THERMAL PRINTER TSP200 Series TECHNICAL MANUAL [SECOND EDITION]
NOTICE • All rights reserved. Reproduction of any part of this manual in any form whatsoever, without STAR’s express permission, is strictly forbidden. • The contents of this manual are subject to change without notice. • All efforts have been made to ensure the accuracy of the contents of this manual at the time of printing. However, should any errors be found, STAR would greatly appreciate being informed of them. • The above notwithstanding, STAR can assume no responsibility for any errors in this manual.
INTRODUCTION This manual describes the thermal printer TSP200 series. It is designed for use as a reference for periodic inspections and maintenance procedures to be executed by service personnel. It is not intended for the general user. Users of this manual should have a basic knowledge and understanding of the English language. • This manual is comprised of the following chapters.
CHAPTER 1 SPECIFICATIONS AND OPERATION 1. General Specifications.......................................................................................... 3 2. External Appearance............................................................................................. 4 3. DIP-Switch Settings .............................................................................................. 5 4. Using the control panel to adjust the sensors, select the head rank, and set the memory switches. ........
SPECIFICATIONS AND OPERATION –2–
SPECIFICATIONS AND OPERATION General Specifications Printing method Resolution Printable width Printing speeds Printable characters Bar codes Character matrix Interfaces Dimensions Weight Power Power consumption Operating environment Storage environment 300, 000 cuts 25.4mm (1 inch) 193mm Automatic paper cutter Life Min. cut length Line thermal direct 8 dots/mm (H) × 8 dots/mm (V) 72 mm 50 mm/sec (max.
SPECIFICATIONS AND OPERATION 2. External Appearance Printer cover Protects the printer from dust and reduces noise. Do not open the cover while printing. Control panel Features two control switches and two indicators to indicate printer status. AC power cord Plugs into an outlet of the specified voltage. Shape of AC power plug will vary according to destinations. Interface connector Connects the printer with host computer.
SPECIFICATIONS AND OPERATION 3. DIP-Switch Settings Be sure to turn the power to both the printer and host computer off before changing the setting of the DIP switches. Power off DIP switch 1 ON OFF 8 DIP switch 1 1 4 DIP switch 2 Fig.1-3 DIP switch array DIP switch #1 The factory settings of DIP switch 1 are all on.
SPECIFICATIONS AND OPERATION 4. Using the control panel to adjust the sensors, select the head rank, and set the memory switches. Hold down the FEED and ONLINE switches while setting power on, then continue to hold the switches down for the time necessary to enter the required mode, as indicated below. Start Buzzer beeps 1 time. Press both switches. Continue to hold down. Release within 2 seconds. Enters "Adjust Paper-Out Sensor" mode. Buzzer beeps twice. Release within 2 seconds.
SPECIFICATIONS AND OPERATION (1) “Adjust Paper-Out Sensor” mode. Adjustment is not necessary if the ONLINE lamp is ON when you enter this mode. If the lamp is OFF, the turn VR1 clockwise until it the lamp comes ON. To exit this mode, press ONLINE. To move back to the start of the sequence, press both ONLINE and FEED at the same time. Please be sure that paper is inserted before entering this mode.
SPECIFICATIONS AND OPERATION 5. Running a test print To generate a test print, hold down the FEED switch while setting the power on. 6. HEX dump mode To enter HEX dump mode, hold down the ONLINE switch while setting the power on, and then release the switch after the buzzer beeps once. When this mode is active, all data sent from the host will be printed in HEX form.
CHAPTER 2 PRINCIPLES OF OPERATION This chapter describes the operating principles of the circuitry and printer mechanism. 1. Block Diagram ..................................................................................................... 11 2. Interface ............................................................................................................... 13 2-1. Interface Types ..................................................................................................... 13 2-1-1.
PRINCIPLES OF OPERATION – 10 –
PRINCIPLES OF OPERATION 1. Block Diagram The following diagram illustrates the relation between the main logic board and its peripherals.
PRINCIPLES OF OPERATION (1) Main Logic Board The main logic board’s CPU passes data transmitted from the host computer into the local RAM. It then reads the data from the RAM, arranges it in accordance with the ROM program, and prints the results by issuing appropriate drive signals to the printer mechanism. [Block Descriptions] a. CPU: HD6413002F16 CMOS single-chip computer. Controls overall printer operation. b. EPROM: 256K × 8 bits Stores the CPU control program. c.
