Star GEMINI-10X Technical Service Data

CP13

08955

STAR®

MODEL

GEMINI-1 OX

TECHNICAL SERVICE

DATA FOR YOUR

PRINTER

SIMS.

COMPUTERFACTS'

STAR

GEMINI-10X

PRELIMINARY

SERVICE

CHECKS

This

data

provides

the user

with

a

time-saving

service

tool

which is

designed

for

quick

isolation

and

repair of

printer

malfunctions.

Check

all

interconnecting

cables

for

good

connection

and

correct

hook-up

before

making

service

checks.

Replacement

or repair

of CPU

board

or

connectors

may be

necessary

after

the

malfunction has

been isolated.

X

o

ec

H

<

z

UJ

o

TEST

EQUIPMENT

AND

TOOLS

TEST

EQUIPMENT

Digital

Volt/Ohm

Meter

Scope

Logic

Probe

CO
a.

O

TOOLS

Phillips

Screwdriver

Small

Screwdriver

Low

Voltage

Soldering

Iron

Desoldering

Iron

REPLACEMENT

PARTS

AND

DESCRIPTION

ITEM

NO. PART

NO.

DESCRIPTION

DB1

08990202

DB2

08990202

F1

09990020

TR6

thru

TR14

07309861

TRA1

07650003

TRA2

07650003

87041011
87222021

87220320
87041020

09010024

87045041

87223010

89070000

87045010
87049040

08200043

07312771

Bridge

Rectifier, KBL02

Bridge

Rectifier, KBL02

Fuse,

1.25A @125V

Slow-Blow

Transistor, 2SD986

Transistor Array, PU4124

Transistor

Array,

PU4124

Carriage Motor

Assembly

Main

Board

Control Panel

Board

Linefeed Motor

Assembly

On-Line Switch, J-P5029
Paper-Out

Detector Switch

Power Supply

Unit (Includes

Power Cord, Power

Switch, AC

Board and

Power Transformer)

Print Head
Print Head Cable

Board

Right-End

Detector Switch

5.0V

Regulator, 7805A

24V

Regulator, 2SD1277

SAMS

Howard

W.

Sams

& Co.,

Inc.

tm

4300 West 62nd Street, P.O. Box 7092,

Indianapolis, Indiana 46206

U.S.A.

The listing of any

available

replacement part herein does

not

constitute in any case a

recommendation,

warranty or guaranty by

Howard W. Sams

S Co.,

Inc., as

to the quality and

suitability

of

such

replacement

part. The numbers of

these parts have been

compiled

from information

furnished to Howard W, Sams & Co.,

inc., by the

manufacturers of the

particular type of

replacement part listed.

Reproduction

or use,

without express permission, of editorial or

pictorial

content,

in any

manner,

is

prohibited. No patent liability is assumed

with

respect to

the

use of the

information contained herein.

©

1985 Howard W.

Sams & Co.,

Inc.

4300 West 62nd Street, P.O. Box 7092, Indianapolis,

Indiana

46206

U.S.A.

Printed

in U.S.

of America

85CP14961

DATE

10-85

PRELIMINARY

SERVICE

CHECKS

(Continued)

AC

BOARD

P0WER

SWITCH

@120VAC

@

590roA

CHASSIS-

TOP

VIEW

5.0V

REGULATOR Jr

ft)

XJ5

rar

.

1

PAPER-OUT

r^

SWITCH

1

J

(6B) (6C)

PRINT HEAD

ASSEMBLY

(3C) (5e)

N

\

PRINT HEAD

CABLE BOARD

(3B)

RIGHT-END i

DETECTOR

SWITCH

a
m

3w

l>

O
X

INTERCONNECTING

DIAGRAM

II

INTERCONNECTING

DIAGRAM

XI

PRELIMINARY

SERVICE

CHECKS

(Continued)

SERVICE

CHECKS

SEE

INTERCONNECTING

DIAGRAM,

PLACEMENT

CHART,

AND PHOTOS

TO MATCH

THE NUMBER

IN THE CIRCLES

WITH

THOSE IN

THE FOLLOWING

DATA

FOR

SERVICE

CHECKS TO

BE PERFORMED.

