Printronix P9012 Maintenance Manual

Download

Page 1

P/N 132305–001, Rev E



P9012 Multifunction Line Printer



Page 2

WARNING

Note: This equipment has been tested and found to comply with the limits for a Class A digital device,

pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

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.

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.

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 digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the radio interference regulations of the Canadian Department of Communications.

Ce matériel numérique n’émet pas de bruits radio–électriques supérieurs aux limites fixées pour les appareils numériques de la Classe A dans le règlement sur le brouillage radio–électrique publié par le Ministère des Communications du Canada.

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.

, 1992.

P9012 Multifunction Line Printer Maintenance Manual

, P/N 132305–001, Revision E,

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 (714) 863–1900 FAX (714) 660–8682

Technical Support (714) 553–1515

Page 3

Table of Contents

Overview

Chapter Contents 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Use This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings and Special Information 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printing Conventions 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Documents 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Features 1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Features 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Switches and Indicators 1–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical Controls 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I/O Panel 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools, Test Equipment, and Supplies 1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Principles of Operation

Chapter Contents 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scope 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purpose 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Matrix Printing 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Dot Matrix 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Hammer Bank 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Character Generation 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printer Functional Elements 2–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 2–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data Control Unit (DCU) PCBA 2–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanism Control Unit (MCU) PCBA 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanism Driver PCBA 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

Page 4

Hammer Driver PCBA 2–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Bank and Shuttle Mechanics/MPU 2–28. . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Bank Assembly/Shuttle 2–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Pickup Unit (MPU) 2–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply 2–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Deck 2–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Feed Control Circuits 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen Open/Paper Out Switches 2–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Circuits 2–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal Operation 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Character Printing 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self–Test 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled Maintenance

Chapter Contents 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Checks and Services (PMCS) 3–2. . . . . . . . . . . . . . . . .

Inspecting the Printer 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Printer 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior of Cabinet 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interior of Cabinet 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Bank Assembly 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

Chapter Contents 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Messages 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Correctable Faults 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field Service Required 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symptoms Not Indicated by Fault Messages 4–11. . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Self–Tests 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running the Self–Tests 4–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hex Code Printout 4–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

Page 5

Alignments and Adjustments

Chapter Contents 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alignments and Adjustments 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Tracking Check and Adjustment 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Hub Height Adjustment 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Shuttle and Counterweight Preload 5–6. . . . . . . . . . . . . . . . . . . . . . . . . .

Shuttle and Counterweight Spring Adjustment 5–10. . . . . . . . . . . . . . . . . . . . . . .

Hammer Spring Retensioning 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Tip Alignment 5–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen Gap 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Pickup Gap 5–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Pickup Phasing Adjustment 5–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shuttle Belt Tension 5–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Feed Belt Tension 5–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Motion Sensor 5–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Out Detector 5–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Procedures

Chapter Contents 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Procedures 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools, Test Equipment, and Supplies 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side Panels 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 6–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Deck 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Control PCBA 6–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Drive Motor 6–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower and Airflow Assembly 6–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shuttle Assembly 6–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Spring 6–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Coil 6–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Assembly 6–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel Assembly 6–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

iii

Page 6

Cam Wick 6–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Pickup Unit 6–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shuttle Motor 6–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shuttle Belt 6–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Ironer 6–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Feed Belt 6–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Feed Motor 6–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractors 6–58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Motion Sensor 6–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Out Switch 6–66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen Open Switch 6–68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Fan 6–70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DCU, MCU, Mechanism Driver PCBAs 6–72. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Driver and Power Supply PCBAs 6–74. . . . . . . . . . . . . . . . . . . . . . . . . .

Card Cage 6–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Card Cage Fan 6–86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Power Bus Assembly 6–88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DC Power Bus Assembly 6–90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Driver Backplane PCBA 6–92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Logic Backplane 6–94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendices

A Power Paper Stacker Maintenance B Interconnect Diagram C Mnemonics D Torque Table E Metric Conversion Tables

Table of Contents

Page 7

Chapter Contents

Overview

About This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Switches and Indicators 1–6. . . . . . . . . . . . . . . . . . . .

Mechanical Controls 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I/O Panel 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools, Test Equipment, and Supplies 1–11. . . . . . . . . . . . . . . . . . . . .

Overview

1–1

Page 8

About This Manual

This manual explains how to maintain and repair P9012 floor cabinet printers at the field service level of maintenance. This manual covers alignments and adjustments, preventive and corrective maintenance, basic troubleshooting, and principles of operation.

This manual does not explain how to configure or operate the P9012 printer. That information is in the P9012 User’s Manual. The User’s Manual therefore supplements this manual.

How to Use This Manual

This manual is designed so that you can quickly find the information you need to maintain and repair the P9012 printer. You can locate maintenance information three ways:

• Use the Table of Contents at the front of the manual.

• Use the Chapter Contents list on the first page of each chapter.

• Use the Index at the back of the manual.

Read the entire procedure before beginning any maintenance task. Gather all required tools and make sure you understand all warnings, cautions, and notes before you begin working on the printer.

Warnings and Special Information

Always read and comply with information highlighted by special headings. The headings reveal the nature of the information:

WARNING

Conditions that could harm you as well as damage the equipment.

CAUTION

Conditions that could damage the printer or related equipment.

IMPORTANT

Information vital to proper operation of the printer.

1–2

Overview

Page 9

NOTE: Information concerning printer maintenance considered important

enough to emphasize.

Printing Conventions

Switches, indicators, and switch positions, if labeled on the printer, are printed in uppercase letters.

Messages that appear on the control panel display are also printed in uppercase letters. Example: “Press the CLEAR switch to take the printer to the OFFLINE READY state.”

Related Documents

For additional information about printer configuration and operation, and optional interfaces, refer to the following documents:

• P9012 Multinational User’s Manual (p/n 133397–001)

• PI 5225 Interface User’s Reference Manual (p/n 140351–001)

• PI 3287 Interface User’s Reference Manual (p/n 108174–001)

• IGP–100/200/400 User’s Manual (p/n 141332–001)

• IGP–110/210/410 User’s Manual (p/n 141333–001)

Overview

1–3

Page 10

Description

The P9012 Printer (Figure 1–1) is a highly reliable, multi–function dot matrix line printer. In addition to basic functions, the printer 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.

1–4

Figure 1–1. P9012 Printer

Overview

Page 11

Standard Features

• Extra Quiet Operation

• P–Series or Serial Matrix Protocols

• Raster Plot and Bit Image Graphics

• Dynamic Character Generation

Selectable Pitch Automatic Underline Shadow Print Superscript Printing Elongated Print Subscript Printing Expanded Print

• Selectable Forms Length

• Nonvolatile Electronic Vertical Formatting

• Resident International Character Sets

• Resident OCR–A and OCR–B Character Sets

• Downloadable Character Sets

• Built–in Self–Tests and Diagnostics

• Configuration Printout

• Datastream Hex Code Printout

• Ribbon Fault Detector

• Resident Serial and Parallel Interfaces

Optional Features

• Intelligent Graphics Processing (IGP)

Forms Generation Reverse Image Printing Bar Code Printing Logo Generation Expanded Character Printing

• Additional Character Sets

• Downline Loadable Character Sets

• IBM Interfaces

3287 5225/5224

• Power Paper Stacker

• Dataproducts Long–Line Interface

Overview

1–5

Page 12

Control Panel Switches and Indicators

The P9012 operator control panel switches and indicators are illustrated in Figure 1–2 and described in Table 1–1. Refer to the P9012 User’s Manual for details on control panel operation.

Status Lamps

Message Display

These

switches are provided only if the printer is equipped with an IBM 3287 interface.

These switches are visible only with the printer cover open.

ON LINE

CLEAR

6/8 LPI

PAPER ADV

HOLD ENABLE

REPRINT

CANCEL PA2

MODE

ALT

MENU UP

MENU DOWN

ON LINE

CHECK

8 LPI

VFU LOADED

RUN/STOP

ENTER F/L

MODE

Figure 1–2. Control Panel Switches and Indicators

1–6

Overview

Page 13

Table 1–1. Control Panel Switches and Indicators

Switch / Indicator Function

Except for ON LINE, all switches function only when the printer is off line.

Status lamps

Message display

ON LINE switch Press to place the printer on line or off line.

ON LINE indicator Illuminates when the printer is on line.

CLEAR switch

CHECK indicator Illuminates when a fault condition occurs.

6/8 LPI switch

8 LPI indicator Illuminates when line spacing is other than 6 lpi.

PAPER ADV

switch

VFU LOADED

indicator

Illuminate when the printer is on line, flash alternately to indicate a fault condition, and remain off when the printer is off line.

Displays printer status and error messages.

Press to clear a fault indication after a fault has occurred. Press while in a configuration menu to return the printer to the of RUN/STOP at the same time to reset the printer.

Press to display and select the current line spacing.

Press momentarily to advance the paper one line. Press and hold to advance the paper to the next top of form.

Illuminates when the format is being controlled by the vertical format unit.

f line state. Press CLEAR and

HOLD ENABLE

REPRINT PA1

CANCEL PA2

ALT MODE

switches

MENU UP switch Press to view the next menu or submenu. Press MENU UP and

MENU DOWN

switch

NEXT switch Press to display the next parameter and its current value in a configuration or

PREV switch

RUN/ST

OP switch Press to run and stop configuration and self tests. Runs and stops hex dump.

Used only if the printer is equipped with an IBM 3287 interface. For details, refer to the

same time to lock or unlock the ENTER switch.

Press to view the previous menu or submenu. Press MENU DOWN and at the same time to lock or unlock the ENTER switch.

diagnostic test menu.

Press to display the previous parameter and its current value in a configuration or diagnostic test menu.

Press RUN/ST

PI 3287 Interface User’s Refer

OP and CLEAR at the same time to reset the printer.

ence Manual, P/N 108174–001.

(???)

at the

(???)

Overview

1–7

Page 14

Switch / Indicator Function

ENTER switch Press to enter a displayed parameter into the printer’s nonvolatile memory.

Must be unlocked before using, via the MENU UP or MENU DOWN switch.

PRINT MODE

switch

F/L switch Press to display and select the current forms length.