PRINCIPLES OF OPERATION 2. Interface 2-1. Interface Types 2-1-1. RS232 interface CN6 IC10 IC1 CPU RXD RXD 0 TXD TXD 0 DSR P93 DTR P91 ADM232LJR RTS TTL 232C FAULT TTL 232C INIT P94 Comparator Dipswitch 2-3 Comparator Dipswitch 2-4 Fig. 2-2 Serial Interface Data flow from host to printer: IC10 receives serial data from the host through RXD, converts the voltage level from RS232C to TTL, and passes the result to the CPU.
PRINCIPLES OF OPERATION 2-1-2. Parallel interface CN4 IC4 IC1 DATA 1 CD0 DATA 2 CD1 DARA 3 CD2 DATA 4 CD3 DATA 5 CD4 DARA 6 CD5 DATA 7 CD6 DATA 8 CD7 STROBE CSTB IC5 BUSY BUSY ACK ACK CPU ERROR ERROR SELECT SELECT PAPER OUT POUT Gate array LS05 Fig. 2-3 Parallel interface When the printer is ready (BUSY is LOW), the host computer transmits eight bits of parallel data (DATA1,...,DATA8) to CN4. The data passes through the gate array and moves into the CPU.
PRINCIPLES OF OPERATION 2-2. Data Arrangement and Printing 2-2-1. Arrangement The CPU reads data sequentially from RAM and arranges this data in accordance with program instructions stored in EPROM. The arranged data is then converted from parallel to serial form. The gate array then outputs the resulting serial data to the drive controller in the thermal printhead. 2-2-2. Thermal printhead The thermal printhead has 576 heat elements. Printing is executed by switching these elements ON and OFF as required.
PRINCIPLES OF OPERATION DO1 DO2 DO3 DO62 DO63 DO64 GNDH VDD BUFFER GNDL VDD CHECKER VDD STB BEO Q L Q D L Q D L LATCH Q L D Q D L Q D L D LAT CTL D Q SI C D Q C D Q C SHIFT REGISTER D Q D Q D Q C C C SO CLK Fig. 2-5 Block Diagram of Drive IC 2-2-3. Head current control Although the thermal printhead has four different STROBE lines, in fact it uses only three strobe signals to control its 576 elements. Specifically, each signal drives 192 of these elements.
PRINCIPLES OF OPERATION Strobe signals are output in one of five patterns, depending on the number of dot lines that are simultaneously ON. The following table shows each of the patterns. Figure 2-7 shows the timing for Pattern (5).
PRINCIPLES OF OPERATION CLOCK SI LATCH 24V COMMON STB1 STB2 STB3 Fig. 2-7 Timing Chart 2-2-4. Head current control Heat buildup in the thermal printhead can cause print quality to degrade. To maintain uniform quality, the printer varies the energizing time (time that STROBE remains LOW) in accordance with the head temperature. The print head’s surface temperature is calculated based on the resistance value of the attached thermistor, and energizing time is controlled accordingly. 2-2-5.
PRINCIPLES OF OPERATION STB1 STB2 STB3 HD ON (B) Trigger Retrigger Retrigger BEO (Q) tw Fig. 2-9 Timing Chart 2-3. Feed-Motor Drive Circuit The printer uses a 4-phase step motor (phase 1-2 excitation) to implement paper feed. The motor rotates through a certain angle each time it receives a pulse from the drive circuit. The following diagram illustrates the excitation method. Figure 2-11 shows the feed-motor drive circuit.
PRINCIPLES OF OPERATION The feed-motor pulse width varies according to the strobe output pattern (where the output pattern is determined by the print rate, as described above). The following diagram shows the pulse width for each pattern. Pattern 1 STB1 STB2 STB3 LF COMMON T1 T1 T1 Pattern 2 STB1 STB2 STB3 LF COMMON T2 T2 T2 Pattern 5 STB1 STB2 STB3 LF COMMON T3 T3 Fig.