©

©

©

©

POWER

SUPPLY

(A)

Check Connectors

CN10A,

CN10B and

CN11 for

good connections.

(B) Check for

an open Power

Switch

(S1)

or

an open

power cord.

(C) Check the Power

Transformer

(T1)

for an open

winding.

(D) Check AC

Fuse

F1. If the fuse is

open, check the

Power Transformer,

Bridge

Rectifiers

(DB1 and

DB2),

the

5.0V

Regulator and the

24V Regulator

Transistors for

possible

shorts.

(E) Check Print

Head

Driver Transistors

TR6 thru

TR14,

Linefeed

Motor Driver

TRA1 and

Carriage

Motor Driver

TRA2

for shorts.

PRINTER

CARRIAGE

ASSEMBLY

DOES NOT

MOVE

(A) Check

Connector

CN6 for

a good connection.

(B) Check the

resistance

of the

Carriage Motor

wind-

ings.

Unplug

Connector

CN6 and

check for 11.3

ohms between

pins

2

and

3,

pins

2 and

4,

pins 1

and5and pins

1 and

6. If the resistance

of any

winding is

abnormal,

replace

the Carriage

Motor.

(C) Check for

24.5V

at the emitter of

Transistor TR5.

If the voltage

is

missing, check

the power

sup-

ply.

(D) Check for

a shorted

Right-End

Detector Switch.

PRINT HEAD WILL

NOT PRINT

(A) Check

Connector

CN7 for

good connections.

(B)

Check

for

a

defective

Head

Cable Board.

If the

board is defective,

replace

the Print

Head Cable

Board.

(C) Check for

a defective Print

Head.

MISSING

DOTS IN

THE PRINT PATTERN

(A) Check Connector

CN7 for

good connections.

(B) Disconnect

Connector CN7

and check

the re-

sistances

of the Print

Head solenoids.

Measure

between

pin

6

and

pins 1 thru

5

and pins

9 thru

12

of Connector

CN7. If any solenoid

is

open,

replace the

Print

Head.

©

©

LINE FEED

WILL

NOT

OPERATE

(A) Check

Connector

CN5 for

good

connections.

(B)

If the Linefeed

Motor

turns

but the paper

does

not feed

when

the

L.F. Button

is pressed, check

the

operation

of the

gear

assembly

on the right

side

of the

platen.

If the

gear assembly

is

not

operating,

check

for

a broken

gear.

(C) If tfje

Linefeed

Motor

is inoperative,

check the

resistance

of the

Linefeed

Motor

windings. Un-

plug

Connector

CN5

and check

for

a

resistance

of

approximately

51 ohms

between

pins

2

and

3,

pins

2

and

4,

pins

1 and

5 and pins

1 and

6. If

the

resistance

of any

of the

windings

is abnormal,

replace

the

Linefeed

Motor.

PAPER-OUT

NOT

DETECTED

(A) Make

sure that pin

1 of

DIP Switch

(DSW2) is set

On.

(B) Check

the

Paper-Out

Detector Switch

to make

sure

that it closes

when

paper is removed from

the

Printer.

If the

switch

does not

close,

check

for a

defective

Paper-Out

Detector Switch.

(C) Make

sure that

the

Paper-Out

detector lever

moves

smoothly

and the

detector

spring is not

broken

or missing.

PRINTER

WILL

NOT

RECEIVE

DATA

FROM HOST

COMPUTER

(A) Check

the

Interface

Cable between

the host

Computer

and the

Printer.

Also

check Connec-

tor

CN1 for

good

connections.

(B) Check

the

ribbon

cable

between

Connectors

CN2 and

CN3.

(C) Check

the

operation

of the

On-Line

Switch. If

the On-Line

status

of the Printer

does

not

change

when

the switch

is

pressed,

check for a

defective

switch.

Also

check

Connector

CN8

for

good

connections.

