Page 2 - Table of Contents
i Table of Contents CHAPTER 1 PRINTER OVERVIEW & INSTALLATION --------------------------------------------- 1 PRINTER FEATURES ---------------------------------------------------------------------------------------------------------------1PRINTER OPTIONS -----------------------------------------...
Page 8 - Safety Summary; WARNING; Personal Safety
TC9830SM Rev. B 7/98 Confidential vii Safety Summary Warning and caution messages appear throughout this manual. They alert you to potentially safety hazards orpotential damage to equipment. The messages and there meaning are shown below. WARNING Calls attention to improper practices that couldresul...
Page 10 - CHAPTER 1 PRINTER OVERVIEW & INSTALLATION; PRINTER FEATURES; PRINTER SPECIFICATIONS
July 1998 TC9830SM Rev. B 7/98 Confidential 1 CHAPTER 1 PRINTER OVERVIEW & INSTALLATION PRINTER FEATURES The 9820/9830/9835 printers are on-line table-topprinters that accepts Monarch Printer ControlLanguage II (MPCLII) data structure. They use a 203 dpi thermal printhead for printing. Theprinth...
Page 11 - STOCK SPECIFICATIONS
9820/9830/9835 Service Manual Printer Overview and Installation 2 TC9830SM Rev. B 7/98 Confidential July 1998 Fuse, Inlet Module: 4.0 amp, 250 V Slo-Blow® (1 required) Fuse, Main PCB 7.0 amp, 125 V Slo-Blow (Soldered radial leads) Tear Bar: 9830/9835 (Service Installed) Programming: Flash Communicat...
Page 12 - UNPACKING THE PRINTER
Printer Overview and Installation 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 3 UNPACKING THE PRINTER 1. Clear a work area approximately four feet wide. 2. Open shipping carton top flaps. 3. Remove the Documentation Package. and top pad 000655-05. Figure 1 - 2. Printer ...
Page 13 - FUSE REPLACEMENT; CONNECTING TO A HOST
9820/9830/9835 Service Manual Printer Overview and Installation 4 TC9830SM Rev. B 7/98 Confidential July 1998 1. Locate Upper or Lower DIP Switch block as shown in Figure 1-3. 2. Turn printer off and change individual DIP switches as required. Use Table 1-1 as a guide. 3. Daughter board SW1 settings...
Page 16 - CHAPTER 2 FUNCTIONAL DESCRIPTION; OVERVIEW OF MODULES
July 1998 TC9830SM Rev. B 7/98 Confidential CHAPTER 2 FUNCTIONAL DESCRIPTION OVERVIEW OF MODULES • Power Transformer Assembly (Power Supply and Distribution) • Control Board Assy. (Data Handling and Control) • Peel Module (Supply/Backing Separation) • Print Assembly (Thermal Control and Motion Synch...
Page 17 - Power Transformer Assembly; Inlet Power Module; Functional Description
9820/9830/9835 Service Manual Functional Description 8 TC9830SM Rev. B 7/98 Confidential July 1998 Power Transformer Assembly The power transformer assembly is located beneaththe printer’s back cover and includes threecomponents: Inlet Power Module The power module is attached to the printer’s rearp...
Page 18 - Power Conversion; Printer Control
Functional Description 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 9 Power Conversion Power conversion interface receives AC and DCvoltage from the Power Transformer assembly.35VAC is converted to +12VDC and -12VDC, whilethe 40VDC input is converted to +25VDC and +5VDC....
Page 19 - Contrast Control; PRINT ASSEMBLY; Thermal Printhead
9820/9830/9835 Service Manual Functional Description 10 TC9830SM Rev. B 7/98 Confidential July 1998 RS-232 interface This interface allows connection to devices capable ofRS-232 communications. The interface is incorporatedin the microcontroller and has DIP switches to setcommunications parameters. ...
Page 20 - FEED ASSEMBLY
Functional Description 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 11 Ribbon Spool Drive Motors wo DC ribbon drive motors are mounded to the backof the module wall. Each motor drives a ribbon spool.The motors are connected directly to the ControlBoard Assembly via separ...
Page 21 - Printhead Locking; SUPPLY HOLDER ASSEMBLY; CONTROL PANEL ASSEMBLY
9820/9830/9835 Service Manual Functional Description 12 TC9830SM Rev. B 7/98 Confidential July 1998 Printhead Locking Printhead release knob is used to release the printmodule from its open position. SUPPLY HOLDER ASSEMBLY Figure 2- 3. Supply Holder Assembly Functional Description The supply holder ...
