Printronix P6000 series, P6040, P6080 Maintenance Manual

R

Maintenance Manual

Volume 1 of 2

P6000 Series Pedestal Model

P6000 Series Pedestal Model

Maintenance Manual, Vol. 1

P/N 108692–001, Rev B

olume 1 of 2

V

R

US and CANADA Radio Interference Note

Note: This device complies with Part 15 of the FCC Rules. Operation is subject to the following two

conditions: (1) this device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.

Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits.
The manufacturer is not responsible for any radio or television interference caused by using other than
recommended cables and connectors or by unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user’s authority to operate the equipment.

The input/output (I/O) cable must be shielded for the printer to comply with FCC rules and regulations Part
15 governing the radiation limits for Class “A” equipment.

This Class A digital apparatus meets all requirements of the Canadian Interference–Causing Equipment
Regulations.

Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouilleur
du Canada.

WARNING

This is a Class A product. In a domestic environment this product may cause radio interference in which
case the user may be required to take adequate measures.

Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not
limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not
be held responsible for errors contained herein or any omissions from this material or for any damages,
whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution,
performance or use of this material. The information in this manual is subject to change without notice.

This document contains proprietary information protected by copyright. No part of this document may be
reproduced, copied, translated or incorporated in any other material in any form or by any means, whether
manual, graphic, electronic, mechanical or otherwise, without the prior written consent of Printronix, Inc.

All rights reserved. Revision B. January 1996.

Trademark Acknowledgements

IBM is a registered trademark of International Business Machines Corporation.
Printronix is a registered trademark of Printronix, Inc.



17500 Cartwright Road, P.O. Box 19559

Irvine, California 92713

Telephone [phone] FAX [phone]

Technical Support (714) 221–2686

COPYRIGHT  1986, 1996 PRINTRONIX, INC.

Table of Contents

VOLUME 1

Paragraph ăăăăăTitle Page

CHAPTER 1. MAINTENANCE O

1-1 Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 P

1-3 Specifications 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4 Operation 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 Scope 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 Purpose 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3

2-4 General 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5
2-6 L
2-7
2-8
2-9 P
2-10
2-11 P
2-12
2-13

rinter Description

CHAPTER 2. PRINCIPLES OF OPER

Section I. GENER

Matrix P

Control P

ogic C3 PCBA
Hammer Driver PCBA
Hammer Bank and Shuttle Mechanism/MPU

ower Supply

Ribbon Drive

aper F
Platen Open/P
Safety Circuits, P6080 Only

rinting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section II. PRINTER FUNCTION ELEMENTS

anel 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

eed Control Circuits

aper Out Switches

AL DESCRIPTION

VERVIEW

ATION

1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-44. . . . . . . . . . . . . . . . . . . . . . . . .

2-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section III. OPER

2-14

3-1 General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 P

3-3 Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 Cleaning 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5 Lubrication 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 Common Causes Of Malfunctions 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 Testing 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4 F
4-5 P

Normal Operation

CHAPTER 3. PREVENTIVE MAINTENANCE

reventive Maintenance Checks And Service

CHAPTER 4. TROUBLESHOOTING

ault Isolation

erformance T

ests 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATION

2-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. . . . . . . . . . . . . . . . . . . . . . . . .

4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iP6040/P6080 Maintenance

Table of Contents

Paragraph ăăăăăTitle Page

CHAPTER 5. CORRECTIVE MAINTENANCE

Section I. GENER

5-1 Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 Tools, T

5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12 A
5-13
5-14 P
5-15 P
5-16 P

Ribbon Height A
Ribbon T
Shuttle Spring F
Setting Shuttle and Counterweight P
Hammer Spring R
Hammer T
Platen Gap
Magnetic P
Magnetic P

Shuttle Belt

est Equipment, and Supplies

Section II. ALIGNMENTS AND ADJUSTMENTS

djustment 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

racking Check And A

orce A

djustment 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

etensioning 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ip Alignment

ickup Gap 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ickup Phasing A

dapting Shuttle Motor to Line F

aper F

eed Belt
aper Motion Sensor
aper Out Detectors

Section III. REPLACEMENT

djustment 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

djustment 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

requency 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . .

AL

reload 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-17 P
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
5-26
5-27
5-28
5-29
5-30
5-31
5-32 P
5-33 P
5-34 P

5-35 Tractor 5-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-36 P
5-37 P

rinter Cover

Control P
Ribbon Drive
Ribbon Control PCBA
Ribbon Drive Motor
Ribbon Drive Blower
Shuttle Assembly
Hammer Spring
Hammer Coil
Counterweight Assembly
Flywheel Assembly
Cam W
Magnetic P
Shuttle Motor
Shuttle Belt

aper Ironer
aper F
aper F

aper Motion Sensor
aper Out Mechanical Switch

anel 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ick 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ickup 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

eed Belt

eed Motor

5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P6040/P6080 Maintenanceii

5-38 P
5-39

aper Out Optical Sensor

Platen Open Switch

5-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

Paragraph ăăăăăTitle Page

5-40 DC P
5-41 P
5-42 P
5-43 R
5-44 L
5-45
5-46

ower Supply F
ower Supply PCBA
ower Supply

ear F

an 5-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ogic PCBA
Hammer Driver PCBA
Hammer Bank Cable Harness

use 5-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VOLUME 2

APPENDICES

APPENDIX A. MNEMONIC TERMS A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX B. ELECTRONIC DRAWINGS B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX C. MECHANICAL DRAWINGS AND PARTS LISTS

INDEX I-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C-1. . . . . . . . . . . . . . .

List of Tables

Table ăăăăăăTitle Page

1-1
1-2

External Controls and Indicators
Internal Controls and Indicators

1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1
2-2 P
2-3 F
2-4 F
2-5
2-6
2-7 F
2-8 L
2-9 Logic C3 I/O A
2-10 L
2-11 L
2-12 L

3-1 P
3-2

4-1
4-2
4-3

5-1 Tools, T

Host Interface Connector P

ower Supply Connector P
ront P

anel Connector P

our Phase Stepper Connector P
Microprocessor Bus Expansion Connector P
DMA P

Physical Inspection

Malfunction Symptom Index
Supplemental T
Malfunction Symptom Index

arallel I/O Setup Parameters 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ront P

anel and F

ogic C3 Memory Map

ogic C3 Interrupt V
ogic C3 Unused Interrupt V
ogic C3 Hardware Jumpers

reventive Maintenance Checks and Service

est Equipment, and Supplies

in Assignments

in Assignments

in Assignments

in Assignments

in Assignment

ault Status Assignments

ddress Map

ectors

ectors 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ests 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18. . . . . . . . . . . . . . . . . . . . . . . . . . .

2-19. . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20. . . . . . . . . . . . . . . . . . . . . .

2-21. . . . . . . . . . . . .

2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. . . . . . . . . . . . . . . . . . . . . . . . .

3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iiiP6040/P6080 Maintenance

List of Illustrations

Figure ăăăăăTitle Page

1-1 P
1-2
1-3

2-1
2-2 T
2-3
2-4 P
2-5
2-6. P
2-7
2-8
2-9 P
2-10
2-11
2-12
2-13 L
2-14 L
2-15
2-16
2-17
2-18
2-19
2-20 P
2-21 P

2-22 +36 V and +70 V Supplies, P6080 2-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-23 R

2-24 +5 V and MOS Supplies, P6080 2-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-25 R
2-26
2-27
2-28
2-29
2-30 P
2-31 P
2-32
2-33 P
2-34
2-35

rinter with P
External Controls and Indicators
Internal Controls and Indicators

Defining the Dot Matrix

ypical Characters
Elongated Characters

ositioning and R
Hammer and Shuttle Arrangement (T

rint Hammer A
Standard Character F
Character F

rinter F
System Block Diagram
Control P
Control P

ogic C3 PCBA

ogic C3 PCBA Block Diagram
Hammer Driver PCBA
Hammer Driver Block Diagram
Hammer Driver Circuit T
Dot R

ow T

Operation of MPU Circuit

ower Supply
ower Supply Assembly, P6080

eference V

elay Switching Details, P6080
Motor R
Ribbon Drive Block Diagram
Ribbon Drive
Ribbon Control PCBA Simplified Schematic

aper F
aper F

Platen Open Switch

aper Out Switch
Safety Circuits
Operation Flow Diagram

edestal 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

elease of Odd and Even Hammers

ypical) 2-5. . . . . . . . . . . . . . . . . . . . . . . . .

ction 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ormation 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ormation by One Hammer

unctional Elements

anel 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

anel Block Diagram

iming 2-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iming vs T

oltage Circuit, P6080

elay T

eed Control Circuits Block Diagram
eed Components

iming Disk and Cam P

rigger Circuit, P6080

osition 2-45. . . . . . . . . . . . . . . . . . . .

1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. . . . . . . . . . . . . . . . . . .

2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-61. . . . . . . . . . . . . . . . . . . . . . . . .

2-62. . . . . . . . . . . . . . . . . . . . . . . . . .

2-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1
3-2
3-3
3-4
3-5
3-6

Cleaning Interior of Cabinet
Cleaning Hammer Bank Assembly-Ribbon Drive to Service P
Cleaning Hammer Bank Assembly-Hammer Bank to Service P
Lubrication, Counterweight and Cam W
Lubrication, Self-Aligning Cam F
Lubrication, Antirotation Arm, P6040 Only

ick 3-10. . . . . . . . . . . . . . . . . . . . . . . . . .

ollowers, P6080 Only

P6040/P6080 Maintenanceiv

3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

osition 3-6. . . .

osition 3-7. . .

3-11. . . . . . . . . . . . . . . .

3-13. . . . . . . . . . . . . . . . . . . . . . . . . .

List of Illustrations

Figure ăăăăăTitle Page

4-1
4-2
4-3
4-4
4-5
4-6

4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19 P
4-20 P
4-21
4-22
4-23 V
4-24 V
4-25 V
4-26 V
4-27
4-28
4-29 P
4-30 P
4-31 Top-of-F
4-32
4-33
4-34
4-35 R
4-36 Underline/V

Confidence Check
New P

rinter Does Not Operate
POWER Indicator Not Illuminated
Error Indication on Display Stays On
Online Not Indicated on Display
Shuttle Does Not A
is P

ressed 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Does Not A
Ribbon F
Ribbon Not F
End of Ribbon Not Detected
Not P
Missing Characters
Missing Characters, Example of
Missing Dots
Missing Dots, Example of
Light and/or Smeared Characters
Light and/or Smeared Characters, Example of
Misplaced Dots

rint T

rint T
Horizontal Misalignment
Horizontal Misalignment, Example of

ertical Misalignment
ertically Misaligned Character P
ertically Deformed Characters, Example of

ertical Compression of P
Garbled L
No P

aper F
aper Drags

Shift R
Plot P
MPU Phasing T

ow Increment T

olds Over 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rinting 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oo Light or Dark

oo Light or Dark, Example of 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

etters and/or Incorrect F

aper F

eeds Erratically

ecycle T

attern T

ccelerate to Speed When ON LINE Switch

dvance 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

eeding Smoothly

osition, Example of

rint 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ont 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

eed 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

orm Does Not Operate

est - Sliding P

est 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

est - All H's

est - Uppercase Characters

ertical Hammer Alignment T

attern 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

est 4-76. . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-39. . . . . . . . . . . . . . . . . . . . . . . .

4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-53. . . . . . . . . . . . . . . . . .

4-54. . . . . . . . . . . . . . . . . . . . . . . . .

4-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-75. . . . . . . . . . . . . . . . . . . . . . . .

5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9

Ribbon Height A
Ribbon T
Shuttle Spring F
Setting Shuttle and Counterweight P
Hammer Spring R
Hammer T
Platen Gap A
Magnetic P
Shuttle Belt T

racking Check and A

ip Alignment

ickup Gap and Phasing A

djustment 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

djustment 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

orce A

djustment 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

reload 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . .

etensioning 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

djustment 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

djustment 5-16. . . . . . . . . . . . . . . . . . . . . . .

ension Check and A

djustment 5-19. . . . . . . . . . . . . . . . . . . . . . . . . .

