Page 1
R
Maintenance Manual
P9212 Line Matrix Printer
Page 2
Page 3
P9212 Line Matrix Printer
Maintenance Manual
P/N 134630–001, Rev B
R
Page 4
US and CANADA Radio Interference Note
Note: This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.
Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits.
The manufacturer is not responsible for any radio or television interference caused by using other than
recommended cables and connectors or by unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user’s authority to operate the equipment.
The input/output (I/O) cable must be shielded for the printer to comply with FCC rules and regulations Part
15 governing the radiation limits for Class “A” equipment.
This Class A digital apparatus meets all requirements of the Canadian Interference–Causing Equipment
Regulations.
Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouilleur
du Canada.
WARNING
This is a Class A product. In a domestic environment this product may cause radio interference in which
case the user may be required to take adequate measures.
Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not
limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not
be held responsible for errors contained herein or any omissions from this material or for any damages,
whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution,
performance or use of this material. The information in this manual is subject to change without notice.
This document contains proprietary information protected by copyright. No part of this document may be
reproduced, copied, translated or incorporated in any other material in any form or by any means, whether
manual, graphic, electronic, mechanical or otherwise, without the prior written consent of Printronix, Inc.
All rights reserved. Revision B. January 1996.
Trademark Acknowledgements
IPDS is a trademark of International Business Machines Corporation.
17500 Cartwright Road, P.O. Box 19559
Irvine, California 92713
Telephone (714) 863–1900 FAX (714) 660–8682
Technical Support (714) 221–2686
COPYRIGHT 1993, 1996, PRINTRONIX, INC.
Page 5
Table of Contents
1
Overview
About This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings and Special Information 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printing Conventions in this Manual 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and Indicators 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Controls and Indicators 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Controls 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools, Test Equipment, and Supplies 1–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Principles of Operation
Line Matrix Printing 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Hammer Bank 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Character Generation 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 Architectures 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 (CCB, Triple I/O) 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212–CT 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 LMI (Quad I/O) 2–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 CTHI 2–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Elements of the Printer 2–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Control Panel 2–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Boards 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Communication with the Host and Operator 2–18. . . . . . . . . . . . .
Control Panel 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic UART (LMI models) 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floppy Disk Controller Module (LMI models) 2–18. . . . . . . . . . . . . . . . .
Printing 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents
i
Page 6
Hammer Driver Interface Functions 2–19. . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Interface Functions 2–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Monitoring 2–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank and Hammer Driver Faults 2–21. . . . . . . . . . . . . . . . . . . .
Paper Faults 2–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon and Shuttle Faults 2–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCB Hardware Summary 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communicating With the Host Computer 2–24. . . . . . . . . . . . . . . . . . . . .
Communicating With the Operator 2–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Printing 2–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Monitoring 2–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LMI Hardware Summary 2–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communicating With the Host Computer 2–28. . . . . . . . . . . . . . . . . . . . .
Communicating With the Operator 2–29. . . . . . . . . . . . . . . . . . . . . . . . . .
Printing 2–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Monitoring 2–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanism Driver Board 2–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Drive System 2–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Velocity 2–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Tension 2–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start / Stop Ribbon 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Shuttle Drive System 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Feed System 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Paper Feed System 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Driver Board 2–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Driver Logic and Control 2–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Filtering 2–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank Cooling 2–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Power 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Mechanisms 2–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank, Shuttle, and MPU 2–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
Table of Contents
Page 7
Ribbon Deck 2–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Feed Control 2–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Preventive Maintenance
Preventive Maintenance 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Printer 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Troubleshooting
Introduction 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48V Power Fail 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 Volt Failed * 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCB to Mech Err. 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DCU RAM 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disk Read Error 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disk Write Error 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dynamic RAM Fault 4–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Font PROM 4–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Bank Hot 4–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Coil Open * 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Coil Short * 4–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Drv. Short * 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hmr Coil Too Hot 4–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hmr Driver Short 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Error 4–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mech Driver Hot * 4–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mech Driver Link * 4–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NVRAM 4–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Off Line / Line Check Par. 4–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On Line / Line Check Par. 4–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Jam 4–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Out 4–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents
iii
Page 8
Platen Open 4–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Stall 4–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Fan * 4–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Jam 4–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Error * 4–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Symptoms Not Indicated by Fault Messages 4–28. . . . . . . . . . .
Troubleshooting Aids 4–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Confidence Check 4–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCB Diagnostic Check 4–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTPC Diagnostic Check 4–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Self–Tests 4–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hex Code Printout 4–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASCII Character Set 4–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Nonvolatile Memory (NVRAM) 4–41. . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Adjustments
Hammer Bank Service Position 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Spring Retensioning 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Tip Alignment 5–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Pickup Gap 5–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Pickup Phasing Adjustment 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Feed Belt Tension 5–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Gap 5–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Tracking Check and Adjustment 5–26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Shuttle and Counterweight Preload 5–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle and Counterweight Spring Adjustment 5–32. . . . . . . . . . . . . . . . . . . . . . .
Shuttle Belt Tension 5–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
Table of Contents
Page 9
6 Replacement Procedures and Parts
Replacement Procedures
Blower Assembly 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Cooling Fan 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card Cage Fan 6–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel 6–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counterweight Assembly 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Shuttle) Cam and Flywheel 6–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Shock 6–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Cover Assembly 6–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Spring and Hammer Coil 6–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Panel and Cable Assembly 6–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Pickup Assembly (MPU) 6–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Wick 6–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Feed Motor and Belt 6–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Motion/Out Detector 6–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Open Motor and Belt 6–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Open Switch 6–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed Circuit Board Assemblies (PCBAs) 6–32. . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply 6–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Hub 6–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Motor 6–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Motor 6–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Motor Belt 6–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Assemblies 6–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustrated Parts Lists
Printer Assembly 6–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Mechanism 6–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Deck 6–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Shafts 6–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents
v
Page 10
Motors and Switches 6–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank Assembly 6–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Springs and Coils 6–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Counterweight Assembly 6–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Cam and Flywheel 6–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card Cage and Control Panel (CCB) 6–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Card Cage and Control Panel (LMI) 6–58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly 6–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply and I/O Assemblies 6–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Appendices
A Wire Data
B Signal Mnemonics and Acronyms
C PROM and Chip Locations
D Torque Table
E Metric Conversion Tables
F Printer Specifications
vi
Table of Contents
Page 11
1 Overview
Chapter Contents
About This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings and Special Information 1–2. . . . . . . . . . . . . . . . . . . . . . .
Related Documents 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printing Conventions in this Manual 1–3. . . . . . . . . . . . . . . . . . . . .
Electrical Controls and Indicators 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Electrical Controls 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coax Electrical Controls 1–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Twinax Electrical Controls 1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IPDS Electrical Controls 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Controls 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools, Test Equipment, and Supplies 1–14. . . . . . . . . . . . . . . . . . . . . . . . .
Overview
1–1
Page 12
About This Manual
This is a field service maintenance manual for the P9212 line matrix printer.
This manual is designed so that you can quickly locate maintenance
information.
How to Use This Manual
You can locate information three ways:
♦ Use the Table of Contents at the front of the manual.
♦ Use the Chapter Contents listed at the front each chapter.
♦ Use the Index at the back of the manual.
When following a maintenance procedure, read the entire procedure before
beginning the task. Gather all required tools and make sure you understand
all warnings and special information before you begin working on the printer.
(See below.)
Warnings and Special Information
For your safety and to protect valuable equipment, it is very important that
you read and comply with all information highlighted under special
headings. Special heading are defined below:
WARNING
A warning tells you of conditions that can harm you and damage the
printer.
CAUTION
A caution tells you of conditions that can damage the printer.
IMPORTANT
Important draws your attention to information vital to proper operation
of the printer.
NOTE: A note gives you helpful tips about printer operation and
maintenance.
1–2
Overview
Page 13
Related Documents
This manual does not explain how to operate or configure the printer. For
that information, refer to the Operator’s Guide and Setup Guide that
accompany each model.
Information pertaining to printer control languages, emulations, and codes is
in the Impact Printer Programmer’s Reference Manual.
Printing Conventions in This Manual
Switches, indicators, and switch positions that are labeled on the printer are
printed in uppercase letters.
Example: Press the CLEAR switch.
Messages that appear on the liquid crystal display (LCD) are printed in
quotation marks.
Example: Press the CLEAR switch. “Off–Line” appears on the LCD.
Overview
1–3
Page 14
Controls and Indicators
Standard Electrical Controls (Figure 1–1)
Switch or
Function
Indicator
NOTE: ON LINE and VIEW are the only switches that operate when the printer
is on–line. The other switches operate only when the printer is off–line.
Power Switch
Status lamps
LCD
ON LINE
FF Advances paper to top of form on next page.
NLQ
CLEAR
VIEW
Turns printer on and off: up = on, down = off. This
switch is also a circuit breaker.
On when the printer is on–line, off when printer is
off–line. Flash to indicate a fault or warning.
The Liquid Crystal Display (LCD) displays printer status
and error messages.
Toggles the printer on–line and off–line.
Toggles the printer font between NLQ–10 or DP–10.
Clears printer after a fault is corrected. Returns printer to
off–line state from within a configuration menu. Resets
printer to most recently saved configuration when
pressed simultaneously with ENTER switch.
Advances paper for viewing through cover window,
then returns paper to print position.
1–4
SET TOF
CONFIG
ENTER
Y
(UP)
B
(DOWN)
A
(PREV)
"
(NEXT)
Sets location of first line of print on a page.
Selects one of four predetermined printer configurations.
Enters displayed parameter into printer nonvolatile
memory. Must be unlocked before using.
Locks and unlocks ENTER switch when pressed with B
switch. Causes display of configuration menus,
submenus, and diagnostic tests.
See above.
Displays previous parameter in a configuration or
diagnostic test menu.
Displays next parameter in a configuration or diagnostic
test menu.
Overview
Page 15
Printer Cover
On
Off
UP
NEXTPREV
DOWN
RAISE PRINTER
COVER TO USE
THESE SWITCHES
VIEW
SET
TOF
CONFIG
ENTER
Status LampsLiquid Crystal Display (LCD)
ON LINE FF CLEAR
NLQ
Figure 1–1. Standard Electrical Controls
Overview
1–5
Page 16
Coax Electrical Controls (Figure 1–2)
Switch or
Indicator
Power Switch
Status lamps
LCD
ENABLE/HOLD
FORM FEED
INDEX
SETUP
CU
SCS
ALT
CHECK
TEST/ENTER
Function
Turns printer on and off: up = on, down = off. This switch is also a circuit breaker.
On when the printer is on–line, off when printer is off–line. Flash to indicate a fault or
warning.
The Liquid Crystal Display (LCD) displays printer status messages.
Toggles the printer between the enable and hold modes.
Advances paper to top of form on next page. Used with SETUP to set top of form.
Advances paper one line at a time.
Sets the logical print head to line one, column one. In hold mode, used with FORM FEED
to set top of form.
Lit when the printer communicates with the host computer.
Lit when the printer operates in SCS mode.
Lit when alternate switch functions are active.
Lit when an error occurs.
TEST prints an 80–column sliding alphabet test pattern. In program mode, ENTER
confirms a selected configuration value as the active value.
BUFRP
PA1
CANCL
PA2
FUNC
INSPC
Y
ADJUST
B
PGM
A
ALT
"
0 – 9
Numbered Switches
Prints the contents of the buffer. Press ALT, then PA1 to send Program Attention 1 (PA1)
message to the control unit.
Cancels a print job. Press ALT, then PA2 to send Program Attention 2 (PA2) message to
the control unit.
Locks and unlocks program mode.
Press and release to move paper up for inspection. (Press ADJUST to continue.) In hold
mode, moves paper up in steps of 1/72 inch. In alternate and program modes, moves
“up” in and displays menus and submenus.
Returns paper to print position after using INSPC. In hold mode, moves paper down in
micro–steps of one dot row. In configuration mode, moves paper down in of 1/72 inch
steps. In program mode, moves “down” in menus and submenus.
