Intermec Technologies BTM311 BTM311 User Manual part 3

Intermec Technologies Corporation BTM311 part 3

User Manual part 3

6822 Series 80-Column PrinterUser’s ManualPhoto of printer not available at this time
6822 Series 80-Column PrinterUser’s Manual
6822 Series 80-Column Printer User’s Manual 976TroubleshootingThis chapter helps you correct printing problems that may occur. If you experience a printing problem, you can perform several tests to find and possibly correct the problem. In this chapter you will find these sections:•Checking the power source•Aligning the printer mechanism•Troubleshooting system components•Communications pin-out configurations
Chapter 6 — Troubleshooting98 6822 Series 80-Column Printer User’s ManualChecking the Power SourcePress any button on the printer control panel. If there is power, the power indicator (green LED) turns on and the printhead moves to its starting position. If the printer emits beeps and any of the other indicators light up or flash, observe the number of beeps and indicator flashes and see “Printer Failure Indicators” on page 102If there is no reaction from the printer after you press a key on the control panel, or only the green power light blinks, verify that the power cables are properly connected between the printer mechanism and its power source (internal battery, vehicle cable, or ac). If none of these steps “wake” up the printer with the problem, then you need to return the printer for service.•Internal batteryCheck the battery and its cable by installing into another known-good printer.•Vehicle cable Attach the printer in question to another vehicle power cable.•AC powerPlug the printer into another outlet.Aligning the Printer MechanismIf head jams occur, you may need to align the printer mechanism.To align the printer mechanism1Open the printer top cover, then install a ribbon cartridge (see page 15) and position the printhead to the far left toward the green thumb wheel.
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 992Check the area between the printhead and the printer cavity. If the ribbon cartridge touches the pivot frame, the printer mechanism needs realignment.Printhead at far left in the printer3Loosen the four screws that hold the mechanism in place using a Phillips screwdriver (see the following illustration).4Push the printer mechanism to the right away from the green thumb wheel.5Press on the right side of the printer mechanism to the back as far as it will go.Pivot frameNote: In this position, the right back edge of the printer mechanism may touch the pivot frame. The left side must not touch the pivot frame.
Chapter 6 — Troubleshooting100 6822 Series 80-Column Printer User’s Manual6Hold the printer mechanism in place and tighten the screws in the sequence shown below.Four screws hold down the printer mechanism Troubleshooting System ComponentsThe printing system is composed of four basic components: printer, computer, power source, and communications. Any one of these components can prevent the printer from functioning properly.Verifying the Printer ComponentsPower Source VerificationStart by verifying that power is available at the printer. Visually inspect the control panel to verify that the power indicator (green LED) is lit. If it is not, press the Set Page button and note if the power indicator lights up. If it does, the power system is all right. If it does not, press the printer reset button. If the power indicator still does not light, check the power cable, by connecting it to a different printer. If the power indicator works on the new printer, then the cable is all right, and the printer that was originally connected is suspect. If it does not light, then the problem is most likely the cable or the power source. Depending on the results, either replace the cable or return the printer for service.3 Top left2 Bottomleft1 Top right4 Bottom right
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 101Printer VerificationIf the power indicator works properly and the printer still does not print, then printer errors are noted. If any indicators light when you press the Set Page button, or the printer beeps, refer to the Printer Failure Indicators table on page 102 to determine the problem.If none of the listed conditions are indicated by the beep codes and LEDs, yet the printer does not perform properly, then perform a printer self-test. Press and hold (for several seconds) both Form Feed and the Set Page buttons at the same time, until the printer beeps and all indicator lights come on. The lights change throughout the test, as it progresses.At the end of the self-test, the printer generates a report. This report verifies the following: errors detected during self-test, the error history, and the communication configuration. If the printer self-test report does not print, then reset the printer. If the report does print after resetting, then the printer is all right and the reason the printer does not respond to PC print requests is probably communications or PC related. If the report is partially completed, and a printer error occurs during the printing of self-test, refer to the Printer Failure Indicators table on page 102 for the cause of the printer failure.Perform a power-on-self-test (POST) to test for errors either by resetting the printer or powering it up. If errors occur, audible error codes, along with indicator light status, are produced during POST (see the POST Error Codes table on page 104).If the POST completes without error, try the printer self-test again. If the self-test prints correctly, but the printer does not respond to the PC, then the problem may be related to communications or PC problems.Communications / PC VerificationUse the self-test report to verify that the communications protocol options, selected at the printer, match those expected by the host. If they do not match the expected results, reconfigure the printer using the control panel configuration modes described below in the Configuration part of this chapter.