Press to display and select the current print mode.

Mechanical Controls

P9012 mechanical controls are described in Table 1–2 and illustrated in Figure 1–3.

Table 1–2. Mechanical Controls

Item No.

(Figure 1–3)

Control or

Indicator Function

Forms Thickness

Adjustment Lever

Sets the platen for different thickness forms or paper. Open (raise) fully for loading paper.

3 Horizontal

4 Tractor Lock (2) Locks tractors in position.

5 Vertical

6 Tractor (2) Used to set the left margin and paper width. The left tractor moves

Forms Thickness

Scale and Pointer

Adjustment Knob

Indicates the relative thickness of forms or paper.

Allows fine positioning of the left print mar slightly to the left or right.

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

approximately one inch. The right tractor moves the full range.

gin. Moves paper

1–8

Overview

Page 15

1. Forms

2. Forms Thickness Scale/Pointer

4. Tractor Lock (2)

5. V

6. Tractor (2)

Thickness Adjustment Lever

Horizontal Adjustment Knob

ertical Adjustment Knob

Overview

Figure 1–3. Mechanical Controls

1–9

Page 16

I/O Panel

The P9012 printer supports serial and parallel interfaces. Figure 1–4 shows the I/O panel on the rear of the printer.

1. RS–232

2. AC On/Off Switch

3. AC Power Connector

Serial Connector

Dataproducts Parallel Connector Centronics Parallel Connector

1–10

Figure 1–4. I/O Panel

Overview

Page 17

Tools, Test Equipment, and Supplies

The tools, test equipment, and supplies required for field level maintenance of P9012 printers are listed in Table 1–3.

Table 1–3. Tools, Test Equipment, and Supplies

Item Part Number Recommended Item

Adjustable W Diagonal Cutters Digital Voltmeter — — Extension, 3 in., 3/8 Drive — — Feeler Gauge Set — Proto 000AA Hammer Tip Alignment Tool 132266–001 — Isopropyl Alcohol — — Kimwipes — — Lubricant 101805–001 — Nut Driver Set — Xcelite P2120 Oscilloscope and Probes (≥35 MHz) Pliers, Grip Ring — Truarc 1120 Pliers, Chain Nose Ratchet, 3/8 in. Drive — — Rule, Steel, 6 in. — General 616 Scale, Spring, 0 to 40 lbs. — — Driver, Torque Screwdriver — Utica TS35 Adapter, Torque Screwdriver —

rench —

— Erem 91EH

— —

— Erem 11DH

Utica 91–4C

Utica HW–18 Extension, 6 in., Torque Screwdriver — — Hex Bit, 3/16 in., Torque Screwdriver — Hex Bit, 3/32 in., Torque Screwdriver — Hex Bit, 5/32 in., Torque Screwdriver — Hex Bit, 5/64 in., Torque Screwdriver — — Screwdriver, Allen Hex — Xcelite 99PS40 Screwdriver, Phillips — Screwdriver, Phillips — Screwdriver, Slot — Screwdriver, Slot —

Overview

Utica W–8 Utica HW–4 Utica HW–6

Xcelite X100 Xcelite X102 Xcelite A184

Xcelite R3164

1–11

Page 18

Item Recommended ItemPart Number

Shims, Counterweight 101564–001 — Shims, Shuttle Assembly Socket, 7/16 in., 3/8 in. Drive — — Soldering Iron and Tips — — X–acto Knife and Blades

103422–001 —

— —

1–12

Overview

Page 19

Chapter Contents

Principles of Operation

Scope 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purpose 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Matrix Printing 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printer Functional Elements 2–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 2–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data Control Unit (DCU) PCBA 2–14. . . . . . . . . . . . . . . . . . . . . . . .

Mechanism Control Unit (MCU) PCBA 2–18. . . . . . . . . . . . . . . . . .

Mechanism Driver PCBA 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Driver PCBA 2–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Bank and Shuttle Mechanics/MPU 2–28. . . . . . . . . . . . . . .

Power Supply 2–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Deck 2–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Feed Control Circuits 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen Open/Paper Out Switches 2–36. . . . . . . . . . . . . . . . . . . . . . . .

Safety Circuits 2–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal Operation 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Principles of Operation

2–1

Page 20

Scope

Purpose

This chapter presents the principles of operation for the P9012 printer. This information is intended to provide the technician with a basic understanding of printer functional operation.

This chapter also provides illustrations which show the location of test points on the P9012 PCBAs.

For a complete list of signal mnemonics mentioned in this chapter, refer to Appendix C.

The P9012 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.

2–2

Principles of Operation

Page 21

Matrix Printing

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.

When in the data processing print mode, for spacing of six lines per inch there are 12 dot rows from the top of one character line to the top of the next (Figure 2–1 and Figure 2–2). With spacing of eight lines per inch there are nine dot rows per character line, for nine lines per inch there are eight dot rows per character line, and for spacing of ten lines per inch there are seven dot rows per character line.

Elongated characters can be generated by printing each row twice, except for the first and last (Figure 2–3).

0.01389

0.02

112COLUMN NO.

”

0.10

0.00835

”

Figure 2–1. Defining the Dot Matrix

FIRST ROW AND COLUMN OF NEXT CHARACTER

LOWEST DESCENDER

LINE

DOT

FIRST ROW AND COLUMN OF NEXT CHARACTER LINE

6 LPI)

(AT

Principles of Operation

2–3

Page 22

UPPERCASE

(REFERENCE)

UNDERLINE

Figure 2–2. Typical Characters

LOWERCASE

WITH DESCENDER

PRINTED

WITH

UNDERLINE

WITH UNDERLINES

DOT COLUMN

13579

DOT ROW

1 2

’

2 3

’

3 4

’

4 5

’

5 6

’

6 7 7

’

8 9

UNDERLINE

WITHOUT

DOT ROW

’

2 3

’

3 4

’

4 5

’

5 6

’

6 7

UNDERLINES

DOT COLUMN 13579

2–4

Figure 2–3. Elongated Characters

Principles of Operation

Page 23

The Hammer Bank

In order to use matrix printing, you must have a method to print the required dots. The P9012 uses the hammer bank.

The hammer bank contains a number of print hammers mounted on a shuttle that can move back and forth horizontally. The shuttle prints a full line of dots during each cycle of back and forth motion.

Each hammer consists of a stiff leaf spring attached at one end to the hammer bank with a screw (Figure 2–4). The end opposite the screw has a pointed tip attached. A permanent magnet keeps all the hammers retracted and under tension. Each hammer has a magnetic coil which when energized counteracts the permanent magnet, causing the hammer to release and strike the ribbon and paper, leaving a dot (Figure 2–5). After printing, the rebounding hammer is recaptured by the permanent magnet.

RIBBON

RIBBON MASK

MAGNET

SHUTTLE SHAFT

HAMMER BANK COVER

PAPER

HAMMER TIP

COIL

PLATEN

HAMMER SPRING

PAPER IRONER

Figure 2–4. Hammer and Shuttle Arrangement (Typical)

Principles of Operation

2–5

Page 24

DE–ENERGIZED ENERGIZED

PERMANENT MAGNET

COIL

COIL COIL

NORMAL (RETRACTED) STATE ACTIVATED (RELEASE) STATE

HAMMER TIP

HAMMER SPRING

COIL

Figure 2–5. Print Hammer Action

2–6

Principles of Operation

Page 25

Character Generation

Paper advances one dot row after each shuttle cycle, causing the dot matrix to be filled as required to generate each character (Figure 2–6 and Figure 2–7).

DIRECTION OF SHUTTLE MOVEMENT

ONE

CHARACTER

ROW

DOT

ROW START

1 2 3 4 5 6 7 8

10 11

SPACE

1 2

1 HAMMER PRINT SPAN

USED FOR LOWERCASE DESCENDER ONLY

USED FOR UNDERLINE AND LOWERCASE DESCENDER

NOTE:

The P9012 shuttle sweeps through 1.5 character positions at 10 cpi.

1 HAMMER PRINT SPAN

PAPER

ADVANCES

PAPER

FEED

PAPER

ADVANCES

Figure 2–6. Standard Character Formation

Principles of Operation

2–7

Page 26

SHUTTLE SCAN

DOT

* 1 * 1

ROW

SUCCESSIVE HAMMER STROKES PER SCAN

DOT COLUMN

1 3

* 1

3 5 7 1 3 5 7 9

* * 3

1 2

1 2 3

1 2 3 4

1 2

3 4 5

1 2 3 4 5 6

* EVEN COLUMN DOT CENTERS WITHIN THE PRINTED CHARACTER AREA

AND CHARACTER SPACE HAMMER POSITIONS ARE NOT ILLUSTRATED IN THIS DIAGRAM.

NOTE: = DOT

= NO DOT WHERE HAMMER HAS BEEN = HAMMER POSITION

Figure 2–7. Character Formation by One Hammer

2–8

Principles of Operation

Page 27

Printer Functional Elements (Figure 2–8 and Figure 2–9)

The printer is made up of the following functional elements:

• Control Panel

• Data Control Unit (DCU) PCBA

• Mechanism Control Unit (MCU) PCBA

• Mechanism Driver PCBA

• Hammer Driver PCBA(s)

• Hammer Bank and Shuttle Mechanics/Magnetic Pickup (MPU)

• Power Supply PCBA(s)

• Ribbon Deck

• Paper Transport

• Platen Open/Paper Out Switches

Figure 2–8 shows the basic interrelation of these elements and Figure 2–9 is a simplified block diagram of the printer.