Ill

PRELIMINARY

SERVICE

CHECKS

(Continued)

o

m

|S

2

>

I"

o
X

MAIN

BOARD

IV

MAIN

BOARD

IX

PRELIMINARY SERVICE

CHECKS

(Continued)

MISCELLANEOUS

ADJUSTMENTS

PRINT HEAD TO

PLATEN

ADJUSTMENT

Place the

Platen Adjust

Lever

at the

second

step

positon

(handle

straight up).

Insert

a feeler

gauge

between

the rib-

bon

guide and

the

platen. The

gap

should

measure

between

0.25mm and

0.35mm.

Check the

gap

with

the

print head

at

the

left, center and

right

of

platen for

uniformity.

If the

platen

gap

is

out of

tolerance, the

following

adjust-

ment is required.

Move

the Platen

Adjust Lever all the

way forward

(lock

in

bottom notch). Fasten the left

and right

adjust

bushes

with

two

(M3

x

6)

screws into

the frame

tap holes.

Remove

nut

and lock washer holding

adjust lever. If

the

gap is

too

wide

place

the adjust lever on

point

A or

B. See Figure

1. If

gap

is too

narrow

place the

adjust lever

on

point

C or

D.

See

Figure 1. Retighten nut

on

adjust lever

and

remove

the

two

retaining screws

from frame

tap holes.

Check

gap

measure-

ment.

Adjust

Lever

Adjust

Bush

Figure 1

,Adjust

Bush

.1

^

2mm

Carriage

^Printer

Frame

(Left)

Figure

2

RIGHT

END DETECTOR

ADJUSTMENT

It the right

end detector

switch is not

closing when the car-

riage

assembly is moved

to the

far right, adjustment is re-

quired. Remove

the ink ribbon

spools.

Remove two pins

holding ribbon

base plate and

remove

plate. Slide

carriage

assembly

to

far right.

Loosen

screw in slotted hole

of

detector

switch. Pivot switch

until it

just closes and tighten

screw.

TIMING

BELT TENSION

ADJUSTMENT

Slide carriage

assembly

to

far

right.

Locate left timing belt

pulley

adjusting plate.

Loosen

screw in slotted hole of ad-

justing

plate. Adjust

belt tension for

30 grams ± 10%. Ad-

justment

is made by pushing

the pulley

to

the

left

until

pro-

per tension

is obtained.

If adjustment

cannot

be

made

within tolerance

replacement

of timing

belt is

required.

Tighten

screw

and

apply

screw lock.

CARRIAGE POSITION

ADJUSTMENT

(HOME

POSITION)

Turn ON the Printer. The

carriage

will move

to the

left and

stop. Measure

the gap

between the

adjust bush and

the car-

riage.

It should

be between 1 and

2mm.

See Figure

2. To

adjust, loosen

the screw

on the Home

Position

Detector

board.

Pivot

the

board either left or

right

depending

if the

gap is too wide or

too narrow.

To check the

adjustment

turn

ON the Printer

and

measure the

gap. Repeat

procedure

until

gap

setting

is correct.

PRELIMINARY

SERVICE

CHECKS (Continued)

©

ON-LINE

SWITCH

®

FUSE

m

m

-v

•

^m

i

f

CONTROL PANEL

BOARD

VI

FUSE

BOARD

PRELIMINARY

SERVICE

CHECKS

(Continued)

@@

@

@@

®

® ®

3

APEB~0UT

SWITCH

REGULATOR

24V

REGULATOR

»0WER

TRANSFORMER

FUSE

F1

SW POWER

SWITCH

PRINT

HEAD

ASSEMBLY

PRINT

HEAD

CABLEBOARD

GEAR

ASSEMBLY

RIGHT-END

DETECTOR

SWITCH

,2D,

Q
m

z

>

1

=

o

X

LINEFEED

MOTOR

CARRIAGE

MOTOR

CHASSIS-TOP

VIEW

VII

DIP

SWITCH

SETTINGS

DSW1

FUNCTIONS

DSW1

ON

1-1

Selection

of

Character

Set

1-2

Print

Mode

at

Power

ON

1-3

Set of Print

Pitch

1-4

Selection

of

Character

Set

1-5

Line

Feed

Value

1/6

inch

1-6

Selection

of

1-7

International

1-8

Character

Set

Form

Length

(Refer

below)

Normal

10CPI

(Refer

below)

(Refer

below)

DSW1

OFF

Emphasized

17CPI

1/8 inch

DSW1

Pin

No.