Chapter 6 — Troubleshooting102 6822 Series 80-Column Printer User’s ManualIf the protocol options match, then the communications cable may be defective. To determine if the cable is working, substitute a new cable. If the PC is suspect, substitute a different PC. A defective computer dock might be another possibility.Understanding Printer ErrorsPrinter Errors are divided into classes: •Runtime errors•POST errors,•Fatal errors (consisting of flash write errors and EEPROM block errors).Runtime ErrorsRuntime errors can occur during the course of printing. These errors are displayed on the LEDs, along with beep sequences. This causes the printer to stop printing and enter an error state. Then beep sequences are emitted, LED codes are displayed, the error status may be sent to the host (depending on the protocol), and the printer goes into suspend mode.The printer exits from the suspend mode when the user presses one of the keyboard keys or communications is resumed from the host. The printer also places the printhead in its home position and attempts to recover from the error condition. Until the error condition is corrected, the error procedure does not end, and the error state is not removed.For paper out errors, load paper and press the Set Page button before printing begins. Press the Form Feed button to load the paper to the top of form. The following table provides a listing of printer failure indicators and describes what they mean.Printer Failure Indicators Sets of Beeps Paper Out Head Jam Low Batt Meaning1 beep Off Off On 12 V under voltage fault (Low Battery)1 set of 2 beeps Off Off 2 blinks 12 V over voltage fault (Input Voltage too high)1 set of 3 beeps Off Off 3 blinks 24 V under voltage fault (internal power supply failure)
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 103Power-On-Self-Test (POST) ErrorsWhen you reset the printer, a POST runs to determine why the printer might be failing. Audible error codes, along with indicator light status, are produced during POST if an error occurs. See on POST Error Codes on page 104.To perform a POST1Open the printer case.2Insert the printer diagnostic cable into the phone jack on the printer and then connect the 9-pin D-Sub plug to your PC. The cable is used during POST to configure the printer, access printer diagnostics, update software, and install new fonts.1 set of 4 beeps Off Off 4 blinks 24 V over voltage fault (internal power supply failure)1 set of 13 beeps Off Off Off Configuration error2 sets of 2 beeps Off 2 blinks 2 blinks printhead over temperature2 sets of 3 beeps On Off Off Paper Out2 sets of 4 beeps Off On Off Head Jam5 sets of 2 beeps 5 blinks 5 blinks 5 blinks Paper feed current fault(Possible paper jam or feed motor failure)3 sets of 2 beeps 3 blinks Off 3 blinks printhead over current (printhead failure)3 sets of 4 beeps Off 3 blinks Off Home switch failure4 sets of 2 beeps 4 blinks 4 blinks Off printhead short (printhead failure)12 sets of 12 beeps Off Off Off Operating System software failurePrinter Failure Indicators (continued)Sets of Beeps Paper Out Head Jam Low Batt MeaningNote: The most common errors are Paper Out, Low Battery, and Head Jam. Status indicators on the front panel alert you to these errors. For a description see “Understanding the Status Indicators” on page 3
Chapter 6 — Troubleshooting104 6822 Series 80-Column Printer User’s Manual3Press the Reset button to start the POST. When the POST starts, green Power LED will come on followed by a single beep indicating that the printer is active.The printer emits beeps and flashes the LEDs to indicate the cause of any POST errors. POST error codes are described in the following table.Fatal ErrorsThere are two types of fatal errors, flash write errors and EEPROM configuration block errors. These errors are extremely rare, but measures are built into the printer diagnostics to track possible occurrences.Flash Write ErrorsErrors related to writing or erasing flash are critical errors. These errors cause the printer to stop all processing and produce an LED code and a sequence of beeps. The LED code indicates the address of the segment where the error occurred in octal notation. Note: After the test is completed, all LEDs turn off and the printhead moves to the home position. Only runtime errors or fatal errors are reported until the next time the printer is reset and POST is performed.POST Error CodesLong BeepShort BeepPaper OutHead JamLow Batt Power Meaning0 1 Off Off Off On Operational00Off Off Off Off No Power0 0 Off Off Off On Control program Initial Program Load (IPL) successful11Off On Off On Invalid CRC on boot block1 2 Off On On On Invalid CRC on control program or program not found14Off Off Off On Upper 192K RAM failure1 4 Off Off On On Upper 64K RAM failure00On Off Off On Diagnostic mode command check1 5 On Off On On Diagnostic flash memory check failed or is not initialized15On On Off On Diagnostic memory write failure0 0 OnOnOnOnControl program IPL
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 105The octal digit changes every four beeps until four octal digits are output. Only four octal digits are output since blocks are 256 bytes in size and flash can be addressed with a total of 0x7ff blocks. The segment address output is the runtime address of the flash block and not the offset of the block within flash.To obtain the block offset within the flash•Subtract 0x800 from the address output to determine the block offset.The printer suspends after the processing the error code. When the printer resumes, an error again and the printer suspends again. Reset the printer to correct the error. If a reset does not correct the error, have the printer checked by a qualified service technician.EEPROM Configuration Block ErrorsErrors related to an invalid configuration block (diagnostic block) produce 13 beeps, and then the printer suspends. It continues to produce this symptom until the configuration block error is corrected. Configuration block errors may be caused by a flash write error or an incorrect printer configuration. Reset the printer to correct the error. If a reset does not correct the error, have the printer checked by a qualified service technician.Self-Test Function DescriptionsThe self-test performs the following functions.Boot Block Program VerificationA CRC (Cyclic Redundancy Check) is performed on the boot block program. The calculated CRC is compared to the CRC embedded in the program module.Control Program VerificationA CRC is performed on the control program, which is loaded into writable flash program memory. The calculated CRC is compared to the CRC embedded in the program module. The results of this test are printed on the self-test report.Note: Flash write errors may be unrecoverable.
