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IntelliBar All Series Printers User Manual

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Label Printer
User's Guide
For All Series Printers
Changing the way the world prints labels...

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Summary of Contents for IntelliBar All Series Printers

  • Page 1 Label Printer User’s Guide For All Series Printers Changing the way the world prints labels…...
  • Page 2 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.

  • Page 3: Table Of Contents

    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...
  • Page 4 Contents Model 88....................... 2-23 Installing the Thermal Ribbon ................2-26 Model 48 or 412 ................... 2-26 Model 88....................... 2-30 Print Head Removal and Installation ............... 2-34 Print Head Removal ................... 2-35 Model 48 and Model 412 ................2-35 Model 88....................... 2-38 Print Head Installation ..................
  • Page 5 Contents Label Cutter Installation Procedure Overview (Model 48 and 412)...... 4-11 A. Remove the Standard Peel-Off Assembly (Model 48 and 412).... 4-12 B. Install the Cutter Option (Model 48 and 412)........4-14 C. Configure the Printer to Use the Cutter (Model 48 and 412)....
  • Page 6 Contents Sample Adjustment..................5-19 Timing Belt Tension Adjustment (Model 48 and 412) ....... 5-20 Model 88......................5-21 Label Width and Pressure Adjustment (Model 88)........5-21 Label Thickness Dial (Model 88)..............5-23 Ribbon Tension Plate (Model 88)..............5-24 Print Density Adjustment..................5-26 Section 6 Troubleshooting Troubleshooting the Problem..................

  • Page 7: Preface

    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.

  • Page 8: Abbreviations

    xiii Abbreviations ampere facsimile transmission alternating current Federal Communications Commission acknowledge frame ground ASCII American Standard Code for Information Interchange field-replaceable unit BIOS basic input/output system gigabyte binary digit ground bits per inch hexadecimal bits per second horizontal motion index centigrade Hewlett Packard carrier detect...
  • Page 9 Abbreviations millimeter write millisecond most-significant bit not connected non-maskable interrupt nanosecond personal computer printed circuit board printer control language page description language pixel picture element peak-to-peak PROM programmable ROM P.S. power supply random-access memory read-only memory revolutions per minute read received data request to send read/write...

  • Page 10: General Information

    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”...

  • Page 11: Models 48 And 412

    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.
  • Page 12 General Information 1-3 Left Side Front Panel Panel Latch Print Head External Label Entrance Slot Print Head Release Lever Serial Port Ribbon Takeup Parallel Spindle Port Ribbon Supply AC Power Spindle Inlet Label Supply Power 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.

  • Page 13: Model 88

    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 Serial Release Latch Port...

  • Page 14: Hardware Description

    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...
  • Page 15 1-6 General Information CN11 (Power) 6-pin CN7 (Power) CN14 (Model 412 2-pin Pre-Heater) 2-pin CN6 (Print Head) CN17 (Stepper 14-pin Motor) 4-pin CN8 (Front Panel CN16 (Stepper Open) 4-pin Motor) 6-pin CN4 (Label Sensor Diode) 2-pin P2 (Serial) 25-pin CN3 (Label Sensor LED) 3-pin CN2 (Label Cutter Option) P1 (Parallel)

  • Page 16: Ribbon And Label Feed Mechanisms

    General Information 1-7 CN14 (Power for M odel 412 Pre-H eater) C N 1 1 ( P o w e r ) 2 - p in 6 - p in C N 7 ( P o w e r ) CN17 (Stepper M otor 2 - p in P o w e r ) 4 - p i n...
  • Page 17 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.

  • Page 18: Print Mechanism

    General Information 1-9 Ribbon Supply Ribbon Take-Up Print Head Spindle Spindle (Open) Stepper Motor Label Exit Slot Sensor Plate Label Supply Label Width Spindle 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.

  • Page 19: 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, user- installable, SIMM memory modules made for Apple or PC products. SIMM modules are available from retail or mail order computer hardware suppliers.

  • Page 20: Factory-Installable Options

    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.

  • Page 21: Specifications

    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.
  • Page 22 General Information 1-13 Table 1-2 IntelliBar Standard Series Specifications Feature Model 48, 48E Model 412, 412E Model 88, 88E Operating environment 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)

  • Page 23: Interface

    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.

  • Page 24: Data Transmission

    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. 1200 2400...