Pin

No.

1-1

1-4

ON

ON

ON

OFF

OFF

ON

OFF

OFF

DSW1

INTERNATIONAL

CHARACTER

SET

DESIGNATION

Character

Set

Standard

ASCII

Character

Set

Download

Character

Set

Italic

ASCII

Character

Set

Italic

ASCII

Character

Set

DSW1-6

DSW1-7

DSW1-8

U.S.A.

ON

ON

ON

England

OFF

ON

ON

Germany

ON

OFF

ON

Denmark

OFF

France

ON

Sweden

OFF

Italy

ON

Spain

OFF

OFF

ON

ON

OFF
OFF

DSW2

FUNCTIONS

2-1

Paper-Out

2-2

Buffer-Full

Printing

2-3

7/8

Bit Inter-

face

Selection

2-4

Automatic

Line

Feed

ON

OFF
OFF
OFF
OFF

ON

Disables

the

printer

when

paper-out.

Paper-

,,out

signal

is

transmitted

from

the

printer

mechanism

to

the

computer.

CR

code

is

ignored,

and

print

data

of one

line

is

stored

in

the

buffer

until

the

memory

is full

or

by input

of a

LF

code.

Interface

is

set to

7 bits.

OFF

Allows

the

printer

to

print

with no

paper.

Paper-out

signal

is not

transmitted

from

the

printer

mechanism

to the

computer.

Printing

is

performed

every

time

CR

code is

input.

Interface

is

set to

8 bits.

Automatic

line

Line

feed

is not

feed

is

performed

performed

by

by input

of CR

input

of

CR

code,

code.

(Note)

DIP

switch

pin

No.

2-2

overrides

DIP

switch

pin

No.

2-4.

VIII

DISASSEMBLY INSTRUCTIONS

CABINET TOP

REMOVAL

Remove the

platen knob

on the right

side. Remove

two

philips

screws from

cabinet

top. Remove

the

dust

cover,

gently

pull

the front

edge of cabinet

top to release three

tabs, and

lift cabinet

top upwards.

Unplug

the function

board

connector and

remove

cabinet top.

Remove

two

screws holding

function

board to cabinet

top

and

remove

the function

board.

CHASSIS REMOVAL

Remove four

screws holding

the chassis

to the

cabinet bot-

tom. Unplug

connectors

CN4,

CN5, CN6,

CN7 and

CN8

from

the Main

board. Remove

the chassis

assembly

from

Printer.

PRINT

HEAD

REMOVAL

Remove

the printer

cover. Remove

ink ribbon from

front

of

the print

head.

Remove

two screws

and washers holding

print head

to

carriage

assembly.

Disconnect the head

cable

from the

head

connector.

Print head

may not be removed.

PRELIMINARY

SERVICE

CHECKS

(Continued)

PREVENTATIVE

MAINTENANCE

ENVIRONMENT

Computers

perform

best

in

a

clean, cool area

that

is

below

80

degrees Fahrenheit and

free

of dust

and smoke particles.

Even

though

home Computers

are not affected by

cigarette smoke as much

as

commercial Computers are affected, it is

better to

maintain

a

smoke-free

area around

the Computer. Do

not block cabinet vents of any of the Computer system;

Computer,

Monitor,

Printer, or

other power devices.

ELECTRICAL

POWER

Variations

in the

line voltage can affect

the Computer. Try to avoid

these

fluctuations by using

an AC receptacle that

is on a

power

line

not

used by

appliances or other heavy

current demand devices. A power-surge protector, power-line

conditioner,

or

non-interruptable

power supply may be

needed

to

cure the problem. Do not

switch

power On

and Off frequently.

KEYBOARD

Liquids spilled

into the Keyboard

can ruin

it.

Immediately

after

a

spill occurs, disconnect the Computer power plug

from AC

power outlet.