PRINCIPLES OF OPERATION 2-4. Power-On Reset Circuit The power-on reset signal initializes all elements so as to protect against possible operating errors at power-on. The signal is held for approximately 160ms when power comes on. The reset circuit is shown below. Fig. 2-13 Power-On Reset Circuit +5V +5V +5V IC4 Drive circuit +5V IC3 IC1 : CPU VCC +5V RESET CPU CD RES OUT RESO + C9 Gate array GND D1 RESET IC Fig.
PRINCIPLES OF OPERATION 2-5. +5V Line Voltage Detector Circuit The voltage-detection IC (IC3 in Fig. 2-13) detects momentary drops or unstable levels in the +5V line voltage. The following shows an IC3-equivalent circuit. VCC 1 SµA typ R1 5 – OUT – + R2 1.25V 3 GND 4 Cd Fig. 2-14 Equivalent Circuit, Voltage Detection IC Figure 2-15 shows the IC’s operational timing. The IC asserts a reset signal at its output terminal when the -5V line voltage falls below 4.
PRINCIPLES OF OPERATION 3. Printer Mechanism 3-1. Thermal Printhead The TSP400 printers utilize thermal line printing. The thermal printhead consists of a horizontal line of 576 heat elements. These elements print one line of dots at a time as the paper passes over the head. The printhead is fixed in position; only the paper moves. The printer prints a dot by heating the corresponding heat element.
PRINCIPLES OF OPERATION 3-3. Detectors 1 Paper-Out Detector The paper-out detector (reflective photosensor) is located at the paper entry slit. The photosensor’s phototransistor remains ON while paper is present. It goes OFF when paper runs out, generating output of a paper-out signal. IC1 CPU CN2 +5V +5V Paper 4 – P45 Photosensor + +5V 5 3 Fig. 2-18 Paper-Out Detector 2 Paper-Near-End Detector The near-end detector is mounted in the paper-roll holder.
PRINCIPLES OF OPERATION 3 Head-Up Detector This detector senses the position of the thermal printhead. The leaf switch closes when the printhead is in contact with the platen, and opens when the printhead is separated from the platen. IC1 CPU +5V CN7 Leaf Switch 2 P44 1 Fig. 2-20 Head-Up Detector 4 Cover-Open Detector This detector senses whether the upper cover is open or closed. The leaf switch closes when the cover closes, and opens when the cover opens. IC1 CPU +5V CN1 Leaf Switch 1 P46 2 Fig.
PRINCIPLES OF OPERATION < Full Cut > P40 H L P41 H L Switch ON OFF 40ms 100ms Brake < Partial Cut > P40 H L P41 H L Switch ON OFF 40ms Fig.
CHAPTER 3 PART REPLACEMENT AND RELATED ADJUSTMENT This chapter presents printer disassembly and reassembly procedures. Please note the following important points. 1. Always disconnect the power cord from the AC outlet before beginning work. 2. Except where otherwise indicated, the reassembly procedure is the reverse of the disassembly procedure. 3. Coat screw heads with locking sealant after completing of reassembly. 4. Refer to Chapter 4 Section 2 for information about lubrication.
PARTS REPLACEMENT – 28 –
PARTS REPLACEMENT 1 1. Upper Case Unit (1) Switch off the power, and unplug the power cord from the power outlet. Remove: • Cover 1 • Four tapping screws 2 • Upper case unit 3 Remove the upper case unit by lifting it up and off. (2) 2 3 2. 1 5 2 4 6 1 Auto-Cutter Unit (1) Remove: • Upper case unit (See 1. above.
PARTS REPLACEMENT 5 3. 4 7 3 2 1 6 1 (1) Remove the upper case unit (see 1. above), then proceed to (2) below. (1) Remove the auto-cutter unit. (See 2. above.) (2) Remove: • Two screws 1 • Sub-chassis 2 • Guide 3 • Two tapping screws 4 • Three tapping screws 5 • Flat cable 6 • Connector • Printer mechanism 7 4. Near-End-Sensor Unit (1) (2) Remove the upper case unit. (See 1. above.
PARTS REPLACEMENT 5 5. Power Unit (TSP200-120/230) (1) (2) (3) Remove the upper case unit. (See 1. above.) Remove the connector cover 1. Remove the main chassis unit 5 from the lower casing unit 2. Remove: • Two screws 3 • Cord bushing 4 • Connector • Power unit 6 from main chassis 5 (4) 6 4 3 1 2 Power Unit (TSP200-24) 5 (1) (2) (3) (4) 6 3 4 3 1 2 – 31 – Remove the upper case unit. (See 1. above.) Remove the connector cover 1. Remove the main chassis unit 5 from the lower casing unit 2.