5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vP6040/P6080 Maintenance

List of Illustrations

Figure ăăăăăTitle Page

aper F

5-10 P
5-11 P
5-12 P

5-13 Cover Removal/Installation 5-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
5-26
5-27
5-28 P
5-29 P
5-30 P
5-31 T
5-32 P
5-33 P
5-34 P
5-35
5-36 DC P
5-37 P
5-38 P
5-39 R
5-40 L
5-41
5-42

Control P
Ribbon Drive R
Ribbon Control PCBA R
Ribbon Drive Motor R
Ribbon Drive Blower R
Shuttle Assembly R
Hammer Spring R
Hammer Coil R
Counterweight Assembly R
Flywheel Assembly R
Cam W
Magnetic P
Shuttle Motor R
Shuttle Belt R

Platen Open Switch R

Hammer Driver PCBA R
Hammer Bank Cable Harness R

eed Belt T
aper Motion Sensor Check and A
aper Out Detector A

anel R

ick R

aper Ironer R
aper F

eed Belt R
aper F

eed Motor R
ractor R
aper Motion Sensor R
aper Out Mechanical Switch R
aper Out Optical Sensor R

ower Supply PCBA R
ower Supply R

ear F

ogic PCBA R

emoval/Installation 5-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ower Supply F

an R

ension Check and A

djustment 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-31. . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-34. . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-47. . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ickup R

emoval/Installation 5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-66. . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-70. . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

uses R

emoval/Installation 5-73. . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-81. . . . . . . . . . . . . . . . . . . . . . . . .

djustment 5-20. . . . . . . . . . . . . . . . . . . . . .

djustment 5-22. . . . . . . . . . . . . . . . . . . . . . . . .

emoval/Installation 5-68. . . . . . . . . . . . . . . . . . .

emoval/Installation 5-83. . . . . . . . . . . . . . . . . . .

P6040/P6080 Maintenancevi

ABOUT THIS MANUAL

This

manual has been organized and written to make it easy to use. The following information will

help

you use this P6040/P6080 Maintenance Manual.

What This Manual Contains

This

manual contains the following information. Consult your table of contents to locate this infor

mation.

Ć

Introduction -

P

rovides brief printer description.

Principles of Operation - Describes functional operation of printer through the use of

block

diagrams and associated text.

Preventive

operation.

Troubleshooting

common

Maintenance

- Presents fault isolation procedures required to determine the source

malfunctions.

-

Lists

detailed procedures required to maintain normal printer

of

Corrective Maintenance - Presents procedures for printer adjustment and alignment

and

replacement of faulty hardware.

Mnemonic Terms -

Lists and defines mnemonics.

Electronic Drawings - Electronic drawings and schematics required for field mainteĆ

nance

are included here.

Mechanical Drawings -

Mechanical drawings and parts lists are included here.

Controls and Indicators

Throughout this manual controls and indicators are printed in text exactly as they appear on the
printer, with all capital letters. Controls and indicators that do not have labeled names are given
functional names that are printed with the first letter of each word capitalized. For example, the
POWER switch has two settings, ON and OFF. The Forms Thickness Adjustment Lever is operĆ

by raising and lowering.

ated

Warnings, Cautions, and Notes

In this manual, extra information is given under the headings WARNING, CAUTION, AND
NOTE.
information about conditions that could lead to injury. Cautions provide information about condi
tions that could lead to equipment damage. Both warnings and cautions are printed in bold type.
Notes

They are set off from the text around

provide extra information and are printed in

What This Manual Does Not Contain

Detailed,
in

the maintenance manual.

specific information which appears in the User's R

them and appear in special typefaces. W

italics.

eference Manual will not be repeated

arnings give

Ć

viiP6040/P6080 Maintenance

P6040/P6080 Maintenanceviii

CHAPTER 1

MAINTENANCE OVERVIEW

1-1. Introduction

This manual contains information required to maintain and repair the Printronix P6040 and
P6080 Printers (hereafter referred to as P6000 Series or simply, the printer). Print speed is the

difference between printers.

basic

The following documents provide detailed information which supplements this manual:

a. P6000 Series Multifunction Line Printer Pedestal Models Operator's Guide, P/N

108525-001

b. P6000

108534-001 - Describes functions and applications available for the printer.

- Contains instructions for unpacking, installing, and operating the printer.

Series Multifunction Line P

rinter P

edestal Models User's R

eference Manual, P/N

1-2. Printer Description (Figure 1-1)

a. General

The Printronix P6000 Series P
addition to basic functions, the P6000 Series can produce correspondence quality print for near
letter quality (NLQ) printing requirements, draft print for higher speed, and character attributes
(dynamic

character generation) for wider application compatibility.

rinter is a highly reliable, multi-function dot matrix line printer. In

b. Standard Features

1. Quiet

2.

3.

4.

5.

6.

7. R

8. 5 Built-in Self-T

Operation

P-Series or Serial Matrix P

Plot and Bit Image Graphics

Dynamic Character Generation

-Selectable P

-Elongated Print

-Expanded P
utomatic Underline

-A

-Bold Character P

-Superscript P

-Subscript P

Selectable F

Electronic V

-14 Channel Electronic V

-12 Channel Direct A

esident International Character Sets

itch

rint

rint

rinting

rinting

orms L

ength

ertical F

ormatting

ests and Diagnostics

rotocols

ertical F

ccess V

ertical F

ormat Unit (EVFU)

ormat Unit (D

AVFU)

1-1P6040/P6080 Maintenance Overview

1-2. Printer Description-continued

b. Standard Features-continued

9. Configuration Printout

10.

Datastream Hex Code P

11. R

esident Serial and P

c. Optional Features. tbd

rintout

arallel Interfaces

P6040/P6080 Maintenance Overview1-2

Figure 1-1. P

rinter with P

edestal

1-3P6040/P6080 Maintenance Overview

1-3. Specifications

For

a detailed list of printer specifications refer to the User's R

eference Manual, P/N

108534-001.

1-4. Operation

a. Operating Procedures

For

detailed operating procedures, refer to Operator's Guide, P/N 108525-001.

b. Controls and Indicators

a. External Controls and Indicators. External controls and indicators are illustrated in

1-2 and described in T

Figure

b. Internal Controls and Indicators. Internal controls and indicators are illustrated in

1-3 and described in T

Figure

Table 1-1. External Controls and Indicators

able 1-1.

able 1-2.

KEY

(FIG 1-2)

1

2

3

4

5

6

7

8

9

10

CONTROL OR

INDICATOR

ON/POWER/OFF
1 0

POWER

ON LINE

TOP OF FORM

Display

SET
TOF

PRINT MODE

CONFIG
VA LU E

CLEAR
FAULT

RUN/STOP

TEST

FUNCTION

Sets AC power on or off.

Indicates power is applied to printer.

Places printer online or offline.

Advances paper one form length to top of next
form.

Displays printer status and error messages.

Establishes TOF (top of form) position.

Selects and displays current print mode.

Selects and displays individual parameters with­in configuration menu.

When configuration values are displayed, this
switch selects and displays the next config­uration menu. When fault message is dis­played, resets printer after fault is corrected.

Executes one of three basic functions:

1. Saves newly selected parameters or loads

default parameters.

2. Runs or stops configuration and self-tests.

3. Runs or stops hex dump.

continued

P6040/P6080 Maintenance Overview1-4

Table 1-1. External Controls and Indicators

-continued

KEY

(FIG 1-2)

11

12

13

14

CONTROL OR

INDICATOR

CONFIG

MENU

LINE

SPACING

FORMS

LENGTH

PAPER

ADVANCE

FUNCTION

Cycles through configuration menus.

Selects and causes display of current line spacing
in lines per inch.

Selects and causes display of current forms length

Advances paper one line when pressed momentarily
or continuously as long as it is pressed.

Figure 1-2. External Controls and Indicators

1-5P6040/P6080 Maintenance Overview

Table 1-2. Internal Controls and Indicators

KEY

(FIG 1-3)

1

2

3

4

5

6

7

CONTROL OR

INDICATOR

Forms Thickness
Adjustment Lever

Forms Thickness
Scale and Pointer

Tractors

Tractor Locks

Horizontal

Adjustment

Knob

Vertical Position

Knob

Vertical Position

Disk

FUNCTION

Sets platen for different thickness forms or paper.
Opened (raised) fully for loading paper.

Indicates relative thickness of forms or paper.

Used to set left margin and paper width. Left
tractor moves about one inch. Right tractor moves
full range.

Lock tractors in position.

Allows fine positioning of left print margin. Moves
paper slightly to left or right.

Sets top of form or first line to be printed. Rotate
to move paper vertically.

Provides reference for setting top of form or first
line to be printed.

P6040/P6080 Maintenance Overview1-6

Figure 1-3. Internal Controls and Indicators

1-7P6040/P6080 Maintenance Overview

P6040/P6080 Maintenance Overview1-8

CHAPTER 2

PRINCIPLES OF OPERATION

Section I. General Description

2-1. Scope

This

chapter presents the principles of operation for the P6000 Series printer. This information is
intended
specific

to provide the technician with a basic understanding of printer functional operation. F

circuits, see Appendix B. Mnemonics are defined in Appendix A.

or

2-2. Purpose

The P6000 Series printer is a computer output device. It receives data from a host computer and
provides

hard copy text or graphics. The hard copy is composed of an array of dots. In the case of

text, these dots are arranged in a matrix to produce characters.

2-3. Matrix Printing

a. The Dot Matrix

In

order to generate characters from dots, the dots must be arranged properly. The imaginary grid

on

which the dots are positioned is referred to as the matrix.

In normal six line per inch spacing there are 12 dot rows from the
top

of the next (Figures 2-1 and 2-2). Spacing of eight lines per inch has nine dot rows per charac

line, nine lines per inch has

ter

eight dot rows per character line, and spacing of ten lines per inch

top of one character line to the

has seven dot rows per character line.

Elongated

characters

can be generated by printing each row twice, except for the first and last (Fig

ure 2-3).

112COLUMN NO.

“

0.10

“

FIRST ROW AND
COLUMN OF NEXT
CHARACTER

LOWEST
DESCENDER
DOT LINE

FIRST ROW AND
COLUMN OF NEXT
CHARACTER LINE
(AT 6 LPI)

0.01389

0.02

0.00835

”

“

Ć

Ć

2-1P6040/P6080 Principles of Operation

Figure 2-1. Defining the Dot Matrix

PRINTED

WITH

UNDERLINE

UPPERCASE

(REFERENCE)

UNDERLINE

WITH DESCENDER

Figure 2-2. Typical Characters

WITH UNDERLINES WITHOUT UNDERLINES

DOT ROW

1

2

’

2

3

’

3

4

’

4

5

’

5

6

’

6

7

7

’

8

’

8

9

DOT COLUMN

13579

UNDERLINE

DOT ROW

1

2

’

2

3

’

3

4

’

4

5

’

5

6

’

6

7

DOT COLUMN

13579

LOWERCASE

2-2 P6040/P6080 Principles of Operation

Figure 2-3. Elongated Characters

2-3. Matrix Printing-continued

b. The Hammer Bank

In order to use matrix printing, you have to have a method to print the required dots. Printronix

the hammer bank.

uses

The

hammer bank contains a number of print hammers (44 for P6040; 66 for P6080) mounted on a

shuttle

that can move back and forth horizontally. On the P6080, hammers are grouped into

and

designated odd or even. The shuttle prints a full line of dots during each cycle of back and

motion

Each hammer consists of a stiff leaf spring attached at one end to the hammer bank with a screw
(Figure
all
gized counteracts the permanent magnet causing
paper
manent

(Figure 2-4).