Puts the printer in program mode. In program mode, selects the previous option in a menu.
Activates control panel switches for alternate functions. In program mode, selects the next
option in a menu.
Enter numerical values when printer is in program mode. Numeric entries must total three
digits; use intial zero(s) if necessary.
1–6
Overview
Page 17
Printer Cover
On
Off
4
INSPC
ALTPGM
8
ADJUST
5
9
RAISE PRINTER
COVER TO USE
THESE SWITCHES
TEST
ENTER
BUFRP
PA1
CANCL
PA2
FUNC
Status LampsLiquid Crystal Display (LCD)
6
SCS
7
CU
ALT CHECK
ENABLE/HOLD
FORM FEED SETUP
0123
INDEX
Figure 1–2. Coax Electrical Controls
Overview
1–7
Page 18
Switch or
Indicator
Twinax Electrical Controls (Figure 1–3)
Function
Power Switch
Status lamps
LCD
ENABLE/HOLD
FORM FEED
INDEX
SETUP
LINE SYNC
SYS AVAIL
BUFFER PRINT
ATTN
TEST/ENTER
INSPC
ADJUST
Turns printer on and off: up = on, down = off. This switch is also a circuit breaker.
On when the printer is on–line, off when printer is off–line. Flash to indicate a fault or
warning.
The Liquid Crystal Display (LCD) displays printer status messages.
Toggles the printer between the enable and hold modes.
Advances paper to top of form on next page. Also used with SETUP to set top of form.
Advances paper one line at a time.
Sets the logical print head to line one, column one. In hold mode, used with FORM FEED
to set top of form.
Lit when there is activity on the twinax line.
Lit when the printer communicates with the host computer.
Lit when the buffer print option is turned on.
Lit when an error occurs.
TEST prints an 80–column sliding alphabet test pattern. In program mode, ENTER
confirms a selected configuration value as the active value.
Press INSPC to move paper up for inspection. Press again to return paper to print
position. Also used to check and adjust top of form.
CANCL
FUNC
Y
B
PGM
A
PRT 1
"
0 – 9
Numbered Switches
1–8
Cancels a print job from either enable or hold mode.
Press simultaneously with PGM to unlock program mode; then press PGM to enter
configuration menu. Press simultaneously with CANCL to lock program mode.
In hold mode, moves paper up in steps of 1/72 inch. In program mode, moves “up” in
and displays menus and submenus.
In hold mode, moves paper down in micro–steps of one dot row. In configuration mode,
moves paper down in of 1/72 inch steps. In program mode, moves “down” in menus and
submenus.
Puts the printer in program mode. In program mode, selects the previous option in a menu.
In hold mode. press to print one line of data. In program mode, selects the next option in a
menu.
Enter numerical values when printer is in program mode. Numeric entries must total three
digits; use intial zero(s) if necessary.
Overview
Page 19
Printer Cover
On
Off
4
PRT1PGM
8
9
5
RAISE PRINTER
COVER TO USE
THESE SWITCHES
TEST
ENTER
INSPC
ADJUST
CANCL
FUNC
Status LampsLiquid Crystal Display (LCD)
6
SYS
LINE
7
SYNC
AVAIL
BUFFER
PRINT ATTN
ENABLE/HOLD
FORM FEED SETUP
0123
INDEX
Figure 1–3. Twinax Electrical Controls
Overview
1–9
Page 20
IPDS Electrical Controls (Figure 1–4)
Switch or
Indicator
Power Switch
Status lamps
LCD
START/STOP
FF Advances paper to top of form on next page.
LF ↑ /LF ↓
SET TOF
LINE SYNC
SYS AVAIL
JOB IN PROGRESS
CX/SCS
TEST/ENTR
Function
Turns printer on and off: up = on, down = off. This switch is also a circuit breaker.
On when the printer is on–line, off when printer is off–line. Flash to indicate a fault or
warning.
The Liquid Crystal Display (LCD) displays printer status messages.
Toggles the printer on–line and off–line.
Advances paper one line at a time. Press with ALT to reverse one line.
Sets location of first line of print on a page.
Lit when there is activity on the line to the host computer.
Lit when the printer communicates with host. Not used on coax printers.
Lit when printer is receiving data or when data are in buffer.
Lit when a coax printer is on non–IPDS (SCS) mode.
Starts and stops tests in diagnostic mode. In configuration mode, enters displayed
parameter into printer memory.
EJECT
CAN/BPRT
ALT
UP
PA1
DWN
PA2
PGM
(PREV)
PRT1
(NEXT)
Interrupts a print job and feeds paper up for inspection.
Cancels a print job, an error message, and turns off audible alarm. Coax only: when
pressed with ALT, prints contents of buffer.
Enables alternate functions of LF ↓ , PR1, PA2, BPRT switches.
Moves paper up in micro–steps of one dot row. In configuration mode, moves “up” in
and displays menus, submenus, and diagnostic tests. Coax only: press with ALT to send
Program Attention 1 (PA1) signal to host.
Moves paper down in micro–steps of one dot row. In configuration mode, moves “down”
in and displays menus, submenus, and diagnostic tests. Coax only: press with ALT to
send Program Attention 2 (PA2) signal to host.
Puts the printer in program mode. In program mode, selects the previous option in a menu.
Prints one line of data. In program mode, selects the next option in a menu.
1–10
Overview
Page 21
Printer Cover
On
Off
UP
PA1
PRT1PGM
(PREV)
(NEXT)
DOWN
PA2
RAISE PRINTER
COVER TO USE
THESE SWITCHES
TEST/ENTR
EJECT
CAN/BPRT
ALT
LINE
SYNC
SYS
AVAIL
JOB IN
PRORESSCXSCS
START
STOP TOF
Figure 1–4. IPDS Electrical Controls
Status LampsLiquid Crystal Display (LCD)
FF
LF↑
LF↓
SET
Overview
1–11
Page 22
Mechanical Controls (Figure 1–5)
Control or
Indicator
Forms thickness
lever
Forms thickness
pointer and scale
Tractors (2)
Tractor locks (2)
Horizontal
adjustment knob
Vertical position
knob
Function
Sets platen for paper and forms of different
thicknesses. Must be raised to load paper
Indicates
thickness lever at A for thin (single–part) forms, B for
thicker forms, and so on.
Hold and feed paper.
Lock tractor on support shaft.
Allows fine positioning of left print mar
paper left or right.
Used to set top of form or first line to be printed. Rotate
to move paper vertically.
relative
thickness of paper
.
. Set the forms
gin. Moves
1–12
Overview
Page 23
Tractor Lock
Horizontal
Adjustment
Knob
Forms
Thickness
Scale and Pointer
Forms
Thickness
Lever
Tractor Lock
Vertical
Adjustment
Knob
Tractor
Overview
Figure 1–5. Mechanical Controls
1–13
Page 24
Tools, Test Equipment, and Supplies
The tools, test equipment, and supplies required for field level maintenance
of P9212 printers are listed below.
Item Part Number Recommended Item
Adapter, Torque Screwdriver —
Adjustable W
Anhydrous Alcohol — —
Diagonal Cutters
Digital Voltmeter — —
Driver, Torque Screwdriver — Utica TS35
Extension, 3 in., 3/8 Drive — —
Extension, 6 in., Torque Screwdriver — —
Feeler Gauge Set — Proto 000AA
Force Gauge — —
Hammer Tip Alignment Tool 132266–001 —
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 — —
Hex Key Set, 15 PC
IC Insertion/Extraction Tool — —
rench —
— Erem 91EH
—
Utica HW–18
Utica 91–4C
Utica W–8
Utica HW–4
Utica HW–6
McMaster–Carr Supply
Cat. No. 7125A1
,
1
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.
Scale, Spring, 0 to 40 lbs. — —
Screwdriver
Screwdriver, Phillips —
Screwdriver, Phillips —
Screwdriver, Slot —
, Allen Hex
— —
— Erem 11DH
— General 616
— Xcelite 99PS40
Xcelite X100
Xcelite X102
Xcelite A184
1–14
Overview
Page 25
Item Recommended ItemPart Number
Screwdriver, Slot —
Screwdriver, Stubby
tip–width
Shim, Antirotation (.010 in.) 131493–001 —
Shim, Antirotation (.005 in.) 131493–002 —
Shims, Counterweight 101564–001 —
Shims, Shuttle Assembly
Socket, 7/16 in., 3/8 in. Drive — —
Soldering Iron and Tips — —
Tool, Antirotation 134534–001 —
X–actoT
Knife and Blades
, 1.5 in shank, 0.25 in
— —
103422–001 —
— —
Xcelite R3164
Overview
1–15
Page 26
1–16
Overview
Page 27
2 Principles of Operation
Chapter Contents
Line Matrix Printing 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Hammer Bank 2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Character Generation 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 Architectures 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 (CCB, Triple I/O) 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212–CT 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 LMI (Quad I/O) 2–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P9212 CTHI 2–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Elements of the Printer 2–12. . . . . . . . . . . . . . . . . . . . . . . . . .
The Control Panel 2–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Boards 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Communication With the Host and Operator 2–18. . . . . .
Printing 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCB Hardware Summary 2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LMI Hardware Summary 2–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanism Driver Board 2–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Drive System 2–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Feed System 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Paper Feed System 2–34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principles of Operation
2–1
Page 28
Hammer Driver Board 2–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Driver Logic and Control 2–35. . . . . . . . . . . . . . . . . . . . . . .
Power Filtering 2–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank Cooling 2–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Power 2–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Mechanisms 2–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Bank, Shuttle, and MPU 2–39. . . . . . . . . . . . . . . . . . . . . . .
Ribbon Deck 2–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Feed Control 2–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–2
Principles of Operation
Page 29
Line Matrix Printing
The 9212 creates characters and graphics by a printing technique called line
matrix printing. Line matrix printing consists of printing patterns of ink dots
on paper, an entire line at a time.
Each text character is stored in memory as a pattern of dots on a logical grid
called the dot matrix. (See Figure 2–1.) The actual ink dots are made by a
row of hammer springs mounted on a shuttle that sweeps rapidly back and
forth. Printer logic divides every printable line into horizontal dot rows. The
hammer springs put dots at the required positions for the entire line by
striking a moving ink ribbon and the paper.
0.01389 ”
0.00835
112
Column No.
0.10
”
”
First row and column
of next character.
First row and column of
next character line (at 6
LPI).
When the shuttle reaches the end of a sweep, it reverses direction, the paper
is advanced one dot row, and the hammer springs print the next row of dots
as the shuttle sweeps in the opposite direction. After a line of characters is
printed, hammer action stops and the paper advances to the first dot row of
the next print line. The number of dot rows allowed for line separation
depends on the vertical line spacing the user selects.
The dot patterns of characters vary according to the font selected. For
example, in the data processing (DP) font at a line spacing of six lines per
inch (lpi), the dot matrix contains 12 dot rows from the top of one character
line to the top of the next. (See Figure 2–1 and Figure 2–2.) At eight lpi there
are nine dot rows per character line, at nine lpi eight dot rows per character
line, and so on.
Lowest descender
dot line.
0.02 ”
Figure 2–1. A Dot Matrix
Principles of Operation
2–3
Page 30
Elongated characters are made by printing all but the first and last dot rows
twice. (See Figure 2–3.)
Uppercase
(Reference)
Printed
with
underline
Underline Lowercase with Descender
Figure 2–2. Typical Characters
WITH UNDERLINE WITHOUT UNDERLINE
Dot Column
13579
Dot Row
1
2
2
’
3
’
3
4
4
’
5
’
5
6
’
6
7
7
’
8
’
8
9
Dot Row
1
2
2
’
3
’
3
4
4
’
5
’
5
6
’
6
7
Dot Column
13579
2–4
Figure 2–3. Elongated Characters
Principles of Operation
Page 31
The Hammer Bank
The P9212 uses a hammer bank to print dots. The hammer bank consists of
88 hammer springs mounted on a shuttle that moves horizontally a short
distance back and forth. The hammer bank prints one horizontal line of dots
during each horizontal sweep of the shuttle.