Chapter 6 — Troubleshooting106 6822 Series 80-Column Printer User’s ManualFont Module VerificationA CRC is performed on the font modules, which are loaded into writable flash font memory. The calculated CRC is compared to the CRC embedded in the program module. Results are printed on the self-test report.A2D CheckCurrent reading of the A2D sources are performed, and the results are printed on the self-test report.Nonvolatile Diagnostic Memory VerificationA CRC is performed on the area of the nonvolatile diagnostic memory that has a CRC over it. Results are printed on the self-test report.Nonvolatile Diagnostic Memory UpdateThe nonvolatile diagnostic memory is updated from the nonvolatile diagnostic memory data shadowed in memory.Detailed Printer Self-TestPerform a self-test to verify printer functions, and provide reporting of printer diagnostics. The self-test performs a series of internal diagnostics and prints the results. When the self-test begins, the beeper sounds for half a second and all LEDs turn on for half a second.Initiating Self-Test•While the printer is idle or in Suspend mode, press the Line Feed and Set Page buttons simultaneously to initiate a self-test.Terminating Self-Test•Press the Line Feed and Set Page buttons simultaneously to manually terminate a self-test.Self-Test ReportNote: This method is recommended to determine printer functionality.
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 107A self-test is equivalent to a warm start. Both are performed when you simultaneously press Form Feed and Set Page buttons on the control panel for a few seconds. Release the buttons when the printer beeps and all indicators are lit. If you press the buttons for too long, the self-test will not happen and the printer will form-feed one page.As the self-test progresses, the indicator lights change. Internal tests are performed and the two page report is printed. This report provides helpful information in diagnosing and troubleshooting printer problems. When you perform a self-test, the following actions occur:•All LEDs are turned on to verify the lights work•A 600 ms beep is emitted to verify the beeper works•LEDs flash individually to show progress during internal tests•Current voltage and ambient temperature are obtained•Validity of diagnostic block program is checked•Validity of boot block program is checked•Validity of control program is checked•Validity of loaded fonts is checked•LEDs turn off•Self-test report is printedPrinter capability is diagnosed by printing the report. Device errors are displayed on the LEDs and emitted by the beeper. The printer then does a warm reset (soft reboot) when an error is encountered or when the self-test report prints.Understanding the Self-Test ReportThe self-test report is divided into sections. Refer to page 110 and page 111 for a sample printout. All other values are informational only. Remember that these values are cleared after the self-test.• The printer model number is given on line 1 (first line). This identifies the printer type used, in this case the 6822.• The 8-digit serial number of the printer is listed on line 4 under the “Serial#” heading on line 3. The serial number is also on the inside of the printer. In portable printers, raise the printer mechanism to look for the number on the inside back wall.
Chapter 6 — Troubleshooting108 6822 Series 80-Column Printer User’s Manual•Battery Voltage, (line 13)Indicates the input voltage sampled at the beginning of the self-test. The input range must be between 7.5 and 15 V. The input voltage must be greater than 10.5 V to charge the internal battery. At 7.5 V or less, the Low Batt LED comes on and the printer enters Sleep mode. At 10.5 V or less, the Low Batt comes on but the printer still prints.•Auto Feed (line 16)Auto feed is a configurable item. Carriage Return (CR) means no auto linefeed. This is the most common setting for applications using NPCP CR+LF means a line feed will be added to each CR. This setting can produce double-spacing of reports. See “Setting the Autofeed” on page 29 •Interface Mode (line 17)Interface mode lists the interface protocol for the printer. The typical setting is NPCP. Others include DTR with no, odd, or even parity, and IrDA. See “Protocol Selection Mode” on page 29 •Bit Rate (line 18)Bit rate is commonly set to 19200 (19.2K) or 9600 bps. See “Selecting the Bit Rate” on page 29 •A2D History (lines 21 through 25)Shows the recorded history for voltage measurements and temperature measurements.•Head Jam History (lines 26 through 29)Provides information on head jams. If the printer is having frequent head jams, these lines can assist in determining the problem.Head Jam History Information Heading DescriptionHome Err indicates the home position LED sensor has failed.Command Indicates which printer command was executed when the head jammed.Direction Indicates which way the head was moving, left is toward the home position and right is away from the home position. Home position is at the extreme left, toward the green thumb wheel.Speed Indicates the acceleration speed of the printhead when the jam occurred.