PARTS REPLACEMENT 3 6. Main Logic Board (1) (2) (3) Remove the upper case unit. (See 1. above.) Remove the connector cover 1. Remove the main chassis unit 3 from the lower casing unit 2. Remove: • Two tapping screws 4 • Board chassis unit 5 • Two tapping screws 6 • Two screws 7 • Connector • Main logic board 8 (4) 6 7 6 4 7 8 4 5 1 2 7. Fuses (TSP200-120/230) (1) Remove the main chassis unit from the lower casing unit. (See 5. above.) Check the fuses in the power unit.
PARTS REPLACEMENT Fuses (TSP200-24) (1) 1 (2) Remove the main chassis unit from the lower casing unit. (See 5. above.) Check the fuses in the power unit. • Fuse F1 1 If fuse is blown, replace it with the fuse type indicated below. F1 5TT3A If the replacement fuse also blows out, replace the power unit or check the main logic board. 9 7 6 8 6 8. Thermal-head Unit (1) (2) Remove the printer mechanism. (See 3. above.) Be sure that the unit is in head-down state (that the head-lift lever 1 is back).
CHAPTER 4 MAINTENANCE AND LUBRICATION 1. 2. Maintenance......................................................................................................... 35 1-1. Cleaning................................................................................................................. 35 1-2. Checks ................................................................................................................... 35 Lubrication ....................................................................
MAINTENANCE AND LUBRICATION 1. Maintenance Proper maintenance is necessary to maintain printer performance and forestall potential problems. Please carry out maintenance as described below. 1-1. Cleaning (1) Surface dirt Clear away dirt with a soft cloth. If necessary, apply a small quantity of alcohol to the cloth to improve cleaning power. NEVER use thinner, trichlene, or ketone solvents, as these can cause damage to plastic components.
MAINTENANCE AND LUBRICATION 2. Lubrication Proper lubrication is essential for maintaining the printer’s performance level and preventing breakdowns or other problems. 2-1. Lubricants Choice of lubrication can significantly affect the printer’s performance, longevity, and low-temperature characteristics. We recommend the following lubricant for this printer. Type Name Manufacturer Grease Molykote EM Dow Corning 2-2.
CHAPTER 5 PARTS LIST HOW TO USE PARTS LIST (1) (2) (3) (4) (5) (6) (7) 1. 2. 3. 4. 5. DRWG. NO. This column shows the drawing number of the illustration. REVISED EDITION MARK This column shows a revision number. Parts that have been added in the revised edition are indicated with “#”. Parts that have been abolished in the revised edition are indicated with “*”. #1:First edition → Second edition *1:First edition → Second edition PARTS NO.
1. Printer Assembly 1-1. Disassembly Drawing 1-1-1.
1-1-2.
37 1-1-3.
1-2. Parts List 1-2-1. TSP200-120/230 Printer Assembly(TSP200-120/230) DRWG.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 - REV. PARTS NO.
1-2-2. TSP200-24 Printer Assembly(TSP200-24) DRWG.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 - REV. PARTS NO.
2. Printer Mechanism 2-1. Disassembly Drawing 2-1-1.
2-1-2.
2-2. Parts List Printer Mechanism DRWG.NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 REV. PARTS NO.
3. Cutter Unit 3-1. TSP200-120/230 8 9 7 2 3 6 9 1 5 4 8 DRWG.NO. 1 2 3 4 5 6 7 8 9 REV. PARTS NO. 04991512 32025040 45049930 32045430 32045440 37433500 37433510 00820304 00626404 PARTS NAME CUTTER 4022-24V CUTTER EJECT COVER POLARITY LABEL CUTTER GUIDE A CUTTER GUIDE B CUTTER SUPPORT R ASSY CUTTER SUPPORT L ASSY SCREW TR 2-3 SCREW TR 2.
3-2. TSP200-24 7 5 1 6 7 2 3 8 8 4 8 DRWG.NO. 1 2 3 4 5 6 7 8 REV. PARTS NO. 04991516 30990240 30040020 32045470 37433530 37433520 00926503 01902018 PARTS NAME CUTTER ACS-230STR PAPER GUIDE MOUSE PLATE F2 CUTTER GUIDE C CUTTER SUPPORT L ASSY CUTTER SUPPORT R ASSY SCREW TAT 2.
