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OLIVETTI PR2 E Service Manual

1. 19 GROUND 002 me 20 GROUND 1 03 21 GROUND DATA204 22 GROUND DATA305 23 GROUND DATA406 in 24 GROUND 507 m 25 GROUND DATA608 26 GROUND 7 09 27 GROUND ACKNOWLEDGE 10 28 GROUND BUSY 11 29 GROUND PAPER EMPTY 12 4 30 GROUND ONLINE13 AUTOFEED XTl4 Me W 32ERROR NC 15 33 LOGIC GROUND LOGIC GROUND 16 34NC FRAME GROUND 17 35 5 PULL UP 3 3K ohm 5V18 t 36INPUT SELECT IN Fig 3 10 Parallel Interface Pin Out Y100250 4 Service Manual 3 11 Proceed as follows to install this optional Power off the printer Usinga screwdriver break off the slot cover of the optional serial interface on the rear of the printer Insert the interface card in the slot and slide it along the guideways until it plugs into the related connector on the main board Push firmly to ensure proper connection Tighten the card s two side screws to secure it in place BE Fig 3 11 Installing the Parallel Interface In a printer dual port configuration consisting of the standard serial interface parallel interface in an empty buffer and out of paper condition the printer polls the two ports to see which one will be assigned When asignal is received by any one ofthe two interfaces the printer switc
2. 8 3 42 OPTIONAL SERIAL INTERFACE USB INTERFACE 9 343 OPTIONAL IEEE 1284 PARALLEL INTERFACE CARD 11 25 FINAL TES TING soc da 13 3 6 INFORMATION FOR THE OPERATOR 13 3 7 OPERATING PROCEDURES sscssssssssvsesssssssssvssssssesssnsssssuessssnecsssvesssnssessseessns 14 3 71 INSERTING A DOCUMENT WITH AUTOMATIC ALIGNMENT 14 3 22 INSERTING A SAVINGS BOOK tiennent 15 3 7 3 INSERTING A CHECK FOR HORIZONTAL MAGNETIC DEVICE MICR READ OPERATIONS e 16 3 74 EXPULSION OF PROCESSED DOCUMENTS 17 3 75 REPLACING THE RIBBON CARTRIDGE 17 3 7 6 PAPER JAMS a sisi patatas educat detenta dp 20 vi Y100250 4 4 AUTODIAGNOSTICS SET UP AND ADJUSTMENTS 1 4 11 POWER ON 1 42 PRINI TEST 2 43 uo TA Os Dau cue 2 4 3 1 ACTIVATING THE 5 0 0000 000000000000000 2 43 2 SUPPORT 5 20200200 000 000000000000 0 2 4 3 3 CONFIGURATION PARAM
3. 916 PRINTHEAD CONNECTOR 1 2 3 4 5 6 7 8 9 R0818 SPL 8 R1016 SPL 10 R1214 SPL 14 R0818 SPL 18 R1016 SPL 16 R0915 SPL 15 R0915 SPL 9 R0717 SPL 7 R0321 SPL 3 R0123 SPL 1 R0620 SPL 20 R0224 SPL 24 R0321 SPL 21 PIU35 PIU35 GND GND GND VCC PIU12 MEN12 RESEO Y100250 4 Service Manual 6 3 J4 CARRIAGE RESET 1 2 3 4 VCC VCC GND FAZCA J12 OPTIONS COONDOOARWND 21 20 11 10 2 1 PIU35 PIU35 GND GND J11 OPTIONS UON VCC CKMOT DACOM FAZMA PMAGN VERMA RESEO F2FDA PIU12 GND J2 J1 PAPER FEED MOTOR ROLLERS MOTOR 1 TRF1A 1 2 TRF1B 2 MRO1B 3 TRF2A 3 MRO2A 4 TRF2B 4 MRO2B J6 J99 OPTIONS FRONT PHOTOSENSORS 1 ADSEL FOCOM 2 FDCDM VCCAL2 LECOM 46 OPTIONS VCCAL4 TXDS 2 SCKDS FOAN2 LEAN2 LEAN1 FOAL1 FOAN1 LEAL1 1 2 3 4 5 6 7 8 9 J1 INTERFACE 6 4 Y100250 4 6 3 MAGNETIC OPTIONS CARD The following magnetic options card can be installed on the BAPR2 main board PR2MAGN for the management of the horizontal magnetic device option The option installed is controlled by the FW according to the parameters defined during machine setup 6 3 1 CARD LOCATION AND IDENTIFICATION OF CONNECTORS amp lt amp
4. POSSIBLE CAUSE oz 85 89 5 5 lt Incorrect missing line voltage X Damaged power cord X Power cord partly inserted X Blown fuse X Faulty power supply unit X Faulty main board X X Faulty front photosensors X Faulty carriage photosensor X Faulty rear photosensor X Printer cover open X Jammed paper X Interface connection problems X Interface line problems X Incorrect set up X 5 4 Y100250 4 5 4 DOCUMENT WRITE FAULTS e FAILURE 5 5 E 55 5 i 2 9 olo 5 JES 5 2 535 POSSIBLE CAUSE E 515 9 292 a gt c a D Jas Ribbon cartridge not installed X X Ribbon to be replaced finished X Ribbon cartridge fitted incorrectly XX X Incorrect set up parameters X X Obstruction along the carriage stroke X X Closing levers open X X X X Faulty printhead X X Faulty paper photosensor X X X Faulty head flat cable X X X X Transport motor X X Faulty main board X X Paper feed belt adjustment X Needle platen distance adjustment X X Ribbon needle protection fin adjust X XXX Paper photosensor adjustment X X X Print bar adjustment X X Strap adjustment X Roller gear adjustment X Front pressure roller adjustment X Carriage movement belt adjustment X X Y100250 4 Service Manual 5 5 DO
5. Fig 3 8 Installing the Serial Interface USB Interface Card Once the optional serial interface USB interface card is installed only the two serial interfaces are operational simultaneously In this configuration with an empty buffer and in an out of paper condition the printer polls the two ports to see which one will be assigned When a signal is received by any one ofthe two interfaces the printer switches to the receiving interface and maintains this condition until the end of the print job The assignement of the interfaces is mutually exclusive In addition to the active emulation the two interfaces have the same parameter settings The active emulation can be changed by an on line command 3 10 Y100250 4 3 4 3 OPTIONAL IEEE 1284 PARALLEL INTERFACE CARD The optional parallel interface card hosts a 36 pin Centronics parallel interface It is installed in the specific slot alongside the first serial interface on the rear ofthe printer Itis suggested to use an interface cable up to 1 5 meters long The ECP data exchange protocol is used This card is shown in the following figure CENTRONICS INTERFACE 2 amp 4 ve CONNECTOR J1 FOR CONNECTION TO THE MAIN BOARD Fig 3 9 Parallel Interface Card