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 109•Head Dot Pattern (line 37)Is used to verify the individual dot wires. There should be nine dots. If some dots are missing, it could be a printhead failure or a circuit board failure.•Error Log information appears on lines 38-43. This information is cleared after every self-test.Step The acceleration step at the jam. 0 means no steps were taken, 15 means all steps were taken. 1-14 indicates the printer jammed during acceleration or deceleration.Temp The ambient temperature at the last head jam. The temperature is listed in Celsius.Position Position of carriage at the time of the jam in 1/720 in = 12 * step position. Divide the number by 12 to get the step position. There are 512 steps across the page. If it is jammed at position 0, check the printer mechanism alignment. If it is jamming in the middle, it is more likely a dirty ribbon or obstruction in the printhead’s path.Head Jam History Information (continued)Heading DescriptionError Log Information Heading DescriptionPE Number of paper jams while feeding paperHJ Number of head jams while printhead is moving12Vu Number of 12 V under-voltage12Vo Number of 12 V over-voltage24Vu Number of 24 V under-voltage (head/motor voltage)24Vo Number of 24 V over-voltageHome Number of home detect errors (typically caused by paper scraps or circuit failures)Temp UnusedOverC Number of head over-current errors (typically caused by a bad printhead)HeadS Number of head driver short errors (typically caused by circuit failures)Fault Number of paper feed motor over current errors (excess current in paper feed motor could indicate circuit failure)
Chapter 6 — Troubleshooting110 6822 Series 80-Column Printer User’s ManualSample First Page of the Self-Test ----------------------------------------------------------------------------------------------------------------------------------------- 1NP6822 2 Copyright 1997, 1998, Intermec Technologies Corporation. All Rights Reserved. 3Serial# MFG Date Hardware Check Repairs Svc Date 412345678 yy/mm/dd ddd-ddd-ddd/dddd (TOP) GO/NG 00 yy/mm/dd 5 ddd-ddd-ddd/dddd (MLB) 6 ddd-ddd-ddd/dddd (PS) 7 ddd-ddd-ddd/dddd (IOB) 8Revisions:..........0000000000303100 9Bootblock: NPBB6822.MOD - Version XX.XX XXXX XXXX GO/NG10Control Program: npfl6822.mod - Version XX.XX XXXX XXXX GO/NG11Font Module: nftxxxxx.mod - Version XX.XX XXXX XXXX GO/NG12Font Module: nftxxxxx.mod - Version XX.XX XXXX XXXX GO/NG13Battery Voltage: 012.34 Low...../....High14Total Pages: 12345615Zero Font Style: O16Auto Feed: CR17Interface mode: NPCP18Bit Rate: 1920019Cold Starts: 0002420Warm Starts: 0005021A2D History22 Curr Low High Min Max Error Page Count2324v: 024.00 023.21 023.91 023.21 024.51 027.21 00401 000212412v: 012.55 010.91 013.51 010.90 014.50 8.71 00401 0002125Temp: 023 -020 055 -021 060 000 00401 0002126Head Jam History27Total Head Jams: 0018628Home Command Direction Speed Step Temp Position Page29 Print Left Const 010 -010 01440 1234530NPCP History31Disc Addr Parity IFTS Seq CRC Frame Bind IPLDU3212345 12345 12345 12345 12345 12345 12345 12345 1234533IRDA History34 FramesOk BroadCasts CRC/TMO DISCARD35rx 1234567890 1234567890 0123456789 000000000036tx 1234567890 1234567890 0123456789 000000000037HEAD DOT PATTERN38 Error Log39PE HJ 12Vu 12Vo 24Vu 24Vo Home Temp OverC HeadS Fault ADErr EEErr40Dlink Llink4112345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 123454212345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 12345 123454312345 12345 12345 12345 12345 12345 12345 12345 12345 12345ADErr Number of A2D conversion failuresEEErr Number of EEPROM write failures to diagnostic blockDlink Number of software memory errors (corruption in internal memory)Llink Number of software memory errorsError Log Information (continued)Heading DescriptionNote: Lines 15-18 are factory default printer settings. Take note of these lines when reading the self-test report.
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 111Sample Second Page of the Self-TestPage 2 of the self-test contains the print pattern used to diagnose printer mechanical behavior. The pattern continuously prints the ASCII characters between 33 and 126 decimal inclusive for the entire page, or until you cancel the print by pressing a button on the printer. An example of that rotating pattern is shown below.!”#$%’()*+,–./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_’abcdefghijklmnopqrstuvwxyz{|}~!”#$%’()*+,–./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_’abcdefghijklmnopqrstuvwxyz{|}~!”#$%’()*+,–./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_’abcdefghijklmnopqrstuvwxyz{|}~!”#$%’()*+,–./0123456789:;<=>?@ABCDEFGHIJKLSelf-Test Failure•For help, see “Miscellaneous Troubleshooting Tips” on page 111.•Check the power source (internal battery, charge cable, or ac adaptor) for a possible power failure.Miscellaneous Troubleshooting TipsThe following table lists actual printing problems, possible causes, and actions you should take to correct a problem.Possible Printer Problems Symptom Test or Cause SolutionPrinter does not communicate with the mobile computer. Bluetooth unable to connect.Incorrect protocol selection. Check lines 17 and 18 on the self-test report for correct bit rate and protocol selection. Change protocol settings through configuration process.Make sure you are in range (10 cm to 10 m) Make sure your device is configured to be discoverable and/or connectable. For help, see “Bluetooth Configuration Commands and Specifications” on page 133.Make sure the Bluetooth shutdown timer has not expired Double-spacing on application reports but single-spacing on self-test.Check line 16 on the self-test report. CR+LF indicates an incorrect configuration for NPCP.For help, see “Cleaning the Mask Spring” on page 22.Zero prints incorrectly (with or without slash). Check line 15 on the self–test report for the Zero Font Style setting.If incorrect, adjust the zero print option, see “Cleaning the Mask Spring” on page 22