Principles of Operation

2–9

Page 28

TRACTOR (Paper T

ransport)

PAPER OUT SWITCH

RIBBON DECK

PLATEN OPEN SWITCH

CONTROL PANEL

SHUTTLE MOTOR / MPU (Shuttle Mechanics)

HAMMER BANK / SHUTTLE

2–10

PCBAs

Figure 2–8. Printer Functional Elements

Principles of Operation

Page 29

SERIAL

HOST I/O

PARALLEL

DATA

CONTROL

STATUS

DATA

CONTROL

STATUS

CONTROL

PANEL

S T

I T C H

FAULT/STATUS

DCU MESSAGE

READY, READ

MESSAGE

BEEPER

DCU MCU

DO–D7

HSC

COM

+5V GND

MOTOR

CONTROL

FAULTS

SENSE

PM1–PM4

FROM P/SFROM MECH DRIVER

+36V GND –12V

MECHANISM

DRIVER

FAULT CIRCUITS PAPER TRANSPORT

DRIVE SHUTTLE DRIVE

RIBBON DRIVE P/S CIRCUITS

+5V –12V

+12V

GND

TO DCU AND MCU

POWER

120V 240V

50 or 60 Hz

–12V

GND

+12V

+5V

FROM MECH DRIVER

FROM P/S

POWER SUPPLY

+36V GND –12V

C O M

HAMMER DRIVERS

HAMMER

+36V GND –12V

H S C

L T

BANK

TO HAMMER DRIVER AND MECH DRIVER

O S

I O N

PAPER

DRIVE

STEPPER

MOTORDCMOTORDCMOTORS

SHUTTLE

DRIVE

S E N S E

RIBBON

DRIVE

FAULT

(IL/AIR)

BLOWER

ASSEMBLY

D R

V E

FAN

F A U L T

PLATEN

OPEN/

PAPER

OUT/

PAPER

MOTION

Principles of Operation

Figure 2–9. System Block Diagram

2–11

Page 30

Control Panel (Figure 2–10 and Figure 2–11)

The control panel consists of ten indicators, 16 momentary contact switches, and an LCD alphanumeric display.

The control panel processes and sends switch closure information to the DCU. It receives information on setting up the alphanumeric display as well as status information. For a detailed discussion of panel operation, refer to the P9012 User’s Manual.

Status Lamps

Message Display

These

switches are provided only if the printer is equipped with an IBM 3287 interface.

These switches are visible only with the printer cover open.

ON LINE

CLEAR

6/8 LPI

PAPER ADV

HOLD ENABLE

REPRINT PA1

CANCEL

ALT

MODE

MENU UP

MENU DOWN

ON LINE

CHECK

8 LPI

VFU LOADED

RUN/STOP

PRINT MODE

ENTER F/L

2–12

Figure 2–10. Control Panel

Principles of Operation

Page 31

CONTROL PANEL ASSEMBLY

SW CLOSURES

STATUS

SWITCH CLOSURES

DATA

CONTROL PANEL PCBAPANEL DCU

CONTROL

Figure 2–11. Control Panel Block Diagram

Principles of Operation

2–13

Page 32

Data Control Unit (DCU) PCBA (Figure 2–12 and Figure 2–13)

The data control unit (DCU) PCBA begins the printing process by receiving data through the host interface (J1, J2). Three interfaces are available on the DCU card: the Centronics and Dataproducts parallel interfaces (J2), and an RS–232 compatible serial interface (J1) running up to l9,200 baud. Protocols are set up through the control panel.

In the parallel mode the input data is transferred directly via Direct Memory Access (DMA) into memory. While in the serial mode, the input data is entered into the input buffer with an interrupt–driven software routine. Once the data is in the input buffer, as defined by software, the data is then taken from the ASCII format to the format used in the dot image buffer (DIB). Software determines the special character attributes and any special handling of the data in the DIB due to the control characters.

The data is then loaded to the hammer driver card through the hammer load circuit. The hammer load circuit is activated by the mechanism control unit (MCU) pulling the NLOAD signal low. This signal interrupts the processor at the highest level available. In this case the DCU is a slave to the MCU.

Control of the data transferred to the hammer drivers is done in the DCU. A signal, NHMRBLK (hammer bank), loads all 0’s or non–printables to the hammer driver card if asserted when the hammer load circuit is activated. The DCU commands the MCU to drive all of the motors and other mechanical interfaces. Print densities are transmitted to the MCU from the DCU for proper MCU control of the mechanics.

2–14

Principles of Operation

Page 33

DCU PCBA

Serial I/O

Parallel I/O

(Slot 3)

TP4 (+12VDC) TP3 (–12VDC)

TP2 (VCCP5)

TP1 (GND)

Figure 2–12. Data Control Unit (DCU) PCBA

Principles of Operation

2–15

Page 34

CLOCK

GENERATION

8/4/2 MHZ

NRST

2MHZ

RESET

GENERATION

370 ms

4MHZ

CLK

RESET

HALT

8MHZ

NMC

CLK

68000

CPU

ADDR

DATA

(23)

(16)

ADDRESS

DECODE

BUS

ARBITRATION

CONTROL

ADDRESS BUS

DATA BUS

EPROM

160K x 16

INTERFACES

HOST

RS–232

HOST

DATA

PRODUCTS

CEN–

TRONICS

HOST

RXD DCD DSR

CTS TXD

RTS

DTR

REVCHNL

RX CLK

TX CLK

EXT CLK

GND

IDB8–IDB1

PI IDSTB IDRQ IRDY IONL

ICSTB ICBUSY

IACK ICPE +5V GND NDAV DSTBOUT

BAUD RATE

XTAL OSC

CLK INTA INTERRUPT

HOST SERIAL

AND INTERRUPT

CONTROLLER

(RS–232–DVRS/RCVRS)

PARALLEL

I/F

CONTROL

SIGNALS

DATA

LATCHING

CNTL

DTACK

H O S T

INPUTS

68901

F A U

ERROR

CNTLS

DECODE

BUFFER

H O

S T

D M

A D D R

(18)

T C H

DMA HNDSHK

DTACK

GENERATOR

4MHZ

I/F

I/O

POLARITY

IDS

PARITY CHECK

CONTROL CODE DETECT

DELETE CODE DETECT

OVERRUN DETECT

AND

RD WR

INTA

SERIAL

AND

PARALLEL

I/F DMA

CONTROLLER

68B44

NLOAD

2MHZ

DMA

HNDSHK

BUS

ARBITRATION

ADDRESS BUS

DATA BUS

(16)

Figure 2–13. Data Control Unit (DCU) Block Diagram (1 of 2)

2–16

Principles of Operation

Page 35

MISC.

CONTROL

SIGNALS

NLOAD

NVRAM

2K x 8

ADDRESS

OUTPUT

STATUS

A D

S E

L E C

ADDRESS BUS (23)

DATA BUS

(16)

NSWITCH

FRONT

PANEL

I/F

LOGIC

ADDRESSABLE

LATCHES

A0,

– P/S

S/P

SHIFT REGISTER

NPFAULT REGSEL NENABLE NSWITCH NPCLK NPLOAD

HAMMER DATA CONTROL PARALLEL AND SERIAL I/O CONTROL

MCU

I/O

(8)

PDATA

+5V

GND

J11

C O N T R O L

P A N E L

DOT

PLUCKER

MEMORY

CONTRLR

DRAM

256K X 16

Figure 2–13. Data Control Unit (DCU) Block Diagram (2 of 2)

+5VDC +12VDC –12VDC

GND

MCUFLT

MCUREC

NLOAD

COM HSCK

MCU

HAMMER

DRIVER

MECH

DRIVER

Principles of Operation

2–17

Page 36

Mechanism Control Unit (MCU) PCBA (Figure 2–14 and Figure 2–15)

The mechanism control unit (MCU) PCBA controls the printer mechanism through signals sent to the hammer driver and mechanism driver PCBAs.

The board is controlled by a microprocessor. It contains three sections of memory, timers and control ports in order to control hammer firing, shuttle motion, ribbon movement, and paper feed. It receives instructions and commands from the DCU and communicates status and fault information back to the DCU.

2–18

Principles of Operation

Page 37

TP3 (PPR BUSY)

TP4 (SDIR)

MCU PCBA

(Slot 4)

TP1 (+5VDC)

TP2 (GND)

Figure 2–14. Mechanism Control Unit (MCU) PCBA

Principles of Operation

2–19

Page 38

CLOCK

GENERATION

6/3 MHZ

RESET

GENERATION

750 ms

COMMAND PORT 4 X 8 MCU/R: DCU/W 4 X 8 DCU/R: MCU/W

(4)

A M M

E R

D R

(4)

E R

I/O

(4)

N/A

(4)

CLK

3MHZ

RESET

MCU / DCU

DIP SWITCH

HAMMER

DRIVER

TEST PORT

HAMMER

DRIVER

STATUS PORT

COLOR

CONTROL

PORT

6MHZ

NRST

CLK

Z–80 CPU

BD0–7

D4–7

BD0–3

D0–7

ADDR

DATA

CNTL

(16)

(8)

–7

!/O AND

ADDRESS

DECODE

BUFFERED ADDRESS BUS

EPROM 36K X 8

BUFFERED DATA BUS

CNTLS

DECODE

AND

BUFFER

D 0

Z–80 CTC

8254

TIMER

8254

TIMER

INTA

NUD/HRS

DCMOD HAM

A0, A1

–7

F E

D D

A T A

B U

F E R E D

A D D R E S S

B U S

MCU REC

D0–7

FIRE 0,1,2

(16)

(8)

DCU

I/F

COM HSC

Figure 2–15. Mechanism Control Unit (MCU) Block Diagram (1 of 2)

2–20

Principles of Operation

Page 39

BUFFERED ADDRESS BUS

BUFFERED DATA BUS

SRAM

16K X 8

MCU REC

D0–7

DOT

COUNTER

STATUS

D0–3 D4–7

BD0–3

FIRE 0,1,2

PAPER FEED

FIRE

CONTROL

LOGIC

RIBBON

CONTROL

PF1/2

(4)

PF3/4

AIRFLT IL

NFLT NPLAO NPADO NRIBFLT PMD

NHCK

NUD/HRS

FAULT

I/F

MECH

DRIVER

I/F

(3)

MECH

DRIVER

I/F

DCU I/F

HAMMER

DRIVER

I/F

HAM

COM

HSC

Figure 2–15. Mechanism Control Unit (MCU) Block Diagram (2 of 2)

Principles of Operation

DCMOD

MECH

DRIVER

I/F

2–21

Page 40

Mechanism Driver PCBA (Figure 2–16 and Figure 2–17)

The mechanism driver PCBA contains those circuits required to drive the various motors of the printer mechanism. These driver circuits are under control of the MCU. The mechanism driver PCBA also produces, by use of switching regulators, the DCU. These voltages are generated from the +36 V output of the power supply. A 63 VDC power supply on the board is used in the paper feed motor circuit and the shuttle motor circuit. Fault detect circuits monitor error indications and sends a fault message flag to the MCU.