6. I J1 Fig 6 2 Magnetic Options Card Y100250 4 Service Manual 6 5 6 3 2 VIEW OF THE PR2MAGN CARD 7 J6 ZEN cj 3 1 1 CD Fig 6 8 PR2MAGN Card 6 6 Y100250 4 6 3 2 1 PR2MAGN CARD PIN OUT J1 J2 CONNECTION TO THE MAIN BOARD CONNECTION TO THE MAIN BOARD 1 21 1 VCC 2 MAC20 2 DAWRM 3 MAC11 3 DACOM 4 10 4 FAZMA 5 MAPH2 5 GND 6 MAPH1 6 VERMA 7 PIU35 7 RESEO 8 PIU35 8 F2FDA 9 GND 9 PIU12 10 GND 10 GND J3 J4 J5 MAGNETIC DEVICE MOTOR MAGNETIC RESET PHOTO MAGNETIC HEAD 1 FAMO 1 1 2 1 2 VCC 2 WRIO 3 FAM2 3 LED1 3 GND 4 4 FAZZO 4 GND 5 LEO1 6 LEOO J6 CALIBRATIONS 1 OUT1 2 GND Y100250 4 Service Manual 6 7 6 4 SERIAL AND USB INTERFACE CARD The installation of this interface card provides the printer with an additional serial RS232 and USB interface 6 4 1 CARD VIEW AND LOCATION OF CONNECTORS J3 IE E400 LINT zc I IN Jol 5 161 1110 515 514 RS18 CS13 119 ESI enl lon HB og m YS2 BB O 056 055 Zl ko c S 162
7. Parameters to be checked 1 MINIMUM ACCEPTABLE VALUE 2800 2 VALUE 1500 3 2000 MINIMUM ACCEPTABLE VALUE Perform a further check by inserting a form with a check format code 152136J at the two sides and center of the insertion slot and with its shortest side parallel to the axis of the photosensors Check for correct operation Note The parameters indicated above are useful indications to determine in which operating segment the PR2 E is positioned as far as document acceptance is concerned 4 18 Y100250 4 4 4 1 1 PRINTING PHOTOSENSOR CALIBRATION VALUES Printing photosensor calibration values iis useful as reference between one calibration and the next Proceed as follows for alignment calibration 1 2 Power on the printer with its cover open and while holding down the three buttons on the console Wait for the audible signal to sound indicating that the printer has switched to the calibration and adjustment phase then close the printer cover Press the STATION 1 button Press the LOCAL button When reset is completed insert an A4 sheet of paper The sheet is inserted printed and automatically expelled The printer automatically switches to the next calibration phase Y100250 4 Service Manual 4 19 4 4 2 BI DIRECTIONAL PRINT ALIGNMENT CALIBRATION Provided below is the bi directional print alignment calibration block diagram Note The printer switches between modes and spa
8. The parameters defined for the IBM PP and Olivetti emulations To stop the print test power off the printer The following pages provide examples Fig 3 3 and Fig 3 4 of the information provided by the tests The content of the test depends on the FW release installed on the printer Y100250 4 Service Manual 3 5 FW REL 1 00E VER 010 Needles test 1234567890 CONFIG DRAFT SPEED LQ TYP PAPER WIDTH BUZZER INTERFACE RS1 EMULATION BAUD RATE BIT CHAR PARITY STOP BIT DSR DCD CX EMULATION STROBE ACTIVE PAP EDGE SPECIAL FORMS EMULATION PASSBOOK BINDING SIDE CHAR SET PC CHAR SET PC TABLE CHAR DEFINITION CPI LF LF CR CR CR LF ZERO SLASH LINE LENGHT FORM LENGTH BOF LIKE TOF LIKE OLIVETTI EMULATION PASSBOOK BINDING SIDE CHAR SET OLI CHAR SET Eu DEFINITION P COMPRESSED VERTICAL RESOL LF LF CR LINE LENGHT REPLY SYNCRON STATUS REQUEST CG VER 000 eo0o me s edn de 12345 NORMAL NLQ1 LINE DUAL OLIVETTI 9600 8 UNE Y Y IBM Y N N VERTICAL L PC 437 CINT TABLE 2 DRAFT 10 80 12 X Y vee er eae OLIVETTI ST15INT DRAFT 16 6 1 240inch N 90 N NO WAIT Fig 3 3 Print Test Example PR2 E Basic Version 3 6 Y100250 4 FW REL 1 00E VER 028 CG VER OO2 Needles test
9. PRINTING MODULE PRINTING SPEED PRINT QUALITY RIBBON CARTRIDGE PAPER FEED PAPER SIZE CONSOLE EMULATIONS INTERFACE DIMENSIONS POWER CONSUMPTION POWER SUPPLY Dot matrix printhead with 24 diamond shaped needles and overtemperature protection Printing capability 1 original 4 copies Savings book handling features 86 cps 2 10 cpi in 130 10 cpi in 260 cps 10 cpi in DRAFT 350 cps 9 10 cpi in HSD H S D DRAFT N L Q L Q Indelible fabric with a life span of 3 5 M characters Front feeder with automatic document alignment If the magnetic device is present the savings book must be aligned manually The machine will generate an error message 245 x 450 mm max 70 x 65 mm min For more information refer to section 1 5 Located on the printer cover it has three buttons and five LEDs PR40 PR2 E and IBM PP Il X24 SNI 4915 9068 Standard RS 232C serial with the possibility of installing the following interface cards RS 232C serial USB Centronics parallel Width 384 mm Depth 280 mm Height 195 mm Weight 10 5 Kg Stand by 15 W During operation 170 W max worst case Switching power supply 100 to 130 1090 200 to 240 1090 Y100250 4 Service Manual 1 3 The following figure gives an overall view of the printer Fig 1 1 PR2 E Printer 1 3 HORIZONTAL MAGNETIC DEVICE MICR FEATURES The Horizontal magnetic device MI