Chapter 6 — Troubleshooting112 6822 Series 80-Column Printer User’s ManualDoes not print extended character set — missing font. Check line 11 or 12 on the self–test report to see if the NFT0000.MOD file is listed after Font Module.Use the 6820 Printer Tool Kit to reload the font file or send the printer in for hardware repair.Printer emits 1 or 2 beeps or blinking green light is the only indicator.Printer mechanism does not have adequate power for printing. The 12 V may be under or over voltage fault. (Note: Error lights do not flash if voltage is too high)Check battery or power supply.If battery, recharge or replace (see “Installing the Internal Battery” on page 10 If power supply, adjust supply voltage to 7.5 to 15 V. Check the printer’s internal battery, if installed. Check the vehicle charge cable (see 6822 Printer Installation Instructions P/N 931-052-001).Printer emits 2 sets of 3 beeps Printer out of paper Reload paper into printer mechanism. For help, see “Loading the Paper Tray” on page 13. Printer works but some or all LEDs do not work. Gray ribbon cable connecting control panel board to pivot frame assembly is loose.Call Customer Support (800-755-5505) or send printer for hardware repair.Printer does not print No voltage Voltage too high or low. Check line 13 on the self–test report, under the Battery Voltage headingNo data input Adjust supply voltage to 7.5-15 VTighten computer connections.No paper feed (paper jam or head jam)Te s t: Pull paper toward roller.Cause: If paper is resistant: Paper tray too full Torn paper perforationPaper wrinkled, creased, moist, or perforations missing White ribbon cables obstructing paper Head Jams due to carriage alignment. Check line 29 on self-test report, under Position heading, for value.Ensure fewer than 200 3-ply sheets in the deep paper tray and fewer than 50 3-ply sheets in the shallow paper tray.Remove torn paper, load and center new paper, readjust pinfeed holders.Possible Printer Problems (continued)Symptom Test or Cause Solution
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 113Replace the paper. Straighten the white ribbon cables. If “0,” realign mechanism in pivot tray. See “Aligning the Printer Mechanism” on page 98 No paper feed (paper jam or head jam) Move the printhead manually from side to side. Remove ribbon cartridge, move printhead. If smooth, ribbon is jammed.Remove ribbon cartridge, move printhead. If still resistant, mask spring is bent or damaged.Cause: printhead gap adjuster too tight.Cause: Paper scraps found in printer mechanism or around platen.Printer mechanism unlatched (unlocked). (portable, fixed mount printers)Remove ribbon cartridge and turn knob. If ribbon resists, replace ribbon cartridge (see “Installing the Ribbon Cartridge” on page 11 Replace the mask spring see “Cleaning the Mask Spring” on page 22Set the head gap adjuster to the fifth notch away from the paper see “Adjusting the Printhead Gap” on page 12If ribbon cartridge bumps against inside of printer, check white ribbon cable, home position sensor, and four screws. Remove any paper scraps, do a cleaning.Latch (lock) the printer mechanism into place.Perform a self-test.Possible Printer Problems (continued)Symptom Test or Cause SolutionNote: In paper jams or head jams, press the Set Page button to clear the printer before printing can resume.
Chapter 6 — Troubleshooting114 6822 Series 80-Column Printer User’s ManualCompatibility IssuesUse the following information to determine some compatibility issues that come up relative to the 6822:IUnderstanding Diagnostic InformationDiagnostic information is stored in flash to support the hardware configuration, both at time of manufacture and in the field. This includes recording the initial configuration changes to hardware and software, and various environmental statistics helpful in determining why failures are occurring in the field. The flash is provided for storage of critical data that must remain in the unit after power to the unit is lost. The data in the flash is used for diagnostic information for a catastrophic failure, or over the phone with a customer.Diagnostic information is updated and maintained by the printer. All diagnostic information is shadowed in RAM. At the end of every 50 forms, the flash information is updated from the RAM. The printer also updates the diagnostic information for nonrecoverable error, printer resets, printer self-test, and remote polling of diagnostic information. Fields are stored with ID first, then length, then data. The details of the data and the length of the entire field, including ID and Length bytes, are shown in the “Diagnostic Information” table on page 115.The amount of flash memory reserved for nonvolatile diagnostic memory is 16 K bytes. Printer self-test prints most of the information contained in the diagnostic memory for remote and end-user diagnostic access.Compatibility Issues and ConclusionsIssue ConclusionDoes a 6820 ribbon work on the 6822? Yes.Do 6820 applications work on the 6822? Yes. Applications that work on the 6820 also work on the 6822.Does the 6822 work with an application that downloads some custom characters to the printer?Yes. The downloadable character set feature is the same for both the 6820 and 6822.Can 6820 printers be replaced with 6822s? Yes. 6822s can be installed on existing 6820 mounting brackets.