±12 V and +5 VDC required by the MCU and

2–22

Principles of Operation

Page 41

TP8 (PPF RAMP)

TP7 (+5V)

TP6 (+5 R

TP25 (+58V)

TN)

Mech Driver PCBA

TP11 (PF1 CHOP) TP10 (VREF) TP9 (PF2 CHOP)

(Slot 5)

Note:

TP23 (SHT PROP)

All voltages shown are in VDC.

TP22 (HES A)

TP24 (SHT INTEG)

TP5 (+12V) TP4 (+63V)

TP3 (+36V)

TP2 (MPU)

TP1 (PMD)

Principles of Operation

TP21 (HES RET/–12V)

TP13 (–12V)

J10

TP15 (–12V)

Figure 2–16. Mechanism Driver PCBA

2–23

Page 42

+36V

MCU

PCBA

FILE

MPU

12VDC

+5V IN

MASTER

CLEAR

RIB MOV

GUIDES

RIB TEN

PF1/PF2 NRUN1/NRUN2

PMD NPAPO

NRIBFLT NPLAO

DCMOD NUPTOSPD

MPU PULSE

SHAPER

12 VDC POWER SUPPLY

+5 VDC POWER SUPPLY

POWER UP

RESET

+36V

SWR SWL

STEPPER MOTOR

+63VDC POWER

RIBBON

DC MOTORS

DRIVER

PAPER FEED

DRIVERS

SUPPLY

FAULT

DETECT

DC MOTOR

DRIVER

–12V +36V MPU + MPU –

+36VDC

+36V RTN

+5VDC

BRKRTRP

PMD

AMPLIFIER

DRIVE SENSE

+58 VDC

REGULATOR

BLOWER

DRIVER

–12V +36V

BREAKER

TRIP

LEFT RIB. MTR

RIGHT RIB. MTR.

PAPER FEED MOTOR

PAPER

MOTION DETECT

PAPER TRANSPOR T

RIBBON DRIVE

SHUTTLE MECHANICS

DC SHUTTLE MOTOR

MAGNETIC

SENSOR

BLOWER

AC POWER

CIRCUIT

BREAKER

MECHANISM DRIVER PCBA

Figure 2–17. Mechanism Driver Block Diagram

2–24

GND +36 –12

Principles of Operation

Page 43

Hammer Driver PCBA (Figure 2–18 and Figure 2–19)

Each of the print hammers is controlled by electromagnetic coils, a driver, and a logic circuit which, among other functions, controls the energizing of the coils.

The hammer logic circuits perform the following functions:

• Convert serial data bits on the COM line into parallel data bits.

• Control the energizing of hammer coils to print dots in accordance with

the parallel data.

• Provide safety features to prevent coils from energizing under conditions

that could damage coils and hammer drivers.

• Provide an isolated and regulated +5 VDC supply, 5HL, for TTL logic

on the hammer driver PCBA.

Following a SYNC pulse, hammer shift clock (NHSC) pulses load data from the COM DATA line into the hammer driver shift register. Every bit on the COM line is clocked into the shift register by the rising edge of NHSC, containing dot information for the characters to be printed by each hammer.

After the last bit is clocked into the shift register, the next SYNC pulse causes hammer clock, NHCK, to load the contents of the shift register into the data latches.

When a dot is to be printed, the data latch for that hammer is set and the corresponding Darlington driver transistor is forward biased. At the same time, the overdrive transistor is also forward biased for a period of time controlled by the upper drive (NUD) signal from the MCU. During the overdrive period, 48 volts are placed across the coils whose Darlingtons are energized. After the NUD period is over, a –12V to ground current path provides the current for the remainder of the hammers on time. This process energizes the coil, releasing the hammer to print out.

Hammer reset signal, HRS, resets the output enable (OE) of the latch. The latch output disables all Darlington drivers and deenergizes the coils. The rebounding hammers are recaptured by the permanent magnet.

Principles of Operation

2–25

Page 44

TP10 (–8V)

TP1 (+5V)

TP7 (–12V)

TP8 (OD)

TP2 (COM1)

Hammer Driver PCBAs (1–3)

Note:

All voltages shown are in VDC.

TP3 (–HCK)

TP6 (+36V)

TP4 (NHSCB)

TP5 (–HRS)

TP9 (COMOUT)

2–26

Figure 2–18. Hammer Driver PCBA

Principles of Operation

Page 45

TEST

TIMING

+12V R

+5V

HMC

–12V

+36V

MONITOR #1

HAMMER

DRIVER (H/D)

REGULATOR

FAULT

+5V

HAMMER

OUTPUT DISABLE

CIRCUITS

5HL

DARLINGTON DRIVERS (33)

+36V

–12V

FAULT

MONITOR #2

NHCK

HRS NUD

COM IN

NHSC

OPTO–

ISOLATORS

HCK

HRS

OD COM IN NHSC

D CK

DATA

TCHES (33)

SHIFT REGISTER (33)

OPTO–

ISOLATOR

Figure 2–19. Hammer Driver Block Diagram

COM OUT

Principles of Operation

2–27

Page 46

Hammer Bank and Shuttle Mechanics/MPU (Figure 2–20)

Hammer Bank Assembly/Shuttle

Operation of the hammer bank and shuttle is described on page 2–5.

Magnetic Pickup Unit (MPU)

Printing is synchronized with shuttle movement by the magnetic pickup (MPU) signal. The magnetic pickup, located next to the flywheel timing disk, is so oriented that timing signals relate precisely to the shuttle position. Variations in magnetic reluctance are sensed by the magnetic pickup from apertures on the timing disk as it rotates, generating SYNC pulses. Two aperture locations at opposite ends of the disk are of double width (material between two adjacent apertures is removed). These double width apertures separate the 284 single width apertures into two groups and generate a RESYNC signal coincident with the shuttle starting to move from left to right.

Full rotation of the disk provides eight printing periods and four back and forth shuttle cycles. Each printing period is followed by a turnaround period when the shuttle movement is reversed, paper is advanced 0.0139 inches, and no printing occurs.

The SYNC pulses are distributed to timers on the MCU.

The SYNC signal performs the following functions:

• Signals the MCU to load the hammer driver shift register for the next

hammer firing.

• Activates all hammers armed with a logic “1” during the previous load of

the hammer driver shift register by generating the NHCK signal.

• Initiates two time out periods which control the upper drive (NUD) and

the hammer reset signal (HRS). These signals activate and reset hammer driver circuits previously activated by SYNC.

In the generation of SYNC and RESYNC signals, the roughly sinusoidal output of the magnetic pickup is amplified and converted to a TTL compatible square pulse by a circuit on the mechanism driver PCBA. The

2–28

Principles of Operation

Page 47

resulting MPU signal is synchronized with the timers (CLK) and applied to print synchronizing logic on the MCU PCBA.

Typical signal levels received from the magnetic pickup are:

SYNC: 2.5 to 5.5 Vpp RESYNC: 4 Vpp minimum

SHUTTLE MOTOR

(Shuttle Mechanics)

HAMMER BANK/SHUTTLE ASSEMBLY

Figure 2–20. Printer Functional Elements

MPU

Principles of Operation

2–29

Page 48

Power Supply (Figure 2–21)

The power supply PCBA is a switching power supply. Its regulated outputs are –12 and +36 VDC. These voltages are supplied to the hammer driver and mechanism driver PCBAs.

The printer contains three identical power supply PCBAs. Loading of the PCBAs is such that some operation of the printer may be possible with an inoperable power supply.

The required AC input line voltage for operation of the power supply is as follows:

90 to 128 VAC, 49–51 and 59–61 Hz 190 to 256 VAC, 49–51 Hz

If the AC input voltage is removed from the power supply, during either normal operation or an overload condition, the power supply will recover so that power may be reapplied in less than 2.5 seconds. If an overload occurs, the power supply will return to the normal operation less than 8 seconds after the fault is cleared.

The performance characteristics of the power supply are as follows:

–12 VDC supply, –12.8 V output voltage, ±10% +36 VDC supply, +36 V output voltage, ±10%

Note that the 12V load includes 60,000 mfd of filter capacitors and is considered a part of the power supply output filter.

NOTE: As shown in Figure 2–21, the power supply contains a jumper that

must be configured for the type of P9012 printer in use. For printers that contain an Autotap board, place the jumper in the “SHORT” position. For printers that do not contain an Autotap board, place the jumper in the “OPEN” position.

2–30

Principles of Operation

Page 49

Power Supply PCBAs (1–3)

SHORT

OPEN

Principles of Operation

Figure 2–21. Power Supply PCBA

2–31

Page 50

Ribbon Deck (Figure 2–22 through Figure 2–24)

The ribbon deck 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 by the other motor. When a length of metal tape at either ribbon end is detected by the ribbon guide at either side of the shuttle, the two motors exchange roles and ribbon travel is reversed. This system maintains a relatively constant ribbon speed and tension.

The ribbon moves only while the shuttle is in motion. When the printer is on and no faults have occurred, the ribbons will be tensioned by the application of NRIBEN from the MCU PCBA. When NRIBMOV is applied, the ribbon will move. NRIBMOV is applied when DCMOD comes on starting the shuttle.

The NRIBMOV and NRIBEN signals enable gates which control power to the ribbon drive motors.

When an end of ribbon sensor is activated, the corresponding latch turns on the related FET.

NRIBENMOV

NRIBEN

RIGHT

DETECTOR

LEFT

DETECTOR

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

When the shuttle motor is not running, that is, DCMOD not modulating and NRIBMOV is high, both FETs are held off and the motors act in opposition, as the voltage provides feedback to resist ribbon movement, provided NRIBEN is not deactivated by a printer fault.