10. 11 6 6 M 12 6 7 ALIPR2ZE P 13 6 71 CARD VIEW AND LOCATION OF CONNECTORS 13 6 7 2 CONNECTOR PIN OUT AND FUSE 13 7 PREVENTIVE MAINTENANCE 1 7 1 CLEANING T BRA 1 Fd CLEANING THE CASE em Rp 1 7 1 2 CLEANING THE PAPER PATHS e ert ent ge eis ete eR EIER uds 1 7 1 3 CLEANING THE MAGNETIC READ 1 7 2 MAINTENANCE Ee rta 2 T VBUBRICATION voor sins exules ecco 3 7 31 LUBRICATION POINTS ON THE BASIC 3 7 3 2 HORIZONTAL MAGNETIC DEVICE MICR LUBRICATION POINTS 4 viii Y100250 4 8 MECHANICAL ADJUSTMENTS eene 1 8 1 DOCUMENT FEED BELT ADJUSTMENT entrent ttes ttt 2 8 2 PRINT BAR ADJUSTMENT sscsssssssssssssesssssssssnsssssssusssssnssesssnisssssnesesssnesessnnecess 3 8 3 PARALLELISM ADJUSTMENT BETWEEN THE PRINT BAR AND LEAF SPRING LOAD IN THE BASIC MACHINE enne 4 84 ADJUSTMENT tin 5 8 5 FRONT TAB OPENING CHECK ueesssessssssssssssssssssssssesssnsssssnsssssssnscessnssesssnesessssvees 6 8 6 ROLLER GEAR ADJUSTMENT ssscsssssssssssssssssssesssnssssssssssssnsssssnesesssnsssssnnesees 7 8
11. 3 7 2 INSERTING SAVINGS BOOK Before inserting a savings book open it and press it along its spine so that it remains completely open horizontally Make sure that pages of the book are not folded or ripped so as to prevent a poor print quality and errors during book insertion Place the open savings book on the front shelf with the magnetic stripe on the bottom Fig 3 13 Manual Insertion of a Savings Book Fig 3 14 Manual Insertion of a Savings Book with Magnetic Stripe Y100250 4 Service Manual 3 15 3 7 3 INSERTING A CHECK FOR HORIZONTAL MAGNETIC DEVICE MICR READ OPERATIONS On the front of the machine cover there is a reference stripe to be used when inserting checks Fig 3 15 References for the Insertion of Checks 3 16 Y100250 4 3 7 4 EXPULSION OF PROCESSED DOCUMENTS The processed documents can be expelled from the printer according to the application program in the following ways Returning back to where the documents were manually inserted paper feed slot From the printer s rear slot starting from the front feed slot If the documents that are expelled from the front feed slot areless than 100 mm long they will be released from the feed rollers are100mmlongorlonger they will remain gripped by the last set of rollers to avoid that the document tails off the front shelf 3 7 5 REPLACING THE RIBBON CARTRIDGE The ribbon cartridge must be changed when printing is inc
12. BN 111111111122222 0 12354567897 012354567839 01254 D CONFIG DRAFT SPEED NORMAL LQ TYPE PAPER WIDTH FIRST LINE BUZZER Y INTERFACE DUAL RS1 EMULATION OLIVETTI BAUD RATE 9600 BIT CHAR 8 PARITY NONE STOP BIT 1 DSR Y DCD Y CX EMULATION IBM STROBE ACTIVE N PAP EDGE DETEC SPECIAL FORMS N IBM PP EMULATION P P II PASSBOOK N SIDE L CHAR SET CHAR SET 437 INT PC TABLE TABLE 2 DEFINITION DRAFT CPI 10 LF CR N CRtLF N ZERO SLASH N LINE LENGHT FORM LENGTH 12 BOF IBM PP LIKE Y TOF IBM PP LIKE Y OLIVETTI EMULATION PR2E PASSBOOK N SIDE L CHAR SET CHAR SET 150 150 5 150 8859 5 CHAR DEFINITION DRAFT CPI 10 COMPRESSED 16 6 VERTICAL RESOL 1 216inch LF CR N LINE LENGHT 90 REPLY SYNCRON STATUS REQUEST NO WAIT OPTION HOR MSRW STANDARD IBM 3604 END SENTINEL DISPLACEMENT STANDARD DUPLICATE N DOUBLE FIELD Y RETRY 3 STRIPE HANDLING NORMAL Fig 3 4 Print Test Example PR2 E Horizontal Magnetic Device lt 100250 4 Service Manual 3 4 CONNECTION THE SYSTEM In its basic configuration the printer is equipped with an on board standard RS232 C interface and a slot for the installation in field of an optional interface card that connects to the specific connector on the main board One of the following two optional interface cards can be installed in the slot on the rear of the p
13. option available is printed right after it If the Horizontal magnetic device MICR option is present the caption MICR will appear next to MSRW STANDARD DIN ISO ANSI 3604 Sets the magnetic standard when IBM 3604 END SENTINEL C F Sets the end sentinel code DISPLACEMENT STANDARD 10 20 Defines the position of the magnetic stripe DUPLICATE N Y Selects field duplication or not DOUBLE FIELD CHECK N Y Selects double field check or not RETRY 3 1 Defines the read attempts STRIPE HANDLING NORMAL FAST Defines normal or fast magnetic stripe reading When Normal is selected at each magnetic stripe read or write operation a savings book length measurement is performed so as to determine the exact position of the stripe When Fast is selected the length of the savings book is measured randomly with the procedure explained in the specific chapter savings book measurements are not made during stripe read writes thus speeding stripe management Y100250 4 Service Manual 4 11 when SIDE R AFF STD USA LINE BUFFER PR2845 LIKE Y NATION INT 2 DK N S SF CH UK YU GR CND STD 31 SDC TR IS Selects print line width Defines the reception buffer length like the 2845 512 Bytes or to 8 Kbytes CHAR DEFINITION DRAFT LQ CPI 10 12 LF 1 5 1 6 WARNING END OF PAPER PHOTO SENSORTOP Selects the character definition Selects the print