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 115Diagnostic Information Field Id Length Description Stored asTota l Length01 4 Serial Number 7 digit BCD set at MFG 39 bytes3Date of Manufacture, yy/mm/dd 6 digit BCD set at MFG7777Hardware Configurationddd-ddd-ddd/ddd (top level P/N)ddd-ddd-ddd/ddd (control board)ddd-ddd-ddd/ddd (power supply)ddd-ddd-ddd/ddd (I/O board)52 digit BCD set at MFG2CRC of preceding fields 2 byte binary set at MFG08 8 Hardware Revisions: ECNs. applied. 64 ECNs can record separately by number 1-64. 8 byte bit field 11 bytes1Service Repairs: a two-digit field indicating number of times serviced 2 BCD digits3 Date of last repair, yy/mm/dd 6 BCD digits09 2 Cold starts since MFG or last repair binary digits 8 bytes2 Warm starts since last cold start binary digits2Pages printed over life binary digits10 2 Last high and low voltage extremes on 24 V input over last 50 reports. Extremes stored as 8-bit A2D conversions2 bytes 11 bytes2Voltage extreme history stores min/max 24 V A2D conversions over printer life 2 bytes1 24 V voltage error. Voltages greater than 10% considered errors. A2D error count 1 byte2Form number at last voltage error 2 bytes2 24 V error count 2 bytes20 2 Last high and low voltage extremes on 12 V input over last 50 reports. Extremes stored as 8-bit A2D conversions2 bytes 11 bytes2 Voltage extreme stores min/max 12 V A2D conversions over printer life 2 bytes112 V error. Voltages less than 10.5 V and greater than 14.5 V are considered errors. A2D value is recorded1 byte2 Page number at last 12 V error 2 bytes212 V error count 2 bytes30 2 Temperature, maximum and minimum over last 50 reports. Set A2D value 2 bytes 11 bytes
Chapter 6 — Troubleshooting116 6822 Series 80-Column Printer User’s Manual2Temperature, min/max over printer life. Set A2D value 2 bytes1 Temperature error. Last A2D conversion below -10 or above 60°C recorded 1 byte2Page number at last temperature error 2 bytes2 Total number of temperature errors 2 bytes40 2 Total number of head jams 2 bytes binary 11 bytes1 Command0 = Stop2 = Print4 = Print/LF6 = Seek8 = Slow Seek10 = Change Speed12 = Feed14 = WaitSpeed00 = Init01 = Low10 = HighDirection1 = Left0 = RightHome Switch0 = No Error1 = High Errorbits 0-3bits 4-5bit 6bit 71Acceleration or deceleration stop motor value when jam occurred 1 byte binary1 Ambient temperature when had jam occurred. Set A2D value 1 byte2Form number where head jam occurred 2 bytes binary2 Carriage position where head jam occurred 2 bytes binary in 1/720 in60 4 IrDA rxFramesOK – total frames received OK 4 bytes 46 bytesDiagnostic Information (continued)Field Id Length Description Stored asTota l Length
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 1174 IrDA rxFrameCrcErr – total frames received with CRC error 4 bytes4IrDA rxTotalBytes – total bytes received OK 4 bytes4 IrDA rxFramesDiscardBuf – total frames discarded due to no buffer space 4 bytes4IrDA rxBroadcastFrames – total broadcast frames received OK 4 bytes4 IrDA rxFramesDiscardHwErr – total received frames discarded due to hardware error4 bytes4IrDA txFramesOK – total frames transmitted OK 4 bytes4 IrDA txTotalBytes – total bytes transmitted OK 4 bytes4IrDA txBroadcastFrames – total broadcast frames transmitted OK 4 bytes4 IrDA txFramesNotTxTimeout – total frames not transmitted due to time out 4 bytes4IrDA txFramesNotTxHwErr – total frames not transmitted due to a hardware error 4 bytes70 2 Paper out count 2 bytes 74 bytes2Head jam count 2 bytes2 12 V low count 2 bytes212 V high count 2 bytes2 24 V low count 2 bytes224 V high count 2 bytes2 Home switch error count 2 bytes2Unused 2 bytes2 Over current error count 2 bytes2Head short error count 2 bytes2 Paper fault error count 2 bytes2A2D conv. error count 2 bytes2 EEPROM write error count 2 bytes2Double link error count 2 bytes2 Lost link error count 2 bytesDiagnostic Information (continued)Field Id Length Description Stored asTota l Length
Chapter 6 — Troubleshooting118 6822 Series 80-Column Printer User’s Manual2Out of buffers error count 2 bytes2 Unused 20 * 2 bytesDiagnostic Information (continued)Field Id Length Description Stored asTota l Length
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 119Communications Pin-Out ConfigurationsThis section shows common cable configurations between a mobile computer or a dock and the printer.15-Pin to 25-Pin Cable (P/N 216-605-1XX)Mobile ComputerSignal NameChassis GroundCharge InputSG (Signal Ground)DSR (Data Set Ready)DTR (Data Terminal Ready)CTS (Clear To Send)RTS (Ready To Send)RXD (Receive Data)TXD (Transmit Data)Dock_A/B_SWWall Mount Printer orRemote Mount Terminal Holder15-Pin DSUB Male15-Pin to 25-Pin Cable (P/N 216-605-1XX)25-Pin DSUB MaleSignal NameNC (No Connection)HHC_CHARGEGNDDTRNCRTSCTSTXDRXDTerm A/BPin #shell89726354NCPin #197620543212shield811591312514
Chapter 6 — Troubleshooting120 6822 Series 80-Column Printer User’s Manual25-Pin to 25-Pin Cable (P/N 216-771-XXX)PC* Signals are not available on the 6100 DockSignal NameDTR (Data Terminal Ready)*RC (Receive Carrier)TC (Transmit Carrier)DCD (Data Carrier Detect)SG (Signal Ground)DSR (Data Set Ready)*CTS (Clear to Send)RTS (Ready to Send)RXD (Receive Data)TXD (Transmit Data)Wall Mount Printer25-Pin DSUB Female25-Pin to 25-Pin Cable (P/N 216-771-XXX)25-Pin DSUB MaleSignal NameNC (No Connection)NCNCNCGNDDTRRTSCTSTXDRXDPin #2017158765432Pin #201715876543213125141312514