+36V

RIBBON

DIRECTION

CONTROL

+5V

RIBBON

DC MOTOR

DRIVERS

M M

Figure 2–22. Ribbon Deck Block Diagram

2–32

Principles of Operation

Page 51

+5V

Figure 2–23. Ribbon Deck

+27V

+17.8V

+1V

TO +5V

+5V++

––

+36V

NSD

END OF RIBBON

DETECTORS

LATCH

Figure 2–24. Ribbon Control PCBA Simplified Schematic

Principles of Operation

+5V

IN1

+3.7V +5V

Q1 Q2

(LOW)

(HIGH)

(VOLTAGES ARE AS INDICATED

WHEN RIBBON IS RUNNING FROM

RIGHT

IN2

TO LEFT)

2–33

Page 52

Paper Feed Control Circuits (Figure 2–25 and Figure 2–26)

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 four phase paper feed signals, PF1, PF2, NRUN1, and NRUN2 generated in paper feed logic. Each pair of PF1/PF2/NRUN1/NRUN2 pulses increments the motor one step to advance paper 1/288 inch.

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 is selected by the MCU to obtain precise paper control. Paper is accelerated at a variable rate to optimize both speed and precision and decelerated at a variable rate that prevents overshoot. To achieve this modulated paper movement, paper feed logic generates PF1, PF2, NRUN1, and NRUN2 regulated by the velocity profile software.

NRUN1/PF1

NRUN2/PF2

NRUN1/PF1 and NRUN2/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 provides drive current to one pair of motor coils.

CURRENT

DRIVER

CURRENT

DRIVER

PFM1

PFM2

TO PAPER

FEED MOTOR

PFM3

PFM4

Figure 2–25. Paper Feed Control Circuits Block Diagram

2–34

Principles of Operation

Page 53

TRACTORS (PAPER TRANSPOR T)

PAPER FEED MOTOR

Principles of Operation

Figure 2–26. Paper Feed Components

2–35

Page 54

Platen Open/Paper Out Switches (Figure 2–27)

These switches signal the mechanism driver that the printer is out of paper or the platen has been left open. When either signal is detected, paper transport is disabled and the ribbon loses tension. The signal faults are reported to the control panel from the MCU to the DCU.

2–36

PLATEN OPEN SWITCH

PAPER OUT SWITCH

Figure 2–27. Platen Open/Paper Out Switches

Principles of Operation

Page 55

Safety Circuits (Figure 2–28)

Excessive current and overheating can damage coils and hammer drivers in either of the following situations:

• Current turned on when not needed to release hammer springs.

• Current left on after hammer spring release.

Three safety circuits on the hammer driver board prevent excessive current by disabling the latch output drivers under control of the OE signal. For each of the following three conditions, OE is held low:

• +5VHL supply out of tolerance — when the +5VHL voltage output

exceeds Zener diode avalanche levels, OE is held low.

• –12V, +36V supply ground missing — if the –12V, +36V return is not

connected to the hammer driver board, the OE line is held low.

• +5V, –12V voltages levels are out of tolerance.

Two other circuits monitor the leakage currents of both the overdrive transistor and the lower hammer driver transistors and if the currents are too large, the fault circuit signals the MCU which in turn turns off the printer via BRKRTRIP.

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 of the one millisecond one–shot, U16, is normally kept high while being triggered by HRS pulses. Whenever HRS pulses stop or HMC goes high, the one–shot resets within one millisecond and hammer firing stops.

NORMALLY HIGH

GOES LOW FOR HMC OR LOSS OF HRS PULSES

+5VHL

HRS

HMC

3 4 1 2

U16

1 MILLISECOND

ONE – SHOT

HRS

Figure 2–28. Safety Circuits

Principles of Operation

2–37

Page 56

Normal Operation (Figure 2–29)

Character Printing

During one cycle of normal operation, the printer is set up and put online by the operator, using 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 for each character and build the dot image buffer. Information from the dot image buffer is synchronized with printer requirements using the magnetic pickup signal then shifted out to hammer drivers. The selected hammers are fired. When all dots in a row are printed, the paper is shifted one dot row and the next dot row of data from the dot image buffer is synchronized then shifted out to the hammer driver. Shifting of paper is delayed to allow double printing when adjacent dot printing is required.

Self–Test

During self–test, internally generated data is used to build the dot image buffer. Operation then proceeds as in normal printing.

2–38

Principles of Operation

Page 57

FRONT PANEL

PRINTER SETUP

PRINTER ENABLE

HOST CONNECTION INPUT DATA

THROUGH DMA CONTROLLER

SELF–TEST SELECT FROM FRONT

68B44

(DCU)

ANEL

(DCU)

SOFTWARE

INPUT DATA

BUFFER

(IN DYNAMIC RAM)

ASCII DATA (DCU)

BUILD DOT IMAGE BUFFER (DIB)

FROM LOOK UP

PUT INTO DYNAMIC RAM (DCU)

SYNCHRONIZE THE TIMING TO

THE CODE WHEEL (MPU)

SOFTWARE (MCU)

DEMAND HAMMER LOAD (MCU)

DATA SHIFTED OUT

TABLES IN FONT

TO HAMMER DRIVER (DCU)

(DCU)

CONTROLLED BY SOFTWARE EXECUTED BY HARDWARE

Principles of Operation

FIRE HAMMERS ON NEXT MPU

ALL DOTS IN ROW PRINTED ?NY MOVE

(MCU)

SOFTWARE TIMERS

SOFTWARE DECISION

Figure 2–29. Operation Flow Diagram

PAPER

(MCU/MECH

DRIVER)

2–39

Page 58

2–40

Principles of Operation

Page 59

Chapter Contents

Scheduled Maintenance

Preventive Maintenance Checks and Services (PMCS) 3–2. . . . . . .

Inspecting the Printer 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Printer 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled Maintenance

3–1

Page 60

Preventive Maintenance Checks and Services (PMCS)

Perform Preventive Maintenance Checks and Services (PMCS) every three months or after every 250 hours of operation, whichever comes first.

Do these checks more often if the printer is used for heavy–duty, continuous printing or if it is located in a dusty area.

PMCS are listed in Table 3–1.

WARNING

Disconnect the AC power cord before performing PMCS. Failure to do so could result in injury to you or damage to the equipment.

Table 3–1. Preventive Maintenance Checks and Services

Interval Assembly Procedure Page

Every 3 months or 250 hours of operation, whichever occurs first.

Printer

Shuttle Belt

Paper Feed Belt

Inspect the printer.

Clean the printer.

Check tension.

3–3

3–4

5–24

5–26

3–2

Scheduled Maintenance

Page 61

Inspecting the Printer

Visually inspect the printer using Table 3–2 as a guide. Correct any condition found during inspection that could affect printer performance or reliability.

Item(s) to Inspect Procedure

Table 3–2. Physical Inspection

Cabinet, base, frame

Attaching hardware Inspect fasteners for thread damage, rust, or corrosion.

Nameplates Inspect for legibility and damage.

Printer cover, cabinet door(s), damper/struts

Hinges Inspect for damage and loose or missing hardware.

Electrical connectors Inspect for damage and bent or broken pins.

Controls and indicators

Windows Inspect for breaks, cracks, or discoloration.

Ribbon cables

Circuit boards Inspect for breaks, warpage, and evidence of overheated

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

Inspect for damage and loose or missing hardware. Check that the door(s) open/close without binding and stay closed. Check that the printer cover opens/closes smoothly and damper/struts hold cover open.

Inspect for damage.

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

components. Some printer disassembly is required. See Chapter 6,

Replacement Procedures.

Fans and motors

Flywheel cam, Shuttle and Counterweight cam followers

Scheduled Maintenance

Inspect for obvious damage. Some printer disassembly is required. See Chapter 6, Replacement Procedures.

After checking belt tension, inspect the cam and follower surfaces for excessive wear or damage. If required, replace the parts as described in Chapter 6, Replacement Procedures.

3–3

Page 62

Cleaning the Printer

Do not use abrasive cleaners, particularly on the window. Do not drip water into the printer; damage to equipment will result. When using spray solutions, do not spray directly onto the printer; spray the cloth.

Exterior of Cabinet

1. Wipe the cabinet with clean, lint–free cloth dampened (not wet) with water and mild detergent or window cleaning solution.

2. Dry the cabinet with a clean, lint–free cloth.

3. Vacuum the ventilation slots at the sides of the cabinet.

Interior of Cabinet (Figure 3–1)

CAUTION

1. Set the AC power switch on the rear of the printer to the O (OFF) position.

2. Disconnect the the AC power cord from the rear of the printer and open the top cover.

3. Move the forms thickness adjustment lever (1) to the fully–open position.

4. Remove paper from the printer.

5. Squeeze the lock tabs (2) and lift the ribbon spools (3) from the ribbon hubs (4).

6. Using a soft–bristled brush, wipe off paper dust and ribbon lint. Vacuum up the residue. Pay particular attention to the tractors (5), hammer bank (6), and base casting (7).

7. Wipe the splined shaft (8) with a soft cloth.

8. Using a cloth dampened with alcohol, clean the ribbon guides (9).

3–4

Scheduled Maintenance

Page 63

1. Forms

2. Lock T

5. Tractor (2)

10.

11.

12.Platen

Thickness Adjustment Lever

ab (2) Ribbon Spool (2) Ribbon Hub (2)

Hammer Bank Base Casting Splined Shaft Ribbon Guide Paper Motion Detector Ribbon Path

6 (under cover)

Figure 3–1. Cleaning Interior of Cabinet

Scheduled Maintenance

3–5

Page 64

9. Open the left tractor (5) and clean the paper motion detector (10) with a soft brush.

10. Clean the ribbon path (11) with a soft brush.

11. Inspect the platen (12). If necessary, wipe with a cloth dampened with alcohol to remove ink or dirt.

12. Vacuum dust or residue that has accumulated inside the lower cabinet.

13. Wipe the lower cabinet interior with a clean, lint–free cloth dampened with water and mild detergent or window cleaning solution.

Hammer Bank Assembly (Figure 3–2)

1. Remove the power cord from the rear of the printer and open the top cover.

2. Raise the forms thickness adjustment lever (1) to fully open. Remove any paper present.

3. Squeeze the lock tabs (2) and remove the ribbon spools (3) from the ribbon hubs (4). Slide the right tractor (5) fully to the right.

4. Remove the ribbon deck (6) as described on page 6–8 of Chapter 6, Replacement Procedures. This will provide access to the hammer bank (7).