14. 7 FRONT PRESSURE ROLLER ADJUSTMENT vsccssssssssssssesssssssssssssssssnsesssneesees 8 8 8 OPENING ADJUSTMENT ssssssssssssesssnsssssssssesssnssssssssesssnssssssnsesssnssessnueeess 9 8 9 HORIZONTAL MAGNETIC DEVICE MICR OPTIONCARRIAGE FEED BELT TENSION ADJUSTMENT ovsscssssssssssssssssssssesssnsssssnsesssnisssssnsesssnesesssnnsssssnesessses 10 8 10 HORIZONTAL MAGNETIC DEVICE MICR DOOR ADJUSTMENT 11 8 11 HORIZONTAL MAGNETIC DEVICE MICR PRESS POSITIONING 12 8 12 POSITIONING THE ASSEMBLY ON THE HORIZONTAL MAGNETIC DEVICE MICR aao cities ean in 13 9 DISASSEMBLY REASSEMBLY PROCEDURES 1 91 GENERAL DISASSEMBLY REASSEMBLY PRECAUTIONS 2 9 2 DISASSEMBLY REASSEMBLY OF THE BASIC 3 921 CASE DISASSEMBLY REASSEMBLY ee 3 9 2 2 CONSOLE DISASSEMBLY REASSEMBLY 4 923 MECHANICAL ASSEMBLY DISASSEMBLY REASSEMBLY 5 9 24 PRINTHEAD FLAT CABLE DISASSEMBLY REASSEMBLY 6 9 25 PRINTHEAD DISASSEMBLY REASSEMBLY 8 9 2 6 PRINTHEAD PHOTOSENSOR DISASSEMBLY REASSEMBLY 9 9 27 SUPPER PART OF THE MECHANICAL ASSEMBLY DISASSEMBLY REASSEMBLY 10 9 2 8 PAPER FEED MOTOR DISASSEMBLY REASSEMBLY 11 9 2 9 PRINTHEAD MOVEMENT MOTOR DISASSEMBLY REASSEMBLY 12 9 2 10 CARRIA
15. The table below indicates the meaning of the LEDs according to the type of failure detected during the autodiagnostic phase LED FAILURE ON READY LOCAL ST2 Power supply assy failure OFF OFF OFF OFF OFF On board failure Eprom ROM Microprocessor ON OFF OFF OFF OFF Failure with Fuses Drivers Motors ON ON ON ON ON Activation board failure The motors do not perform any kind of movement Y100250 4 Service Manual 4 1 4 2 PRINT TEST The print test provides a printout of the machine s set up parameters The instructions to run this test are given in section 3 3 Off line Testing 4 3 PRINTER SET UP TheSet up environment should only be accessed by the service engineer and programmer since some ofthe selectable parameters are used to customize the machine or option installed and must therefore not be changed An incorrect intervention by the operator could cause printer malfunction 4 3 1 ACTIVATING THE SET UP To enter the set up environment power off the machie and then power it back on again while pressing the ST1 Station 1 and ST2 Station 2 buttons simultaneously Upon completion of the printer reset phase load an A4 sheet of paper the machine will print a line with ta description of the functions of all the keys in this environment The flow charts on the following pages indicate the d
16. ground and that itis able to supply the power needed by the machine A wall outlet without ground can cause functional problems and can be a safety hazard Do not plug the printer to electrical wall outlets that are already being used by equipment that could cause electrical noise and excessive voltage fluctuations fans and air conditioners large photocopiers lift motors TV radio transmitters and signal generators high frequency safety devices and so on Common office equipment calculating machines typewriters small fotocopiers terminals and personal computers can share the same outlet as long as they do not cause excessive electrical noise 3 1 2 ENVIRONMENTAL CONDITIONS The environmental conditions in which the product can remain for an indefinite period of time are indicated by the AB quality objectives referring to a normal climatized office environment environmental temperture of 15 35 C relative humidity of 15 8596 During machine storage and operation make sure that condensation does not form as the result of extreme environmental variations Dust dirt and smoke can cause the parts in motion to wear excessively short circuits in the presence of a high degree of humidity and read write errors during operation High temperatures and low humidity can cause problems due to static electricity 3 1 3 LOCATING THE MACHINE The printer must be installed on a flat vibration free surface Do not position the machine near air conditi
17. machine must not be positioned near air conditioning system vents or exposed to direct sun light Make sure that the machine s internal ventilation slots are not blocked especially if the printer is installed in furniture Forms documents or office equipment located ACCESSORIES AND FORMS Make sure that the accessories installed in the machine are originals and in good condition Checkthatthe documents inserted in the printer comply with the machine specifications and are in good condition PRINTER OPERATING CONDITION Check that the internal parts of the machine have no dirt deposited or residue of paper or ink that could interfere with the performance of the printer s different components Make sure there is no internal damage caused by the insertion of documents with metal clips staples pins or similar Ensure that the parts specified are correctly lubricated Y100250 4 Service Manual 5 1 5 1 3 IDENTIFYING THE MALFUNCTION Carefully examine all the information collected from the Operator printer error signals analysis of the documents where the fault has occurred repetition of the error when the machine is powered on etc to recognize and identify the machine malfunction to be corrected Attimes a malfunction is generated by more than one cause itis important in such cases to isolate the faults and deal with them one at a time 5 1 4 FINDING THE CAUSE Using experience togethe with the information given in this secti