Page 22 - CHAPTER 3 TROUBLESHOOTING; PRELIMINARY CHECK
July 1998 TC9830SM Rev. B 7/98 Confidential 13 CHAPTER 3 TROUBLESHOOTING This chapter contains suggestions for diagnostic and repair actions. PRELIMINARY CHECK The following checks should be made before going further: 1. Are the DIP switches set properly to match communication values and existing su...
Page 23 - EVALUATION OF A 754 ERROR (OUT OF RIBBON)
9820/9830/9835 Service Manual Troubleshooting 14 TC9830SM Rev. B 7/98 Confidential July 1998 EVALUATION OF A 754 ERROR (OUT OF RIBBON) This error occurs whenever the ribbon stops turning. This can happen if the motors are not working, the stock isbinding, the platen is sticky, or if any condition is...
Page 24 - GENERAL TROUBLESHOOTING SUGGESTIONS
Troubleshooting 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 15 The external Coax/TwinAx Interface is a 15 position connector into which is plugged either a Coax adapter cable or aTwinAx adapter cable. (All electronic activity for the serial port is limited to the Contro...
Page 26 - CHAPTER 4 DIAGNOSTICS; NV RAM ByteTest; System Restart Condition; Printhead Dot Resistance; TEST LABEL
July 1998 TC9830SM Rev. B 7/98 Confidential 19 CHAPTER 4 DIAGNOSTICS If you have any problems using SENDFILE, refer to the Sendfile Manual on your Service CD-ROM. The following diagnostics are resident in the9820/9830/9835 printer’s firmware ROM: • Power-Up Self-Test • Test Label • Service Diagnosti...
Page 27 - SERVICE DIAGNOSTICS; Accessing Diagnostic Modes
9820/9830/9835 Service Manual Diagnostics 20 TC9830SM Rev. B 7/98 Confidential July 1998 Figure 4- 1. Test Labels The first test label prints firmware version and currentprinter configuration in I packet format (refer to the printer’s Packet Reference Manual ). NOTE: Some reported settings may not b...
Page 28 - Serial Loop Back Test; TOOLS REQUIRED; Parallel Port Test; Performing a Virgin Printer Reset
Diagnostics 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 21 applies only when you are in Data Dumpmode. Serial Loop Back Test This test evaluates serial port circuits on the ControlBoard Assembly (nothing external to the ControlBoard), so communication setting DIPs 1 thr...
Page 30 - CHAPTER 5 TESTS AND ADJUSTMENTS; SERVICE TESTS; Continuity Tests
July 1998 TC9830SM Rev. B 7/98 Confidential 23 CHAPTER 5 TESTS AND ADJUSTMENTS SERVICE TESTS The following tests are described in this section: • Voltage Tests • Continuity Tests • Supply Quality NOTE: Sensor tests are described in Chapter 8,“Supply Sensing Systems.” CN6 Power Supply Pin numbers are...
Page 31 - Print Contrast Adjustment; Platen Motor Gear Adjustment; TOOLS/MATERIALS REQUIRED; Ribbon Tension Adjustment; MATERIALS REQUIRED
9820/9830/9835Service Manual Confidential Tests and Adjustments 24 TC9830SM Rev. B 7/98 Confidential July 1998 5. Following a totals number, the routine prompts another response. Any entry other than Y resultsin an abort. 6. Press D to return to the Sensor Display screen or press L to exit the Senso...
Page 32 - CHECKING SUPPLY QUALITY
Tests and Adjustments Confidential 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 25 1. Ensure printer is in Normal Mode with the printhead Wide/Narrow detents set to Wide. 2. Loosen locking screw and set eccentric at the nominal position (vertical for take-up roller,horiz...
Page 34 - CHAPTER 6 SERVICE PROCEDURES; MAINTENANCE OVERVIEW; CAUTION; CONTROL PANEL REMOVAL
July 1998 TC9830SM Rev. B 7/98 Confidential 27 CHAPTER 6 SERVICE PROCEDURES MAINTENANCE OVERVIEW This chapter describes removal and replacementprocedures for the following assemblies: Operator Control PanelCover HousingPower Transformer Assembly Power TransformerBridge RectifierAC Inlet Control Boar...