5. Push the top edge of the ribbon mask (8) on the hammer bank cover assembly (9) toward the platen (10) and hold.

CAUTION

Exercise care when handling the ribbon mask; damage can affect print quality.

6. Use a stiff, nonmetallic bristle brush to remove ribbon lint and paper dust from the hammer springs (11) and tips (12) and from the ribbon mask, especially in the ribbon path. Vacuum loosened particles. Remove stubborn accumulations using a cloth or Kimwipe moistened (not wet) with isopropyl alcohol.

7. Return the ribbon mask to the operating position.

3–6

Scheduled Maintenance

Page 65

1. Forms

2. Lock T

6. Ribbon Deck

9. Hammer Bank Cover

10.Platen

11.

12.

Thickness Adjustment Lever

ab (2) Ribbon Spool (2) Ribbon Hub (2) Right T

ractor (6)

Hammer Bank Ribbon Mask

Hammer Springs Hammer T

ips

Figure 3–2. Cleaning Hammer Bank Assembly

Scheduled Maintenance

3–7

Page 66

8. Install the ribbon deck as described on page 6–8 of Chapter 6, Replacement Procedures.

9. Install the ribbon spools on the ribbon hubs. Replace paper.

10. Close the cover and return the printer to normal operation.

3–8

Scheduled Maintenance

Page 67

Chapter Contents

Troubleshooting

Introduction 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Messages 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symptoms Not Indicated by Fault Messages 4–11. . . . . . . . . . . . . . .

Diagnostic Self–Tests 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running the Self–Tests 4–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hex Code Printout 4–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

4–1

Page 68

Introduction

This chapter contains procedures for troubleshooting printer malfunctions.

You must operate the printer to check printer performance after correcting problems, so have the User’s Manual at the printer site. Although diagnostic self–test procedures are covered in this chapter, basic printer operation is not covered.

Fault Messages

If a fault condition occurs in the printer, the CHECK light illuminates, the status lamps blink alternately, and the first line of the message display indicates “FAULT CONDITION.” If configured, an alarm sounds when the Fault Condition occurs. The second line of the display indicates the specific fault.

NOTE: The alarm can be turned off before the fault is cleared by pressing

the CLEAR switch.

There are two types of displayed faults:

• Operator correctable

• Field–service required, indicated by an asterisk (*) next to the fault

message

When troubleshooting a fault message, always perform the following procedure first:

1. Press the CLEAR switch. If the printer displays “OFFLINE READY” after a few seconds, the message was a false indication. Return the printer to normal service.

2. If the fault message reappears after pressing CLEAR, turn printer power off, wait five seconds, and turn power on. If the message reappears, find the applicable message on one of the following pages, and perform the checks and corrective actions listed.

4–2

Troubleshooting

Page 69

Test the printer after each corrective action. Stop maintenance when the symptom disappears. Always press the CLEAR switch after correcting a fault indicated by a fault message.

Operator Correctable Faults

Printer problems that the operator can correct are self–explanatory and appear on the second line of the display:

CHANGE RIBBON PLATEN OPEN COOLING RIBBON PAPER JAM SHUTTLE STALL PAPER OUT STACKER

After correcting an operator correctable fault, press the CLEAR switch before placing the printer on line. If any other fault messages appear without an asterisk (*), press the CLEAR switch to continue. However, if this problem persists, contact the customer service representative (CSR) to correct the problem.

IMPORTANT

If NVM INITIALIZED PRESS CLEAR appears on the display every time the printer power is cycled, non–volatile memory must be replaced. Non–volatile memory can be temporarily bypassed by pressing the CLEAR switch. However, no configuration data will be saved, and the factory default is loaded. Contact the customer service representative to correct the fault.

Troubleshooting

4–3

Page 70

Field Service Required

Printer problems requiring the attention of the customer service representative also appear on the second line of the display and are indicated by an asterisk (*) next to the message:

FONT PROM * HAMMER DR PCB X * ( X = 1, 2, or 3 ) NOVRAM * PROGRAM PROM *

If HAMMER DR PCB X * appears on the display, printer power will automatically shut off 10 seconds after the fault message is displayed.

If, upon printer power–up, the lamps and/or LEDs flash and no message is provided in the display, contact the customer service representative to correct the fault.

4–4

Troubleshooting

Page 71

CHANGE RIBBON

Instruction Indication Yes No

1. Check for fault message when using the RibbonMinder feature.

COOLING

Instruction Indication Yes No

1. Check for inoperative blower assembly, air flow sensor, or MCU PCBA.

CHANGE RIBBON message.

COOLING message. Replace one at a

Replace the ribbon.

time, in the following order, until the message disappears: mechanism driver, MCU PCBA, sensor, blower.

—

FONT PROM *

Instruction Indication Yes No

1. Set power switch to O (OFF). Wait 5 seconds. Set power switch to 1 (ON).

2. Press the CLEAR switch. FONT PROM *

3. Run a diagnostic self–test (page 4–14).

FONT PROM * message.

message. FONT PROM *

message.

Step 2. Return printer to

normal operation.

Step 3. Return printer to

normal operation.

Replace all font PROM chips on the DCU PCBA.

Return printer to normal operation.

Troubleshooting

4–5

Page 72

HAMMER DR PCB X *

Instruction Indication Yes No

1. Set power switch to O (OFF). Wait 5 seconds. Set power switch to 1 (ON).

2. Press the CLEAR switch. HAMMER DR PCB X *

3. Run a diagnostic self–test (page 4–14).

4. Run a diagnostic self–test (page 4–14).

HAMMER DR PCB X * message.

message. HAMMER DR PCB X *

message.

HAMMER DR PCB X * message.

Step 2. Return printer to

normal operation.

Step 3. Return printer to

normal operation.

Replace the hammer driver PCBA (page 6–74) and go to step 4.

NOTE: X = PCBA 1, 2, or 3. #1 controls hammers 60–88; #2 controls 30–60; #3 controls 1–30.

Replace one at time until the message disappears: power supply PCBA (page 6–74) or shuttle assembly (page 6–18).

Return printer to normal operation.

NOVRAM *

Instruction Indication Yes No

1. Set power switch to O (OFF). Wait 5 seconds. Set power switch to 1 (ON).

2. Press the CLEAR switch. NOVRAM * message. Step 3. Return printer to

3. Cycle power. NOVRAM * message. Replace the

4–6

NOVRAM * message. Step 2. Return printer to

normal operation.

Return printer to non–volatile RAM chip on the DCU PCBA.

normal operation.

Troubleshooting

Page 73

PAPER JAM

Instruction Indication Yes No

1. Inspect paper path for bunched, torn, folded paper or labels.

2. Inspect the narrow passageway between the face of the platen and the ribbon mask for bits of torn paper or ribbon lint. Check the holes in the ribbon mask surrounding each hammer tip.

3. Check that the ribbon mask has not been deformed in such a way as to block the paper path.

Load paper feeds and run a diagnostic self–test (page 4–14).

5. Set the paper motion sensor fault setting to DISABLE. See the

6. Check paper feeding as the printer prints.

. Do some line

P9012 User’s Manual

Paper path is clear. Step 2. Remove paper

and go to step 2.

Debris found. Gently remove

paper or lint particles with a wooden stick or pair of tweezers. CAUTION: Do not pry or apply force to the hammer tips. Go to step 3.

Ribbon mask damaged or bent.

PAPER JAM message. Clean the paper

PAPER JAM message. Return printer to

PAPER JAM message. Check the tractors

Replace the hammer bank cover assembly. Go to step 4.

motion detector with cotton swab. Go to step 7.

and spring behind the tractor door. Replace the mechanism driver (page 6–72).

Step 3.

Step 4.

Return printer to normal operation.

normal operation.

Return printer to normal operation.

7. Run a diagnostic self–test (page 4–14).

8. Check the platen gap adjustment (5–18).

9. Check for damage to the paper feed motor or belt.

10. Run a diagnostic self–test (page 4–14).

Troubleshooting

PAPER JAM message. Replace paper

motion sensor assembly (page 6–62). Go to step

Platen gap incorrect. Adjust the platen

gap until it is within spec and the message disappears. Go to step 9.

Paper feed motor or belt damaged.

PAPER JAM message. Replace the MCU

Replace the paper feed motor (6–56) or belt (6–52). Go to step 10.

PCBA (page 6–72).

Return printer to normal operation.

4–7

Page 74

PAPER OUT

Instruction Indication Yes No

1. Load paper. — Step 2. —

2. Run a diagnostic self–test (page 4–14).

PAPER OUT message.

Replace paper out switch assembly (page 6–66).

Return printer to normal operation.

PLATEN OPEN

Instruction Indication Yes No

1. Load paper. — Step 2. —

2. Close forms thickness adjustment lever.

3. Run a diagnostic self–test (page 4–14).

PLATEN OPEN message.

— Step 3. —

Replace platen open switch assembly (page 6–68).

Return printer to normal operation.

4–8

Troubleshooting

Page 75

PROGRAM PROM *

Instruction Indication Yes No

1. Set power switch to O (OFF). Wait 5 seconds. Set power switch to 1 (ON).

2. Press the CLEAR switch. PROGRAM PROM *

3. Run a diagnostic self–test (page 4–14).

PROGRAM PROM * message.

message. PROGRAM PROM *

message.

Step 2. Return printer to

normal operation.

Step 3. Return printer to

normal operation.

Replace the program PROM chips on the DCU PCBA.

Return printer to normal operation.

RIBBON

Instruction Indication Yes No

1. Wind the ribbon by hand and check for folds, tears, holes, fraying.

2. Install a new ribbon. — Step 3. —

Ribbon damaged. Step 2.

If folded but otherwise okay, rewind and reinstall the ribbon.

3. Run a diagnostic self–test (page 4–14).

RIBBON message. Replace one at a

time until the message disappears: ribbon control PCBA (page 6–10), mechanism driver, or MCU PCBA (page 6–72).

Return printer to normal operation.