2-5). The end opposite the screw has a pointed tip attached. A permanent magnet keeps

the hammers

leaving a dot (Figure 2-6). After printing, the rebounding hammer is recaptured by the per

magnet.

retracted and under tension. Each hammer has a magnetic coil which when ener

the hammer to release and strike the ribbon and

c. Character Generation

Paper

advances one dot row after each shuttle cycle causing the dot matrix to be filled as

to

generate each character (Figures 2-7 and 2-8).

pairs
forth

required

Ć

Ć

2-3P6040/P6080 Principles of Operation

Figure 2-4. P

2-4 P6040/P6080 Principles of Operation

ositioning and Release of Odd and Even Hammers, P6080

-A-

P6040

Figure 2-5. Hammer and Shuttle Arrangement (T

-B-

P6080

ypical)

2-5P6040/P6080 Principles of Operation

-A-

P6040

2-6 P6040/P6080 Principles of Operation

Figure 2-6. P

-B-

P6080

rint Hammer Action

-A-

P6040

-B-

P6080

Figure 2-7. Standard Character Formation

2-7P6040/P6080 Principles of Operation

Figure 2-8. Character Formation by One Hammer

2-8 P6040/P6080 Principles of Operation

Section II. PRINTER FUNCTIONAL ELEMENTS

2-4. General (Figures 2-9 and 2-10)

The

printer is made up of the following functional elements:

n

Control P

n L

ogic C3 PCBA

n

Hammer Driver PCBA

n

Hammer Bank and Shuttle Mechanics/Magnetic P

n P

ower Supply

n

Ribbon Drive

n P

aper T

n

Platen Open/P

Figure 2-10 shows basic interrelation of these elements.

anel

ransport

aper Out Switch

ickup (MPU)

2-9P6040/P6080 Principles of Operation

2-10 P6040/P6080 Principles of Operation

Figure 2-9. P

rinter F

unctional Elements

Figure 2-10. System Block Diagram

2-11P6040/P6080 Principles of Operation

2-5. Control Panel (Figures 2-11 and 2-12)

The

control panel consists of a power-on indicator, eleven momentary contact

alphanumeric

The

electrical interface to the logic C3 PCBA uses a communication scheme that does not
the direct use of the data or address bus. This minimizes RFI/EMI problems due to the high freĆ
quency

The control panel processes and sends switch closure information to the logic C3 PCBA. It reĆ

information on setting up the alphanumeric display as well as status information. For a de

ceives
tailed discussion of panel operation, refer to User's R

display and an optional key-operated switch.

content and sensitivity of these signals.

eference Manual.

switches, an LCD

require

Ć

2-12 P6040/P6080 Principles of Operation

Figure

2-11. Control P

anel

2-13P6040/P6080 Principles of Operation

2-14 P6040/P6080 Principles of Operation

Figure 2-12. Control P

anel Block Diagram

2-6. Logic C3 PCBA (Figures 2-13 and 2-14)

The

logic C3 PCBA is the heart of the printer. It receives input data from the host computer, tem
porarily
and print signals to the hammer driver PCBA. It communicates with the control panel to display
and

Major functions on the board are under control of a 68000 CPU. A replaceable PROM contains
font

stores it in DR

monitor fault information.

and program information.

a. Connectors

There are five connectors on the logic C3 card ranging from 3 to 64 pins.

b. Host Interface Connector (J1)

Several of the pins on this connector are used for both parallel and serial transfer of data control
signals. All of the even numbered pins are grounded. Odd numbered pins are described in Table
2-1.

AM, determines which hammers

shall print and when, then outputs control

Ć

2-15P6040/P6080 Principles of Operation

2-16 P6040/P6080 Principles of Operation

Figure 2-13. Logic C3 PCBA

Figure 2-14. Logic C3 PCBA Block Diagram

2-17P6040/P6080 Principles of Operation

Pin

Table 2-1. Host Interface Connector Pin Assignments

Mnemonic

Description(Par/Serial)

11

13

15

17

19

21

23

1

IBD1/RXDATA PARALLEL - Input Data Bit 1

SERIAL - Received data

3

IBD2/DCD

PARALLEL - Input Data Bit 2
SERIAL - Data carrier detect

5

IBD3/DSR

PARALLEL - Input Data Bit 3
SERIAL - Data set ready

7

IBD4/CTS

PARALLEL - Input Data Bit 4
SERIAL - Clear to send

9

IBD5/TXCLK

PARALLEL - Input Data Bit 5
SERIAL - Transmit clock

IBD6/RXCLK

PARALLEL - Input Data Bit 6
SERIAL - Receive clock

IBD7/EXTCLK

PARALLEL - Input Data Bit 7
SERIAL - External clock

IBD8

IPI

IDSTB

IDRQ/TXDATA

PARALLEL - Input Data Bit 8

PARALLEL - Paper Instruction

PARALLEL - Dataproducts data strobe

PARALLEL - Data request
SERIAL - Transmit data

ICRDY/RTS

PARALLEL - Ready
SERIAL - Request to send

25

27

29

31

33

35

37

39

IONL/DTR

+5V

ICSTB

ICBUSY

IACK/REVCNL

NOT USED

NOT USED

ICPE

PARALLEL - On line
SERIAL - Data terminal ready

+5 Volts

Centronics data strobe

Busy

PARALLEL - Acknowledge
SERIAL - Reverse Channel

Printer Exception

2-18 P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

c. Power Supply Connector (J2)

Refer

to T

able 2-2.

Table 2-2. P

Pin Mnemonic Description

1 +5V Power, +5V
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20

GND
NSD
+30V
MPU
NPDE
PMD
PF1
HMC
PF2
COM
NFLT
NHSC
2MHZ
NHCK
+9V
HRS

-30V
+5V
GND

ower Supply Connector P

Ground
Shuttle Drive Enable
Power +30V
Magnetic Pickup from Codewheel
Paper Drive Enable
Paper Motion Detect
Paper Feed 1
Hammer Master Clear
Paper Feed 2
Hammer Data
Fault Status
Hammer Shift Clock
2MHz Signal
Hammer Clock
Power +9V
Hammer Reset
Power -30V
Power +5V
Ground

in Assignments

2-19P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

d. Front Panel/Color Connector (J3)

Presently, only the front panel interface of this connector is used. As such, only a 20-pin ribbon

is connected to the 40-pin connector; however, T

cable

able 2-3 describes all of the connections.

Table 2-3. F

Pin Mnemonic Description

1 PF1 Paper Feed 1
2
3
4
5
6
7
8

9
10
11

12 GroundGND

13-16

17,26,27

18-20

24

28-30

31
32
33
34
35
36
37
38

21,39
22,40

PF2
NSD
NPDE
CLRE/ND
R/NL
NSWITCH
NOT USED
RIB DIR
CLRTRS
NMC

NOT USED
FPLAMP
NOT USED
NPFAULT
NOT USED
REGSEL
NENABLE
NSWITCH
NOT USED
PDATA
NPLOAD
NOT USED
NPCLK
+5V
GND

ront P

anel Connector P

Paper Feed 2
Shuttle Drive Enable
Paper Drive Enable
Color Expansion
Color Expansion
Front Panel Switch Depressed

Ribbon Direction (Color)
Color Expansion
Master Clear

Front Panel Lamp Enable

Fault via Front Panel

LCD Register Select
Front Panel Write/Read
Front Panel Switch Depressed

Front Panel Data (Bi-Directional)
Latch Data from Front Panel Switch

Clock for Front Panel Data
Power +5V
Ground

in Assignments

e. Four Phase Stepper Connector (J4)

This

connector provides for half-stepping capability. Signals are described in T

Table 2-4. F

Pin Mnemonic Description

1 PF3 Paper Feed 3

2

3

2-20 P6040/P6080 Principles of Operation

PF4

GND

our Phase Stepper Connector P

Paper Feed 4

Ground

able 2-4.

in Assignments

2-6. Logic C3 PCBA-continued

f. Expansion Connector (J5)

Access

is provided to the MC68000 microprocessor bus via an

logic

circuit card.

The bus expansion mating connector is a 64-pin Cannon Part Number G06M64P3BLBL or
equivalent

with signals assigned as shown in T

Table 2-5. Microprocessor Bus Expansion Connector Pin Assignment

Pin Mnemonic Description

1B NBDS Data Strobe Enabled from Address Decode

(4008C)
2B
3B
4B
5B
6B
7B
8B
9B

10B
11B
12B
13B
14B
15B
16B
17B
18B
19B
20B
21B
22B
23B
24B
25B
26B
27B
28B
29B
30B
31B
32B

NDTEXD(O)
BA3
BD9
BD11
BA4
NBUDS
NCIACK
BSN6
NBLDS
BD13
NBERR(O)
BSN4
BA5
BD8
BD10
BA2
BA13
BD12
BD7
BA12
BA10
BA14
BA16
BA18
BA20
BD2
BA23
BA22
IPL2(O)
BD4
GND

DTACK Extended (Wait) CPU Input

Buffered Address Bus Line #3

Buffered Data Bus Line #9

Buffered Data Bus Line #11

Buffered Address Bus Line #4

Buffered Upper Data Strobe from CPU

Vectored Interrupt Acknowledge from CPU

Segment Line #6

Buffered Lower Data Strobe from CPU

Buffered Data Bus Line #13

Bus Error Input to CPU

Segment Line #4

Buffered Address Bus Line #5

Buffered Data Bus Line #8

Buffered Data Bus Line #10

Buffered Address Bus Line #2

Buffered Address Bus Line #13

Buffered Data Bus Line #12

Buffered Data Bus Line #7

Buffered Address Bus Line #12

Buffered Address Bus Line #10

Buffered Address Bus Line #14

Buffered Address Bus Line #16

Buffered Address Bus Line #18

Buffered Address Bus Line #20

Buffered Data Bus Line #2

Buffered Address Bus Line #23

Buffered Address Bus Line #22

Interrupt Priority Level 2 to CPU

Buffered Data Bus Line #4

Signal Ground

able 2-5.

expansion connector located on the

Continued

2-21P6040/P6080 Principles of Operation

Table 2-5. Microprocessor Bus Expansion Connector Pin Assignment

Pin Mnemonic Description

1A +5V
2A
3A
4A
5A
6A

NADRDIS
IPL1(O)

IPL0(O)
BR/NW
BSN5

Supply Voltage
CPU Address Disable
Interrupt Priority Level 1 to CPU
Interrupt Priority Level 0 to CPU
Buffered Read/Not Write
Segment Line #5

7A BSN1 Segment Line #1
8A

9A
10A
11A
12A
13A
14A
15A
16A
17A
18A
19A
20A
21A
22A
23A
24A
25A
26A
27A
28A
29A
30A
31A
32A

BSN3
NBAS
BA7
BD15
BA6
BSN2
BD1
BD3
BD0
BA8
BA15
BD14
BA11
BD6
BA9
BA1
BA17
BA19
BA21
NMC
NBR(0)
NBG
BD5
NBGACK(O)
GND

Segment Line #3
Buffered Address Strobe from CPU
Buffered Address Bus Line #7
Buffered Data Bus Line #15
Buffered Address Bus Line #6
Segment Line #2
Buffered Data Bus Line #1
Buffered Data Bus Line #3
Buffered Data Bus Line #0
Buffered Address Bus Line #8
Buffered Address Bus Line #15
Buffered Data Bus Line #14
Buffered Address Bus Line #11
Buffered Data Bus Line #6
Buffered Address Bus Line #9
Buffered Address Bus Line #1
Buffered Address Bus Line #17
Buffered Address Bus Line #19
Buffered Address Bus Line #21
Master Clear
Bus Request to CPU
Bus Grant from CPU
Buffered Data Bus Line #5
Bus Grant Acknowledge to CPU
Signal Ground

-continued

NOTES:

1.

2.

3.

4.

(O) Denotes signal is open collector
N Prefixing the signal name means active low
All levels are T
Segment lines are held in static states.
BSN6 is pulled high with 4.7K to +5V.
BSN1-BNSN5 all tied low to signal ground.

5.

6.

All data bus signals are buffered bidirectional.
All signals are outputs unless otherwise noted.

2-22 P6040/P6080 Principles of Operation

.

.

TL unless otherwise specified.

2-6. Logic C3 PCBA-continued

g. Host Interfaces

All

three of the popular interfacing formats are available on the L
at a time, and different cables must be installed in order to activate each particular interface.
There is one header associated with the host interface, located at 6A on the logic C3, the header
must be installed per the logic C3 configuration drawing (108078). The use of the header allows

the parallel and serial

both
adjustable hysteresis allowing the reception
to the hysteresis control pin of each receiver.

data to be received with the same device, a 75154. These devices have

of RS-232 or TTL signal levels based on the voltage

h. Serial Interface

The

serial interface is handled through a UART that resides within the 68901 MFP

clock

into the device allows for internally generated baud rates

rates include: 19.2K, 9.6K, 4.8K, 2.4K, 1.2K, 600, 300, 150, 110,

the clock for the baud rates.

erates

Several options are available for clocking in the serial data stream. The RS-232 interface has

clock lines, all of which are jumperable to the transmit clock (TC) or receive

three
on

the 68901. The three clock lines at the interface are Transmit Clock (NTXCLK), receive clock
(NRXCLK),
the

controlling clock to the TC and R

to

the UART provided the proper etch cuts and jumpers are made.

and external clock (NEXTCLK).