Page 35 - Transformer Removal; Bridge Rectifier Removal; AC Inlet Removal
9820/9830/9835 Service Manual Service Procedures 28 TC9830SM Rev. B 7/98 Confidential July 1998 POWER TRANSFORMERASSEMBLY Maintenance of the Power Transformer involves • removing/reassembling the power transformer. • removing/reassembling the bridge rectifier. • removing/reassembling the AC Inlet. T...
Page 36 - Control Board Assy. Removal
Service Procedures 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 29 1. Release wires from loop holder 2. Remove six wires leading to the transformer. 3. Remove flange screw fastening green wire from the AC Inlet to the Control Board Assembly. 4. Slide AC Inlet boot back a...
Page 38 - Print Assembly Removal; Latch Fascia Removal; Platen Module Removal
Service Procedures 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 31 Print Assembly Removal 1. Remove two screws holding pivot retainers to the frame. 2. Lift the upper supply guide and remove the retainer pins from the upper supply guide. 3. Remove the magnet from the tun...
Page 39 - Platen Module Replacement; Lower Supply Guide Removal
9820/9830/9835 Service Manual Service Procedures 32 TC9830SM Rev. B 7/98 Confidential July 1998 5. Unlatch the bearing block latch on each side of the platen roller by inserting a small bladescrewdriver between the latch and the platenframe. While holding the latch out with thescrewdriver, push the ...
Page 40 - SUPPLY HOLDER; Supply Holder Removal; PLATEN MOTOR; Platen Motor Removal; PEEL MODULE; Peel Module Removal
Service Procedures 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 33 Lower Supply GuideReplacement 1. Reinstall sensor harness through retainer loops. 2. Align guide frame with notches in platen frame. 3. Press down on guide frame until latches engage the platen frame. SUP...
Page 42 - CHAPTER 7 USING FLASH
July 1998 TC9830SM Rev. B 7/98 Confidential 35 CHAPTER 7 USING FLASH FLASH DOWNLOADINGPROCEDURES The following information should be used as aguideline for programming a 9800 series printer usingDOS- Flash Download Utility. NOTE: Close all applications to prevent anyconflicts with the communications...
Page 44 - CHAPTER 8 SUPPLY SENSING SYSTEMS
July 1998 TC9830SM Rev. B 7/98 Confidential 37 CHAPTER 8 SUPPLY SENSING SYSTEMS Several supply sensing systems have been used forthe 9800 series printers. This chapter contains: • Supply detection and tracking for each printer. • A description of the supply deflector, Bi-cell emitter, lower supply g...
Page 45 - SUPPLY FEEDING
9820/9830/9835 Service Manual Supply Sensing Systems TC9830SM Rev. B 7/98 Confidential July 1998 38 LOWER SUPPLY GUIDE/BI-CELL SENSOR The supply guide assembly spans the feed moduleframe just behind and below the platen roller. It sitswithin two détentes on each frame edge to maintainproper position...
Page 46 - MECHANICAL ADJUSTMENTS; Bi-Cell Sensor Adjustment
Supply Sensing Systems 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 39 meet, the threshold count is calculated as the sum ofhalf of the differential between the Low and Hi ADcounts captured plus the Low count. When a validBOF has been found it is saved and used as thethr...
Page 47 - REPLACING A SENSOR
9820/9830/9835 Service Manual Supply Sensing Systems TC9830SM Rev. B 7/98 Confidential July 1998 40 20. Remove gray scale and test printer with customer’s supplies. Figure 8- 1. Bi-Cell Sensor Adjustment NOTE: A hood covers the adjusting screw on theback of the housing. REPLACING A SENSOR Use these ...
Page 49 - Performing a Sensor Display Test
9820/9830/9835 Service Manual Supply Sensing Systems TC9830SM Rev. B 7/98 Confidential July 1998 42 Version 5.2 or greater: For the new V5.2 system there will be transmissive,reflective, non-index (continuous), and center aperture.The center transmissive sensor is intended only forsupplies that have...
Page 50 - APPENDIX A PRINTER ERROR/STATUS CODES; READING AN ERROR LABEL; Code
July 1998 TC9830SM Rev. B 7/98 Confidential 43 APPENDIX A PRINTER ERROR/STATUS CODES This section contains the error/status codes used with the 9800 series printers. These same codes are called status codes when they are displayed on the Control Panel LCD; and error codes when they are part of Dia...
Page 58 - APPENDIX B CONNECTORS AND CABLES
July 1998 TC9830SM Rev. B 7/98 Confidential 51 APPENDIX B CONNECTORS AND CABLES This appendix contains charts of the pinouts for the Control Board Assembly connectors 1 F PP STROBE bar 1 2 LC PD00 3 LC PD01 4 LC PD02 5 LC PD03 6 LC PD04 7 LC PD05 8 LC PD06 9 LC PD07 10 F MC ACK bar 11 F MC BUSY 12 F...