A hammer spring is a stiff leaf spring with a hardened steel tip at the upper
end, and is attached to the hammer bank at the lower end. (See Figure 2–4.)
A permanent magnet keeps the hammer springs retracted and under tension.
Behind every hammer is a pair of magnetic coils which, when energized,
neutralize the field of the permanent magnet. This releases the hammer,
which springs forward and strikes the ribbon and paper, leaving a dot. The
hammer is recaptured by the permanent magnet as it rebounds. (See
Figure 2–5.)
Ribbon
Ribbon Mask
Hammer Bank Cover
Magnet
Shuttle Shaft
Paper
Hammer Tip
Coil
Coil
Platen
Hammer Spring
Hammer Spring Mounting Screw
Paper Ironer
Figure 2–4. Hammer Spring and Shuttle Arrangement
Principles of Operation
2–5
Page 32
Normal (retracted) State Activated (released) State
Coils de–energized Coils energized
Permanent Magnet
Coil
Coil Coil
Figure 2–5. Hammer Spring Action
Character Generation
Paper advances one dot row after each horizontal sweep of the shuttle. (See
Figure 2–6 and Figure 2–7.)
Hammer
Tip
Hammer
Spring
Direction of Shuttle Movement
Coil
Character
Row
Dot
Row Start
1
2
3
4
5
6
7
8*
9**
10
11
Space
12
1
2
1 Hammer
Print Span
The P9212 shuttle sweeps
through 1.5 character
positions at 10 cpi.
Figure 2–6. Standard Character Formation
Paper
Advances
Paper
Feed
Paper
Advances
1 Hammer
Print Span
Used for lowercase descender only.
*
Used for underline and lowercase
**
descender.
2–6
Principles of Operation
Page 33
Shuttle
Scan
Dot
Row
* 1 * 1 * * 1 * * 3
Successive Hammer Strokes Per Scan
Dot Column
1 3
5
3 5 7 1 3 5 7 9
1
2
3
4
5
6
1
1
2
1
2
3
1
2
3
4
1
2
3
4
5
1
2
3
4
5
6
1
2
3
4
5
6
7
7
NOTE:
*
Even column dot centers within the printed character area and character space
hammer positions are not illustrated in this diagram.
= Dot
=No dot where hammer has already been
= Hammer Position
Figure 2–7. Character Formation by One Hammer
Principles of Operation
2–7
Page 34
Normal Operation
In normal operation, the user presses a switch on the control panel to put the
printer on–line. Data from the host computer are then read into the input
buffer as ASCII data. (Printers with CT or CTHI options for
twinax/coax/IPDS operation convert IBM EBCDIC code to ASCII before
processing the data.) The data in the input buffer are compared to tables
stored in memory to determine the matrix and location of each character. The
characters are then built in the dot image buffer.
Information from the dot image buffer is synchronized with printer
requirements using the magnetic pickup signal, then shifted to the hammer
drivers. The selected hammers are fired.
When all dots in a row are printed, the paper advances one dot row and the
next dot row of data from the dot image buffer are synchronized then shifted
to the hammer drivers. Vertical paper movement is delayed to allow double
printing if adjacent dot printing is required. (See Figure 2–8.)
During self–tests, data stored in ROM are used to build the dot image buffer.
Operation then proceeds as in normal printing.
2–8
Principles of Operation
Page 35
Control Panel
Printer Setup
Printer Enable
Input Data Buffer
(Dynamic RAM)
ASCII data (DPU) **
EBCDIC to ASCII
conversion.
(CT/CTHI models)
Printer Interface:
Host Input Data
Build dot image from lookup
tables. Put into Dynamic RAM
(DPU).
Synchronize timing to
codewheel (MPU) software.
Demand hammer load data
be shifted to hammer
driver. **
Fire hammers on next MPU.
(Software timers.)
YesNo
All dots in
row printed?
Move paper.
(Mech. Driver)
Principles of Operation
Software
decision
** Controlled by software,
executed by hardware.
Figure 2–8. The Print Cycle
2–9
Page 36
P9212 Architectures
The physical configuration of the P9212 is determined by the type of
processor board and interface it uses. Printers that use the Common
Controller Board (CCB) are PROM–based machines. Printers that use the
LMI print engine are floppy–based machines. CT and CTHI models use
translation interfaces that enable them to emulate IBM printers.
The P9212 Line Matrix Printer has four basic equipment configurations.
P9212 (CCB, Triple I/O)
This is the standard model P9212 printer:
♦ It uses the Common Controller Board (CCB) as the print engine. System,
font, and emulation software are stored in PROMs on the CCB.
♦ It processes three kinds of computer input: Centronics parallel,
DataProducts parallel, and RS–232 serial data. This is termed “triple
I/O” because all three interfaces are carried on a common circuit board
assembly and all are processed directly by the CCB.
P9212–CT
This is a P9212 printer that emulates IBM coax and twinax printers:
♦ It uses the Common Controller Board (CCB) as the print engine. System,
♦ When configured for twinax operation, it emulates IBM 5225 Models 1,
♦ When configured for coax operation, it emulates IBM 4234 Model 1 and
♦ The printer is equipped with a coaxial/twinaxial integrated interface
font, and emulation software are stored in PROMs on the CCB.
2, 3, and 4 printers, and IBM 4234 Model 2 printers.
IBM 3287 Models 1 and 2 printers.
assembly, referred to as the CT. The CT board converts IBM’s EBCDIC
to an expanded ASCII character set and sends the data to the CCB for
further processing.
2–10
Principles of Operation
Page 37
P9212 LMI (Quad I/O)
This is a P9212 printer with a diskette drive and a different controller
scheme:
♦ It uses the Line Matrix Impact (LMI) print engine and disk controller
board.
♦ The 030 microprocessor board plugs into the LMI print engine board.
♦ The LMI/030 board combination plugs into the Feature Backplane board.
♦ It has a floppy diskette drive controlled by the LMI via the Feature
Backplane board.
♦ System, emulation, and font software are loaded into printer memory via
diskette.
♦ The printer uses the “Quad I/O,” an interface assembly with Centronics
parallel, DataProducts parallel, RS–232 serial data connectors, and a
9–pin RS–232 diagnostics port.
P9212 CTHI
This is a P9212 LMI printer capable of emulating IPDS IBM printers:
♦ It uses the Line Matrix Impact (LMI) print engine and disk controller
board.
♦ The 030 microprocessor board plugs into the LMI print engine board.
♦ The LMI/030 board combination plugs into the Feature Backplane board.
♦ It has a floppy diskette drive controlled by the LMI via the Feature
Backplane board.
♦ System, emulation, and font software are loaded into printer memory via
diskette, enabling the P9212 to emulate an IBM 4234 Model 011 (coax)
and Model 012 (twinax) IPDS printer.
♦ The printer is equipped with the Coax/Twinax Host Interface (CTHI)
board, which converts IBM protocols into an expanded ASCII character
set and sends the data to the LMI for further processing.
Principles of Operation
2–11
Page 38
Functional Elements of the Printer
The printer consists of six functional elements:
♦ Control panel
♦ Controller board (CCB or LMI)
♦ Mechanism driver board
♦ Hammer driver board
♦ Power supply
♦ Print mechanisms
Figure 2–9 is a block diagram of the functional elements of printers
controlled by the CCB.
Figure 2–10 is a block diagram of the functional elements of printers
controlled by the LMI.
The rest of this chapter discusses these systems in more detail.
2–12
Principles of Operation
Page 39
AC
POWER
HOST
COMPUTER
Data
PRINTER
INTERFACE
Status
CONTROL PANEL
ON / OFF
Switch
Circuit Brkr
Status
+5 Vdc
Keyboard
Message
Indicator
FILTER
POWER
SUPPLY
CARD CAGE
Data
CONTROLLER
EMI
FAN
FAN
COMMON
BOARD
DPU
SHARED
MEMORY
RTPU
AUTO–RANGING
POWER SUPPLY
BOARD
+5 Vdc
Crowbar
+48 Vdc
MECHANISM
+5 Vdc
Fault
Paper
Control
Shuttle
Timing
Hammer
Driver Data
Hammer
iming Data
T
Shuttle
FAULT CIRCUITS
PAPER TRANSPORT
DRIVE
SHUTTLE DRIVE
RIBBON DRIVE
P/S CIRCUITS
HD CIRCUITS
& Ribbon
Control
+12.5Vdc
+48 Vdc
DRIVER
BOARD
+12.5Vdc
+48 Vdc
HD 1–40
12V / 48V FILTER
BLR DRIVE
Fault
Ribbon Control
Fan Control
HAMMER
DRIVER
BOARD
Control
Hmrs
1–40
Hmrs
41–88
Paper Feed
Motor Control
Platen Open
Motor Control
Ribbon Status
BLR
Control
Hmrs
1–88
Shuttle Drive
PRINT
MECHANISMS
BLOWER
ASSEMBLY
HAMMER
BANK
SHUTTLE
ASSEMBLY
MPU
PAPER
TRANSPORT
RIBBON
TRANSPORT
Figure 2–9. Functional Elements of the Printer with CCB
Principles of Operation
Sensors
CABINET
FAN
PAPER
OUT
PLATEN
OPEN
PAPER
MOTION
2–13
Page 40
AC
POWER
CONTROL PANEL
Key
Indicator
Message
+5Vdc
FEATURE
BACKPLANE
OS & Fonts
ON / OFF
Switch
Circuit Brkr
+5 Vdc
Data
EMI
FILTER
POWER
SUPPLY
FAN
+5 Vdc
PROCESSOR
BOARDS
MEMORY
CONTROLLER
CARD CAGE
LMI &
DPU
SHARED
RTPU
DISK
AUTO–RANGING
POWER SUPPLY
BOARD
FAN
+48 Vdc
+5 Vdc
Fault
Paper
Control
Shuttle
Timing
Hammer
Driver Data
Hammer
iming Data
T
Shuttle
Control
+12.5Vdc
Crowbar
MECHANISM
DRIVER
BOARD
FAULT CIRCUITS
PAPER TRANSPORT
DRIVE
SHUTTLE DRIVE
RIBBON DRIVE
P/S CIRCUITS
HD CIRCUITS
& Ribbon
+12.5Vdc
+48 Vdc
+48 Vdc
Fan Control
HAMMER
DRIVER
BOARD
HD 1–40
12V / 48V FILTER
BLR DRIVE
Control
Hmrs
Fault
1–40
Paper Feed
Motor Control
Platen Open
Motor Control
Ribbon Status
Ribbon Control
BLR
Control
Hmrs
1–88
Hmrs
41–88
Shuttle Drive
PRINT
MECHANISMS
BLOWER
ASSEMBLY
HAMMER
BANK
SHUTTLE
ASSEMBLY
MPU
PAPER
TRANSPORT
RIBBON
TRANSPORT
Data
Status
PRINTER
INTERFACE
Data
HOST
COMPUTER
2–14
Status
CABINET
FAN
Sensors
+5 Vdc
Operating System & Fonts
FLOPPY DISKETTE
DRIVE ASSEMBLY
Figure 2–10. Functional Elements of the Printer with LMI
PAPER
OUT
PLATEN
OPEN
PAPER
MOTION
Principles of Operation
Page 41
The Control Panel
The control panel consists of indicator lamps, LEDs, contact switches, and a
liquid crystal display (LCD).
The control panel processes and sends switch closure information to the
controller board (CCB or LMI) and receives status information.
Control Panel
Assembly
Status
Switch
Closures
Control Panel Circuit Board
Data
Controller Board
(CCB or LMI)
Control
Figure 2–11. Control Panel Functional Block Diagram
Switch
Closures
Principles of Operation
2–15
Page 42
Controller Boards
The printer is controlled by either the Common Controller Board (CCB) or
the Line Matrix Impact (LMI) print engine. These boards control the printer
in very similar ways. The main difference between them is the way operating
system and font information is stored: the CCB gets this information from
PROMs, the LMI loads the information into RAM from floppy disk.