  • Page 25: Section 2 Setup

    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.
  • Page 26 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)
  • Page 27 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.
  • Page 28 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.

  • Page 29: Connecting The Power Cord

    Setup 2-5 Top Cover 25" Side Cover 30.5" 16.5" 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.

  • Page 30: Connecting The Communications Interface Cables

    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.
  • Page 31 Section 1 (see “Interface”). Attach the interface cable as follows. Make sure the power to the printer is turned off. Connect the interface cable to the appropriate standard IntelliBar Series interface port (see Figure 2-6). Secure the cable with the indicated screws or clips.
  • Page 32 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: Attach the twinax or coax cable adapter to the 15-pin port on the interface board (see Figure 2-7).
  • Page 33 Setup 2-9 Interface Board Interface Board Main Switch Bank Board Main Board RS232C/422 Interface Board Serial Port IEEE 1284 Parallel Port 5 mm Hex Nut Interface Board RS232C Serial Port (9-pin) Main Board IEEE 1284 5 mm Hex Nut Parallel Port Interface Board Twinax/Coax Port (15-pin ) 5 mm Hex Nut...

  • Page 34: Label And Ribbon Requirements

    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 NOTE: For updates on IntelliBar label specifications and other information about labels orderable through IntelliTech International, Inc.,...
  • Page 35 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 8.65 inches Top and Bottom (222 mm) maximum AAAAAAA........AAAA...

  • Page 36: Intellibar Ribbons

    Model 48 and 412 Model 88 1.06 in. (27 mm) 6.64 in. (165.0 mm) 2.13 in. (54 mm) 8.65 in. (220.0 mm) 3.27 in. (83 mm 4.37 in. (111 mm) The following tables list IntelliTech order numbers for IntelliBar black and color ribbons.
  • Page 37 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.
  • Page 38 1.08 inches (27 mm) 300 meters (990 feet) 50-522 yellow Process 2.20 inches (54 mm) 300 meters (990 feet) 50-523 yellow ∗ This page was prepared July 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at 800-694-3034.
  • Page 39 3.32 inches (83 mm) 300 meters (990 feet) 50-545 orange Dark 4.44 inches (111 mm) 300 meters (990 feet) 50-546 orange ∗ This page was prepared July 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at 800-694-3034.
  • Page 40 1.08 inches (27 mm) 300 meters (990 feet) 50-571 Green Forrest 2.20 inches (54 mm) 300 meters (990 feet) 50-572 Green ∗ This page was prepared July 1999. For an up-to-date listing of IntelliBar ribbons, please call IntelliTech at 800-694- 3034.
  • Page 41 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 800-694- 3034.

  • Page 42: Ribbon/Label Combination

    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 Label Description Description For economical high to medium speed Express Wax Coated or uncoated paper printing.

  • Page 43: Loading Labels

    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.
  • Page 44 2-20 Setup Pull blue handle to open front panel. Raise print head. Mount label Pull up blue media roll. print head release latch. Figure 2-9 Mounting the Label Roll (Model 48 and 412) 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).
  • Page 45 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.
  • Page 46 2-22 Setup Sensor Plate Label Sensor Label Figure 2-11 Label Sensor Location (Model 48 and 412) Route the label liner through the exit slot in the front panel. Close and latch the print head assembly, making sure the print head is securely latched.
  • Page 47 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) Close the front panel and left side cover. Turn on the printer and wait for it to initialize (“OFFLINE, INITIALIZE” appears in the 2-line control panel LCD display).
  • Page 48 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. Load labels as described in steps 1 through 9 in the previous subsection. From the control panel, select the “LABEL MENU, LABEL MEASURE, FIXED”...
  • Page 49 Setup 2-25 Press Next until “PEEL OFF” appears. Press Select (“PRINT MODE , “PEEL OFF” appears with an asterisk). Open the front panel and print head. 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...
  • Page 50 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 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.

  • Page 51: Model 88

    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.
  • Page 52 2-28 Setup 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.
  • Page 53 Setup 2-29 Figure 2-17 Locking the Print Head (Model 88) 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. From the control panel, select the “LABEL MENU, LABEL MEASURE, FIXED”...
  • Page 54 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. From the control panel, select the “PRINT MENU, PRINT MODE, PEEL-OFF” parameter as follows (see also “Menu Tree”...
  • Page 55 Setup 2-31 Latch Rod Latch Rod (Up Peel-off Roller (Down Position) Position) Figure 2-18 Model 88 Peel-Off Mode Label Routing – Cut-Away View 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.