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 1219-Pin to 15-Pin Cable (P/N 226-016-XXX)PCSignal NameTXD (Transmit Data)RXD (Receive Data)RTS (Ready to Send)CTS (Clear to Send)DSR (Data Set Ready)SG (Signal Ground)Chassis GroundPrinter9-Pin DSUB Female9-Pin to 15-Pin Cable (P/N 226-016-XXX)15-Pin DSUB FemaleSignal NameRCTTXDCTSRTSDTR (Data Terminal Ready)GNDChassis GroundTerminal Charge out to computerPin #327865shellPin #453679shell81569shield18915
Chapter 6 — Troubleshooting122 6822 Series 80-Column Printer User’s Manual25-Pin to 15-Pin Cable (P/N 226-162-XXX)Dock* Signal is not available on the 6100 DockSignal NameTXD (Transmit Data)DTR (Data Terminal Ready)RTS (Ready to Send)RXD (Receive Data)CTS (Clear to Send)DSR (Data Set Ready)*SG (Signal Ground)Printer w/6210 Terminal Holder15-Pin DSUB FemaleSignal NameRXDNC (No Connection)CTSTXDRTSDTRGNDPin #22043567 openPin #4235679 shellshield1891525-Pin DSUB Male25-Pin to 15-Pin Cable (P/N 226-162-XXX)1312514
Chapter 6 — Troubleshooting6822 Series 80-Column Printer User’s Manual 123Data Communications Cable (P/N 226-270-XXX)The printer has a 25-pin connector with the following pinout designations and signal mnemonics:PC PrinterRJ-11 JackPin #75328Pin #653219-Pin DSUB MaleData Communications Cable (P/N 226-270-XXX)519616Printer Communications Connector 15-Pin D–Sub25–Pin D–Sub Signal Name Type I/O Description1 NC NC – – – – – – NC (No Connection)2 20 DSR (Data Set Ready) RS-232 IN Printer’s DSR3 4 CTS (Clear To Send) RS-232 IN Wake up4 2 RXD (Receive Data) RS-232 IN Printer’s RxD5 3 TXD (Transmit Data) RS-232 OUT Printer’s TxD6 5 RTS (Ready To Send) RS-232 OUT Printer’s RTS
Chapter 6 — Troubleshooting124 6822 Series 80-Column Printer User’s Manual7 6 DTR (Data Terminal Ready) RS-232 OUT Printer’s DTR8 9 HHC_CHARGE POWER OUT 11-13 V, 2 A maximum9 7 GND POWER SG (Signal Ground)Printer Communications Connector (continued)15-Pin D–Sub25–Pin D–Sub Signal Name Type I/O Description
6822 Series 80-Column Printer User’s Manual 125ASpecificationsThis appendix provides physical specifications for the 6822 printer models as well as specifications for the media used with the printers.
Appendix A — Specifications126 6822 Series 80-Column Printer User’s ManualSpecificationsPrint Speed230 cpsWeightFixed Mount Printers6.55 kg (14.41 lbs)Portable Printersw/ 4000 or 61XX terminal holder5.80 kg (12.75 lbs)w/ 62XX, 600 series, 700 series, or CK60 holder5.67 kg (12.25 lbs)Mounting plate1.93 kg (4.25 lbs)Flat paper tray2.45 kg (5.40 lbs)Compact paper tray2.05 kg (4.50 lbs)TemperatureDC Operating -20°C to 60°C (-4°F to 140°F)AC Operating -20°C to 45°C (-4°F to 113°F)Storage -30°C to 70°C (-22°F to 158°F)HumidityOperating10 to 85% noncondensingStorage5 to 95% noncondensingAltitudeOperating–100 to 5000 mStorage15,000 mElectricalVoltage13.8 VDC (nominal)Current10 mA (idle, sleep mode not charging batteries);3.5 A (average while printing);450 mA (charging internal battery);Up to 1.5 A (charging computer battery)Vibration12 g RMS for 4 hoursNote: Various print fonts do affect the print speed.
Appendix A — Specifications6822 Series 80-Column Printer User’s Manual 127ESD15 kV noncontact and 8 kV contactBattery Shelf Life1 year at 25°C (77° F)2.3 Ah12 V sealed lead-acid)Printer DimensionsListed below are the dimensions of the fixed mount and portable printers.Fixed Mount PrinterThe base of the fixed mount printer is 32.5 cm (12.75 in) wide by 35.5 cm (14.0 in) front to back. The upper portion varies according to the configurations shown in the following table.Note: The battery goes dead within two weeks when connected to the printer and with no external charge source.Note: A printer and a computer, using the supplied serial cable, can operate up to 9 m (30 ft) apart.Fixed Mount Printer DimensionsConfiguration(with deep paper tray) Width Length Depthwith 61XX Holder Side Mount 51.4 cm (20.25 in) 36.8 cm (14.5 in) 19.1 cm (7.5 in)with 4000 Series, 62XX, 600 Series, 700 Series, or CK60 Holder Side Mount 47.0 cm (18.5 in) 36.8 cm (14.5 in) 20.3 cm (8.0 in)with 61XX Holder Top Mount 42.5 cm (16.75 in) 42.6 cm (16.75 in) 19.1 cm (7.5 in)with 4000 Series, 62XX, 600 Series, 700 Series, or CK60 Holder Top Mount 38.1 cm (15.0 in) 42.6 cm (16.75 in) 20.3 cm (8.0 in)
Appendix A — Specifications128 6822 Series 80-Column Printer User’s ManualPortable PrinterThe portable printer may come with a handle, an AC foot, or with a terminal holder top mount.Media SpecificationsThe printer works with 1-3 ply carbonless paper that is single-edge glued and designed for sprocket feed. Standard paper size is 8.5 x 11 in or 241 x 305 mm international (8.5 x 12 in). Use 3-ply forms up to a maximum of 0.23 mm (0.009 in) thick. A soft, flexible, rubber type cement applied to one perforation strip only is preferred. The paper should wrap around a 1 1/4 in diameter roll without curl or wrinkle.Portable Printer DimensionsConfiguration Width Length Depthwith handle, 61XX Holder Top Mount, and Deep Paper Tray 41.9 cm (16.5 in) 42.6 cm (16.8 in) 20.3 cm (8.0 in)with handle, 61XX Holder Top Mount, Shallow Paper Tray 42.5 cm (16.8 in) 42.6 cm (16.8 in) 19.1 cm (7.5 in)with handle, 4000 Series, 62XX, 600 Series, 700 Series, or CK60 Holder Top Mount, and Deep Paper Tray 38.1 cm (15.0 in) 42.6 cm (16.8 in) 20.3 cm (8.0 in)with handle, 4000 Series, 62XX, 600 Series, or 700 Series, or CK60 Holder Top Mount or Fill Plate, and Shallow Paper Tray41.9 cm (16.5 in) 38.1 cm (15.0 in) 13.0 cm (5.1 in)Note: The AC foot adds 6.35 cm (2.5 in) to the length of the printer.Using paper that matches the following specifications ensures optimum 6822 performance. Variation from these specifications, use of aged paper, or use of paper exposed to elements such as dirt or humidity may cause printing problems.