Because these controllers are nearly identical in function, they are discussed
together in this section, and collectively referred to as “the controller board.”
Differences are noted as they apply.
The controller board oversees and coordinates all printer functions. It is
functionally two units: the data processing unit (DPU) and the real–time
processing unit (RTPU). The DPU converts all character data into printable
dot images. The DPU is the high–level logical controller of the printer; it is
not involved in real–time or hardware–dependent printer operation. The
RTPU operates the host interfaces, operator control panel, and the print
mechanism. The RTPU also monitors the fault circuitry in the mechanism.
On the CCB, these functions are performed on a single circuit board. The
LMI print engine, however, consists of two circuit boards: a DPU processor
board is “piggy–backed” to the larger LMI main board, which carries many
of the resources the DPU needs. The DPU board can have one of three
different microprocessors. On P9212 printers, the DPU uses the Motorola
68EC030 processor, and is called the 030 processor board. In this chapter,
“LMI” refers to the unit formed by the 030 processor board and the LMI
main board.
The DPU and RTPU communicate by means of shared memory. The DPU
gets host and operator input from buffers in shared memory which are filled
by the RTPU, and returns dot images and operator messages to buffers in
memory which the RTPU empties. Figure 2–12 summarizes the architecture
of the CCB and LMI controllers.
2–16
Principles of Operation
Page 43
Common Controller Board
(CCB)
Control Panel
(User Interface)
Data Processing
Unit
(DPU)
Shared
Memory
Line Matrix Impact Print Engine
(LMI)
LMI Motherboard
Real–Time
Processing
Unit
(RTPU)
Printer
Interface
Control Panel
(User Interface)
Printing
Mechanism
Interface
030 Processor
Board
(DPU)
Principles of Operation
Shared
Memory
Real–Time
Processing
Unit
(RTPU)
Printer
Interface
Figure 2–12. Architecture of the CCB and LMI
Printing
Mechanism
Interface
2–17
Page 44
Controller Communication With the Host Computer and Operator
The controller board processes three kinds of computer input: Centronics
parallel, DataProducts parallel, and RS–232 serial data. The RTPU operates
all three interfaces. The parallel interfaces are similar, and the RTPU contains
direct–memory–access (DMA) hardware which loads parallel data directly
into shared memory. The serial interface requires byte–by–byte intervention
by the processor, since ACK/NACK and XON/XOFF protocols require that
every byte be examined as it is received. The universal asynchronous
receiver/transmitter (UART) is internal to the RTPU, which processes any
protocol requirements then puts the data in shared memory, where the DPU
can read it. To the DPU, all input data look the same, regardless of the
interface used to receive the data.
Control Panel
The RTPU handles the control panel interface requirements of shifting and
clocking control panel data, but it is the DPU that processes the data.
Diagnostic UART (LMI models)
LMI printers are equipped with the “Quad I/O” interface, which contains a
diagnostic universal asynchronous receiver/transmitter (UART) for RS–232
serial input/output to a modem or terminal. This diagnostic tool is controlled
by the RTPU.
Floppy Disk Controller Module (LMI models)
The floppy disk controller module is on the LMI main board; it controls the
flow of DPU program data from a standard 3.5 inch floppy diskette to the
DPU program memory. The DPU controls this floppy drive.
Printing
The RTPU coordinates printing of the dot images sent from the DPU.
Printing is a complex process requiring many control functions, but is
logically divided into two groups:
• Hammer driver interface functions
• Mechanical interface functions
2–18
Principles of Operation
Page 45
Hammer Driver Interface Functions
In order to print a dot image, two things must happen. First, the dots must get
to the hammers one dot row at a time and in the correct sequence. Second,
the hammers must be fired at the appropriate time in the stroke of the shuttle.
The RTPU microprocessor controls both of these functions, but each is
actually performed by an application–specific integrated circuit (ASIC)
containing hardware dedicated to the function. These ASICs are the Dot
Plucker Memory Controller (DPMC) and the Fire Timer IC (FTIC). The
hammer driver interface functions of the RTPU are summarized in
Figure 2–13.
DATA PROCESSING
UNIT
SHARED MEMORY
REAL–TIME PROCESSING UNIT
RTPU
PROCESSOR
EPROM
Dot Plucker
ASIC
DMA Controller
Fire Timer
ASIC
Hammer
Driver
Data
Hammer
Timing
Data
Figure 2–13. Hammer Driver Interface Functions of the RTPU
Getting Dots to the Hammers Getting dots to the hammers consists of
going into the shared memory and pulling bits out in a given order and
shifting them to the hammer driver at the correct time. This process is called
“dot plucking.” The order in which dots are plucked from memory depends
on the dot density, the number of dots per hammer, the number of hammers
on the hammer bank, the number of phases, and other factors. These factors
Principles of Operation
2–19
Page 46
are all considered by the RTPU processor as it programs the dot plucker and
the FTIC for each dot row.
Synchronizing Dot Plucking and Hammer Firing Transfer of dots to the
hammer driver must be synchronized with hammer firing. Dots are
transferred to the hammer driver in bursts, serial streams of dots that tell
which hammers will print when their phase is next fired. The bursts are timed
precisely; they must occur neither too early nor too late. Synchronization is
performed by having the FTIC request bursts from the dot plucker. The FTIC
reads the magnetic pick–up unit (MPU) to determine when to request a burst.
The time at which the burst request is made is contained in the fire timing
tables.
Mechanical Interface Functions
Three mechanical operations are coordinated in printing: paper motion,
ribbon motion, and shuttle motion. Virtually all digital handling of paper
motion is contained in the RTPU. The ribbon and shuttle are controlled by
logic on the mechanism driver board, under the direction of the RTPU.
Figure 2–14 shows the mechanical interface section of the RTPU.
DATA PROCESSING
UNIT
SHARED MEMORY
REAL–TIME PROCESSING UNIT
RTPU
PROCESSOR
EPROM
Dot Plucker
UART
Paper Feed
Controller
Figure 2–14. Mechanism Driver Interface Functions of the RTPU
Shuttle
and
Ribbon
Control
Paper
Control
2–20
Principles of Operation
Page 47
Paper Motion The DPU determines when paper must be moved and how far
to move it. It communicates this to the RTPU through the shared memory.
The RTPU processor performs some paper handling operations (such as
holdback on slews), but most RTPU paper handling is done by a dedicated
microcontroller called the paper feed controller (PFC).
The PFC moves paper by looking up motion profiles and driving a sequence
of motor positions to the mechanism driver board. If the motion is a dot row
or interline advance, it is synchronized to hammer firing by a signal from the
FTIC that tell the PFC when to move.
Ribbon and Shuttle Motion The ribbon and shuttle motors are controlled
by a microcontroller on the mechanism driver board. The RTPU interface to
the ribbon/shuttle processor (RSP) is a 2400 baud asynchronous serial line. A
message protocol is used to communicate ribbon and shuttle information.
Fault Monitoring
The RTPU also monitors the hammer driver, mechanism driver, and the
electro–mechanical sensors for fault conditions. Fault conditions are reported
to the DPU.
Hammer Bank and Hammer Driver Faults
The FTIC works with the hammer driver ASIC to monitor coil shorts, opens,
average upper driven phase current, and temperature conditions. The RTPU
reads the FTIC registers to determine out–of–range conditions, and these are
passed on to the DPU.
Paper Faults
Two kinds of paper faults can occur: paper out and paper jammed. Both of
these conditions are monitored through optical sensors. The paper feed
controller watches the paper out and paper motion sensors and reports errors
to the RTPU. The RTPU passes this information on to the DPU.
Ribbon and Shuttle Faults
The mechanism driver ribbon and shuttle controller monitors fault conditions
in the drive circuits and notifies the RTPU if it finds errors. The RTPU can
also use the FTIC to measure time between magnetic pick–up (MPU) pulses,
enabling it to monitor shuttle speed and thus detect some shuttle faults.
Principles of Operation
2–21
Page 48
CCB Hardware Summary
This section summarizes CCB hardware functions. (LMI hardware is
summarized on page 2–26.)
A Motorola 68010 microprocessor performs the DPU functions, a 64180
microprocessor handles the RTPU functions, and an 8032 microcontroller
serves as the paper feed controller (PFC), which is part of the RTPU. Actual
implementation of this hardware blurs the distinctions between the DPU and
RTPU, since the 68010 has access to the parallel port and the real–time
functions of the dot plucker, which are RTPU resources, while the 64180 has
access to the nonvolatile memory (NVRAM), which is a resource of the
DPU. These possibilities exist because of efficiencies in the hardware design;
software maintains the functional differences between the DPU and RTPU.
The CCB has four data buses:
♦ The 68010 has a local sixteen bit bus.
♦ The 64180 uses a local bus eight bits wide.
♦ The DPU and RTPU share a sixteen bit bus arbitrated on a
cycle–by–cycle basis.
♦ The 8032 chip has its own eight bit local bus.
The manner in which the CCB implements this hardware is depicted in
Figure 2–15.
The 64180 IC that oversees the RTPU processor contains a Z80
microprocessor with extended memory management, two DMA controllers,
two asynchronous and one synchronous serial port, two counter timers, and
an interrupt controller.
2–22
Principles of Operation
Page 49
68010
Microprocessor
Shared
Bus
Interface
NVRAM
2 KB
Serial from
Host Computer
Serial to Host,
Mech. Driver
Control Panel
EPROM
512 KB
DATA PROCESSING UNIT (DPU)
REAL–TIME PROCESSING UNIT
(RTPU)
64180
Processor
, and
Shared
Bus
Interface
Fire
Timer IC
(FTIC)
Control
Register
Plucker
Memory
Dot
ASIC
Shared
DRAM
512 KB
Parallel
Port
From
Host
Computer
To
Hammer
Driver
EPROM
Principles of Operation
Hardware
64 KB
SRAM
2 KB
Control
Register
Hardware
Status
Register
Comm.
Port
PAPER FEED
CONTROLLER
(PFC)
Processor
EPROM
Figure 2–15. Hardware Implementation of the CCB
8032
16 KB
Mech.
Driver
2–23
To
Page 50
Communicating With the Host Computer
The 64180 processor runs both the parallel and serial interfaces.
Parallel Input Parallel input data is nine bits wide, and is transferred in one
cycle from the parallel port to shared memory over the shared sixteen bit bus.
Using the internal DMA controller of the 64180 to transfer parallel data
requires some manipulation. The eight bit DMA controller in the 64180
performs either eight or sixteen bit DMA cycles, while the eight bit processor
in the 64180 performs only eight bit memory access cycles. Sixteen bit DMA
is achieved by hardware shifting of the DMA addresses one bit (effectively
multiplying the address by two and changing the DMA auto–increment from
byte to word) and by manipulating the control strobe. Software adjusts the
addresses provided to the DMA controller when it is programmed for sixteen
bit DMA. This manipulation saves both the added cost of a sixteen bit DMA
controller and the second cycle that an eight bit transfer would require.
Serial Input One of the 64180 UARTs handles serial communication with
the host. Additional modem control lines are provided in the 64180 hardware
control register.
Communicating With the Operator
The synchronous serial port in the 64180 shifts data in and out of the
operator control panel. The control register in the RTPU contains three other
control panel bits: one samples the switches, one strobes the liquid–crystal
display, and one strobes a light–emitting diode (LED) holding register.
Printing
Hammer Driver Interface
The 64180 programs the dot plucker ASIC and
the FTIC every stroke, after which the FTIC uses a DMA request line to
control the movement of tables from EPROM to FTIC. The second DMA
controller in the 64180 performs this transfer.
Mechanism Driver Interface The paper feed controller (PFC) directs all
paper motion. During printing, it usually moves paper in response to a trigger
from the FTIC, which synchronizes paper motion with shuttle motion. The
64180 programs the PFC 8032 at the beginning of each dot row, telling the
PFC how far to move when the trigger is received. The PFC sets up for the
move, waits, then moves when the trigger occurs. The other method of
starting paper motion is with a command to move paper immediately. This
2–24
Principles of Operation
Page 51
results in immediate movement. Other paper commands and status signals
are also passed through this port.