  • Page 56: Installing The Thermal Ribbon

    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.
  • Page 57 Setup 2-33 Line up notch to mount Mount ribbon take-up spool. roll. Pull blue handle to open front Take-up panel. spool Ribbon Figure 2-19 Mounting the Ribbon Supply and Take-up Spools (Model 48 and 412) 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).
  • Page 58 2-34 Setup Raise print head. Pull through about 12" to 18" of ribbon. Pull up blue Thread ribbon print head under print head. release latch. Figure 2-20 Threading the Ribbon (Model 48 and 412) Guide the ribbon over the ribbon guide plate and then back toward the take-up spool (see Figure 2-21).
  • Page 59 Setup 2-35 Attach adhesive patch on ribbon leader Guide ribbon over ribbon guide to take-up spool and wind spool plate. several turns counterclockwise. Figure 2-21 Attaching the Ribbon (Model 48 and 412) Close and securely latch the print head (see Figure 2-22). Close and securely latch the front panel.

  • Page 60: Model 88

    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”...
  • Page 61 Setup 2-37 Take-up Core Take-up Core Slot Flange Take-up Core 1 Take-up Spindle Supply Spindle Take-up Core 2 Removal Tape Ribbon Leader Figure 2-23 Assembling the Ribbon Supply and Take-up Cores (Model 88) 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).
  • Page 62 2-38 Setup 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 Take-Up Spindle Spindle Drive Shaft End Hole Round Supply Shaft End Printer Center Frame Supply Ribbon Spindle Holder...
  • Page 63 Setup 2-39 Ribbon Guide Plate Take-Up Spool Figure 2-25 Threading the Ribbon (Model 88) 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).

  • Page 64: 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).

  • Page 65: Print Head Removal

    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”...
  • Page 66 2-42 Setup Loosen (completely) the two front thumb screws on the print head assembly top cover (see Figure 2-28). Loosen or remove the two rear thumb screws. Raise the print head assembly. Print Head Assembly Top Cover NARROW Rear Front THIN Thumb Thumb...
  • Page 67 Setup 2-43 Model 48 Print Head Shown Bottom Cover Figure 2-29 Print Head Removal (Model 48 and 412) 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.

  • Page 68: Model 88

    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) Remove the print head.
  • Page 69 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)

  • Page 70: Print Head Installation

    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”...

  • Page 71: Model 88

    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...

  • Page 72: Print Head Voltage Adjustment

    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.
  • Page 73 Setup 2-49 The words “MAINTENANCE MENU” and “DISPLAY COUNTERS” appear. Press the Next button once. Press the button again. Next The words “MAINTENANCE MENU” and “HEAD VOLTAGE ADJUSTMENT” appear in the LCD display. Press the Select button once. “REPLACING HEAD?” and “NO” appear. Press the button to choose “YES.”...

  • Page 74: Maintenance Menu

    2-50 Setup MAINTENANCE MENU PRESS SELECT T R A N S F E R C O U N 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 D I S P L A Y C O U N T E R S...
  • Page 75 Setup 2-51 ENTERING PRINT HEAD SERIAL NUMBER FROM MAINTENANCE MENU (B) YES 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.
  • Page 76 2-52 Setup SETTING LOW/HIGH HEAD VOLTAGE FROM MAINTENANCE MENU (A) NO O H M S X X X X SERVICE PERSON ENTERS PRINTHEAD RESISTANCE USE "NEXT" AND "PREVIOUS" BUTTONS WITH FAST SCROLL CAPABILITY ALLOWABLE RANGE EQUALS 1100 TO 1400 O H M S 1 2 0 0 WHEN CORRECT RESISTANCE VALUE IS IN DISPLAY, PRESS "SELECT"...
  • Page 77 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,...

  • Page 78: Section 3 Unit Operation

    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.
  • Page 79 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.
  • Page 80 Unit Operation Table 3-1 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).

  • Page 81: Self-Test

    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”...
  • Page 82 Unit Operation 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 —...