18. must come into contact with print bar 2 and simultaneously the balancer 3 must come into contact with the tab support shaft 4 PROCEDURE Loosen screw 5 and position the parts as explained Tighten the screw When adjustment is complete make sure that the following conditions are met when clearing the gap between the balancer and knob the tab must be in contact on the entire paper path or at a maximum distance of 0 5 mm from the platen IN CONTACT Fig 8 4 Note Perform this procedure after adjusting the print bar Y100250 4 Service Manual 8 5 8 5 FRONT TAB OPENING CHECK MACHINE CONDITION Rear frame assy closed and carriage moved completely to the right OBJECTIVE ADJUSTMENT Distance between the front tab and print bar PROCEDURE After making sure that the tab is adjusted correctly as indicated in the previous section close the rear frame assy and then move the carriage to the right Using a probe check that the point of the tab is located at a distance between 8 and 11 mm from the print bar measuring at 5 6 cm from the left edge of the print carriage Fig 8 5 8 6 Y
19. pitch Selects the line feed Selects the indication for out of paper or for photosensor covered 4 12 Y100250 4 OF FORM 1 2 Selects the first or second printable line STATUS REQUEST NO WAIT WAIT Determines the timing of the status reply upon reception of an ESC j command By selecting NO WAIT the reply will be provided as soon as possible and simultaneously with the execution of a print job or paper movements By selecting WAIT the status reply will be provided at the end of the print job SAVE PARAMETER Y N Stores or not the settings made in this Set up section Y100250 4 Service Manual 4 13 4 4 SETTINGS 4 4 1 PHOTOSENSOR CALIBRATION All machine photosensors are calibrated at the factory However a change in the electrical characteristics of the photosensors used or the use of non standard paper may call for the photosensors to be recalibrated at the customer s site All the photosensors present in the machine require calibration the following are installed Paper detection photosensor assembly This assembly consists of two LEDs and two photoreceivers that are the first to detect when a document is inserted in the front insertion slot The ray of light is transmitted by fibre optics Paper font alignment photosensor assembly These photosensors are included in the same mechanical assembly as the paper detection photosensors indicated in this manual as Front photosensor assembly The pape
20. that secure the printhead Partly slide off the printhead from the carriage and unplug the two flat cables 2 from the connectors on the printhead Fig 9 6 Note After printhead reassembly calibrate the printhead photosensor 9 8 Y100250 4 9 2 6 PRINTHEAD PHOTOSENSOR DISASSEMBLY REASSEMBLY Remove the printhead section 9 2 5 Remove screw 1 that secures the printhead photosensor and remove the photosensor from its seat Unplug the photosensor flat cable from its connector 2 on the printhead Replace the old photosensor with the new one making sure that it rests against support shield 3 replace and tighten the securing screw 1 Fig 9 7 Note The printhead photosensor must be calibrated whenever the printhead is replaced Y100250 4 Service Manual 9 9 9 2 7 UPPER PART THE MECHANICAL ASSEMBLY DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 and console section 9 2 2 Liftthe front part of the mechanical assembly off the base of the printer partly rotating it until you are able to reach the connectors on the main board Unplug the printhead and carriage reset photosensor cables from the main board Free the carriage reset photosensor wires from its plastic retainers Unplug connector 1 from the carriage transport motor Raise the upper part of the mechanical assembly using the specific lever Remove the two rear side screws 2 so a