Ribbon and Shuttle Motion The 64180 interfaces through its second UART
to the ribbon / shuttle processor (RSP) on the mechanism driver board. The
64180 begins all transactions on the serial interface.
Fault Monitoring
The RTPU 64180, the PFC 8032, and the RSP monitor different functions for
faults. The 64180 looks for hammer driver faults, shuttle stalls, and an open
platen. The PFC 8032 monitors paper out and the paper motion detector. The
RSP watches for faults in the motor drive circuits. The PFC and RSP report
errors to the 64180, which collates fault status and passes it on to the DPU
68010 processor.
Hammer Bank and Hammer Driver Faults The 64180 and FTIC check the
hammer driver and hammer bank for faults on every shuttle stroke. Faults are
detected by circuits on the mechanism driver and hammer driver boards and
relayed to the CCB. Fault circuitry can detect rising temperatures in the coils.
One coil is checked on every shuttle stroke; therefore, 88 shuttle strokes are
required to check all coils. When the RTPU is notified of a fault, it sends a
message to the 68010. The hammer driver and mechanism driver boards also
continuously monitor for shorts in hammer driver circuits and cables. If they
detect currents that can harm the hammer bank, the +48 volt power supply is
shut down by “crowbar” circuitry within 70 milliseconds.
Paper Faults The PFC 8032 monitors paper faults and reports them to the
64180 through the eight bit parallel port they share. The PFC works with a
friction wheel paper motion detector and a reflective (optical) paper out
sensor. The sensors interface directly to the CCB; there are analog circuits on
the CCB to condition the sensor inputs.
Ribbon and Shuttle Faults The RSP monitors ribbon and shuttle faults and
reports them to the 64180 over the serial interface.
Principles of Operation
2–25
Page 52
LMI Hardware Summary
A Motorola 68EC030 microprocessor performs the DPU functions, a Zilog
Z8S180 (or Z80180) microprocessor handles the RTPU functions, and an
8032 microcontroller serves as the paper feed controller (PFC), which is part
of the RTPU. Actual implementation of this hardware blurs the distinctions
between the DPU and RTPU, since the 68EC030 has access to the parallel
port and the real–time functions of the dot plucker, which are RTPU
resources, while the Z8S180 has access to the nonvolatile memory
(NVRAM), which is a resource of the DPU. These possibilities exist because
of efficiencies in the hardware design; software maintains the functional
differences between the DPU and RTPU.
The LMI has seven data buses:
♦ Z8S180 local bus: an 8–bit data path
♦ Z8S180 local buffered I/O bus: an 8–bit data path
♦ 8032 local bus: an 8–bit data path
♦ Common or shared bus: 16–bit data path shared by the DPU and
Z8S180, arbitrated cycle by cycle
♦ Floppy controller bus: 8–bit data path from floppy disk to buffer memory
♦ DPU local bus
♦ Dot Plucker DRAM bus
The manner in which the LMI implements this hardware is depicted in
Figure 2–16 and Figure 2–17.
2–26
Principles of Operation
Page 53
Figure 2–16. Hardware Implementation of the LMI Board
Principles of Operation
2–27
Page 54
68EC030
CPU
74F245
Data
Buffers
DRAM
68882
Boot ROM
32K Byte
8 Bit Port
16 Bit Port
25 Bit Address
LMI Board
FPU
27256
68EC030 BUS
* RAS = Row Address Strobe
CAS = Column Address Strobe
WE = Write Enable
OE = Output Enable
4 Banks of
1M/4M Byte
32 Bit Port
Row/Col Address
84C31
DRAM
Controller
LMI 030 Board
RAS CAS WE OE*
Figure 2–17. Hardware Implementation of the LMI 030 Board
Communicating with the Host Computer
The Z8S180 processor runs both the parallel and serial interfaces.
Host Parallel Input Parallel inputs are nine bits wide, but the Z8S180 direct
memory access (DMA) used to make the transfer is only eight bits. The
2–28
Principles of Operation
Page 55
transfer is achieved by having hardware shift the DMA addresses by one
bit—effectively multiplying the address by two and changing the DMA’s
auto–increment from byte to word. Software adjusts the addresses provided
to the DMA controller when it is programmed for sixteen bit DMA. This
manipulation saves the cost of a separate sixteen bit DMA controller and
eliminates the extra cycle that would be required if the Z8S180 eight bit
DMA were used without this modification.
Host Serial Input Serial communication with the host is done with an
external ST16C2450 dual asynchronous receiver/transmitter (DUART).
Communicating With the Operator
Control Panel
The synchronous serial port in the Z8S180 shifts data in and
out of the operator control panel. The control register in the RTPU contains
three other control panel bits: one samples the switches, one strobes the
liquid–crystal display, and one strobes a light–emitting diode (LED) holding
register.
Diagnostic UART The LMI interfaces with an external diagnostic RS–232
modem. Diagnostic interface communication is done on channel B of the
ST16C2450 DUART.
Floppy Disk Controller Module The LMI has an on–board floppy disk
controller module that occupies virtual slot 1 on the Printronix bus.
Printing
Hammer Driver Interface
Dot plucking is handled by the Dot Plucker ASIC
(DPMC), which runs at 20 or 32 MHz using the RTPU input clock. The
Z8S180 programs the dot plucker ASIC and the FTIC on every dot row, after
which the FTIC uses a DMA request line to control the movement of tables
from EPROM to FTIC. The second DMA controller in the Z8S180 performs
this transfer.
Mechanism Driver Interface The paper feed controller (PFC) directs all
paper motion. During printing, it usually moves paper in response to a trigger
from the FTIC, which synchronizes paper motion with shuttle motion. The
Z8S180 programs the PFC 8032 through an eight bit parallel port between
processors at the beginning of each dot row, telling the PFC how far to move
when the trigger is received. The PFC sets up for the move, waits, then
moves when the trigger occurs. The other method of starting paper motion is
Principles of Operation
2–29
Page 56
with a command passed through the inter–processor parallel port. This
results in paper movement that begins immediately. Other paper commands
and status signals are also passed between processors through this port.
Ribbon and Shuttle Motion The Z8S180 interfaces through its internal
UART to the ribbon / shuttle processor (RSP) on the mechanism driver
board. The Z8S180 begins all transactions on the serial interface, so there is a
bit in the Z8S180 hardware status register that the RSP sets to tell the
Z8S180 when it needs service. The Z8S180 polls this bit regularly; if it is
true, the Z8S180 initiates service over the serial interface by asking the RSP
what it needs.
Fault Monitoring
The RTPU Z8S180, the PFC 8032, and the RSP monitor different functions
for faults. The Z8S180 looks for hammer driver faults, shuttle stalls, and an
open platen. The PFC 8032 monitors the paper motion detectors. The RSP on
the mechanism driver board watches for faults in the motor drive circuits.
The PFC and RSP report errors to the Z8S180, which collates fault status and
passes it on to the DPU.
Hammer Faults The Z8S180 and FTIC check the hammer driver and
hammer bank for faults on every shuttle stroke. Faults are detected by
circuits on the mechanism driver and hammer driver boards and relayed to
the LMI. Fault circuitry can detect rising temperatures in the coils. One coil
is checked on every shuttle stroke; therefore, 88 shuttle strokes are required
to check all coils. When the RTPU is notified of a fault, it sends a message to
the 68EC030. The hammer driver and mechanism driver boards also
continuously monitor for shorts in hammer driver circuits and cables. If they
detect currents that can harm the hammer bank, the +48 volt power supply is
shut down within 70 milliseconds by “crowbar” circuitry.
Paper Faults The PFC 8032 monitors paper faults and reports them to the
Z8S180 through the eight bit parallel port they share. The PFC works with a
friction wheel paper motion detector and a reflective (optical) paper out
sensor. The sensors interface directly to the LMI; analog circuits on the LMI
board condition the sensor inputs.
Ribbon and Shuttle Faults The RSP monitors ribbon and shuttle faults and
reports them to the Z8S180 over the serial interface.
2–30
Principles of Operation
Page 57
Mechanism Driver Board
The mechanism driver board, acting on timing and control signals from the
CCB or LMI, controls real–time operation of the electromechanical printer
systems. Functionally, the board consists of the following subsystems:
• An 8032 microcontroller (the RSP) controls shuttle, ribbon, and
platen drives, and communication with the controller board.
• The interface to the power supply board.
• Pulse–width modulator (PWM) current mode / voltage mode
full–bridge power amplifiers connected directly to the shuttle,
ribbon, paper feed, and platen open motors. Current mode is used
for the paper feed motor, voltage mode is used for the ribbon and
shuttle motors.
• The paper feed controller (PFC) accepts control codes from the
controller board for each motor phase to vector–control the paper
feed motor.
• The shuttle drive controller receives speed commands from the
controller board through the 8032 microcontroller and commands
the speed of the three–phase brushless dc shuttle motor.
• The ribbon drive controller, based around the 8032 microcontroller,
receives commands from the controller board and drives two dc
stepper motors, regulating the speed and tension of the ribbon and
monitoring the end of ribbon sensors.
• The platen drive controller for reverse paper feed receives
commands from the 8032 microcontroller.
• Fault detection circuitry samples and senses heat sink temperature,
ribbon speed, shuttle speed, hammer driver circuitry, hammer bank
coil temperatures, power supply voltages, and fault communication
with the controller board.
• Circuitry that registers magnetic pick–up unit (MPU) output,
processes it for the logic interface, and sends it to the controller
board for timing hammer fire.
Figure 2–18 summarizes mechanism driver board operation in block diagram
form.
Principles of Operation
2–31
Page 58
MECHANISM DRIVER BOARD
To
CCB/
LMI
Fault
Circuits
Logic
8032
Ribbon
&
Shuttle
Drive
Paper
Transport
Drive
Hammer
Drivers
41–88
Hammer
Driver
Logic
Paper Feed Control
Hammer Driver Board
Hammer
Drivers
1–40
To
Coils
41–88
To
Coils
1–40
Shuttle Drive & MPU
Figure 2–18. Operational Overview of the Mechanism Driver Board
2–32
Platen Open Control
Ribbon Status and Control
Principles of Operation
Page 59
Ribbon Drive System
The ribbon drive system is controlled by the 8032 microcontroller. The
controller board sends commands to the 8032 to start and stop the ribbon, set
the ribbon speed, and apply slack or tension to the ribbon. The real–time
control functions are done by the 8032, acting in accordance with firmware
control algorithms and look–up tables. The 8032 communicates with an
ASIC to provide direct digital PWM drive signals for the ribbon motor PWM
amplifier. The 8032 drives the ribbon motors through PWM generators in the
mechanism driver integrated circuit (MDIC). Nearly all mechanical control
functions are carried out through the MDIC ASIC. Digital I/O is done
through latches connected to the 8032 I/O ports and MDIC. Ribbon faults are
passed to the controller board.
Ribbon Velocity
Ribbon velocity is controlled by means of a closed–loop system that first
measures the speed of the two ribbon drive motors. One motor is driven; the
other motor is not driven and applies tension to the ribbon through its drag
circuitry. The velocity of the driven motor is known, while the velocity of the
tensioning motor is measured by converting the zero crossing of the
back–EMF signal to a digital pulse signal. This signal is processed by the
8032 to determine the radius of the ribbon on the take–up reel. The processor
monitors this information and adjusts the velocity of the driven motor to
maintain constant linear speed. The roles of the two motors reverse at the end
of ribbon travel, when a metallic strip crosses the ribbon guide of the
emptying reel and closes a circuit that causes the RSP to reverse motor
functions.
The four PWM amplifiers in the ribbon drive system are voltage mode to aid
in system damping (as opposed to current mode). The 8032 input to the
PWM amplifiers maintains a constant voltage/frequency ratio at the motor.
The ribbon drive is protected from over current.
Ribbon Tension
The 8032 processor regulates tension in three discrete steps by using
information gathered by the zero–crossing circuitry and ribbon information.