  • Page 83: Test Page

    Unit Operation Test Page Figure 3-3 Self-Test Sample Printout (All Models)

  • Page 84: Bar Code

    Unit Operation 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.
  • Page 85 Unit Operation Table 3-2 IntelliBar Default Printer Settings Main Menu Printer Default PRINT MENU Print method Thermal transfer Print mode Standard Ribbon type Express wax Print speed 4, 8, or 12 in. per second (ips) maximum (depending on model) LABEL MENU...

  • Page 86: Changing Settings

    Unit Operation 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. Turn the printer ON. Press to take the printer offline. The 2-line display will read “OFF LINE, Online PAUSE.”...

  • Page 87: Main Menu

    3-10 Unit Operation MAIN MENU M A I N M E N U SELECT TO PRINT MENU P R I N T M E N U NEXT TO LABEL MENU M A I N M E N U L A B E L M E N U M A I N M E N U...
  • Page 88 Unit Operation 3-11 PRINT MENU PRESS SELECT P R I N T M E N U 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 P R I N T M E T H O D...
  • Page 89 3-12 Unit Operation LABEL MENU PRESS SELECT L A B E L T Y P E L A B E L M E N U C U T * L A B E L T Y P E D I E PRESS T Y P E = L A B E L...
  • Page 90 Unit Operation 3-13 ADJUSTMENTS MENU P R I N T D E N S I T Y - 1 5 PRESS SELECT A D J U S T M E N T S M E N U P R I N T D E N S I T Y P R I N T D E N S I T Y...
  • Page 91 3-14 Unit Operation LJ3 SETUP MENU S O U R C E = M E N U F O N T B E R F O N T L I N E T E R F O N T S O U R C E I N T E R N A L * S O U R C E = B E R...

  • Page 92: Configuration Menu

    Unit Operation 3-15 CONFIGURATION MENU PRESS SELECT C O N F I G U R E M E N U T E S T P R I N T T E S T P R I N T T E S T P A G E PRESS T E S T...
  • Page 93 3-16 Unit Operation SERIAL SUBMENU PRESS SELECT B A U D 9 6 0 0 B A U R A T E B A U D D A T A B I T S = B I T S 1 9 2 0 0 D A T D A T A B I T S...
  • Page 94 Unit Operation 3-17 MAINTENANCE MENU PRESS SELECT C O U N M A I N T E N A N C E M E N U T R A N S F E R D I S P L A Y C O U N D I S P L A Y C O U N T E R S...
  • Page 95 3-18 Unit Operation SETTING LOW/HIGH HEAD VOLTAGE FROM MAINTENANCE MENU (A) NO O H M S X X X X SERVICE PERSON ENTERS PRINTHEAD RESISTANCE USE "NEXT" AND "PREVIOUS" BUTTONS WITH FAST SCROLL CAPABILITY ALLOWABLE RANGE EQUALS 1100 TO 1400 O H M S 1 2 0 0 WHEN CORRECT RESISTANCE VALUE IS IN DISPLAY, PRESS "SELECT"...
  • Page 96 Unit Operation 3-19 ENTERING PRINT HEAD SERIAL NUMBER FROM MAINTENANCE MENU (B) YES 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.

  • Page 97: Controlling The Printer

    3-20 Unit Operation Controlling the Printer Table 3-3 explains the settings and functions of menu choices. Table 3-3 Controlling the Printer Menu Selection Description Print Menu PRINT METHOD Selects thermal transfer printing and enables Transfer the ribbon sensor. Thermal transfer printing requires less print head energy and therefore increases print head life.
  • Page 98 Unit Operation 3-21 Table 3-3 Controlling the Printer (cont’d) Menu Selection Description Label Menu LABEL TYPE Use to select die-cut labels and enable the Die cut printer’s label sensor, which detects the beginning of a label. Die-cut labels must have a minimum label gap of 0.125 in.
  • Page 99 3-22 Unit Operation Table 3-3 Controlling the Printer (cont’d) Menu Selection 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;...
  • Page 100 Unit Operation 3-23 Table 3-3 Controlling the Printer (cont’d) Menu Selection Description LJIII Setup FONT SOURCE Selects the printer’s internal resident fonts. Internal Selects the downloaded (soft) fonts as default Soft font fonts. Not selectable if soft font is not loaded. FONT NUMBER Used to select the type face.
  • Page 101 3-24 Unit Operation Table 3-3 Controlling the Printer (cont’d) Menu Selection Description Configuration TEST PRINT Prints a preformatted test label listing the Test page standard default settings. Prints a preformatted bar code used for Bar code adjusting print quality. Lists the resident fonts and their assigned Font list number.
  • Page 102 Unit Operation 3-25 Table 3-3 Controlling the Printer (cont’d Menu Selection Description Flow control Selects Data Terminal Ready (DTR) to control communications from the host to the printer. Selects X-ON or X-OFF to control X-ON communications from the host to the printer. The printer sends an X-ON character to the host when it is ready to receive data.