Then, if circuitry or contacts

are contaminated, disassemble

the

Keyboard and carefully rinse the

Keyboard

printed circuit board

with distilled water and let it dry.

Use

a

cotton swab to clean between the

keys. Use

a

non-abrasive

con-

tact cleaner and

lint-free wipers on accessible connectors

and contacts.

DISK DRIVES

Clean

the read/write

heads of the Disk Drives about once a

month or after 100 hours

usage. Use

only an approved head

clean-

ing

kit.

Handle

carefully

to

preserve proper

disk head alignment. A sudden

bump or jolt

to

the Disk

Drives

can knock the disk

head out

of alignment.

If the disk drive must

be

transported,

place an old disk

in

slot and close door during transport.

Store disks

in their protective covers and

never touch the disk surface.

Observe

the disk handling precautions

usually

found

on

the back of disk protective covers.

PRINTERS

Carefully vacuum

the Printer regularly. Wipe surface areas clean using a

light all-purpose cleaner.

Do

not oil the

machine.

The oil

will collect abrasive

grit and

dust. The dust

will

act as a

blanket. This can cause components to

overheat and

fail.

STATIC ELECTRICITY

Static electricity

discharge can affect the Computer. In order

to

minimize the possibility,

use

anti-static mats, sprays,

tools

and materials, and

maintain

good

humidity in the Computer environment.

MONITOR

Use

an isolation transformer

with any Monitor

that does

not come

as

part of the system since some

Monitors

use a

HOT

chassis (chassis connected to one side of the AC

line).

The

faceofthe Monitor should never

be

left on for long

periods

of time

at

high brightness level except when pattern is being changed periodically. Use

caution when cleaning anti-glare

screens, to

preserve the glare-reduction feature.

XI!

gflM

$

COMPUTERFACTS"

STAR

GEMINI-10X

X

o

DC

1

o

CO

o

PRELIMINARY

SERVICE CHECKS

ENCLOSED

INDEX

SAFETY

PRECAUTIONS

See

page

10.

o

CO

o

m

z

>

o

X

Page

Block Diagram

28

DIP

Switch Settings

10

Disassembly Instructions 9

Exploded View Mechanical

27

GridTrace Location Guide

6

IC Pinouts and Terminal Guides

4,29

Line Definitions

9

Logic Chart

23,24

Mechanical Parts List

19

Miscellaneous Adjustments

13

Parts List 14 thru 18

Page

Photos

Chassis Top

22

Control Panel

Board

20

Fuse Board

21

Main Board

7,8,25,26

Safety

Precautions

10

Schematics

Input Buffer

3,30

Main

2,31,32,33

Serial Interface

5

Schematic

Notes

29

Test Equipment

11

Troubleshooting

11,12

Star Micronics Printers are

warranted

for one year from date of purchase. If any service or modifications

are performed during this time by other than Authorized Star Micronics Service Centers, the manufac-

turers' warranty will be

void.

SAMS*

Howard

W.

Sams

& Co., Inc.

4300 West 62nd

Street, P.O.

Box

7092, Indianapolis,

Indiana 46206

U.S.A.

The

listing

of any available replacement part

herein does no*

constitute in any

case a

recommendation,

warranty or guaranty

by

Howard W.

Sams & Co. , Inc. . as

to the quality

and suitability of such

replacement part. The numbers of these parts have

been compiled

from information furnished to Howard W.

Sams & Co., Inc.,

by

the

manufacturers of the particular type

of replacement

part

listed.

Reproduction or

use, without express

permission,

of editorial or pictorial

content, in any manner,

is prohibited.

No patent liability

is assumed

with

respect to the

use of the information

contained herein.

©

1985 Howard

W,

Sams

& Co., trie.

4300 West 62nd

Street,

P.O.

Box 7092, Indianapolis,

Indiana 46206 U.S.A.

Printed

in U.S. of America.

85CP1 4961

DATE 1

0-85

MAIN

BOARD

A PHOTOFACT

STANDAUD

NOTATION

SCHEMATIC

wiTHQmsnsa

©

Howard

W. Sams

& Co.,Inc. 1985

MAIN

BOARD