C pins of the 68901. Any of the RS-232 inputs are available

The etch is configured so that the timer C output is

ogic C3. Only one can be active

. A 2.4576 MHz
of up to 19.2K. The available baud
100,

75 and 50 baud. T

imer C gen

clock (R

C) pins

Ć

The

option for auto baud rate configuration is available. The timer B input pin (TBI) is tied to the

receive data (RXD) line so that in an auto configuration mode, the software driving the 68901

determine the baud rate of the incoming data stream, and set up timer C accordingly.

could

RS-232 control signals are also handled through the UART in the 68901. Data carrier detect
(NDCD)
Clear
ing to begin. The software response to the transition will cause the assertion of some combination
of the interface response lines. The response lines include: request to send (RTS), data terminal
ready
from
ing

and data set ready (NDSR) are anded together and routed to one of the status port lines.

to Send (CTS)

(DTR) and reverse channel. These

the 68901 general purpose I/O ports GPIB1 and

to a software setable latch at hex address 040152 and reset by writing to 040150.

is routed to the 68901 GPIB2. T

lines are controlled by software. DTR and R

ransitions on these pins cause serial process

TS originate

GPIB0. R

everse channel is asserted by writ

i. Parallel Interfaces

Both the Centronics and Dataproducts parallel interfaces are available to the user. The selection
of the interface used is based solely on the cable that is plugged into the printer during interface
configuration.

parallel interface required to run at rates of 500 kb/s

The
troller to permit the high speed transfer of the parallel data stream into the DRAM. The DMA

is a 68B44, a 2 MHz device that arbitrates for the bus on every character that it sends into the

used
DRAM.

in Dataproducts mode uses a DMA con

Ć

Ć

Ć

After an NMC is asserted (RESET), several operations must occur before data reception can be
enabled. To ensure that no data transfers take place during the parallel port initialization, ONL

RD

and

Y control signals must not be asserted.

2-23P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

i. Parallel Interfaces-continued

The

DMA must be set up for the transfer of data through channel 0. See table 2-6 for the

setup

parameters.

T

able 2-6. DMA P

Register Hex Address Hex Data

arallel I/O Setup P

arameters

DMA

CHNL 0 Start Address HI Byte 040040 SW Select

CHNL 1
CHNL 2
CHNL 3

CHNL 0
CHNL 1
CHNL 2
CHNL 3

The control signals that drive the interface initialize the printer in a not ready, not online condiĆ

All of the signals described below initialize in the reset, or low condition. The signals change

tion.
state

by writing to addresses as described below.

ONL - On Line
040144 ONL RESET 0
040146 ONL SET 1

active high signal should reflect the condition

This
printer

is online, this signal is set, after software writes to the address.

Start Address LO Byte 040042 SW Select
Byte Count HI Byte
Byte Count LO Byte
Not Used
Not Used
Not Used

Channel Control Register
Not Used
Not Used
Not Used

Priority Control Register
Interrupt Control Register
Chaining Control Register

040044
040046
040048-04004E
040050-040056
040058-04005E

040060
040062
040064
040066

040068
04006A
04006C

of the ON LINE switch on the front panel. If the

SW Select
SW Select
XX
XX
XX

00
XX
XX
XX

01
01
00

MCHA
040140 MCHACK RESET 0
040142 MCHACK SET 1

When
To enable the interrupt on match, set MCHACK. When clearing the interrupt condition, reset
MCHACK

BUSY - Busy

040148
04014A

Active
when the input buffer is almost full, while parallel interrupt processing is in process, or when the
condition

2-24 P6040/P6080 Principles of Operation

CK - Match Character Interrupt A

low, the MCHA

active low for a minimum of 25ns.

BUSY RESET
BUSY SET

high control signal that causes the printer interface to go busy. This signal should go active

of the printer prevents data reception.

CK control line disables interrupts to the processor from match characters.

cknowledge (always low)

0
1

2-6. Logic C3 PCBA-continued

i. Parallel Interfaces-continued

RDY - Ready

04014C RDY RESET 0
04014ERDY SET 1

Active high signal indicates that the interface is ready to be placed online, should be sent during
normal

operation, and reset during check conditions.

IBSYRST - Interrupt Busy R

040154 IBSYRSET RESET 0
040156 IBSYRSET SET 1

When

set, the IBSYRST signal enables the ICBUSY (BUSY at the interface) to be set by the inter

caused by the DMA or a match character. The signal must be reset for at least 25 ns to clear the

rupt
ICBUSY

OPS - Output P

040158 OPS RESET 0
04015A OPS SET 1

When
scribed
LINE.

FBSYEN - F

04015C FBSYEN RESET 0
04015EFBSYEN SET 1

When set, the FBSYEN signal causes the assertion of ICBUSY (BUSY) upon the reception of
each
memory.

signal to the host and reset the flip flop.

olarity Select

reset, this signal sets the control lines to the host

in 900197. If set, the OPS signal inverts the output control signals, IDRQ, IRD

ast Busy Enable

character. The fast busy is reset by the hardware upon the completion of the

eset

in the normally expected condition, as de

Y and

ION

data transfer into

Ć

Ć
Ć

2-25P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

i. Parallel Interfaces-continued

The

parallel port interrupt is input to the 68901 at GPIB4. DMA End (DEND) causes ICBUSY to

go

active, preventing further host data transfers.

The

DMA

will only interrupt the processor when the byte count is zero, provided that the DEND/

IRQ

enable bit is set (Interrupt Control R

ICBUSY, the busy signal at the interface, has several sources. When fast busy is not enabled, the
interface
To

will go busy (ICBUSY asserted) on the reception of a DMA END interrupt to the 68901.

clear the busy set by an interrupt, the software must pulse IBSYRST for a minimum of 25 ns.

egister Bit 0).

Software,
ONL

If

the fast busy function is enabled, by setting, FBSYEN, the printer asserts ICBUSY as each
acter
into

through the busy control port, can create an ICBUSY

is not active, the printer interface sets ICBUSY.

is clocked into the printer. ICBUSY is reset automatically by hardware once

memory.

1.

Dataproducts F

Signals

received in the

to the host from the logic C3 include IDRQ, IONLINE and ICRDY. The polarity of the

strobe, IDSTB, is selectable by hardware and readable by software. The polarity in

input
version signal name is IDS. If IDS is active (low) software can change the polarity of the
output signals by asserting OPS (output polarity select). The interface follows the
Dataproducts protocols defined in 900197. Note that the activation of the Dataproducts
interface

2.

Centronics F

Signals

received in the Centronics format include: IBD1-8, PI and ICSTB. Signals sent

the

host from the logic C3 include IA
generated when the DMA completes the transfer of
ments see 108037 and 108083.

ormat

Dataproducts format include IBD1-8, PI and IDSTB. Signals sent

requires that the proper cable kits are installed (see 108037 and 108083).

ormat

CK, ICPE and ICBUSY. IA

at the interface at any time. When

the character is

CK is a 4ms (typ.) pulse

each character. F

or cabling require

char

to

j. Mechanism Interface

The

J2 connector is the connector through which the

Circuits controlled through this connector include the hammer driver PCBA and the shuttle, ribĆ

and paper drive systems on the power supply PCBA.

bon,

logic C3 controls the printer mechanism. The

Ć

Ć

Ć

The hammer driver PCBA control signals are optically isolated from the backplane (mechanism
interface) to provide noise immunity. The optical isolators require high current drivers. A7406

drives the COM line. Hammer shift clock NHSC is

gate
by a 74LS125 buffer with a 330 pull up, and the hammer reset (HRS) uses a 7400 nand gate. The

sink current requirements of the hammer driver PCBA makes these selections necessary.

high

Some of the power supply PCBA signals are optically isolated, and most have a high current reĆ
quirement.
(NSD).
motor

2-26 P6040/P6080 Principles of Operation

7406 gates drive

An LS gate drives the 2 MHz signal which is used to time the disengagement of the shuttle

start circuitry.

driven by a 74S32, hammer clock (NHCK)

paper feed enable (NPDE), paper feed (PF1, PF2), and shuttle drive

2-6. Logic C3 PCBA-continued

j. Mechanism Interface-continued

Many

signals from the printer are received by the logic C3 card through the J2 connector. The most
important
be printed with the mechanism. The MPU pulse train generates interrupts with every pulse, and
these interrupts are used by software to time the transfer of data to the hammer driver card. The
signal NRESYNC is detected by using a one-shot circuit. The NRESYNC signal also generates
an interrupt. The time of the retriggerable one-shot is varied when using a P6040 or a P6080 by
the

The
and NRESYNC interrupts are at the same vector GPI6 of the 68901, the status port is used for
differentiation

k. NRESYNC Generation

As stated above, on the logic C3 card the NRESYNC signal is generated by the use of the one­shot circuit that is jumper selectable for either of the P6040 or a P6080. For the P6040 the one­shot timer will trigger if the MPU pulse train is slower than a 720ms period. For the P6080, the
RESYNC signal is generated when the MPU pulse train is slower than a 550ms period. Note that
the jumper E20-E21 selects the P6080 NRESYNC timing when installed. NRESYNC is treated

an interrupt to the processor, handled through the 68901 MFP

as

l. Hammer Load Circuit

signal is MPU, since this is the signal which the software uses to synchronize the data to

addition of the jumper E20-E21.

NRESYNC is detected by the software reading the status port address 40082. Since the MPU

between the two interrupt sources.

.

The

hammer load circuit unloads the dot image buffer after the software writes to an address

the circuit. The circuit operates entirely from hardware,

bling
dot image buffer. The circuit will transfer dots to the hammer driver card at one of two rates, 1

or 3.33 MHz. The jumpers which change the hammer load rate are called E38, E39 and

MHz
With E38 and E39 shorted the rate to transfer to the hammer driver card is 3.33 MHz, while E39
and E40 shorted, the data transfer rate is restricted to 1MHz (P6080 hammer driver PCBA comĆ
patibility).

active this circuit stops the processor by not returning

When
the

hammers is complete. This means that this circuit will tie up the bus for 44ms and 66ms respec

when running at 1MHz transfer rates in a P6040 or P6080.

tively

except for the starting address of the

the DTACK signal until the loading of

ena

E40.

m. Hammer Reset Timer

This circuit is controlled by a one-shot timer. The pulse train to the one-shot is controlled by
software hammer reset (NSWHRS) and the pulsed train is driven by MPU. The hammer reset
timer is set for approximately 384ms, so that 384ms after the MPU pulse, the hammers are reset.
This is true for the P6040 configuration, but in the P6080 configuration, the hammer reset timer

is added as a piggyback card on the PCBA.

card

The

hammer reset timer PCBA, p/n 104363, is located at 4A. When this card is in place, its actions

override

that of the one-shot HRS signal generated on the logic C3 card.

Ć

Ć

2-27P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

n. Power Circuits

The power supply generates +5V, GND, +30 V and -30V. Two other voltages are required that

power supply does not generate, +12V and -12V

the
and -30V available at J2
the page with the 68901 MFP
signals

from being received by the host. When the printer is powered down, the +5 volts supplying

the

logic driving the RS-232 line drivers goes away long before the  30V which drives the 12V



will. If the

or R

RT S

12V circuits do not turn off when +5V goes away, erroneous control signals (DTR,

everse Channel) may be generated and sent to the host.

and are required for serial interface circuitry. The logic can be found on

. The optical circuits (TIL111) are used to prevent erroneous control

o. Motor Controls

The

ribbon motors and shuttle motor are turned on by shuttle drive enable (NSD). P

by

asserting paper drive enable (NPDE) and toggling P

above

signals are under software control.

1. P

aper Movement

PF1 400C0 RESET

400C2 SET

PF2 400C4 RESET

400C6 SET

NPDE 400D4 RESET

400D6 SET

PF1 and PF2 are used in conjunction with each other to move the paper. If NPDE is not
set, paper will not move when PF1 and PF2 are switched. To move paper forward, set
NPDFE

and then switch PF1 and PF2 in the following manner:

. These voltages

aper F

eed 1 and

are derived from the +30V

aper is moved

2 (PF1 and PF2). All of the

PF2 SET
PF1 SET
PF2 RESET
PF1 RESET

Shuttle and Ribbon Movement

2.