  • Page 103: Lcd Display Messages

    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...
  • Page 104 Unit Operation 3-27 Table 3-4 Error Messages (cont’d) Status Message Definition MEDIA JAM IntelliBar cannot measure label length or gap. • Sensitivity of label sensor needs adjustment (call Intelli Tech for service information at 800-694-3034). • Wrong media in use; change to label type that matches sensitivity setting of label sensor.
  • Page 105 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.
  • Page 106 Unit Operation 3-29 Table 3-5 Status Messages Status Message Definition BUFFER CLEAR The print buffer contains no data. DATA IN BUFFER Feed Data remains in the print buffer. Press print the last label. CANCEL=NOREPRINT Cancel If a recoverable error occurs, press and the last label will not reprint.

  • Page 107: Printing Modes

    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.

  • Page 108: Tear-Off Mode

    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.

  • Page 109: Section 4 Options

    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.
  • Page 110 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...

  • Page 111: User-Installable Options

    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.

  • Page 112: Memory Expansion Module Installation (All Models)

    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;...
  • Page 113 Options 4-5 Screws Screws (Hidden) Note: Model 48 shown Figure 4-1 Right Side Cover Screws Lift the right side cover up and away from the printer (see Figure 4-2).
  • Page 114 4-6 Options Right Side Cover Note: Model 48 shown Figure 4-2 Right Side Cover Removal 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.
  • Page 115 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).

  • Page 116: Installing Simms

    4-8 Options Clips Figure 4-5 Removing a SIMM Installing a SIMM Install a SIMM as follows. 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).
  • Page 117 Options 4-9 Notch Figure 4-6 Notched End of SIMM Notche d End of SIMM Figure 4-7 Aligning the SIMM Insert the SIMM at an angle into the left or right socket. Carefully tilt the SIMM toward the locking tabs (see Figure 4-8).
  • Page 118 4-10 Options Figure 4-8 Inserting the SIMM 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). Repeat the installation procedure for the other SIMM. NOTE: Be careful when handling the SIMM;...

  • Page 119: Label Cutter Installation Procedure Overview (Model 48 And 412)

    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.

  • Page 120: Remove The Standard Peel-Off Assembly (Model 48 And 412)

    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. Turn off and unplug the printer. Open the left side cover (see Figure 4-10). 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.
  • Page 121 Options 4-13 Slide the peel-off assembly upward and out of the notches in the front panel and lift off the assembly. 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...

  • Page 122: Install The Cutter Option (Model 48 And 412)

    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.

  • Page 123: Configure The Printer To Use The Cutter (Model 48 And 412)

    Options 4-15 Front Panel Release Latch Cable Connector (Color-Coded) Label Cutter Option Control Panel Board (Hidden) 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.

  • Page 124: Internal Rewinder (Model 48 And 412)

    4-16 Options 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.
  • Page 125 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) Remove the peel-off/tear bar by sliding it out of the notches (see Figure 4-15).
  • Page 126 4-18 Options 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.

  • Page 127: Loading Labels In Peel-Off Mode

    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.
  • Page 128 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).

  • Page 129: Section 5 Cleaning And Adjustments

    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.
  • Page 130 5-2 Cleaning and Adjustments Print Head (Hidden) Front Panel Latch Ribbon Tension Release Lever 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...

  • Page 131: Print Head

    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.

  • Page 132: Sensors

    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...

  • Page 133: Print Position Adjustment

    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”...

  • Page 134: Print Head Voltage Adjustment

    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.

  • Page 135: Print Head Adjustments

    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...

  • Page 136: Print Head Latch

    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.

  • Page 137: Mechanical Adjustments

    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...

  • Page 138: Model 48 And 412

    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...