Tension is adjusted by controlling the load on the drag motor back emf. This
load generates drag torque on the ribbon hub that maintains tension.
Principles of Operation
2–33
Page 60
Start / Stop Ribbon
The ribbon motors are started and stopped by a digital signal from the
controller board. After a stop signal is received, the ribbon is locked to
maintain tension. If the controller board sends a slack signal, the PWM
amplifiers are tri–stated.
The Shuttle Drive System
The shuttle drive system is an analog closed–loop speed controller that
accepts commands from the controller board through the 8032
microcontroller and MDIC ASIC. The controller board writes a word
containing start, stop, and speed data to the 8032, which in turn writes a word
to the MDIC. The MDIC generates a clock signal based on this word.
The shuttle is protected from overspeed and over current.
Paper Feed System
Dot row advance and slew tables are stored in the controller board The paper
feed drive circuit takes commands directly from the controller board to
control the two–phase dc paper feed stepper motor. A controller board paper
feed command is a digital word containing a value proportional to the desired
current level in the paper feed motor, enabling the motor to be
quarter–stepped. Two PWM current mode amplifiers, protected against
overloads and short circuits, drive the paper feed motor. The paper feed
motor is usually energized whenever printer power is on in order to maintain
tension and position of the paper. The paper feed motor is disabled in a
platen open, paper jam, or paper out fault condition.
Reverse Paper Feed System
To reverse paper motion, the printer must open the platen, move the paper
backwards vertically, close the platen, and remove the slack in the paper. A
platen open or close command is generated on the controller board and
communicated to the RSP 8032 processor. The RSP generates control and
step clock signals for the platen driver circuitry. The platen driver circuitry is
connected to a stepper motor that drives the platen through a toothed belt.
The platen motor is only energized during the open and close cycles. The
platen driver is protected from over current.
2–34
Principles of Operation
Page 61
Hammer Driver Board
The hammer driver board consists of three functional elements: hammer
driver logic and control circuits, blower drive and monitoring circuits, and
filter capacitors for the +48 V and +12.5 V power supplies.
Hammer Driver Logic and Control
Each hammer spring is controlled by two electromagnetic coils, a driver, and
a logic circuit. 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 the coils and hammer drivers.
The buffered hammer
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 BHSC, containing dot
information for the characters to be printed by each hammer.
After the last bit is clocked into the shift register, the FIRE signal causes the
contents of the shift register to be loaded into the data latches. These latches
drive the gates of each lower drive MOSFET (Metal Oxide Semi–conductor
Field Effect Transistor).
The FIRE signal also turns the upper drive transistors on. When FIRE is high
and a lower driver is on, 48 volts are applied across the hammer coil. This
causes the coil current to rise rapidly, cancelling the magnetic field holding
the hammer retracted. With the magnetic field cancelled, the hammer starts
to fly forward. The FIRE signal drops, disabling the upper drivers. The coil
current is sustained by the upper driver diodes and the lower driver
MOSFETs. This combination applies 12.5 volts across the coil, keeping the
magnetic field cancelled until hammer impact.
After the dot is printed, the NLD_RST signal resets the lower driver
MOSFETs. The remaining coil current returns to the 48 volt supply through
flyback diodes. The magnetic field is restored and the permanent magnet
captures the hammer. (See Figure 2–19.)
shift clock (BHSC) pulses load data from the COM
Principles of Operation
2–35
Page 62
+24
V
bootstrap
NLD_RST
Test Mode
COM
CLK
FIRE
Level
Shift
Boot
Strap
Shift
Register
Latch
+48 V
12.5
V
SUS
LD
FET
Flyback
Diodes
V
ramp
Hammer
Coil
12.5
Coil Temp.
&
Open Detect
1%
Window Compare
&
Fault Detect
12.5 V
HD Coil Temp.
HD Short
Power Filtering
The power supply is housed in a protected and independently cooled steel
module separate from the card cage containing the hammer driver and
mechanism driver boards. The hammer driver board therefore provides bulk
filtering of the +48 and +12.5 (V
+48V
From
Power
Supply
+12.5V
GND
Figure 2–19. Hammer Driver Logic
) supplies. (See Figure 2–20.)
SUS
Filter
Capacitors
+48V
+12.5V
GND
To
Mechanism
Driver
Figure 2–20. Hammer Driver Power Filtering
2–36
Principles of Operation
Page 63
Hammer Bank Cooling
The hammer driver board also powers a blower that cools the hammer bank.
A fixed 60/40 signal (PWM) is provided to the hammer driver board to run
the blower. The hammer driver board demodulates this signal to a binary
logic (on/off) signal, then drives a MOSFET that powers the blower. A
current monitoring circuit tells the RTPU when the blower is running. If the
blower is stalled or not connected, the RTPU declares a fault. (See
Figure 2–21.)
48 V
Blower +
Blower –
Bank Fan
PWM
Demodulator
Figure 2–21. Hammer Bank Cooling
Blower
Running
Blower
Fault
Principles of Operation
2–37
Page 64
Power Supply
The power supply board, ac input connector, power switch/circuit breaker,
and a cooling fan are contained in a removable steel module at the rear of the
printer. The power supply senses and adjusts to any commercial electrical
system that provides ac mains potential in 50 or 60 Hertz systems. AC input
power is converted to +48 volt and +12.5 volt dc power and sent to the
hammer driver board for filtering. The hammer driver board passes the
filtered +48 and +12.5 Vdc to the mechanism driver board for distribution to
logic and electromechanical circuits. The power supply board supplies +5
Vdc power directly to the mechanism driver board or to the backplane in
printers using the LMI print engine.
AC Power
The power supply operates on ac voltages ranging from 88 to 135 or
176 to 270 volts. It can tolerate variations in frequency of 47 to 63 Hz. The
power supply is designed to withstand an ac input overvoltage of 125% of
nominal for one second with no degradation of dc output voltage or damage
to printer circuits.
DC Power
The power supply board contains two dc power supply systems for the
printer. The first is a + 5 volt bus for logic circuits. The second consists of
+ 48 volt and + 12.5 volt buses for the electromechanical sections of the
printer (all drive motors and the hammer bank).
The + 5 volt and + 48/12.5 volt supplies have separate return lines. Both
returns are tied together in a single–point ground at the mechanism driver
board.
There is an opto–isolated logic level input from the printer that can shut
down and latch off the + 48 volt and + 12.5 volt supplies while maintaining
the + 5 volt output. The return for this signal is the + 5 volt return. In
addition, this shutdown circuit discharges and latches the + 48 volt down to a
level lower than 15 volts in less than 300 milliseconds and requires recycling
of the power switch/circuit breaker to reset the latch.
The + 5 volt power supply has its own inverter, separate from the + 48 volt
and + 12.5 volt outputs to provide logic power if the +48/12.5 volt supply is
shut down.
2–38
Principles of Operation
Page 65
Print Mechanisms
Hammer Bank, Shuttle, and MPU
Printing is synchronized with shuttle movement by signals from the magnetic
pickup unit (MPU). The MPU, 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 MPU 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.
One 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 a distance
determined by the vertical dot density, and no printing occurs.
Typical signal levels received from the magnetic pickup are:
SYNC: 2.5 to 5.5 Vpp
RESYNC: 4 Vpp minimum
Operation of the hammer bank and shuttle is described on page 2–5.
Principles of Operation
2–39
Page 66
Hammer Bank / Shuttle Assembly
Shuttle Motor
(Shuttle Mechanics)
MPU
Figure 2–22. Hammer Bank and Shuttle Mechanical Elements
2–40
Principles of Operation
Page 67
Ribbon Deck
The printer ribbon winds and unwinds continuously on a pair of spools
latched to hubs driven by the ribbon motors. The ribbon motors operate only
while the hammer bank assembly is running. Ribbon motion reverses when
the metal strip at either end of the ribbon crosses the left or right ribbon
guide, completing a circuit that causes both motors to reverse direction.
Constant ribbon tension is maintained by controlling each motor with a drive
or drag circuit. While the hammer bank assembly is in motion, one motor
acts as a driving motor, drawing the ribbon against the resistance exerted by
the other motor—the drag motor. This system maintains a constant motor
speed and constant ribbon tension.
Principles of Operation
Figure 2–23. Ribbon Deck
2–41
Page 68
Paper Feed Control
The paper transport system accepts continuous, fan–folded, edge–perforated
paper from three to 16 inches wide and from one to six sheets thick.
Horizontal positioning is provided by the horizontal adjustment knob and
two tractors. The tractors are laterally adjustable along the splined and
support shafts. Each tractor engages paper perforations with eight pins and
locks in place with a friction lock. During printing, the paper feed motor
drives the splined shaft with a toothed belt. The splined shaft drives the
tractors. The paper feed drive motor is a two–phase step motor controlled by
the paper feed sections of the mechanism driver board and the paper feed
controller on the controller board.
Paper is manually advanced with the vertical adjustment knob.
Tractors
Horizontal
Adjustment
Knob
Support
Shaft
Paper Feed Motor
(under paper guide)
Vertical
Adjustment
Knob
1
Splined
Shaft
2–42
Friction
Lock
Figure 2–24. Paper Feed Components
Principles of Operation
Page 69
3 Preventive Maintenance
Chapter Contents
Preventive Maintenance 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Printer 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance
3–1
Page 70
Preventive Maintenance
The printer requires no preventive maintenance beyond normal
replenishment of paper and ribbons and periodic cleaning. Since operating
conditions vary widely, the user must determine how often to clean the
printer.
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.
1. Turn the printer off.
2. Disconnect the printer power cord.
CAUTION
3. Open the printer cover.
4. Remove paper from the printer.
5. Wipe the cabinet exterior with a clean, lint–free cloth dampened (not
wet) with water and mild detergent or window cleaning solution.
6. Dry the cabinet with a clean, lint–free cloth.
7. Open the forms thickness lever all the way. (See Figure 3–1.)
8. Squeeze the lock tabs on the ribbon hubs and remove the ribbon spools.
9. Using a soft–bristled brush, remove paper dust and ribbon lint from the
tractors, ribbon deck, ribbon path, and base casting. Vacuum up the
residue.
10. Wipe the splined shaft and support shaft with a soft cloth.
CAUTION
To avoid corrosion damage, use only anhydrous alcohol to clean the
print mechanism.
11. Using a cloth dampened with anhydrous alcohol, clean the ribbon guides.
3–2
Preventive Maintenance
Page 71
Forms
Thickness
Lever
Ribbon
Spools
Left
Tractor
Splined
Shaft
Support Shaft
Right Tractor
Platen
Lock Tab (2)
Ribbon Hub (2)
Ribbon Deck
Preventive Maintenance
Ribbon Guide (2)
Figure 3–1. Cleaning Interior of Cabinet
Base Support
3–3
Page 72
12. Wipe the platen with a cloth dampened with anhydrous alcohol.
13. Unlock the right tractor and slide it all the way to the right. (See
Figure 3–2.)
14. Remove the ribbon deck to gain access to the hammer bank.
15. Push the top edge of the ribbon mask on the hammer bank cover
assembly toward the platen and hold it in that position as you do step16.
NOTE: Handle the ribbon mask carefully. A damaged ribbon mask can
degrade print quality.
16. Use a stiff, nonmetallic brush to remove ribbon lint and paper dust from
the hammer springs and ribbon mask along the ribbon path. Vacuum up
loose particles. Remove stubborn accumulations using a cloth or
Kimwipe moistened (not wet) with anhydrous alcohol.
17. Return the ribbon mask to the operating position.
18. Install the ribbon deck.
19. Vacuum up dust or residue that has accumulated inside the lower cabinet.
20. Wipe the lower cabinet interior with a clean, lint–free cloth dampened
with water and mild detergent or window cleaning solution.