Troubleshooting

4–9

Page 76

SHUTTLE STALL

Instruction Indication Yes No

1. Check that forms thickness adjustment lever is not closed too tightly; this can jam the ribbon and shuttle.

2. Run a diagnostic self–test (page 4–14) and check for shuttle obstruction.

3. Check the magnetic pickup sensor for proper gap and output (page 5–20), and a broken or loose connector.

4. Run a shuttle/ribbon test. SHUTTLE STALL

5. Check for a broken or damaged shuttle belt.

6. Run a shuttle/ribbon test. SHUTTLE STALL

Forms thickness adjustment lever is set correctly.

SHUTTLE STALL message.

message. Belt is damaged. Replace the

message.

Step 2. Readjust the

setting of the forms thickness adjustment lever. Go to step 2.

Remove the obstruction and go to step 3.

Replace the MPU (page 6–42). Go to step 4.

Step 5. Return printer to

shuttle belt (page 6–48). Go to step

6. Replace one at a

time until the message disappears: mechanism driver, MCU, or DCU PCBA (page 6–72). Go to step

Return printer to normal operation.

normal operation. Step 6.

Return printer to normal operation.

7. Run a shuttle/ribbon test. SHUTTLE STALL

message.

8. Run a shuttle/ribbon test. SHUTTLE STALL

message.

STACKER

Instruction Indication Yes No

1. Check for proper paper stacking when using the power paper stacker.

4–10

STACKER message. Clear the paper

Replace the shuttle motor (page 6–44) and go to step 8.

Replace the shuttle assembly (page 6–18).

exit path.

Return printer to normal operation.

Troubleshooting

Page 77

Symptoms Not Indicated by Fault Messages

Troubleshoot malfunctions not indicated by fault messages using standard fault–isolation techniques:

1. Debrief the operator for a general description of the problem.

2. Verify the fault by running diagnostic self–tests or replicating conditions reported by the user.

3. Locate the malfunction using the half–split method:

a. Isolate faults to half the remaining system at a time, until the

final half is a field–replaceable part or assembly. (Chapter 6 lists all field–replaceable assemblies.)

b. Start at a general level and work down to details.

4. Replace the defective part or assembly.

IMPORTANT

Do not attempt field repairs on electronic components or assemblies — replace the entire assembly with an operational spare. Most electronic problems are corrected by replacing the printed circuit board assembly (PCBA), sensor, or cable that causes the fault indication. The same is true of electro–mechanical failures traced to the shuttle frame assembly or the hammer bank. Replace the entire assemblies; they are not field repairable.

5. Test printer operation after every corrective action.

6. Stop troubleshooting and return the printer to normal operation when the reported symptom(s) disappear.

Troubleshooting

4–11

Page 78

NO DISPLAY

Instruction Indication Yes No

1. Remove the right side panel (page 6–4).

2. Inspect control panel ribbon cable connector on card cage logic backplane PCBA for bent or broken pins.

3. Power up printer and check display and card cage fan operation.

4. Power up printer and check display.

—

Pins are damaged. Straighten bent

Display comes on. Resume printing. Replace one at a

Display comes on. Resume printing. Replace the

Step 2.

pins on card cage logic backplane PCBA. If broken, replace card cage logic backplane PCBA (page 6–94).

—

Step 3.

time: power supply PCBAs (page 6–74), mechanism driver PCBA (page 6–72). Test printer operation.

control panel assembly (page 6–6). Test printer operation.

4–12

Troubleshooting

Page 79

PRINTING INCORRECT DATA

Instruction Indication Yes No

1. Verify printer is plugged into correct power source. (See

User’s Manual

2. Inspect for debris that could cause short circuits (loose fasteners, foil, etc.).

3. Disconnect the interface (data) cable from the host computer to isolate the printer, then run a diagnostic self–test (page 4–14).

4. Connect the interface (data) cable to the host computer and printer.

5. Make a configuration printout. (See

User’s Manual

6. Turn off the power and remove the card cage (page 6–76).

Power cable installed correctly to proper source.

Metallic debris. Remove debris.

Printer operates correctly.

— Step 5. —

a) Configuration is correct for the user’s application. b) Host computer and printer use the same protocol (emulation). c) Configuration has not been inadvertently changed by the user.

—

Step 2. Connect printer to

Clean printer.

Fault is not in the printer.

Step 6. Reconfigure the

Step 7.

correct power source.

Step 10.

Step 4.

printer. (See

User’s Manual

—

7. Check all electrical connectors.

8. Check that PCBAs are seated correctly in edge connectors (back of card cage).

9. If an IGP PCBA is installed, check its connectors. See the

IGP User’s Manual

running IGP self–tests.

10. Set power switch to 1 (on). Printer powers up and

for

Connections are clean, tight, and oriented correctly. Wires are not stripped, frayed, or out of connectors.

PCBAs are firmly seated in card cage connectors. Ribbon cables between boards are properly seated.

—

OFFLINE READY displays.

Step 8. Replace stripped,

frayed, or broken wires.

Step 9. Reseat PCBAs.

Step 10.

Return printer to normal operation.

—

Troubleshoot fault message.

Troubleshooting

4–13

Page 80

Diagnostic Self–Tests

Run diagnostic self–tests to check the print quality and operation of the printer. The self–tests are listed below.

NOTE: Included with the description of each diagnostic test is a list of items

that may require field replacement or adjustment if the test produces a bad print pattern.

• Shift Recycle

A “sliding” alphanumeric pattern useful for identifying missing or malformed characters, improper vertical alignment, or vertical compression.

• All E’s

Shuttle assembly Hammer bank cover Hammer spring

A pattern of all uppercase letter E’s useful for identifying missing characters, misplaced dots, smeared characters, improper phasing, or light/dark character variations.

Ribbon Hammer bank cover MPU Sensor Hammer spring Hammer coil

• E’s plus TOF

A pattern of all E’s followed by a form feed to the next page top of form, useful for identifying paper motion or feeding problems (e.g., paper path obstruction, improper forms).

Hammer bank cover Power supply PCBA Mechanism driver or MCU PCBA Paper motion sensor or cable Paper feed motor or belt Splined shaft bearings Tractors or tractor belts

4–14

Troubleshooting

Page 81

• All H’s

A pattern of all uppercase letter H’s useful for detecting missing characters or dots, smeared characters, or improper phasing.

Ribbon Hammer bank cover MPU Sensor Hammer spring Hammer coil

• All Underlines

An underline pattern useful for identifying hammer bank misalignment.

Mechanism driver or MCU PCBA Hammer back cover Hammer tips Paper feed motor or belt Splined shaft bearings Tractor bearings or belts

• All Black

All dot positions are printed, creating a solid black band. Exercises shuttle and hammer bank at maximum capacity.

Hammer coil Hammer spring Hammer bank cover Power supply PCBA Mechanism driver PCBA

Troubleshooting

4–15

Page 82

Running the Self–Tests

P9012 printers include various self–test functions. Use the self–test as needed to determine if the printer is functioning normally.

To run the self–tests:

1. Place the printer off line and raise the printer cover.

2. Press MENU DOWN; repeatedly press NEXT or PREV until “DIAGNOSTICS” is displayed.

3. Press MENU DOWN, then repeatedly press NEXT or PREV until either “PRINTER TEST FULL WIDTH” or “PRINTER TEST 8 INCH WIDTH” message is displayed.

4. To select one of the 8 INCH WIDTH or FULL WIDTH paper tests, press MENU DOWN; then repeatedly press NEXT or PREV until the appropriate test is displayed. Tests include shift recycle, all E’s, and others.

5. Press RUN/STOP to begin the selected self–test; press RUN/STOP again to stop it.

NOTE: Any data remaining in the buffer will be printed before the self–test

begins.

Examine the print quality. The characters should be horizontally and vertically aligned and correctly formed. If print quality problems exist, contact the customer service representative.

6. Press CLEAR to place the printer off line. The display will read “OFFLINE READY.”

7. Close the printer cover and place the printer on line.

4–16

Troubleshooting

Page 83

Hex Code Printout

The hex code printout (often called a “hex dump”) is useful for debugging when troubleshooting printer data reception problems. Hex dumps list ASCII character data received from the host with the corresponding two–digit hexadecimal code. Printable characters print their assigned symbol; nonprintable characters are indicated with a period symbol. A “p” before the hex code indicates an active Paper Instruction (PI) line; a blank space before the hex code indicates an inactive PI line.

To print the data stream received from the host computer in hex code with ASCII character equivalents, perform the following steps.

1. Place the printer off line and raise the printer cover.

2. Press MENU DOWN; repeatedly press NEXT or PREV until “DIAGNOSTICS” is displayed.

3. Press MENU DOWN, then repeatedly press NEXT or PREV until either “PRINT DATA STREAM IN HEX CODE” message is displayed.

4. Press MENU DOWN; the display will show “OFFLINE HEX DUMP.”

5. Press ON LINE. The display will indicate that the printer is on line and in hex dump mode.

6. Send the data from the host; the hex dump will print.

7. Press ON LINE again to stop the hex dump. The display will read “OFFLINE HEX DUMP.”

8. Press CLEAR to return printer to “OFFLINE READY.”

9. Close the printer cover and place the printer on line.

NOTE: Any data remaining in the buffer will be printed before the hex code

printout starts.

Troubleshooting

4–17

Page 84

4–18

Troubleshooting

Page 85

Chapter Contents

Alignments and Adjustments

Alignments and Adjustments 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Ribbon Tracking Check and Adjustment 5–2. . . . . . . . . . . . . . . . . .

Ribbon Hub Height Adjustment 5–4. . . . . . . . . . . . . . . . . . . . . . . . .

Setting Shuttle and Counterweight Preload 5–6. . . . . . . . . . . . . . . .

Shuttle and Counterweight Spring Adjustment 5–10. . . . . . . . . . . . .

Hammer Spring Retensioning 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Tip Alignment 5–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platen Gap 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Pickup Gap 5–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Pickup Phasing Adjustment 5–22. . . . . . . . . . . . . . . . . . . .

Shuttle Belt Tension 5–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Feed Belt Tension 5–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Motion Sensor 5–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper Out Detector 5–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alignments and Adjustments

5–1

Page 86

Alignments and Adjustments

This chapter contains the alignment and adjustment procedures done at the field service maintenance level.

Ribbon Tracking Check and Adjustment (Figure 5–1)

1. Make sure paper is loaded in the printer and a full ribbon spool is on the right. Turn power on and open the printer top cover.

