws BDC PCB 1. Remove the outer casing (see section 2.5, items 1 to 4). 2. Remount the print mechanism (see section 2.6, item 4) and hing it up. 3.
Brady IP Series Printer Replacing assembly units 2.14 Replacing the power unit DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply before opening the outer casing, and wait at least one minute to allow the power unit to discharge. 1 2 3 4 5 6 7 8 9 5 Fig. 13: Replacing the power unit 1 2 3 4 5 6 7 8 9 Power unit cover Base tub latch Two screws Recess Screw Power unit cable Power supply unit Mains input plug Bottom lug 1.
Brady IP Series Printer Settings and Adjustments 3 Settings and Adjustments 3.1 Measuring the rewind torques The winding torques on the ribbon rewind hub and ribbon supply hub are measured by determining the traction. The physical relation between torque and traction is as follows: F= M / r F: Traction [N], M: Rewind torque [Ncm], r: Radius of the hub (12.
Brady IP Series Printer Settings and Adjustments Measuring the torque of the clutch and brake on the ribbon rewind hub: 1. Wind the cord several times round the tape holder on the rewind hub (1) (see fig. 14 A). 2. Attach a spring scale [20 N] (2) to the end of the cord, raise it vertically until the holder starts to turn. 3. Allow the cord to unwind at least one full turn from the holder, and read off the traction F for the clutch on the spring scale. 4.
Brady IP Series Printer Settings and Adjustments 3.2 Adjusting the rewind torques DANGER! Danger to life and limb from electric shock! ⇒ Disconnect the device from the mains supply before opening the outer casing. 3 4 5 6 7 7 4 5 2 6 1 5 4 6 3 1 2 6 4 7 3 5 3 5 7 4 6 1 2 3 1 2 3 5 6 5 4 4 6 3 Fig. 15: Adjusting the rewind torques 1 2 3 4 5 6 7 Knurled ring Locking device Printhead assembly Unwinder friction clutch Rewind hub friction clutch Cover Three screws 1.
Brady IP Series Printer Settings and Adjustments 3.3 Adjusting the print mechanism Major adjustment of the print mechanism beyond format-based settings is only required if the printhead assembly has been removed or parts in this area have been replaced. Excluded from this is the replacement of the printhead, after which readjustment is generally not required.
Brady IP Series Printer Settings and Adjustments Screws for horizontal alignment (2) − Turning the screws clockwise will move the printhead to the front. − Turning the screws counter-clockwise will move the printhead to the back. For an optimum print quality, the heating elements of the printhead must be aligned to the peak of the print roller. This setting guarantees the best print darkness and the parallelism of printed horizontal lines and the label edge.
Brady IP Series Printer Settings and Adjustments 3.3.2 Adjusting 1. Load such media (label and transfer ribbon) which extends over the entire print width. 2. In the Printer Configuration set the heat level to 0 and the print speed to 100 mm/s. 3. Loosen the screw for printhead bending (4) by turning it counter-clockwise until it turns noticeably easy. This should occur after a maximum of half a turn. 4. Print out some test patterns with the test function "Test grid“ or similar test labels. 5.
Brady IP Series Printer Settings and Adjustments 3.4 Adjusting label sensor Access only when service key is inserted! You can adjust the label sensor with the Adj. gap sensor function. This is necessary if the sensor or CPU PCB has been changed. Carry out adjustment of the sensor with the cover closed and housing mounted to keep out external light sources. 1. Insert service key into a USB master interface. 2. Press the menu button. 3. Select Service > Adj. gap sensor menu. 4. Press the button.
Brady IP Series Printer Block diagram 4 Block diagram Fig.
Brady IP Series Printer Block diagram Fig.
Brady IP Series Printer Index 5 Index A Adjusting label sensor .................................27 Assembly units, replacing ..............................6 B Block diagram ..............................................28 Brake ribbon rewind hub .............................22 C Clutch ribbon rewind hub .............................22 Clutch ribbon supply hub .............................22 CompactFlash card slot .................................6 Control panel .........................................