21. 1 Reserves operator 2 Olivetti STD 12 14 or assigns the printer to operator 2 Toggles the printer between the on line and off line states Ejects the paper of operator 1 or ejects the paper present Ejects the paper of operator 2 You can access the different machine states by powering on or resetting the printer while holding down oneor more buttons The buttons assume different functions depending on whether the printer top cover is opened or when the printer is powered on or reset while holding down determined console buttons The following table provides the meaning of the console buttons in both cases Local ST 1 ST 2 Cover open MACHINE STATE Print test Set up Clear paper jam procedure Printer set for the on line updating of the firmware onto Flash EPROM Access to the following procedures Photosensor adjustment User TOF setting Left hand margin setting Paper or savings book length measurement Print alignment adjustment Photosensor adjustment printout D EL Disable cover open signal Y100250 4 Service Manual 2 3 2 2 2 MEANING OF THE CONSOLE LEDS When on the LEDs inform of the following machine states ON Machine powered on READY Printer on line in receive mode or document present LOCAL Machine in LOCAL off line STATION 1 When on Waiting for a document from operator 1 Oliveti STD 12 14 or machine assigned to operator 1 or document p
22. 100250 4 8 6 ROLLER GEAR ADJUSTMENT MACHINE CONDITION Upper mechanical assembly closed OBJECTIVE ADJUSTMENT Mesh between cogged wheels 1 and 2 with a maximum radial clearance of 0 2 mm between the teeth Check this clearance throughout the entire wheel rotation Adjust the two matings on the right hand side of the printer PROCEDURE Turn screws 3 that secure the bushing tightening them with a torque equivalent to 6 0 5 Kgcm Post adjustment clearance Fig 8 6 Note Perform this adjustment on both gear pairs on the printer Y100250 4 Service Manual 8 7 8 7 FRONT PRESSURE ROLLER ADJUSTMENT MACHINE CONDITION Service cam with its minimum throw area facing the probe roller OBJECTIVE ADJUSTMENT Make sure that there is a small clearance between the probe roller 7 and the service cam 6 To check the correctness of the adjustment remove the probe and without changing the fase check for a slight clearance between the roller and cam without loading the springs There must be no clearance when the probe is inserted again PROCEDURE Insert an 0 5 mm thick probe 1 between the pressure rollers 5 and the feed rollers 8 by acting on shaft 2 position the three levers 3 so that they come into contact with the springs and then tighten screws 4 with a torque of 20 Kgcm while holding the roller against the cam s smallest radius 0 5 Fig 8 7 Note The adjustment value can vary for certai
23. 25 024 022 JTpai Bas 05 018 157 016 41015 J11 J6 J14 J12 J8 Dat 43 0 0512 dasu eur 0912 0511 15 h De 105 g X sig 059 or 101 Nf CT g oss 057 056 ass Joss 057 056 055 410 M 49 US13 URI n 052 951 EET 081 Cui L J4 5 oA 9 42 RS1 J3 J1 m 95 Fig 6 1 Main Board the PR2 E 6 2 Y100250 4 6 2 3 CONNECTOR PIN OUT Provided below are the pinouts of the connectors on the PR2 E main board Connector J33 is not indicates since it is only present on the BAPR2E Cost Improvement version J18 J3 RS 232 INTERFACE CONSOLE GND P5CONS LED3 LEDLOC LED2 LED1 LEDON 501 TALOC 502 GND DCD1 RX01 TX01 DTR1 GND DSR1 RTS1 CTS1 TERRSE 1 2 3 4 5 6 7 8 9 OANOAARWND 99 915 TRANSPORT MOTOR PRINTHEAD CONNECTOR 1 TESTE 2 FASEB TEBGA FOBCA FASED VCCTES R0224 SPL 2 R0422 SPL 4 R0620 SPL 6 R1214 SPL 12 R0717 SPL 17 R1113 SPL 13 R1113 SPL 11 R0519 SPL 5 R0422 SPL 22 R0123 SPL 23 R0519 SPL 19 910 POWER SUPPLY
24. 3 EE neues fal no Eo YS2 IQ YY o Ol lol 156 055 71 Big O B Iu Ny a 59 054 um 062 Hif 1 XE CONNECTOR J1 FOR gc eel CONNECTION TO THE MAIN BOARD Fig 3 6 Serial Interface USB Interface Card This serial interface has the same characteristics as the main board serial interface while the USB interface complies with the Universal Serial Bus Specification Revision 1 1 reference standard and has a transfer rate of gt 200 kBps J2 J3 RS232 Serial Interface USB Interface 1 DCD1 1 VBUS 2 REXD1 2 DMENO 3 TXD1 3 DPIU 4 DTR1 4 GND 5 GND 6 DSR1 7 CTS1 8 501 9 TERRSE Fig 3 7 USB Interface Pin Out Y100250 4 Service Manual 3 9 Proceed as follows to install this optional Power off the printer Usinga screwdriver break off the slot cover of the optional serial interface on the rear of the printer Insert the interface card in the slot and slide it along the guideways until it plugs into the related connector on the main board Push firmly to ensure proper connection Tighten the card s two side screws to secure it in place us E Bu o BIG
25. CR Magnetic Ink Character Recognition device reads characters printed on checks with magnetic ink Horizontal magnetic device MICR applications are compatible with the CMC7 and E13B standards CMC7 This standard uses a coding technique similar to bar codes In this case the character consists of seven black bars of equal width and spaced by four narrow gaps and two wide gaps E13B Inthis case the characters are continuous not bars and have a precise shape The magnetic reader must also interpret the amplitude of the wave form and therefore not only its variation in time 1 4 Y100250 4 1 4 PRODUCT VARIABLES VOLTAGE AND FREQUENCY 023 TEN 204 POWER CORD COR 005 COR 041 COR 042 COR 043 COR 050 COR 080 110 120V 50 60 Hz 220 240V 50 60 Hz Europe Switzerland Great Britain Australia USA South Africa CRT FIRMWARE Olivetti standard IBM X24 9068 X24 SNI 4915 EPSON 2550 Y100250 4 Service Manual 1 5 DOCUMENTS HANDLED BY THE BASIC MACHINE 1 5 1 SINGLE AND MULTI COPY FORMS Maximum width Minimum width Maximum recommended length Maximum accepted length Minimum length Single sheet weight Single sheet thickness Transparency Multicopy weight chemical Carbon paper weight Maximum printable copies with chemical paper Maximum printable copies with carbon paper Recommended weight Multicopy glueing Maximum weight of multicopy forms Print quality with multicopy for