21. Dry the cabinet interior with a clean, lint–free cloth.
22. Install the ribbon.
23. Install the printer power cord.
24. Load paper.
25. Close the printer cover and return the printer to normal operation.
3–4
Preventive Maintenance
Page 73
Lock Tab (2)
Ribbon Hub (2)
Right Tractor
Forms
Thickness
Lever
Platen
Screw (3)
Ribbon
Deck
Ribbon Mask
Hammer Spring
Hammer TIp
Figure 3–2. Cleaning Hammer Bank Assembly
Hammer Bank
Cover
Preventive Maintenance
3–5
Page 74
3–6
Preventive Maintenance
Page 75
4 Troubleshooting
Chapter Contents
Introduction 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48V Power Fail 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 Volt Failed * 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCB to Mech Err. 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DCU RAM 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disk Read Error 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disk Write Error 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dynamic RAM Fault 4–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Font PROM 4–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Bank Hot 4–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Coil Open * 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Coil Short * 4–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ham. Drv. Short * 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hmr Coil Too Hot 4–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hmr Driver Short 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Error 4–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mech Driver Hot * 4–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mech Driver Link * 4–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NVRAM 4–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Off Line / Line Check Par. 4–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1Troubleshooting
Page 76
On Line / Line Check Par. 4–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Jam 4–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Out 4–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platen Open 4–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ribbon Stall 4–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Fan * 4–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Jam 4–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Error * 4–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Symptoms Not Indicated by Fault Messages 4–28. . . . .
Troubleshooting Aids 4–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Confidence Check 4–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCB Diagnostic Check 4–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CT Board Diagnostic Check 4–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Self–Tests 4–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hex Code Printout 4–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASCII Character Set 4–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Nonvolatile Memory (NVRAM) 4–41. . . . . . . . . . . . . . . . . . . .
4–2 Troubleshooting
Page 77
Introduction
This chapter contains procedures for troubleshooting printer malfunctions.
Diagnostic test procedures are also covered in this chapter. Basic printer
operation is not covered. Since you must operate the printer to check its
performance, have the Operator’s Guide or User’s Manual at the printer site.
Fault Messages
This section contains troubleshooting tables for fault messages that can
appear on the Liquid Crystal Display (LCD) of the control panel.
The LCD can display two kinds of faults:
1. Operator correctable faults.
2. Faults requiring the attention of a field service technician. This type of
fault message can appear in two forms:
On some models, this type of message is indicated by an asterisk (*)
after the fault message.
On IPDS–capable models, this type of message is indicated by the
phrase PRINTER HALTED.
IMPORTANT
Test printer operation after each corrective action you take, and stop
troubleshooting as soon as the symptom disappears. Always press the
control panel switch that clears messages after you correct a fault.
4–3Troubleshooting
Page 78
48 Volt Failed *
48V Power Fail
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
“48 Volt Failed * ” message. Go to step 2. Return printer to
“48 Volt Failed * ” message. Go to step 3. Return printer to
3. Turn printer off. —
4. Disconnect CCB/Mech
Driver cable from connector
J2 on the controller board
and connector J6 on the
mech driver board.
5. Turn printer on and observe
card cage fan: feel for air flow
beneath the card cage.
6. Cycle power and check
operation of the power supply
fan.
7. Cycle power and check
operation of the power supply
fan.
8. Cycle power and observe the
power supply fan above the
on/off switch.
9. Cycle power and check for
the fault message.
Card cage fan comes on. Replace the
Power supply fan runs, then
stops.
Power supply fan runs, then
stops, with new mech. driver
board installed.
Power supply fan does not run
at all.
“48 Volt Failed * ” message. Replace +5V
—
Go to step 4.
Go to step 5.
controller board.
Replace the
mech. driver
board.
Replace the
hammer driver
board.
Replace the
power supply.
cable assembly.
(See Appendix A.)
Go to step 10.
normal operation.
normal operation.
—
Reattach
CCB/Mech Driver
cable to connector
J2 on the
controller and
connector J6 on
the mech driver
board, and go to
step 6.
Go to step 7.
Go to step 8.
Return printer to
normal operation.
Return printer to
normal operation.
10. Cycle power and check for
the fault message.
4–4 Troubleshooting
“48 Volt Failed * ” message. Replace Hi
voltage cable
assembly. (See
Appendix A.) Go
to step 11.
Return printer to
normal operation.
Page 79
Instruction NoYesIndication
11. Cycle power and check for
the fault message.
12. Cycle power and check for
the fault message.
“48 Volt Failed * ” message. Replace Main
Wire Harness.
(See Appendix A.)
Go to step 12.
“48 Volt Failed * ” message. Replace hammer
bank cables. (See
Appendix A.)
Return printer to
normal operation.
Return printer to
normal operation.
4–5Troubleshooting
Page 80
CCB to Mech Err.
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
3. Run a diagnostic self–test
(page 4–37).
4. Remove the card cage cover.
Check ribbon cable
connectors between
controller board and
mechanism driver board.
5. Check installation of
controller board and
mechanism driver board.
6. Check for correct installation
and revision levels of
EPROMs and
microprocessors for the
RTPU on the controller board
and RSP on the mechanism
driver board. (Appendix E.)
“CCB TO MECH ERR.”
message.
“CCB TO MECH ERR.”
message.
“CCB TO MECH ERR.”
message.
Connectors are attached
properly.
Boards are installed correctly. Go to step 6. Reseat controller
RTPU and RSP EPROMs and
microprocessors are correct
versions and installed correctly.
Go to step 2. Return printer to
normal operation.
Go to step 3. Return printer to
normal operation.
Go to step 4. Return printer to
normal operation.
Go to step 5. Connect and latch
ribbon connectors.
Go to step 5.
and mechanism
driver boards in
their edge
connectors at
back of card cage.
Go to step 7.
Go to step 7. Install correct
RTPU and RSP
EPROMs and
microprocessors.
Go to step 7.
7. Power up printer and check
for fault message.
8. Power up printer and check
for fault message.
9. Power up printer and check
for fault message.
“CCB TO MECH ERR.”
message.
“CCB TO MECH ERR.”
message.
“CCB TO MECH ERR.”
message.
Replace the
controller board,
then go to step 8.
Replace the
mechanism driver
board, then go to
step 9.
Replace
CCB/Mech. Dr.
cable. (See
Appendix A.)
Return printer to
normal operation.
Return printer to
normal operation.
Return printer to
normal operation.
4–6 Troubleshooting
Page 81
DCU RAM
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
3. Run a diagnostic self–test
(page 4–37).
4. Run a diagnostic self–test
(page 4–37).
“DCU RAM” message. Go to step 2. Return printer to
normal operation.
“DCU RAM” message. Replace DPU and
RTPU on
controller board.
(See Appendix C.)
Go to step 3.
“DCU RAM” message. Replace all RAM
on controller
board. (See
Appendix C.) Go
to step 4.
“DCU RAM” message. Replace controller
board.
Return printer to
normal operation.
Return printer to
normal operation.
Return printer to
normal operation.
4–7Troubleshooting
Page 82
Disk Read Error
Disk Write Error
Instruction Indication Yes No
1. Turn printer off. Verify that the
system diskette is not
read/write protected. Insert
floppy diskette in drive. Turn
printer on.
2. Turn printer off. Remove front
panel. Check connections of
the floppy interface cable
assembly and floppy power
cable assembly at the disk
drive unit and the featurebus
backplane. (See Appendix
A.)
3. Check continuity of the floppy
interface cable assembly and
floppy power cable assembly.
(See Appendix A.)
“DISK READ ERROR”
or
“DISK WRITE ERROR”
message.
Connections are correct, clean,
and tight.
Continuity checks out okay for
both cables.
Go to step 2. Return printer to
normal operation.
Go to step 3. Clean and
connect cables as
necessary.
Replace diskette
drive.
Replace cable
assembly that fails
continuity test.
4–8 Troubleshooting
Page 83
Dynamic RAM Fault *
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Disconnect the input data line
from the host computer. Set
power switch to off. W
seconds. Set power switch to
on.
ait 15
“Dynamic RAM Fault * ”
message.
“Dynamic RAM Fault * ”
message.
Go to step 2. Return printer to
normal operation.
Make a Diagnostic
Check of the CCB
(page 4–30). If
any problems are
found on the CCB,
replace the board.
Return printer to
normal operation.
4–9Troubleshooting
Page 84
Font PROM
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
“Font PROM” message. Go to step 2. Return printer to
normal operation.
“Font PROM” message. Replace all font
PROMs on
controller board.
(See Appendix C.)
Return printer to
normal operation.
4–10 Troubleshooting
Page 85
Ham. Bank Hot
Hmr Coil Too Hot
NOTE: The printer has protective circuits designed to sense conditions that
Instruction Indication Yes No
can lead to overheating. When such conditions are sensed, print
speed is reduced 50%. If the printer consistently prints at half speed,
it may be printing long jobs of very dense graphics or operating in a
severe environment. A severe environment is consistently above 90°
Fahrenheit (32° Celsius) or is dirty enough to create blockage of the
blower ducts. If the printer is located in such an environment,
consider relocating it to a cooler, cleaner area or reducing the size
and duration of the print jobs.
1. Press the control panel
switch that clears fault
indications.
2. Check the ambient
temperature where the printer
is operated.
3. Run a diagnostic self–test
(page 4–37). While test is
running, check operation of
blower fan and air flow
through blower duct.
4. Cool the hammer bank for 2
hours. (It must be at room
temperature.) Run a
diagnostic self–test (page
4–37).
The printer continues the print
job.
Printer area at or above 100° F
(37° C).
Unobstructed air flow through
blower duct.
“Ham. Bank Hot”
or
“HMR COIL TOO HOT”
message.
No further
attention required.
Allow hammer
bank to cool for 10
minutes. Cool
printer area or
reduce size and
duration of print
jobs.
Go to step 4. If blower duct was
Replace the
hammer bank.
The printer
continues original
print job, then the
fault message
reappears.
Go to step 3.
blocked, remove
obstructions. If
blower fan did not
operate, check
electrical
connections. If
connections are
okay, replace the
blower assembly.
Return the printer
to normal
operation.
4–11Troubleshooting
Page 86
Ham. Coil Open *
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
3. Run a diagnostic self–test
(page 4–37).
4. Run a diagnostic self–test
(page 4–37).
5. Switch hammer bank cable
connectors at the hammer
driver board. (Top connectors
are for the left side of the
hammer bank.)
6. Run a diagnostic self–test
(page 4–37). Observe where
the non–printing hammer is
located.
“Ham. Coil Open * ” message. Go to step 2. Return printer to
normal operation.
“Ham. Coil Open * ” message. Go to step 3. Return printer to
normal operation.
“Ham. Coil Open * ” message. Go to step 4. Return printer to
normal operation.
Observe where the non–printing
hammer is located.
—
Position of the non–printing
hammer remains the same.
Go to step 5.
Go to step 6.
Replace the
of
fending coil then
go to step 7.
—
—
If the non–printing
hammer is 1–40,
replace the
hammer driver
board. If the
non–printing
hammer is 41–88,
replace the
mechanism driver
board. Go to step
7.
7. Return the hammer bank
cables to their correct
connectors on the hammer
driver board. Run a
diagnostic self–test (page
4–37).
“Ham. Coil Open * ” message. Replace the
hammer bank
cables.
Return printer to
normal operation.
4–12 Troubleshooting
Page 87
Ham. Coil Short *
Instruction Indication Yes No
1. Cycle power: Turn the printer
off. Wait 15 seconds. Turn
the printer on.
2. Turn the printer off. Remove
the ribbon deck. Measure the
coil resistance at hammer
bank connectors J1 – J6:
each coil has a red and a
white wire; put probes where
wire enters the top of the
connector.
3. If a coil is less than 4 Ohms,
disconnect its hammer bank
connector and measure the
coil resistance again, as in
step 2.
4. Disconnect the hammer bank
cable connectors J1 – J6.
Measure resistance of the
coil leads of the hammer
driver cable. (You are
checking resistance through
both the hammer driver cable
and the hammer driver board.
Do not disconnect the
hammer driver cable at the
hammer driver board. See
Appendix A for pin
assignments.)
“Ham. Coil Short * ” message. Go to step 2. Return the printer
to normal
operation.