Appendix A — Specifications6822 Series 80-Column Printer User’s Manual 129Material BreakdownThe following tables show the material broken down per ply:14# CBF (Carbonless Back and Front) Target Under OverBasis Weight 14 lb 13.3 lb 14.7 lbCaliper 2.9 2.6 3.2Moisture 5.0 4.0 6.0Smoothness (RS) 165 110 230Smoothness (CB) 270 220 320Brightness (Wht) 88 86 90Colors available: White, Canary, Pink, Goldenrod, Blue, Green15# CF (Carbonless Front) Target Under OverBasis Weight 15 lb 14.43 lb 15.8 lbCaliper 3.0 2.5 3.2Moisture 5.0 4.0 6.0Smoothness (RS) 140 100 180Smoothness (CB) 140 100 180Brightness (Wht) 85 84 86Colors available: White, Canary, Pink, Goldenrod, Blue, Green16# CB (Carbonless Back)Target Under OverBasis Weight 16 lb 15.2 lb 16.8 lbCaliper 3.3 2.8 3.8Moisture 5.7 4.2 6.7Smoothness (RS) 180 120 270Smoothness (CB) 270 220 320Brightness (Wht) 86 84 88Opacity (Wht) 81 78.5 82Colors available: White, Canary, Pink, Goldenrod, Blue, Green
Appendix A — Specifications130 6822 Series 80-Column Printer User’s ManualCaliper BreakdownThe following table shows the caliper of forms broken down by ply:20# OCR Laser BondTarget Under OverBasis Weight 20 lb 15.2 lb 16.8 lbCaliper 4.0 3.8 4.2Moisture 3.8 4.7 5.0Smoothness 140 100 170Brightness (Wht) 94 82 N/AOpacity (Wht) 85 84 N/ACaliper BreakdownTarget Maximum1-Ply (20 lb) 4.0 4.22-Ply (15 lb and 16 lb) 6.3 7.03-Ply (14 lb, 15 lb, and 16 lb) 9.2 10.2
Appendix A — Specifications6822 Series 80-Column Printer User’s Manual 131Understanding the Fanfold Paper Page LayoutThe following illustration shows the printable area of the lower section of a page of fanfold paper and the upper section of the next page. The Assured Print Area is the best area to use for printing.Printable Area of Fanfold PageYou should leave a 1 in margin at both the top and the bottom of the page. This provides for a margin of six lines at 1/6 in line spacing. Even though printing in Area 1 (before or after the perforation) may be possible, you should keep in mind that paper feed precision is reliable only within the Assured Print Area. Page widthPaper End Detection PositionAssured Print Area55 lines max(at 1/16” line spacing)PerforationAbcdef... ...XyzAbcdef... ...XyzAssured Print Area8 inches Max.(area 2)0.75 inch(or more)(area 2)0.75 inch(or more)(area 1)1 inch1 inch (area 1)(area 3)1.833 inches(11 lines)
Appendix A — Specifications132 6822 Series 80-Column Printer User’s Manual•The top and bottom margins are represented by Area 1, as shown in the previous illustration. The top margin is defined as the distance between the top edge of the paper and the first row of printed characters. The bottom margin is defined as the distance between the last row of printed characters and the bottom edge of the paper.•There is a possibility that printing can start within one line below the perforation and printing could continue beyond the Assured Print Area, however paper feed precision is only reliable with top and bottom margins of approximately one inch. Basically, you should consider there are only 55 lines available for reliable printing.•The left and right margins are represented by Area 2. For reliable printing, use a margin of at least 0.75 in for the left and right margins.The Paper End Detection line indicates the point where the Paper Out sensor detects the bottom edge of the paper.Area 3 represents the distance between the Paper End Detection position and the bottom edge of the page.Once the last page of the fanfold paper stack is in the printer, and the printhead has advanced past this Paper End Detection line, printing is no longer reliable.When the bottom end of the last page has advanced through the printer, past the spring plate along the front of the platen, the paper should not reverse back through the printer, because the printer could jam and cause paper feed problems.

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