26. CUMENT HANDLING FAULTS 8 B 8 9 5 D Ox 2 gt FAILURE D 3 em o 8516 8 38 829 POSSIBLE CAUSE og o9 o0 o Document within specifications X X X X Ruined document X X X X Closing levers open X X Faulty front photosensors X Faulty paper photosensor X Faulty rear photosensor X Faulty services motor X Faulty paper feed motor X X Faulty main board X Document feed belt adjustment X Needle platen distance adjustment X Ribbon needle protection fin adjustment X Paper photosensor adjustment X X Print bar adjustment X Strap adjustment X Roller gear adjustment X Front pressure roller adjustment 5 6 Y100250 4 5 6 MAGNETIC STRIPE READ WRITE FAILURES FAILURE POSSIBLE CAUSE Horizontal magnetic device Incorrect set up Ruined savings book Incorrect savings book insertion Dirty magnetic head Faulty magnetic head Faulty paper feed motor Faulty magnetic device card Faulty main board Faulty magnetic head movement motor gt lt x gt lt x read write errors Y100250 4 Service Manual 6 ELECTRICAL INTERCONNECTIONS 6 1 GENERAL PRINTER INTERCONNECTION DIAGRAM TOLINE VOLTAGE RS 232 SERIAL INTERFACE CONSO
27. ERRCX 17 36 GND SELINP VCC 18 37 TERRCX J1 MAIN BOARD INTERFACE Y100250 4 Service Manual 6 11 6 6 CONSOLE YELLOWLED2 YELLOW LED YELLOW LED 4 YELLOW LED 5 READY SE r Pas olivetti Gz ON JECS BRENS GREENLED 1 BUTTON 1 BUTTON2 BUTTON3 Fig 6 6 Console 1 GND 2 VCC 3 YELLOWLED5 4 YELLOWLED4 5 YELLOWLED3 6 YELLOWLED2 7 GREENLED1 8 BUTTONS 9 BUTTON2 10 BUTTONI 11 dry reed 12 GND Fig 6 7 Console Electrical Diagram 6 12 Y100250 4 6 7 ALIPR2E CARD Two codes can be assigned to the ALIR2 card depending on the line voltage supported 115 V or 230 V Also the value of fuse F1 varies according to the line voltage 6 7 1 CARD VIEW AND LOCATION OF CONNECTORS Fig 6 8 ALIPR2 Card 6 7 2 CONNECTOR PIN OUTS AND FUSE J1 J2 EXTERNAL POWER SUPPLY MAIN BOARD POWER SUPPLY 5 es ROUT 3 VAC 12 412V 45V GND GND GND 35V 35V F1 Fuse 250V 3 15A OANOAARWND Y100250 4 Service Manual 6 13 7 PREVENTIVE MAINTENANCE 7 1 CLEANING For a correct printer operation it is suggested that the internal components of the machine be cleaned periodically and whenever the machine is serviced 7 1 1 CLEANING THE CASE Power off the machine unplug it from the electrical outlet and then clean its case using a damp cloth avoid using corrosive substances such as solvents alcohol solutions petrol or abrasive components 7 1 2 CLEANI
28. ERTICAL MAGNETIC DEVICE FACE DOWN CLEANING CARD AND POSITION THE STRIPE VERTICALLY ALONG THE REFERENCE SIDE 1b HORIZONTAL MAGNETIC DEVICE FACE DOWN THE CLEANNING CARD AND POSITION THE STRIPE HORIZONTALLY TOWARD THE OPERATOR 2 FEED THE CLEANNING CARD AS YOU USUALLY DO WITH YOUR PASS BOOK TWO PASSES 3 REMOVE THE CLEANNING CARD AND MARK IT TO INDICATE THAT THE CLEANNING PROCESS HAS CARRIED OUT VERTICAL MAGNETIC STRIPE IDENTIFICATION CLEANNING CARD POSITIONING 1 3 5 s s 2 Fig 7 1 Magnetic Head Cleaning Card 7 2 MAINTENANCE Inside the machine to the right hand side there is a brush which is used to clean the paper edge detection photosensor located behind the printhead This brush has a span equivalent to that of the printhead If in exceptional cases the paper photosensor becomes dusty it is suggested that you replace the cleaning brush 7 2 Y100250 4 7 3 LUBRICATION Although machine lubrication is not scheduled throughout its entire life span during each service call you are expected to checkthe lubrication of the differnet parts by referring to the lubrication points table indicated below 7 3 1 LUBRICATION POINTS ON THE BASIC MACHINE DESCRIPTION CODE GREASE OIL Printhead carriage slide shafts X Carriage felt 473150E X Ribbon feed gear assy X Cam in the contact area with 473072X X reed support pin 473076T X pressure br
29. ETERS 2 2 212 00 00000000000 000 0 00 3 44 ae nd ee 14 4 4 1 PHOTOSENSOR CALIBRATION 14 4 4 2 BI DIRECTIONAL PRINT ALIGNMENT CALIBRATION 20 4 4 3 OF FORM TOF CALIBRATION 22 4 4 4 LEFT PRINT MARGIN 00 000 060000006000 000 0010 24 445 DOCUMENT LENGTH MEASUREMENT 2 7 0 0000000 0000000 26 4 4 6 SKEW AND SIGNAL AMPLITUDE CONTROL eese 28 44 7 SIGNAL AMPLITUDE CONTROL 00 0 0 000000000 28 5 PRODUCT 5 1 5 1 SERVICING 1 5 1 1 FAULT DETECTION ANALYSIS 1 2 2 200 00001 00000 5 1 2 ANALYSIS OF THE OPERATING CONDITIONS eese 1 5 1 3 IDENTIFYING THE 0 0 0000 00000000000 000 000 2 5 1 4 FINDING THE CAUSE 2 5 1 5 SOLVING THE PROBLEM 22 7 20 000 00600000000006 6060 2 5 1 6 TESTING THE MACHINE 2 2 7 00 0 000000000 2 5 2 FAULT CLASSIFICATION ssscesscnccanscascenssescnnssncssescenconssassonsceussossnccaascasssencaassasse 3 5 3 POWER ON FAULTS cissceccccnnscnsceascanssercdesadernsconesas