Resistance is 4–8 Ohms for all
coils.
Coil resistance still less than 4
Ohms.
Cable resistance is more than
1K Ohm.
Go to step 4. For coils less than
4 Ohms, go to
step 3.
Replace the coil. Go to step 4.
For hammers 1 –
40, replace the
hammer driver
board. For
hammers 41 – 88,
replace the
mechanism driver
board.
Replace the
hammer driver
cable.
4–13Troubleshooting
Page 88
Ham. Drv. Short *
Hmr Driver Short
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
3. Disconnect connectors J4,
J5, and J6 from hammer
driver board. Cycle power.
4. Disconnect connectors J1,
J2, J3, and J4 from the
hammer driver board.
Connect J5 and J6. Cycle
power.
5. Connect all cables. Cycle
power.
6. Check resistance to ground
of all contacts in the bad
cable. If any measure v100
KΩ to ground, replace the
cable and the coil.
“Ham. Drv. Short * ” message. Go to step 2. Return printer to
normal operation.
“Ham. Drv. Short * ” message. Go to step 3. Return printer to
normal operation.
“Ham. Drv. Short * ” message. Replace the
mechanism driver
board.
“Ham. Drv. Short * ” message. Replace the
hammer driver
board.
“Ham. Drv. Short * ” message. Disconnect
hammer driver
cables one by one
until of
fending
cable is isolated.
Go to step 6.
“Ham. Drv. Short * ” message. Return printer to
Go to step 4.
Return printer to
normal operation.
Return printer to
normal operation.
normal operation.
4–14 Troubleshooting
Page 89
Internal Error
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
3. This message indicates a
software bug. Call the
Printronix Technical
Assistance Center for help:
(714) 863–1900 or (714)
553–1515.
“Internal Error” message. Go to step 2. Return printer to
normal operation.
“Internal Error” message. Go to step 3. Return printer to
normal operation.
— — —
4–15Troubleshooting
Page 90
Mech Driver Hot *
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Observe operation of card
fan: check for air flow at the
bottom of card cage.
3. Observe operation of cabinet
exhaust fan: check for air
flow out of the grid at the rear
of the printer.
4. Observe operation of power
supply fan above the on/off
switch at the rear of the
printer.
5. Press the control panel
switch that clears fault
indications.
6. Run a diagnostic self–test
(page 4–37).
“Mech Driver Hot * ” message. Go to step 2. Return printer to
normal operation.
Card cage fan operates. Go to step 3. Replace the card
cage fan.
Cabinet exhaust fan operates. Go to step 4. Replace the
cabinet exhaust
fan.
Power supply fan operates. Go to step 5. Replace power
supply.
“Mech Driver Hot * ” message. Go to step 6. Return printer to
normal operation.
“Mech Driver Hot * ” message. Replace
mechanism driver
board.
Return printer to
normal operation.
4–16 Troubleshooting
Page 91
Mech Driver Link *
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
3. Run a diagnostic self–test
(page 4–37).
“Mech Driver Link * ” message. Go to step 2. Return printer to
“Mech Driver Link * ” message. Go to step 3. Return printer to
“Mech Driver Link * ” message. Go to step 4. Return printer to
4. Remove the card cage cover. —
5. Check ribbon cable
connectors between
controller board and
mechanism driver board.
6. Check installation of
controller board and
mechanism driver board.
7. Check for correct installation
and revision levels of
EPROMs and
microprocessors for the
RTPU on the controller board
and RSP on the mechanism
driver board. (Appendix C.)
Connectors are attached
properly.
Boards are installed correctly. Go to step 7. Reseat controller
RTPU and RSP EPROMs and
microprocessors are correct
versions and installed correctly.
normal operation.
normal operation.
normal operation.
Go to step 5.
Go to step 6. Connect and latch
Go to step 8. Install correct
—
ribbon connectors.
Go to step 6.
and mechanism
driver boards in
their edge
connectors at
back of card cage.
Go to step 8.
RTPU and RSP
EPROMs and
microprocessors.
Go to step 8.
8. Power up printer and check
for fault message.
9. Power up printer and check
for fault message.
10. Power up printer and check
for fault message.
“Mech Driver Link * ” message. Replace the
controller board,
then go to step 9.
“Mech Driver Link * ” message. Replace the
mechanism driver
board, then go to
step 10.
“Mech Driver Link * ” message. Replace
CCB/Mech. Dr.
cable. (See
Appendix A.)
Return printer to
normal operation.
Return printer to
normal operation.
Return printer to
normal operation.
4–17Troubleshooting
Page 92
NVRAM
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Press the control panel
switch that clears fault
indications.
“NVRAM” message. Go to step 2. Return printer to
normal operation.
“NVRAM” message. Replace NVRAM
on Coax/Twinax
Integrated
Interface Board.
(See Appendix C.)
Return printer to
normal operation.
4–18 Troubleshooting
Page 93
Off Line
Line Check Par.
Instruction Indication Yes No
1. Wait a few seconds.
2. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
“OFF LINE
LINE CHECK PAR.” message.
“OFF LINE
LINE CHECK PAR.” message.
Go to step 2. Return printer to
normal operation.
Communications
problem. Check
lines, controller,
etc.
Return printer to
normal operation.
4–19Troubleshooting
Page 94
On Line
Line Check Par.
Instruction Indication Yes No
1. Wait a few seconds.
2. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
“ON LINE
LINE CHECK PAR.” message.
“ON LINE
LINE CHECK PAR.” message.
Go to step 2. Return printer to
normal operation.
Communications
problem. Check
lines, controller,
etc.
Return printer to
normal operation.
4–20 Troubleshooting
Page 95
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.
4.
Load paper and run a
diagnostic self–test (page
4–37).
5. Run a diagnostic self–test
(page 4–37).
Paper path is clear. Go to 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. Replace the
hammer bank
cover assembly.
Go to step 4.
Paper moves correctly but
“Paper Jam” message still
appears.
“Paper Jam” message appears
and paper does not move.
Clean the paper
motion detector
with cotton swab.
Go to step 5.
Replace following
until paper moves
correctly:
1) mech driver
board
2) paper feed
motor
3) main wire
harness
Go to step 3.
Go to step 4.
Go to step 5.
Return printer to
normal operation.
6. Run a diagnostic self–test
(page 4–37).
Go to step 6.
“Paper Jam” message. Replace the
following until the
message clears:
1) paper detector
switch assembly.
2) intermediate
cable assembly.
3) controller
board.
Return printer to
normal operation.
4–21Troubleshooting
Page 96
Paper Out
Instruction Indication Yes No
1. Load paper. —
2. Run a diagnostic self–test
(page 4–37).
3. Run a diagnostic self–test
(page 4–37).
4. Run a diagnostic self–test
(page 4–37).
“Paper Out” message. Replace paper
“Paper Out” message. Replace the
“Paper Out” message. Replace the
Go to step 2.
detector switch
assembly. Adjust
the new paper
motion switch
assembly. Go to
step 3.
sensor harness
assembly. Go to
step 4.
controller board.
—
Return printer to
normal operation.
Return printer to
normal operation.
Return printer to
normal operation.
4–22 Troubleshooting
Page 97
Platen Open
Instruction Indication Yes No
1. Load paper and close the
forms thickness lever.
2. Run a diagnostic self–test
(page 4–37).
3. Run a diagnostic self–test
(page 4–37).
4. Run a diagnostic self–test
(page 4–37).
—
“Platen Open” message. Replace platen
“Platen Open” message. Replace sensor
“Platen Open” message. Replace the
Go to step 2.
interlock switch
assembly. Go to
step 3.
harness assembly.
Go to step 4.
controller board.
—
Return printer to
normal operation.
Return printer to
normal operation.
Return printer to
normal operation.
4–23Troubleshooting
Page 98
Ribbon Stall
Instruction Indication Yes No
1. Check that forms thickness
lever is not closed too tightly;
this can jam the ribbon and
shuttle.
2. Run a diagnostic self–test
(page 4–37) and check for
shuttle obstruction.
3. Check ribbon path for
blockage or obstruction.
4. Wind ribbon by hand and
inspect for folds, tears, holes,
fraying.
5. Do a fast shuttle self–test
(page 4–37) and check the
alignment of the ribbon
guides and hubs if the ribbon
was folded.
6. Using a screwdriver, short
across the ribbon guide
screws to reverse ribbon hub
motion. Check for a ribbon
drive motor that will not wind
ribbon.
Forms thickness lever is set
correctly.
“Ribbon Stall” message. Go to step 3. Return printer to
Ribbon path is clear. Go to step 4. Remove
Ribbon is OK. (Folds are
permitted, if the ribbon is
otherwise undamaged.)
Ribbon tracks OK. Go to step 6.
Only one motor winds the
ribbon.
Go to step 2. Readjust the
setting of the
forms thickness
lever.
Go to step 2.
normal operation.
obstructions from
ribbon path and
go to step 4.
Rewind and
reinstall ribbon.
Go to step 5.
Replace the
following until
symptom clears:
1) mechanism
driver board.
2) defective ribbon
drive motor.
Replace ribbon, if
damaged. Unfold
and rewind ribbon
if it was folded.
Go to step 5.
Align ribbon
guides.
Go to step 6.
Return printer to
normal operation.
4–24 Troubleshooting
Page 99
Shuttle Fan *
Instruction Indication Yes No
1. Cycle power: Turn printer off.
Wait 15 seconds. Turn printer
on.
2. Run a shuttle/ribbon
diagnostic test (page 4–37)
and observe the blower fan.
3. Turn off the printer. Check all
cable connections between
hammer drivers, power
supply wire harness, and the
sensor harness assembly.
4. Check for indication shown at
right.
5. Turn the printer on and run a
diagnostic self–test (page
4–37).
6. Run a diagnostic self–test
(page 4–37).
7. Run a diagnostic self–test
(page 4–37).
“Shuttle Fan” error message. Go to step 2. Return printer to
normal operation.
Blower starts and runs, but
“Shuttle Fan” error message
displays.
Cables are connected and
undamaged.
“Shuttle Fan” error message
displays and blower does not
run.
“Shuttle Fan” error message
displays and blower does not
run.
“Shuttle Fan” error message
displays and blower does not
run.
“Shuttle Fan” error message
displays and blower does not
run.
Go to step 3. Go to step 4.
Replace the
controller and
hammer driver
boards.
Replace the
blower. Go to step
5.
Replace the
hammer driver
board. Go to step
6.
Replace the
mechanism driver
board. Go to step
7.
Replace the
power supply high
voltage cable
assembly.
Replace the
defective cable
assembly.
Return printer to
normal operation.
Return printer to
normal operation.
Return printer to
normal operation.
Return printer to
normal operation.
4–25Troubleshooting
Page 100
Shuttle Jam
Instruction Indication Yes No
1. Check the forms thickness
lever: if it is set too tightly
can slow the shuttle enough
to trigger the fault message.
, it
2. Run a diagnostic self–test
(page 4–37) and check for
shuttle obstruction.
3. Remove ribbon deck. Inspect
shuttle area and mechanism
for obstruction.
4. Run a diagnostic self–test
(page 4–37).
5. Run shuttle/ribbon diagnostic
test and check MPU voltage.
6. Run a diagnostic self–test
(page 4–37).
Forms thickness lever set
correctly.
“Shuttle Jam” message. Go to step 3. Return printer to
Shuttle movement blocked. Remove
Nothing obstructing shuttle, but
“Shuttle Jam” message
appears.
MPU voltage is 2.5–6 VAC. Replace
“Shuttle Jam” message. Replace hammer
Go to step 2. Set forms
thickness lever for
thicker paper. Go
to step 2.
normal operation.
Install ribbon
obstruction. Go to
step 4.
Go to step 5. Return printer to
mechanism driver
board. Go to step
6.
bank.
deck. Go to step
4.
normal operation.
Replace the MPU.
Adjust the gap to
0.008 inches and
adjust the
phasing. Go to
step 6.
Return printer to
normal operation.
4–26 Troubleshooting
Loading...