NSD 400D0 RESET

400D2 SET

o make the shuttle and ribbon motors turn on, set NSD.

T

p. Front Panel Interface

The

logic C3 front panel interface is used with
not backward compatible to the logic C2, C1 or A and B board sets. Signals to the front panel inĆ
clude: NENABLE, NPLOAD, PDATA (bidirectional), NPCLK, and REGSEL. Signals from the
front panel include NSWITCH and NPFAULT. NPCLK is used in conjunction with PDATA to

the serial data stream into or out of the front panel.

clock

NPCLOCK is the anded combination of front panel data write (NFPDATAW) and panel clock
(PCLK).
Panel L

The
by

The NPCLK signal is active when PCLK

oad (PLO

front panel switches and three fault status lines can be read as a single eight-bit word any time

software using the steps following:

AD) must be set when the data is shifted out to the panel.

the front panel defined by PCBA 107823-002 and is

is reset and NFPD

ATA

W is written to. Note that

2-28 P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

p. Front Panel Interface-continued

- ENABLE

- RESET NPLOAD

- RESET PCLK and write to NFDATAW port ($40084) eight times, then read from
NFPDATA

- Write to NFPDATAW ($40084) eight more times and read NFPDATA port ($40084) for
the

The switches and fault status in this 16-bit word have the bit assignments as described in Table
2-7.

SET (PDATA input), to HI on front panel

($40084) for the high byte.

low byte.

ront P

Table 2-7. F

Key Bit Hex Code

Paper Advance
Clear Fault
Config Value
Form Length
Print Mode
Set TOF
Form Feed
On Line
Run/Stop
Lock Key
Config Menu
Line Spacing
N/C
Paper Out
Platen Open
Ribbon Fault

anel and Fault Status Assignments

15
14
13
12
11

10

8000
4000
2000
1000
0800

9
8
7
6
5
4
3
2
1
0

0400
0200
0100
0080
0040
0020
0010
0008
0004
0002
0001

NFPDATAW

This permits writes to the shift register latch and enable shifting of data to/from the front panel.

NPCLK 40108 RESET

PLCK allows shifting of data in/out of F

PLOAD 4010C RESET

When

set,

allows the shift register latch to load with the data but data during NFPD

When

reset, permits the serial loading of data to the front panel.

40084 when writing only

4010A SET

ront P

anel if toggled.

4010E SET

ATA

W active.

2-29P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

p. Front Panel Interface-continued

ENABLE 40104 RESET

40106 SET

reset, ENABLE (NENABLE at the J3 interface) enables the C3 shift register latch to shift

When
data

on the PDATA line. When set, enables the front panel to shift data

disables

REGSEL 40100 RESET

When set, permits the shifted data to go into the LCD display registers. This is used during the
power-up

NSWITCH

This is an interrupt input to the 68901 on GPIB3.

the C3 driver.

40102 SET

initialization of the front panel.

q. Bus Structure

The Motorola MC68000 microprocessor unit (MPU) was chosen for the processor for the logic
C3. This processor has 32-bit internal data and address registers with 16-bit external data bus
(D0-D15)
with the logic C3 card. Two address busses are used for microprocessor interfacing and latch setĆ
ting,
memory access (DMA) device resides on the upper data bus (D8-D15), while the 68901 multi­function peripheral (MFP) resides on the lower data bus (D0-D7). The 68901 MFP must reside

the lower data bus to provide vectored interrupt processing capabilities.

on

and 23-bit external address bus (A1-A23). There are three address busses associated

while the other address bus is

used for access of the DR

AMS on the C3 card. The 68B44 direct

over the PDATA line and

r. Reset Control

Not master clear (NMC-low true) can be asserted from three sources. The three sources are:
power-on reset, hammer master clear (HMC), (a signal from the power supply card), and the

reset instruction that drives the NMC line low under software control.

68000

The power-on reset circuit, found on the page of the schematic with the CPU, has a reset time
about 350ms. The P6000 Series power supply stabilizes +5V within 70ms after power-on. The

requires that the reset line held low at least 170ms after +5V is stable.

68000

The HMC signal is low for about 70ms after power-up, and does not effect the operation of the

except when the card is not plugged into the printer (bench test). During bench testing the

circuit
HMC

line must

run.

be pulled low for the NMC signal to become inactive, allowing the 68000 MPU to

2-30 P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

s. Control Signals

The control signals to and from the processor control the bus activity on the card. Several of the
control
MHz

clock).

1.

signals on the 68000 are unused. The unused signals include: VP

CPU Bus Control Signals

The control signals on the bus that are controlled by the 68000 include: NAS, R/NW,

and NDTACK (N denotes active low).

NUDS

NAS Active low signal that asserts 70ns (min.) after the address that 68000 MPU

on the bus stabilize.

put

R/NW When high, the processor reads from the data bus. When low, the processor

to the data bus.

writes

A, VMA, BERR, and E (1

NUDS

NLDS

NDTACK Sampled by the processor to determine if the peripheral that was addressed

2.

Bus Arbitration Control Signals

The bus arbitration signals include: NBG, NBR and NBGACK. Presently, the 68B44 is

only device on the C3 card that asserts the bus request (NBR) and grant acknowledge

the
(NBGACK)
Note that the PAL decode logic takes the positive true BGACK signal from the circuitry
around
sion connector does not effect this decode logic. Both the
the

68000 are open collector.

3.

Interrupt Control Signals

The signals used for the interrupt processing include IPL0, IPL1, IPL 2, FC0, FC1 and
FC2.
request lines (IPLX) go to the expansion connector and are open collector lines. In reĆ
sponse
when

When

that interfaces to the 68901 MFP

line
of the interrupt on the lower data bus for the processor to read. When the MFP asserts
NDTACK, the 68000 latches the data and negates NUDS and NLDS, completing the inĆ
terrupt

Asserts low when the data on the upper data bus is valid (D8-D15).

Asserts low when the data on the lower data bus is valid (D0-D7).

received the information that was sent to it. Until this signal goes low, the

has
processor

signals. The bus arbitration signals are

the

68B44 and decodes the space of R

The C3 card uses only the IPL2 line, or level four interrupt.

to an interrupt, the function code lines (FCX) all assert high. The function

in interrupt mode, disable the address decode circuitry.

all of the function codes are high in the interrupt acknowledge cycle, the NCIA

acknowledge cycle.

will wait with the address and data busses asserted.

available at the expansion connector.

AM0. The NBGACK signal from the expan

NBR and NBGACK signals into

All three of the interrupt

goes active low. A

t this time the MFP puts the vector

Ć

codes,

CK

2-31P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

t. Address Bus

Three

address busses exist on the C3

bus BA1-BA23, and the memory address bus, MA0-MA7.

dress

card: the unbuffered address bus, A1-A23, the buffered ad

Ć

Devices
and the 74ALS244 buffers. Devices on the buffered address bus include: the buffer outputs, the
rest of the decode logic (74LS138) and address selectable latches (74LS259) the EPROM, the
EEPROM

The
three sources for DRAM addresses include the refresh circuit, the processor DRAM addresses,
and

on the unbuffered address bus include: the 68000 MPU the 68B44 DMA, the 12L10 P

and the DR

buffered memory address bus drives the DR

the hammer load circuit addresses.

AM memory address switching circuit.

AM addresses

that are going to be accessed. The

AL

u. Data Bus

There

is one data bus on the card divided into two groups of eight: the upper and lower data byte.

The

68901 MFP resides on the lower data bus so the interrupt

read

by the 68000. The 68B44 resides on the upper data bus for easier
provide
Acknowledge)

the bidirectional buffering of the data bus and are tri-stated when NBGACK (Bus Grant

is asserted. The 74ALS245s are the only devices on the 68000 data bus pins.

vector generated by the 68901 can be

software access. 74ALS245

v. Address Decoding

Extensive,
12L10 PAL, several address selectable latches (74LS259), and several demultiplexors (74LS138).
The

but not complete address decoding is provided. The address decode circuit consists of a

address decode, or memory map follows in T

ables 2-8 and 2-9.

2-32 P6040/P6080 Principles of Operation

Table 2-8. Logic C3 Memory Map

Address (A23-A0) Function Comments

00000

00FFF

010000

01FFFF

020000

02FFFF

030000

03FFFF

040000

04FFFF

050000

05FFFF

060000

067FFF

068000

06FFFF

EPROM0 32Kx16 (27256)

EPROM1

EPROM2

NO DECODE

I/O SPACE

EEPROM

RAM0

RAM1

32Kx16 (27256)

32Kx16 (27256

Not Implemented

See I/O Map for Details

512x8 Lower Byte Only

16Kx16

16Kx16

070000

FDFFFF

FE0000

FEFFFF

FF0000

FFFFFF

Not Assigned

FONT0

FONT1

32Kx16 (27256)

32Kx16 (27256

2-33P6040/P6080 Principles of Operation

Table 2-9. Logic C3 I/O Address Map

Address (A23-A0) Function Comments

040000

NMFPE 68901 Address Range

04003E

040040

NDMACS 68B44 Address Range

04007E

UNLATCHED DECODE SIGNALS

040080
040082
040084
040086
040088
04008A
04008C
04008E

NHSTCNFW
NSTSOE
NFPDATA
NHMCNF1W
NHMCNF2W
NPLLCNF
NBDS

NHMCNF3W
040090
TO

DECODED, BUT NOT DEFINED
0400BE

LATCHED DECODE SIGNALS

0400C0
0400C2
0400C4
0400C6
0400C8
0400CA
0400CC
0400CE
0400D0
0400D2
0400D4
0400D6
0400D8
0400DA
0400DC
0400DE
040100
040102
040104
040106
040108
04010A
04010C
04010E
040110
040112
040114
040116
040118
04011A

PF1 RESET

PF1 SET

PF2 RESET

PF2 SET

PF3 RESET

PF3 SET

PF4 RESET

PF4 SET

SD RESET

SD SET

PDE RESET

PD SET

270/N120 RES

270/N120 SET

SWHRS RES

SWHRS SET

REGSEL RES

REGSEL SET

ENABLE RES

ENABLE SET

PCLK RESET

PLCK SET

PLOAD RESET

PLOAD SET

CLR E/ND RES

CLR E/ND SET

R/NL RESET

R/NL SET

FPLAMP RES

FPLAMP SET

Match Char. Address
Status Port
FR. Panel Data
Hammer Config 1
Hammer Config 2
Not Used
Expansion Fault I/F
Hammer Config 3

Stepper Motor Control
Stepper Motor Control
Stepper Motor Control
Stepper Motor Control
Stepper Motor Control
Stepper Motor Control
Stepper Motor Control
Stepper Motor Control
Shuttle Drive Control
Shuttle Drive Control
Paper Drive Enable Control
Paper Drive Enable Control
Not Used
Future 270 DPI Resolution
Software Hammer Reset
Software Hammer Reset
Register Select, Front Panel
Register Select, Front Panel
Enable, Front Panel Control
Enable, Front Panel Control
Clock, Front Panel Serial Data
Clock, Front Panel Serial Data
Load, Front Panel Control
Load, Front Panel Control
Not Used
Future Color I/F
Not Used
Future Color I/F
Lamps off
Lamps on

Continued

2-34 P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

Table 2-9. Logic C3 I/O Address Map-continued

Address (A23-A0) Function Comments

04011C
04011E
040140
040142
040144
040146
040148
04014A
04014C
04014E
040150
040152
040154
040156
040158
04015A
04015C
04015E

w. Memory Circuits

NHMRBLK RES

NHMRBLK SET

MCHACK RES

MCHACK SET

ONL RESET

ONL SET

BUSY RESET

BUSY SET

RDY RESET

RDY SET

REVCHNL RES

REVCHNL SET

IBSYRST RES

IBSYRST SET

OPS RESET

OPS SET

FBSYEN RES

FBSYEN SET

Hammer Blank
Hammer Blank
Char Acknowledge
Char Acknowledge
Online Control
Online Control
Busy Control
Busy Control
Ready Control
Ready Control
Reverse Channel Control
Reverse Channel Control
Busy Reset Control
Busy Reset Control
Output Polarity Control
Output Polarity Control
Fast Busy Enable Control
Fast Busy Enable Control

Three different memories are used on the logic C3. EEPROM for the system setup parameters,
EPROM
stored

data.