  • Page 139: Horizontal Print Head Alignment (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.
  • Page 140 5-12 Cleaning and Adjustments 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.

  • Page 141: Print Head Pressure Knob For Label Thickness (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.

  • Page 142: Print Head Balance Lever For Label Width Adjustment (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).

  • Page 143: Print Head Position Dial For Label Thickness Adjustment (Model 48 And 412)

    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).
  • Page 144 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).
  • Page 145 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.

  • Page 146: Ribbon Guide Plate (Model 48 And 412)

    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.

  • Page 147: Sample Adjustment

    Troubleshooting and Repair 5-19 Ribbon Guide Plate Sc rew N AR R OW T H IN Ribbon Guide Plate W ID T H IC KN ESS T H IC K AD J . W ID T H AD J . Ribbon Guide Plate Sc rew Figure 5-17 Ribbon Guide Plate...

  • Page 148: Timing Belt Tension Adjustment (Model 48 And 412)

    5-20 Cleaning and Adjustments Readjust the print head pressure to obtain the best possible print quality within its range. 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.

  • Page 149: Model 88

    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...
  • Page 150 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.

  • Page 151: Label Thickness Dial (Model 88)

    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.

  • Page 152: Ribbon Tension Plate (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.
  • Page 153 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)

  • Page 154: Print Density Adjustment

    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.
  • Page 155 Troubleshooting and Repair 5-27 Figure 5-26 Print Density Samples...
  • Page 156 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.))

  • Page 157: Section 6 Troubleshooting

    Section 6 Troubleshooting Jump to Section 5 This section contains troubleshooting information for isolating problems in the printer to a field- replaceable 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.

  • Page 158: Using Lcd Display Error Messages

    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. Make sure the print head is securely mounted to the housing. Enter the maintenance menu and check that the print head resistance value matches the print head.
  • Page 159 IntelliTech International, Inc. at 800-694-3034). • More than one label missing from release paper (liner). MEDIA JAM IntelliBar cannot measure label length or gap. • Sensitivity of label sensor needs adjustment (for more information, call IntelliTech International, Inc. at 800-694-3034). •...
  • Page 160 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.
  • Page 161 Troubleshooting 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.

  • Page 162: Correcting Print Quality

    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).
  • Page 163 Troubleshooting 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). • Reduce print density using the control panel (see “Print Density Adjustment” in Section 5) or software (see the Programmer’s Reference Guide).

  • Page 164: Top-Level Problem Solving

    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.
  • Page 165 Troubleshooting NOTE: To have a printer repaired, place a service call to IntelliTech International, Inc. at 800-694- 3034. 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 •...
  • Page 166 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.
  • Page 167 WARRANTY AND SERVICE PROGRAMS The following IntelliTech International, Inc. Limited Warranty policy and procedures are described in this subsection: IntelliBar Printer Warranty IntelliBar Printer Option Warranty IntelliBar Printer Ribbon Warranty IntelliBar Replacement Parts Non-Warranty Service and Repair IntelliTech International, Inc. products are warranted in accordance with the terms of this LIMITED WARRANTY.
  • Page 168 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:...
  • Page 169 Troubleshooting 6-13 Modification or alteration of the printer by any party other than IntelliTech International, Inc. Misadjustment, repair or attempted repair or service of the printer by any party other than IntelliTech International or an authorized representative. Damage caused by shipment of the printer (claims must be submitted to the carrier). Installation or removal of the Printer.
  • Page 170 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.
  • Page 171 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.
  • Page 172 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.

  • Page 173: Common Questions And Answers

    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.
  • Page 174 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.
  • Page 175 (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.
  • Page 176 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.
  • Page 177 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”).
  • Page 178 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?
  • Page 179 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.
  • Page 180 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.

  • Page 181: Fax Form

    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...
  • Page 182 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: support@intellitech-intl.com 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.
  • Page 183 Troubleshooting 6-27 Who sold you the printer? __________________________...
  • Page 184 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:...
  • Page 185 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.

  • Page 186: Appendix A Packing

    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. Remove the label and ribbon rolls from the printer.
  • Page 187 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.
  • Page 188 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.
  • Page 189 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.
  • Page 190 Glossary-3 pressure sensitive label -- label material with adhesive backing and protective silicone- coated 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.
  • Page 191 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.

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