4. Wiring Scheme of Printer 4-1.
4-2.
5. Main Logic Board 5-1.
Main Logic Board (2/6) – 51 –
Main Logic Board (3/6) – 52 –
Main Logic Board (4/6) – 53 –
Main Logic Board (5/6) – 54 –
Main Logic Board (6/6) – 55 –
5-2.
5-3. Parts List Main Logic Board DRWG.NO. IC1 IC2 IC3 IC4 IC5 IC6 IC7 IC8 IC9 IC10 IC11 IC12 IC13 IC14 IC15 IC16 IC17-19 TA1 TA2 TR1 TR2 TR3 TR4 TR5 TR6-7 TR8 TR9 TR10 ZD1 DSW1 DSW2 SW1-2 LED1-2 XTAL1 C1 C2-3 C4 C5 C6-8 C9 C10-11 C12 C13-17 C18-22 C23-24 C25-26 C27 C28-31 C32 C33 C34-35 REV. PARTS NO.
Main Logic Board DRWG.NO. C36-41 CRA1-3 CRA4-8 CRA9-10 D1-2 D3 D4-5 D6 D7-9 DT1 DT2-4 DT5 DT6 DT7 DT8-9 DT10-11 DT12 DT13 DT14 DT15 DT16 L1-6 L7 L8-10 L11-17 L18-20 VR1 RA1 RA2 R1-3 R4-7 R8-9 R10-14 R15-17 R18 R19-20 R21 R22-23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 R34 R35-39 R40 R41 R42 R43 R44 REV. PARTS NO. PARTS NAME Q’TY 06542211 06544711 06542211 08000047 08000068 08000059 RESIS. ARRAY CHIP V8V221J RESIS. ARRAY CHIP V8V471J RESIS.
Main Logic Board DRWG.NO. R45-53 R54 R55 R56-58 R59 R60-61 R62-63 R64 R65-67 R68-70 R71 R72 R73 R74 R75-76 R77-80 R81 R82 R83 R84 R85-86 R87-88 R89 R90-91 R92 R93 R94-95 T96-98 R99 R100-101 R102 R103-105 R106 R107 R108 R109 R110 R111 R112 R113-114 R115-116 R117-123 R124 R125 R126 R127 R128 R129-133 BZ1 CN1 CN2 CN3 CN4 CN5 CN6 CN7 REV. PARTS NO.
Main Logic Board DRWG.NO. CN8 CN9 CN10 CN11 REV. PARTS NO.
6. Power Supple Unit (120VAC/230VAC) 6-1.
6-2. Parts List Power Supply Unit(120VAC/230VAC) DRWG.NO. IC1 DB1 R1 R2 R3 R4 C1 C2-3 C4 C5 C6-7 C8 C9 SW1 REV. PARTS NO.
7. Power Supple Unit (24VDC) 7-1. Circuit Diagram 7-2. Component Layout 7-3. Parts List Power Supply Unit(24VDC) DRWG.NO. IC1 ZD1 C1 C2 C3 SW1 F1 CN1 CN2 JP1 - REV. PARTS NO. PARTS NAME Q’TY 08202048 08020090 05043387 IC-REG SI-8401L ZENER DIODE RD7.5EB1T CHEM. CAPA. 3300UF 35V 1 1 1 05014775 09030036 09991011 09991024 09100636 30720080 93930006 09991910 CHEM. CAPA.
8. Paper Near-End Sensor 8-1. Circuit Diagram CN3 2 BLU 1 WHT 3 TRI C1740 PSI PS6002A R3 3.3K R1 12K GRN R2 750 C1 0.022µF 8-2. Parts List DRWG.NO. TR1 PS1 R1 R2 R3 C1 - REV. PARTS NO. 07227853 08300082 06051235 06057514 06053324 05532234 30721241 PARTS NAME TRANSISTOR 2SC1740SE PHOTO-INTERRUPTER PS6002A-KS RD RESISTOR 12 K-OHM 1/6W RD RESISTOR 750 OHM 1/6W RD RESISTOR 3.3 K-OHM 1/6W CAPACITOR 0.
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