for program and FONT data, and DR

AM for

the dot image buffer and other temporarily

x. EEPROM

The EEPROM, residing on the lower data bus, stores all the setup/restore values for the printer.
The addressing of the EEPROM starts from 050000 and extends to 05FFFF. Presently, a 512 x 8

is

device
on
different addresses between 050000 and 05FFFF can access the same byte within the EEPROM.
This is due to incomplete address decoding. A memory disable circuit inhibits writes to the
EEPROM

called out, but larger devices (2K x 8) are available if required. The 512 bytes are mapped

top of each other throughout the 50000 to 5FFFF address space. This means that any one if 128

if the +5V supply goes below 3.3V

. The EEPROM is located at 14G on the logic C3.

y. EPROM

The

logic C3 card has sockets for 10 EPROM devices. Devices that will work in the sockets include
2764, 27128
accessed are defined in Table 2-8. Locations for the EPROMs are: EPROM0 (7G, low byte, 7J
high byte), EPROM1 (8G low byte, 8J high byte), EPROM2 (10G low byte, 10J high byte),
FONTO
byte EPROMs must be placed at each memory decode for the required word (16-bit) wide data
path.

from the processor or the expansion interface.

sible

and 27256 (with BA15 jumpers installed). The addresses where the EPROMs can be

(11G low byte, 11J high byte) and FONT1 (12G low byte, 12J high byte). The high and low

The EPROM0 proms must be in place in order to run any program. EPROMs are only

acces

Ć

2-35P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

z. DRAM

There are 32K words (32K x 16) of DRAM on the logic C3. The 32K is divided up into two 16K

decoded as R

blocks
devices. This method of using the x4 devices yields the most space efficient way to build large

of DR

blocks
blocks that can access the DRAM. The 68000 or any bus master can access DRAM, the refresh
circuitry accesses the DRAM for refresh only, and the hammer load circuit accesses DRAM to
transfer
as
function codes (FC0-FC2) which the processor asserts prior to the execution of a cycle. Each
DRAM

68000
clock. The hammer load circuit also accesses the DRAM starting at an address specified by the
software,
P6080
switching

data to

such, is synchronous with the processor. P

memory location must be pulsed once every 4ms to remain refreshed.

DR

AM access with 150ns memory devices occurs with no wait states with an 10MHz 68000

then skips 64 locations and accesses the next word of data for 44 or 66 cycles for P6040

respectively. The most critical timing associated with the DR

of the address buffers between the three functional blocks that access the DR

aa. Interrupt Structure

All interrupts derived on the logic C3 are level 4 vectored interrupts due to the use of the 68901

as the vectored interrupt controller. The vector register of the 68901 MFP is at address loca

MFP

040016H and must be loaded with 40H. T

tion
of

each interrupt, and the function of each interrupt.

AM0 and R

AM. The host DMA can only transfer data into RAM0. There are several functional

the hammer drive card. RAS only refresh occurs only during program accesses, and

AM1. Each 16K word block is built by using four 16K x 4 DR

rogram accesses are determined from the state of the

AM circuit originates from the

AM.

able 2-10 defines the interrupt vectors, the priority

AM

or

Ć

Table 2-10. Logic C3 Interr

Priority Vector (Hex) Definition Function

Highest 4F GPIB 7

4E GPIB 6 MPU or RESYNC

4D Timer A

4C

4B

4A

49

47

46

43

42Lowest

RCV. BUF. Full

RCV. Error

XMT. BUF.

XMT. Error

GPIB 5

GPIB 4

GPIB 3

GPIB 2

upt V

ectors

Timer A Paper Feed

Paper Feed

Receiver Buffer Full

Receiver Error

Transmit Buffer Empty

Transmit Error

Fault Summary

DMA/MATCH - Host Parallel
Interface

NSWITCH," front panel,
Auto-Baud rate
Start Bit Pulse Width

CTS (Clear to Send)

2-36 P6040/P6080 Principles of Operation

Not all of the available 68901 MFP vectors are used. T

able 2-11 defines unused vectors.

Table 2-11. Logic C3 Unused Interr

Vector (Hex) Definition Function

48 Timer B

45

44

41

Timer C

Timer D

GPIB1

GPIB 1 is configured as an I/O output
port, DTR (Data Terminal Ready) to the
Host.

40 GPIB 0

GPIB 0 is configured as an I/O output
port, RTS (Request to Send) to the
Host.

upt V

ectors

2-37P6040/P6080 Principles of Operation

2-6. Logic C3 PCBA-continued

ab. Clock Circuits

The 68000 MPU runs at 10MHz, the 68901 MFP runs at 2.5MHz, and the 68B44 DMA runs at

1.25MHz.
and
est loading since this signal is used for many functions, it also drives circuits on the power supply in
present

ac. Hardware Jumpers

Table 2-12 briefly describes these jumpers. For a more detailed description of jumpers, refer to
the

All of these clocks are derived from a 20MHz crystal running in the fundamental mode

divided by 2, 4 and 8 by a 74HC161. CLK2 is derived from the 20MHz signal and

P6000 Series printers.

User's R

eference Manual.

has the high

Ć

2-38 P6040/P6080 Principles of Operation

Table 2-12. Logic C3 Hardware Jumpers

Jumper Description

Software

Readable Signal

E1-E2

E3-E6

E4-E7

E5-E8

E6-E9

E7-E10

E8-E11

E12-E13

E14-D15

E18-E19

E20-E21

E22-E23

E24-E25

E26-E27

E28-E29

EPROM wait state jumper

NTXCLK input

NRXCLK input

NEXT CLK input

Clock to 68901 TC input

Clock to 68901 RC input

Timer C output to clock

Spare

Dataproducts strobe polarity

P6040/P6080 Select

P6080 NRESYNC timer

Not Used

Not Used

Not Used

Not Used

N

N

N

N

N

N

N

N

IDS

Y (Low P6080
High P6040)

N

Y (not assigned)

Y (not assigned)

Y (not assigned)

Y (not assigned)

E32-E33

E34-E35

E36-E37

E38-E39

E39-E40

E41-E42

E43-E44

E45-E46

E47-E48

E49-E50

E50-E51

E52-E53

E53-E54

Phase Fire select

27256 addressing EPROM0

Clock 20 MHz

3.33MHz hammer load

1MHz hammer load

27256 Addressing EPROM 1

27256 Addressing EPROM 2

27256 Addressing FONT 0

27256 Addressing FONT 1

Data Latch Edge Select

Data Latch Edge Select

DRQ Latch Edge Select

DRQ Latch Edge Select

Phase Fire

N

N

N

N

N

N

N

N

N

N

N

N

2-39P6040/P6080 Principles of Operation

2-7. Hammer Driver PCBA (Figure 2-15 through 2-17)

Each

of the print hammers (44 for P6040; 66 for P6080) is controlled by an electromagnetic coil, a

driver,

and a logic circuit which, among other functions, controls the energizing of the coil.

The hammer logic circuits perform the following functions:

- Convert serial data bits (44 for P6040; 66 for P6080) on the COM line into parallel data
(44 for P6040; 66 for P6080).

bits

- Control

- Provide

age

- Provide an isolated and regulated +5 VDC supply, 5HL, for TTL logic on the hammer

driver

Following a SYNC pulse, hammer shift clock (NHSC) pulses loading from the COM DATA line

the hammer driver shift register. Every odd bit on the COM line is clocked into the shift regis

into
ter by the rising edge of NSC, selecting dot information for the odd numbered characters to be
printed

After the last bit is clocked into the shift register, the next SYNC pulse causes hammer clock,
NHCK,

When
driver
the hammer coil to ground. The coil is energized and the hammer is released to print the dot.

Hammer
deenergizes

Hammers are reset except for a specific period of time after the SYNC pulse.

by each hammer.

to load the contents of the shift register into the data latches.

a dot is to be printed, the data latch for that hammer is set and the corresponding Darlington
transistor is forward biased. This completes the current

reset signal, HRS, resets the OE latch. The latch output disables all tri-state buffers and

the

energizing of hammer coils to print dots in accordance with the parallel data.

safety features to prevent coils from energizing under conditions that could dam

coils and hammer drivers (P6080 only).

PCBA.

path for the +36 V supply through

the coils. The rebounding hammers are recaptured by the permanent magnet.

Ć

Ć

2-40 P6040/P6080 Principles of Operation

Figure 2-15. Hammer Driver PCBA

2-41P6040/P6080 Principles of Operation

-A-

P6040

2-42 P6040/P6080 Principles of Operation

-B-

P6080

Figure 2-16. Hammer Driver Block Diagram

-A-

P6040

-B-

P6080

Figure 2-17. Hammer Driver Circuit T

iming

2-43P6040/P6080 Principles of Operation

2-8. Hammer Bank and Shuttle Mechanics/MPU

a. Hammer Bank Assembly/Shuttle

Operation

of the hammer bank is as described in paragraphs 2-3b and c.

b. Magnetic Pickup (MPU) (Figures 2-18 and 2-19).

Printing is synchronized with shuttle movement by the magnetic pickup (MPU) signal. The magĆ

pickup, located next to the flywheel timing disk, is so oriented that timing signals relate pre

netic

to the shuttle position. V

cisely
from apertures (198 for P6040; 138 for P6080) on the timing disk as it rotates, generating SYNC

T

pulses.
two adjacent apertures is removed). These double width apertures separate the 138 single width
apertures
the

Full
printing
advanced 0.0139 inches, and no printing occurs. During each of the four printing periods each
hammer covers an area three characters wide for P6040 and two characters wide for P6080. An
entire

The SYNC pulses are distributed to other printer logic including missing pulse" detection logic
that

The SYNC signal performs the following functions:

wo aperture locations at opposite ends of the disk are of double width (material between

into two groups and generate a

right.

rotation of the

period is followed by a turnaround period when the shuttle movement is reversed, paper

dot row is printed in 36 SYNC periods for P6040 and in 24 SYNC periods for P6080.

generates the RESYNC pulse.

disk provides four printing periods and two back and forth shuttle cycles. Each

ariations in magnetic reluctance are sensed by the magnetic pickup

RESYNC signal each time the shuttle begins moving to

is

Ć

- Initiates

presented

- Activates all hammers armed with a logic 1" during the previous scan of the printer

buffer.

- Initiates

This signal resets hammer driver circuits previously activated by SYNC for the prior dot
location.

In the generation of SYNC and RESYNC signals, the roughly sinusoidal output of the magnetic

is amplified and converted to a TTL compatible square pulse by a circuit on the power sup

pickup
ply

PCBA. The resulting MPU signal is synchronized with the printer clock (CLK) and applied to

print

synchronizing circuits on the logic C3 PCBA.

T

ypical signal levels received from the magnetic pickup are:

SYNC: 2.0 to 3.5 Vpp

RESYNC: 4 to 6 Vpp

a high speed scan of all 132 print buffer locations during which each character is

to the character generation logic.

a time out period which controls generation of the hammer reset signal

(NHRS).

Ć

2-44 P6040/P6080 Principles of Operation

-A-

P6040

Figure 2-18. Dot R

-B-

P6080

ow T

iming vs Timing Disk and Cam Position

2-45P6040/P6080 Principles of Operation

2-46 P6040/P6080 Principles of Operation

Figure 2-19. Operation of MPU Circuit

2-9. Power Supply (Figure 2-20)

a. P6040

The

power supply assembly consists of chassis mounted transformer/rectifier/filter circuits and the

power supply PCBA. AC line voltage is connected to the transformer at primary winding taps seĆ

for the line voltage in use.

lected

Secondary
erate

windings of the transformer provide power to rectifiers, regulators, and filters that gen

the following voltages to the PCBA:

18 V, unfiltered - regulated on the PCBA to provide +28 V to the hammer bank drive circuits

and

the paper feed control circuits through fuse F3.

+8 V - applied through fuse F1 to the reference voltage circuit and the logic +5 V supply.

-30 V - applied to the paper feed control circuit through fuse F2.