Page 62 - Daughter Board Connectors
Connectors and Cables 9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 55 1 TDX ANODE 2 TDX COMM Figure B- 10. CN 11 GND Two-wire harness connect red wire to TP5 (+25 volts) Figure B- 11. CN 14 1 RT_MTR_1 2 RT_MTR2 Figure B- 12. CN 15 1 RS_MTR_1 2 RS_MTR2 Figure B- 13. CN 16 1 +1...
Page 64 - APPENDIX C CONNECTOR LOCATIONS
July 1998 TC9830SM Rev. B 7/98 Confidential 57 APPENDIX C CONNECTOR LOCATIONS Figure C- 1. Control Board Assy. (Mother Board) Legend: CN1 IEEE 1284 Parallel Port CN2 Printhead Assy CN3 Platen Stepper Motor CN4 Control Panel CN5 Coax/Twinax CN6 Transformer Output Power CN7 RS-232 Serial Port CN8 Inde...
Page 66 - APPENDIX D MODEL 928 STACKER; SPECIFICATIONS
July 1998 TC9830SM Rev. B 7/98 Confidential 59 APPENDIX D MODEL 928 STACKER The 928 Stacker only works with a 9835 printer with a 926 Knife attached. SPECIFICATIONS Height: 14.4 inches (366 mm) Base Width: 25.6 inches (650 mm) Tag Bed: 29.6 inches (752 mm) Depth: 7.9 inches (201 mm) Weight: 18 pound...
Page 67 - TROUBLESHOOTING; Error Messages; CABLES AND CONNECTORS
9820/9830/9835 Service Manual Model 928 Stacker 60 TC9830SM Rev. B 7/98 Confidential July 1998 2. Turn printer off. 3. Lift the knife/printer slightly and slide the knife on to the stacker mounting plate tabs. 4. Attach stacker AC power cable to stacker and AC power outlet. 5. Attach knife-to-stacke...
Page 69 - LUBRICATION
9820/9830/9835 Service Manual Model 928 Stacker 62 TC9830SM Rev. B 7/98 Confidential July 1998 Table D- 6. Power Supply Connector J1 Connector J1 Pin Color To 1 GND 2 N/C 3 Black On/Off Switch 4 N/C 5 White AC Inlet Figure D- 1. Stacker Control Board. LUBRICATION The stacker should be lubricated whe...
Page 70 - REPLACE ROLLERS; Replacing Transport Assembly
Model 928 Stacker 9820/9830/9835 Service Manual July 1998 TC9830SM Rev. B 7/98 Confidential 63 Front Frame Rear Frame Full Sensor ElectronicsCover Side Cover Back Cover Jam Sensor Rear Cover Stacker-to-Knife Cable Figure D- 3. Model 928 Stacker Assembly. REPLACE ROLLERS Figure D- 4. Lower Transport ...
Page 72 - APPENDIX E 926 KNIFE ASSEMBLY; KNIFE SPECIFICATIONS; Evaluation of Error 760
July 1998 TC9830SM Rev. B 7/98 Confidential 65 APPENDIX E 926 KNIFE ASSEMBLY The 926 Knife only works with a 9835 printer. KNIFE SPECIFICATIONS Height: 8.5 inches (216mm) Width: 9.3 inches (236mm) Depth: 7.6 inches (193mm) Weight: 9.0 pounds (4.1 Kg) Shipping Wgt: 9.5 pounds (4.3 Kg) Power: Input Vo...
Page 73 - VOLTAGE TESTS
9820/9830/9835 Service Manual Model 926 Knife 66 TC9830SM Rev. B 7/98 Confidential July 1998 3. Check Blade Assembly alignment and ensure assembly mounting screws are tight. 4. Verify supply type; cutter only cuts tags. Labels should not be cut. 5. Check to ensure tags being used do not exceed 0.010...
Page 76 - CONNECTORS AND CABLES
Model 926 Knife 9820/9830/9835 Service Manual Julyl 1998 TC9830SM Rev. B 7/98 Confidential 69 8. Adjust belt tension. 9. Squeeze halfway between pulleys. When distance from outside of one side of belt to outsideof opposite side is approximately 1.0”, tightenscrews on motor. 10. Turn printer on and t...