2. Set the forms thickness adjustment lever (1) to any position between “A” and “B.” Make sure no error indications appear.

3. Refer to the P9012 User’s Manual and command a shuttle/ribbon self–test. Shuttle action and ribbon motion should begin.

4. On either the left or right ribbon guide (2), momentarily short across the skids (3).

5. Let the ribbon run completely out of the spool. Verify the ribbon is centered in the guide. If not, follow these steps:

a. Loosen two screws (4) with washers (5) until the left ribbon guide

can be rotated about the guide post (6).

b. Pivot the guide until the ribbon tracks in the center.

c. Tighten two screws.

d. Verify that the ribbon is centered and winds up without interference

on the left spool.

6. The spool should automatically reverse. If it does not, follow these steps:

a. Replace the ribbon (page 6–8). Rerun the test.

b. If there is still an error, check the cabling.

c. If ribbon tracking is still unsuccessful, replace the ribbon deck

assembly (page 6–8).

5–2

Alignments and Adjustments

Page 87

1. Forms

4. Screw (2)

5. W

Thickness Adjustment Lever Right Ribbon Guide Right Guide Skid (2)

asher (2)

Guide Post

Figure 5–1. Ribbon Tracking Check and Adjustment

Alignments and Adjustments

5–3

Page 88

Ribbon Hub Height Adjustment (Figure 5–2)

1. Open the printer cover.

2. Squeeze the lock tabs (1) and remove the ribbon spools (2) from the hubs (3).

3. Check the distance between the bottom of the hub and the gearbox (4). The hub should just clear the gearbox.

4. If the clearance is incorrect, adjust as follows:

a. Loosen the hub setscrew (5).

b. Reposition the hub.

c. Tighten the setscrew.

5–4

Alignments and Adjustments

Page 89

1. Lock Tab (2)

Ribbon Spool (2)

Hub (2)

4. Gearbox

5. Setscrew

Figure 5–2. Ribbon Hub Height Adjustment

Alignments and Adjustments

5–5

Page 90

Setting Shuttle and Counterweight Preload (Figure 5–3)

NOTE: The preload of the shuttle and counterweight must be set when

improper shuttling action or excessive rattle is detected, or whenever shuttle drive components have been replaced.

1. Remove the ribbon deck assembly as described on page 6–8 of Chapter 6, Replacement Procedures.

2. Perform steps 1 through 5 of the counterweight removal procedure, as described on page 6–32 of Chapter 6, Replacement Procedures. This will provide access to the equipment to be adjusted.

3. Remove the right side panel as described on page 6–4 of Chapter 6, Replacement Procedures.

4. Remove the dust barrier (8).

5. Insert the force gauge (1) in the hole in the counterweight (2).

6. Insert a 0.003 inch flat feeler gauge (3) between the cam (4) and the right cam follower (5).

7. Pull the force gauge horizontally to the right. Note the gauge indication when the feeler gauge comes loose.

a. If the indication is between 12 and 17 pounds, go to step 8.

b. If the indication is less than the lower value, install a shuttle

counterweight shim as described on page 5–10 and repeat steps 5 through 7.

c. If the indication is greater than the higher value, remove a

counterweight spring shim and repeat steps 5 through 7.

8. Insert a 0.003 inch flat feeler gauge between the cam and the left cam follower (6).

9. Press the rod end of the force gauge against the cam follower yoke (7), positioning the gauge as close to parallel with the shuttle shaft as possible.

5–6

Alignments and Adjustments

Page 91

1. Force

2. Counterweight

4. Cam

8. Dust Barrier

Gauge

Feeler Gauge

Right Cam Follower Left Cam Follower Cam Follower Y

oke

Figure 5–3. Setting Shuttle and Counterweight Preload

Alignments and Adjustments

5–7

Page 92

10. Push the force gauge horizontally to the left. Note the gauge indication when the feeler gauge comes loose.

NOTE: If springs have been replaced, set the preload at the high end of

range, otherwise set at the low end.

a. If the indication is between 12 and 17 pounds, go to step 11.

b. If the indication is less than the lower value, install a shuttle spring

shim as described on page 5–10 and repeat steps 8 through 10.

c. If the indication is greater than the higher value, remove a shuttle

spring shim and repeat steps 8 through 10.

11. Operate the printer.

a. Run the printer for 10 minutes using a shuttle/ribbon fast test. Check

for rattle and increase the preload if necessary.

b. Run the printer using a shuttle/ribbon slow test. Check for stalls or

no–start conditions and decrease the preload if necessary.

12. Install the dust barrier.

13. Install the right side panel as described on page 6–4 of Chapter 6, Replacement Procedures.

14. Perform steps 7 through 11 of the counterweight installation procedure, as described on page 6–34 of Chapter 6, Replacement Procedures.

15. Install the ribbon deck assembly as described on page 6–8 of Chapter 6,

Replacement Procedures.

16. Install paper and close the printer cover.

5–8

Alignments and Adjustments

Page 93

1. Force

2. Counterweight

4. Cam

8. Dust Barrier

Gauge

Feeler Gauge

Right Cam Follower Left Cam Follower Cam Follower Y

oke

Figure 5–3. Setting Shuttle and Counterweight Preload

Alignments and Adjustments

5–9

Page 94

Shuttle and Counterweight Spring Adjustment (Figure 5–4)

NOTE: Spring force adjustments may be made with or without a force

gauge. The procedure on page 5–6 describes the use of a force gauge and is preferred over the following.

NOTE: Although the following procedure is not recommended, it may be

performed if excessive rattle is detected under the cam cover and it is not possible to perform the procedure on page 5–6. Such rattle indicates incorrect spring force, which can result in impaired print quality.

1. Open the cover.

2. Loosen two screws (1). Remove the cam cover (2) and the attached gasket (3).

3. Inspect the area around the shuttle spring (4) and the counterweight spring (5) for shims that may have broken or come loose. Replace any loose shims per steps 6 and 7 below.

4. Set the AC power switch to the ON position. Run the printer using a shuttle/ribbon test to keep the shuttle moving as necessary.

5. Loosen screw (9) about three turns. With the screwdriver, press in on the loosened screw to apply heavy pressure to the right side of the counterweight (6). Check for rattle.

a. If the rattle does not change, go to step 6.

b. If the rattle decreases, go to step 7.

6. Install a shuttle spring shim (0.01 in) as follows:

NOTE: More than one shim may be required to obtain the desired effect.

a. Set the AC power switch to OFF.

b. Use a screwdriver to pry the spring away from the yoke (7).

c. Insert a shim (8) and press down until it is flush with the yoke.

5–10

Alignments and Adjustments

Page 95

1. Screw

2. Cam Cover

3. Gasket

6. Counterweight

7. Yoke

8. Shim

9. Screw

10.Shim

11.Casting

(2)

Shuttle Spring Counterweight Spring

2 3

10 (hidden)

Figure 5–4. Shuttle Spring Force Adjustment

Alignments and Adjustments

5–11

Page 96

7. Install a counterweight spring shim as follows:

NOTE: More than one shim may be required to obtain the desired effect.

a. Loosen screw (9) about three turns.

b. With the screwdriver, press in on the loosened screw to create space

for a shim (10).

c. Install a shim between the spring spacer and the casting (11).

d. Tighten the screw.

8. Operate the printer.

a. Run the printer for 10 minutes using a shuttle/ribbon fast test. Check

for rattle and increase the preload if necessary.

b. Run the printer using a shuttle/ribbon slow test. Check for stalls or

no–start conditions and decrease the preload if necessary.

9. Install the cam cover and the attached gasket.

10. Tighten two screws and close the printer cover.

5–12

Alignments and Adjustments

Page 97

1. Screw

2. Cam Cover

3. Gasket

6. Counterweight

7. Yoke

8. Shim

9. Screw

10.Shim

11.Casting

(2)

Shuttle Spring Counterweight Spring

2 3

10 (hidden)

Figure 5–4. Shuttle Spring Force Adjustment

Alignments and Adjustments

5–13

Page 98

Hammer Spring Retensioning (Figure 5–5)

Print Too Light

1. Perform steps 1 and 2 of the hammer spring removal procedure, as described on page 6–22 of Chapter 6, Replacement Procedures. This will place the hammer bank in the service position.

2. Using the tip of a screwdriver, carefully flex the tip of the hammer spring (1) away from the pole pin (2) under the spring.

CAUTION

The hammer tip is fragile. Take care not to damage the hammer tip with the screwdriver when flexing the spring.

3. Restore the printer to the normal operating configuration by performing the hammer spring installation procedure, as described on page 6–24 of Chapter 6, Replacement Procedures.

Print Too Dark

1. Remove the hammer spring as described on page 6–22 of Chapter 6, Replacement Procedures.

2. Grip the spring with long nose pliers so the screw hole is just covered. Using the tip of the screwdriver, carefully flex the spring in a direction away from the hammer tip (3).

The hammer tip is fragile. Take care not to damage the hammer tip with the screwdriver when flexing the spring.

3. Install the hammer spring as described on page 6–24 of Chapter 6, Replacement Procedures.

CAUTION

5–14

Alignments and Adjustments

Page 99

1. Hammer

Pole Pin

Hammer T

Spring

PRINT TOO LIGHT

PRINT TOO DARK

Figure 5–5. Hammer Spring Retensioning

Alignments and Adjustments

5–15

Page 100

Hammer Tip Alignment (Figure 5–6)

1. Remove the ribbon deck assembly as described on page 6–8 of Chapter 6, Replacement Procedures.

2. Perform steps 1 and 2 of the hammer spring removal procedure, as described on page 6–22 of Chapter 6, Replacement Procedures. This will place the hammer bank in the service position.

3. Loosen the screw (1) of the hammer spring (2) to be aligned.

4. Place the alignment tool (3; P/N 132266–001) over the hammer tips. Move the hammer spring until the tip is in an appropriate hole in the alignment tool.

5. Torque the screw to 6 to 8 in–lbs and remove the tool.

6. Return the hammer bank to the operating position as described on page 6–24 of Chapter 6, Replacement Procedures.

7. Install the ribbon deck assembly as described on page 6–8 of Chapter 6,

Replacement Procedures.

5–16

Alignments and Adjustments