Ć

2-47P6040/P6080 Principles of Operation

P6080 Shown

2-48 P6040/P6080 Principles of Operation

Figure 2-20. P

ower Supply

2-9. Power Supply-continued

b. P6080 (Figures 2-20 and 2-21)

The

power supply assembly consists of chassis mounted transformer/rectifier/filter circuits and the
power supply PCBA. The ac line voltage passes through one or both sides of a dual circuit breaker
and appears at the transformer primary winding taps selected for the line voltage. The circuit
breaker

Secondary windings of the transformer provide reduced ac voltage to bridge rectifiers and filters
that

The power supply PCBA contains several dc voltage supplies used throughout the printer. AddiĆ
tionally, fault detection circuits monitor the supplies and the paper out switch. A paper feed disĆ
able circuit controls the action of the paper feed drive circuit. Finally, the motor relay trigger cirĆ
cuit

trips when excess voltage is detected in the +36 Vdc on the power supply PCBA.

provide the following voltage to the PCBA:

36 V

ac - used to produce unfiltered +36 Vdc and +70 Vdc for the paper feed drive circuits.

+9.5 Vdc - applied to the reference voltage circuit, the +5 Vdc supply for the logic PCBAs

to the +9.5 V fault circuit.

and

-36 Vdc - input to the -12 Vdc voltage regulator on each of the printer PCBAs, and to the
V fault circuit.

-36

provides temporary ac voltage to the shuttle motor start winding to start the motor turning.

2-49P6040/P6080 Principles of Operation

2-50 P6040/P6080 Principles of Operation

Figure 2-21. P

ower Supply Assembly

, P6080

2-9. Power Supply-continued

c. +36 V Supply, P6080 Only (Figure 2-22)

A full wave rectifier consisting of half of the +70 Volt bridge and two SCRs rectifies the voltage

the +36 V winding. Each SCR controls the duration of

from
feedback

The pulsating dc voltage passes through a choke on the power supply chassis to filter R1/C1. FilĆ
tered
regulated,
age becomes excessive. Regulated +36 Vdc is also connected to a switching circuit that produces
switched +36 Vdc voltage, VSW

The
level.
crossover

circuit maintains a relatively constant pulsating dc voltage at the SCR cathodes.

+36 Vdc powers the hammer bank and the hammer

and connected to the circuit breaker to trip the circuit breaker when the +36 Vdc volt

, for the ribbon drive assembly.

comparator amplifier samples the regulated voltage and compares it with the 1.0 V

The SCR in the optical coupler ensures that the rectifier SCRs are turned

of the ac waveform.

d. +70 V Supply, P6080 Only (Figure 2-22)

The

+70 Vdc supply powers the paper feed drive circuits. The supply is derived

rectifier

produces a pulsating +70 Vdc which is filtered.

e. Reference Voltage Circuit, P6080 Only (Figure 2-23)

Filtered
used
fused and applied to the +2.6 V regulator. The +2.6 V regulator provides the bias for the +5 V
regulator
tory

+9.5 Vdc from the transformer secondary is attached to the reference voltage circuit and

as a positive voltage reference source (+9.5 V) for the fault detection circuitry. The

and is the input

selected resistor.

to the 1.0 V VREF amplifier. The reference level is precisely set by fac

current flow during one half cycle. A

driver PCBA. Filtered +36 Vdc is fused,

olt VREF

off only at the zero

from the 36 V

ac. A

+9.5 V is

Ć

Ć

f. +5 V Supply, P6080 Only (Figure 2-24)

The

regulated +5 Vdc supply provides power to all TTL circuits

hammer

bank master clear signal, HMC, at initial power-on to prevent spurious hammer release.

in the printer. It also generates the

g. Fault Detection, P6080 Only

Four

fault sources are monitored: +5 Vdc, -36 Vdc, +9 Vdc, and the paper out switch. Any time a

voltage

supply is out of tolerance or

the paper out switch is actuated, the corresponding LED is lit.

h. Paper Feed Disable, P6080 Only

The paper feed disable circuits are controlled by the paper drive enable signal, NPDE. When
NPDE is active, the paper feed disable signal NPFD is inactive and the paper feed pair signal,
PF1/PF2, reach the paper feed drivers. The VSW logic switch is enabled, and VSW powers the

assembly thereby activating the ribbon transport. When NDPE is inactive, NPFD becomes

ribbon
active, PF1/PF2 are kept from the paper feed driver and VSW is switched off, halting the ribbon
transport.

2-9. Power Supply-continued

i. MOS Supplies, P6080 Only (Figure 2-23)

There are MOS circuit elements that require +12 Vdc and/or -12 Vdc. These two voltages are
supplied by simple zener regulators on the PCBA. +12 Vdc is derived from the +36 Vdc supply,

-12 Vdc is derived from the -36 Vdc supply.

while

2-51P6040/P6080 Principles of Operation

Figure 2-22. +36 V and +70 V Supplies, P6080

2-52 P6040/P6080 Principles of Operation

Figure 2-23. Reference V

oltage Circuit, P6080

2-53P6040/P6080 Principles of Operation

2-54 P6040/P6080 Principles of Operation

Figure 2-24. +5 V and MOS Supplies, P6080

2-9. Power Supply-continued

j. Motor Relay Trigger, P6080 Only (Figures 2-25 and 2-26)

The

motor relay
disconnect
brought
winding energy is added to that of the run winding to produce a high starting torque. Once the
shuttle
ing is deenergized.

The motor trigger relay circuit is shown in Figure 2-26. While the printer is offline, NSD is high,
and
low
(1 microsecond) by
stage divider and becomes a 59.7 millisecond pulse, which is further divided by stages of the clock
counter

Then,
which
ing MPU pulses detected at the flywheel. A count of 96 is decoded at the output of the counter.
Initially,

119.4 millisecond pulse resets the MPU counter. The MPU counter is reset by the clock counter

59.7 milliseconds after the relay is actuated and at 119.4 milliseconds later. The MPU counter is
released midway between resets. Each time the counter is released, it begins a new count. When
the shuttle motor is turning fast enough, a count of 96 is decoded and the lower flip-flop is set.
Setting the flip-flop halts the relay actuation and the start winding is deenergized. The set flip­flop
is
would have a braking effect on the motor.

online,

motor approaches normal operating speed, actuation of the relay ends and the start wind

the clock counter and dual flip-flop are held in reset. When the printer goes online, NSD goes

releasing the counter and flip-flops. The 2 MHz system clock, NCLK, is converted to 1 MHz

to produce a 119.4 millisecond pulse and a 238.8 millisecond pulse.

238.8 milliseconds after NSD goes low, the 238.8 millisecond pulse sets
actuates the solid state relay and the motor begins turning. The MPU

the shuttle motor is

also resets and holds the clock counter and the MPU counter. Counting stops until the printer

cycled offline/online again to

trigger is used to apply a high starting torque to the shuttle motor at rest and later

the starting torque once the motor is running at the proper speed. When the printer is

a solid state relay is actuated to apply ac line voltage to the start winding. The start

the

first element of the counter. The 1 microsecond pulse passes through a 17

the upper flip-flop

counter begins receiv

not turning fast enough for 96 MPU pulses to be generated before the

keep the relay from being actuated at normal motor speed, which

Ć

Ć

2-55P6040/P6080 Principles of Operation

2-56 P6040/P6080 Principles of Operation

Figure 2-25. Relay Switching Details, P6080

Figure 2-26. Motor R

elay T

rigger Circuit, P6080

2-57P6040/P6080 Principles of Operation

2-10. Ribbon Drive (Figures 2-27 through 2-29)

The ribbon drive assembly contains two dc servomotors that move the ribbon continuously while
there is shuttle action. One motor acts as the driver, drawing the ribbon against opposing torque
exerted
motors exchange roles and ribbon travel is reversed. This system maintains a relatively constant
ribbon

by the other motor. When a length of metal tape at either ribbon end is detected, the two

speed and tension.

The ribbon moves only while the shuttle is in motion. The high side of
which also powers the hammer bank blower, is switched by a triac switching circuit controlled by

signal NSD. The switching circuit consists of an opto-isolator device and a zero-crossing de

the
tector circuit. The optical device isolates the control logic from the ac power circuit. The zero­crossing detector prevents an excessive transient by switching the triac only when the ac voltage

through zero volts.

passes

The NSD signal enables gates which control switching to the ribbon drive servo.

When

an end of ribbon sensor is activated, the corresponding latch turns on the related FET
example,
ing
ing motor, with
tor

When the right end of the ribbon is detected, the latch is set to the opposite state and the motors
again

When
act

the left sensor resets the latch FET

the divider of amp K2 to the

drive

current flowing through constant voltage amplifier K1, motor M1, and resis

Rc.

reverse roles.

the shuttle motor is not running, that is, NSD is high, both FET

in opposition, as the voltage across Rc provides feedback to resist ribbon movement.

upper end of the resistor Rc. This connects motor M1 as the driv

, Q1 acts as an open circuit and Q2 conducts, connect

the ac shuttle drive circuit,

. If, for

s are held off and the motors

Ć

Ć
Ć
Ć

2-58 P6040/P6080 Principles of Operation

Figure 2-27. Ribbon Drive Block Diagram

Figure 2-28. Ribbon Drive

2-59P6040/P6080 Principles of Operation

Figure 2-29. Ribbon Control PCBA Simplified Schematic

2-60 P6040/P6080 Principles of Operation

2-11. Paper Feed Control Circuits (Figures 2-30 and 2-31)

The paper feed motor contains two pairs of coils, driven in sequence. As the electromagnetic
detent locking the rotor is released, the rotor is advanced one increment, and the detent is set
again. One pair of coils is driven by the push-pull signal, PFM1/PFM2, and the other pair by
PFM3/PFM4.

The drive signals are controlled by the two phase paper feed signals, PF1 and PF2, generated in

feed logic. Each pair of PF1/PF2 pulses increments the motor one step to advance paper one

paper
dot

row.

When paper is to be advanced either to the next character line, to the top of form, to a selected
vertical tab or by being put under EVFU control, the corresponding profile of paper movement
velocity
a variable rate to optimize both speed and precision and decelerated at a variable rate that preĆ
vents
PF2 at a frequency regulated by addressed velocity profile software.

PF1 and PF2 each drive identical independent control circuits. Either circuit operates when the
paper feed pulse passes through gates and drives a push-pull current amplifier circuit that proĆ
vides

is selected from the

overshoot. T

drive current to one pair of motor coils.

o achieve this modulated paper movement, paper feed logic generates PF1 and

velocity profile to obtain precise paper control. P

aper is accelerated at

Figure 2-30. P

aper F

eed Control Circuits Block Diagram

2-61P6040/P6080 Principles of Operation

2-62 P6040/P6080 Principles of Operation

Figure 2-31. P

aper F

eed Components

2-12. Platen Open/Paper Out Switches (Figures 2-32 and 2-33)

These switches signal the control panel that the printer is out of paper or the platen has been left

When either signal is detected, paper transport is disabled. The signal faults are reported

open.
the

logic C3 through the control panel NFPF

AUL

T switch.

to

2-63P6040/P6080 Principles of Operation

2-64 P6040/P6080 Principles of Operation

Figure 2-32. Platen Open Switch

Figure 2-33. P

aper Out Switch

2-65P6040/P6080 Principles of Operation

2-13. Safety Circuits, P6080 Only (Figure 2-34)

Excessive
situations:

Three safety circuits on the hammer driver board prevent excessive current by disabling the tri­state
low:

current and overheating can damage

- Current

-

Current left on after hammer spring release.

buffers under control of the OE signal. F

-

Initial power on - the OE flip-flop is held reset until +9.5 V rises
ance.

- 5HL supply out of tolerance - when the 5HL voltage output exceeds Zener diode avaĆ
lanche

- +36V
board,

turned on when not needed to release hammer springs.

This prevents spurious release of hammer springs.

levels, the OE flip-flop is reset and held low.

supply ground missing

the OE line is held reset.

- If the +36 V return is not connected to the hammer driver

coils and hammer drivers in either of the following

or each of the following three conditions, OE is held

to a value within toler

Ć

2-66 P6040/P6080 Principles of Operation

2-13. Safety Circuits-continued

A

fourth safety circuit halts hammer firing in the event of a hammer master clear, HMC, or the loss

of

the hammer reset pulse, HRS. When HMC is low, the output

U16, is normally kept high while being triggered by HRS pulses. Whenever HRS pulses stop or

goes high, the one-shot resets within one millisecond and hammer firing stops.

HMC

of the one millisecond one-shot,

Figure 2-34. Safety Circuits

2-67P6040/P6080 Principles of Operation

Section III. Operation

2-14. Normal Operation (Figure 2-35)

a. Character Printing

During

one cycle of normal operation, the printer is setup and put online by the
control panel. Host computer data is then read into the data input buffer. ASCII data from the
input buffer is compared to tables stored in memory to determine the matrix locations to be
printed
synchronized with printer requirements using magnetic pickup signal then shifted
drivers. The selected hammers are fired. When all dots in a row are printed, the paper is shifted
one
the hammer driver. Shifting of paper is delayed to allow double printing when bold or enhanced
print

for each character and build the dot image buffer. Information from the dot image buffer

dot row and the next line of data from the dot image buffer is synchronized then shifted out to

is required.

b. Self Test

During

self test, data from memory is used to build the dot image buffer. Operation then proceeds
as

in normal printing.

operator, using the

is

out to hammer

2-68 P6040/P6080 Principles of Operation

Figure 2-35. Operation Flow Diagram

2-69P6040/P6080 Principles of Operation

2-70 P6040/P6080 Principles of Operation

CHAPTER 3

PREVENTIVE MAINTENANCE

3-1. General

This

chapter provides instructions necessary to maintain the printer in operating condition.

3-2. Preventive Maintenance Checks and Service (PMCS)

Printer

PMCS are listed in T

Remove power before performing PMCS. Failure to do so could result in

or equipment damage.

injury

NOTE: Perform PMCS every three months or after 250 hours of operation,
whichever comes first. Lubricate every 12 months or after 1000 hours of opĆ
eration, whichever comes first. Perform these services more often when operĆ

under severe conditions.

ating

able 3-1.

WARNING -

-

Item
No

1

2

3

4

5

6

7

8

Table 3-1. Preventive Maintenance Checks and Service

Name

Entire Printer

Entire Printer

Entire Printer

Shuttle Belt

Paper Feed Belt

Cam Wick and
Counterweight

Self-aligning
Followers
(P6080 Only)

Antirotation Arm
(P6040 Only)

Perform overall physical inspection per paragraph
3-3. Do no disassembly for this inspection.

Clean per paragraph 3-4.

Run print sample. Adjust (retension) hammers
if/as required.

Check tension per paragraph 5-13.

Check tension per paragraph 5-14.

Lubricate per paragraph 3-5a.

Lubricate per paragraph 3-5b.

Lubricate per paragraph 3-5c.

Procedure

3-3. Inspection

Visually inspect printer using Table 3-2 as a guide. Perform no disassembly for this inspection.
Correct

any condition that could affect performance or reliability.

3-1P6040/P6080 Preventive Maintenance

3-4. Cleaning

- CAUTION -

Do not use abrasive cleaners, particularly on window. Do not drip water

printer

into

a. Exterior of Cabinet

1. Wipe cabinet with clean, lint free cloth dampened (not wet) with water and mild deterĆ
Alternate method: spray exterior surfaces lightly with window cleaner.

gent.

2. W

ipe dry with clean, lint free cloth.

3.V

acuum ventilation slots at sides of cabinet.

. Damage to equipment will result.

Table 3-2. Physical Inspection

Item

Cabinet, Base,
Structure

Attaching
Hardware

Nameplates

Latches and,
Catches (cover
and shuttle)

Hinges

Electrical
Connectors

Controls and
Indicators

Window

Ribbon Cables

Circuit Boards

Fan and Motors

Inspection

Check for damage, cracks, breaks, dents, gouges, scratches, de­lamination, warpage, rust, corrosion, and proper finish.

Inspect screws, bolts, nuts, washers for thread damage, rust, or
corrosion

Inspect for legibility and damage.

Inspect for damage and loose or missing hardware.

Inspect for damage and loose or missing hardware.

Inspect for damage, bent or broken pins.

Inspect for damage.

Inspect for breaks, cracks, or discoloration.

Inspect for broken wire or strands, damaged insulation, pinched
wiring, and possible shorting conditions.

Inspect for breaks, warpage, evidence of overheated components.

Inspect for obvious damage.

b. Interior of Cabinet (Figure 3-1)

1. Disconnect

2.

Open cabinet cover (2).

3.

Move forms thickness lever (3) to full open. R

4.

Squeeze locking latch (4) and lift ribbon spools (5) from ribbon hubs (6).

ac power cord (1).

emove paper from printer.

P6040/P6080 Preventive Maintenance3-2

Figure 3-1. Cleaning Interior of Cabinet

3-3P6040/P6080 Preventive Maintenance

3-4. Cleaning-continued

b. Interior of Cabinet-continued

5. Dislodge

attention to tractor (7), hammer bank (8), and base pan (9).

6. W

7.

Using cloth dampened with alcohol, clean ribbon guides (11) at each side of cabinet.

8.

Open door (12) of left tractor (7). Clean paper motion detector (13) with soft brush.

9.

Clean ribbon path (14) with soft brush.

10. Inspect platen (15). If necessary, wipe with cloth moistened (not wet) with alcohol to reĆ

move

11. V

acuum up residue. A

paper dust and ribbon lint with a soft brush. V

ipe spline shaft (10) with soft cloth.

ink or dirt.

void using vacuum on ribbon path - damage can result.

acuum up residue. P

ay particular

c. Hammer Bank Assembly (Figure 3-2)

1. Remove

2.

Open front cover (2).

3.R

4.

Place ribbon drive assembly in service position.

power cord (1).

aise forms thickness adjustment lever (3) to open. Remove any paper present.

(a)

Squeeze locks (4) and remove ribbon spools (5) from ribbon hubs (6).

(b) R

emove two socket head screws (7).

(c) R

aise ribbon drive assembly (8) slightly and lift it off retaining clips (9).

(d) Mount ribbon drive assembly (8) on vertical cover support pin (10) and shoulder

(11).

screw

5.

Place hammer bank assembly in service position (Figure 3-3).

(a) If P6040, go to (b) below. On P6080 only, loosen two screws (1) and lift comb

bracket

(b) Remove

ing

(c)

Slide right tractor (6) fully to right.

(d) R

(e)

Lift ends of hammer bank cover (7) from roll pins (8), rotate off and lift out.

ă6. Use a stiff, nonmetallic bristle brush to remove ribbon lint and paper dust from hammer

(9) and tips (10). V

springs
using

a cloth or Kimwipe moistened (not wet) with isopropyl alcohol.

ă7. Remove filter (11), back flush with warm water, shake out excess water, allow to air dry,

reinstall.

(2).

two screws (3). R

slightly forward to clear hammer bank (5).

otate hammer bank assembly (5) toward front of printer.

emove antirotation arm (4) by moving it

acuum up loosened particles. R

emove stubborn accumulations

upward then tilt

Ć

ă8. Return

hammer bank assembly to operating position.

P6040/P6080 Preventive Maintenance3-4

3-4. Cleaning-continued

c. Hammer Bank Assembly-continued

P6080 Only

(a) R

otate hammer bank assembly (5) to operating position.

(b)

Place antirotation arm (4) in position.

(c)

Install two screws (3). T

(d)

Install comb bracket (2). T

(e)

Install power cord (1, Fig 3-2). Set POWER to ON.

(f)

Start printer shuttling by pressing ON LINE.

Torquing
may damage bearings.

bearing clamp bolts to an incorrect value or while

orque to 12 in-lbs.

- CAUTION -

ighten two screws (1).

shuttle is idle

(g) With

(h)

(i)

NOTE: Placing a piece of paper between the hammer tips and paper ironer
makes it easier to install the hammer bank cover. Paper should be installed
through the top of the hammer bank.

(j)

P6040 Only

(a) Place hammer bank cover assembly (7) on hammer bank (5). Make sure holes in

(b) R

(c) R

9.

Install ribbon drive assembly (Figure 3-2).

(a) Disengage ribbon drive assembly (8) from vertical cover support pin (10) and

shuttle running, torque bearing block screws (12, Fig 3-3) to 36 inch-lbs for

machined bearing blocks or 8 to 10 inch-lbs for diecast bearing blocks. Recycle

LINE switch as necessary to continue shuttle action.

ON

Set POWER to OFF

Check platen to hammer tip gap and adjust per paragraph 5-9 if necessary.

Install hammer bank cover assembly (7, Fig 3-3) on hammer bank (5).

(7) go over roll pins (8) on hammer bank.

cover

otate hammer bank (5) to normal position.

eplace antirotation arm (4). Install two screws (3). T

shoulder

screw (11).

.

orque to 12 in-lbs.

(b)

Put ribbon drive assembly (8) in position and press onto retaining clips (9).

(c)

Install two socket head screws (7).

(d)

Install ribbon spools (5) on ribbon hubs (6).

10.

Close front cover (2).

3-5P6040/P6080 Preventive Maintenance

1. POWER CORD

2. FRONT COVER

3. FORMS THICKNESS LEVER

4. RIBBON LOCKS

5. RIBBON SPOOLS

6. RIBBON HUBS

7. SCREW, SOCKET HD (2)

8. RIBBON DRIVE ASSEMBLY

9. RETAINNG CLIP (2)

10. SUPPORT PIN, VERTICAL COVER

11. SHOULDER SCREW

Figure 3-2. Cleaning Hammer Bank Assembly - Ribbon Drive to Service Position

P6040/P6080 Preventive Maintenance3-6

1. SCREW

2. COMB BRACKET

3. SCREW (2)

4.

ANTIROTATION ARM

5. HAMMER BANK

6. RIGHT TRACTOR

7. HAMMER BANK COVER

8. ROLL PINS

9. HAMMER SPRINGS

10. HAMMER TIPS

11. FILTER

12. BEARING BLOCK SCREW (2)

Figure 3-3. Cleaning Hammer Bank Assembly - Hammer Bank to Service Position (1 of 2)

-A-

P6080

3-7P6040/P6080 Preventive Maintenance

NOTE: See Sheet 1

for Legend.

Figure 3-3. Cleaning Hammer Bank Assembly - Hammer Bank to Service Position (2 of 2)

-B-

P6040

P6040/P6080 Preventive Maintenance3-8

3-5. Lubrication

a. Counterweight and Cam Wick (Figure 3-4)

ă1. Gain

ă2. Lubricate

ă3.

ă4. Restore printer to normal operating configuration by performing steps 10 through 13 of

access to counterweight and cam wick by

5-26.

counterweight.

(a)

Using serrated, long nose pliers, pull out two oil port plugs (1).

(b) A

dd one drop of S

(c)

Install oil port plugs (1).

Lubricate cam wick.

(a) Check for presence of oil by pressing a thin, flat tip object into wick (2) where

and inspecting tip for an oil film.

shown

(b) If lubrication is required, slowly add SAE 20 (or equivalent) oil until wick (2) is

on top surface. Inspect and reoil daily until oil is no longer being absorbed.

moist

(c) Check

paragraph 5-26b.

action of leaf spring (3). Be sure that cam wick (2) stays in

(4)

through one revolution of cam. If there is a problem, remove cam wick per
graph 5-26a and inspect. If damaged or worn, replace it. Install original or reĆ
placement

per paragraph 5-26b.

AE 20 oil to each port.

performing steps 1 through 4 of paragraph

contact with cam

para

Ć

b. Self-Aligning Cam Followers, P6080 Only (Figure 3-5)

ă1. Remove

ă2.

Clean cam follower yoke (1) with solvent and lubricate with S

ă3.

Install follower yoke and counterweight per paragraph 5-26b steps 1 through 6.

ă4. Place heavy shanked flat blade screwdriver between magnet block (2) and right bearing

block (3) and pry to left as shown until follower yoke (4) clears pin (5). Lift out cam folĆ
lower

ă5.

Clean cam follower yoke (4) with solvent and lubricate with S

ă6. R

ă7.

Inspect cam follower yokes (1 and 4) for proper seating and freedom to pivot.

ă8. P

counterweight per paragraph 5-26a.

AE 20 oil.

- CAUTION -

screwdriver exactly as directed or damage to hammer coil is possible.

Use

yoke (4).

AE 20 oil.

eplace cam follower yoke (4) on pin (5) using screwdriver as described in step 4 above.

erform steps 7 through 13 of paragraph 5-26b.

3-9P6040/P6080 Preventive Maintenance

Figure 3-4. Lubrication, Counterweight and Cam Wick

1. OIL PORT PLUG (2)

2. CAM WICK

3. LEAF SPRING

4. CAM

P6040/P6080 Preventive Maintenance3-10