30. GE RESET PHOTOSENSOR DISASSEMBLY REASSEMBLY 13 Y100250 4 Service Manual ix 9 3 9 211 ROLLER SUPPORT TRAY 5 55 5 14 9 2 12 SERVICES MOTOR DISASSEMBLY REASSEMBLY esee 15 9 2 13 FEEDER PHOTOSENSORS DISASSEMBLY REASSEMBLY 16 9 2 14 PRINT BAR DISASSEMBLY REASSEMBLY nenne 19 9 2 15 MAIN BOARD DISASSEMBLY REASSEMBLY 20 9 2 16 POWRER SUPPLY ASSY DISASSEMBLY REASSEMBLY 21 BASIC MACHINE OPTIONS DISASSEMBLY REASSEMBLY 22 9 3 1 HORIZONTAL MAGNETIC DEVICE MICR DISASSEMBLY REASSEMBLY 22 9 32 HORIZONTAL MAGNETIC DEVICE MICR MOTOR DISASSEMBLY REASSEMBEY ie et p rto neta Pa te seve 23 9 3 8 HORIZONTAL MAGNETIC DEVICE MICR HEAD ASSY DISASSEMBLY REASSEMBDLY ene dicla eat e t OB 24 a Y100250 4 1 PRODUCT OVERVIEW 1 1 INTRODUCTION The PR2 E is a specialized mid range banking printer It can handle ordinary stationary single and multicopy forms and savings books for deposit withdrawl transactions Very versatile this printer can also be used in Public Administration front office environments and in Post offices It can be equipped with a horizontal magnetic device for reading writing horizontal magnetic bands or with a horizontal magnetic device and MICR Magnetic Ink Character Reader reader for reading the c
31. H PAPER PRESENT READ NO OK YES THE SHEET IS EXPELLED AND ALL THE LEDS GO OFF v INTRODURRE UN FOGLI A4 BIANCO v STAMPA DEI VALORI DI TARATURA E REGISTRAZIONE IN EEPROM v ACOUSTIC SIGNAL AND LEDS ON v MOVE THE PRINTHEAD TO THELEFT AND CLOSE THE COVER ST 1 THE SHEET IS NOT EXPELLED A LONG BEEP SOUNDS THE FLASHING LEDS IDENTIFY THE FAULTY PHOTOSENSOR SEE THE TABLE ON THE PREVIOUS PAGE 4 v PRESS ANY BUTTON POWER OFF THE PRINTER ALONG BEEP SOUNDS AND THE FLASHING LEDS IDENTIFY THE FAULTY PHOTOSENSOR SEE THE TABLE ON THE PREVIOUS PAGE 4 16 Y100250 4 Proceed as follows to calibrate the photosensors 1 2 Power on the printer with its cover open and while holding down the three buttons on the console Wait for the audible signal indicating that the printer has switched to the calibration and adjustment procedures Manually position the printhead towards the left hand side and then close the cover Press the Station 1 button twice to enter the menu Upon the completion of this phase the sensors have stored the electrical current ratings with the printer in an out of paper condition Insert a sheet of 60 gr m paper in the landscape position into the front insertion slot During this phase the motor continues to turn forcing the pape
32. IC 1250 WIN Latin2 1252 WIN Latint when ISO SET OLI UNIX ISO 8859 1 ISO 8859 2 ISO 8859 5 ISO 8859 6 ISO 8859 7 ISO 8859 8 ISO 8859 9 ISO 8859 15 Y100250 4 Service Manual 4 9 when OLIVETTI CHAR SET INT USA E2 DK N S SF CH UK YU IL GR CND STD 31 SDC TR ARABIC USSR CIBC CHAR DEFINITION DRAFT LQ OCRA OCRB CPI 5 10 12 15 16 6 17 1 COMPRESSED 16 6 17 1 VERTICAL RESOLUTION 1 216 1 240 CR N Y Selects the character definition Selects the print pitch Defines the spacing selected with ESC gt Selects the vertical resolution Selects whether to execute or not an automatic carriage return each time a line feed command is received 4 10 Y100250 4 LINE LENGTH 90 94 Selects the maximum print line length expressed in numper of characters at 10 cpi PRINTER REPLY SYNCRONIZED Y DSR management during a transmission STATUS REQUEST NO WAIT WAIT Determines the timing of the status reply upon reception of an ESC j command By selecting NO WAIT the reply will be provided as soon as possible and simultaneously with the execution of a print job or paper movements By selecting WAIT the status reply will be provided at the end of the print job if the Horizontal Magnetic device MICR is present OPTION HORIZONTAL MSRW This message warns that the option is installed There is no selection to be made and the next
33. LE RANSPORT MOTOR PRINTHEAD AND PAPER PHOTOSENSOR OPTIONS NTERFACE OPTIONS NTERFACE ROLLER MOTOR CARRIAGE RESET PHOTOSENSOR PAPERFEED MOTOR FRONT PHOTOSENSORS J16 J12 J11 ALIPR2E CARD BAPR2E MAIN TRANSFORMER MAGNETIC OPTIONS CARD Y100250 4 Service Manual 6 1 6 2 BAPR2 MAIN BOARD The BAPR2 main board has an onboard serial interface The printer can be configured with one of the following two interface cards RS232 serial UBS Centronics parallel 6 2 1 MAIN BOARD VIEW AND LOCATION OF CONNECTORS J18 dis 516 036 J15 J16 Io 034 4035 F 032 7210332 41031 025 027 026 0
34. LQ2 FROM THE LINE LQ2 OCRA OCRB ITALICO DRAFT ITALICO NLQ1 ITALICO NLQ2 ITALICO LQ2 IBM PP 1 24 HSD DRAFT NLQ1 LQ2 FROM SET UP DRAFT NLQ1 FROM THE LINE 100250 4 2 OPERATING COMMANDS The machine s operating commands are the following power switch console buttons upper mechanical assembly lifting lever CONSOLE BUTTONS UPPERMECHANICAL ASSEMBLY LIFTING LEVER POWERSWITCH Fig 2 1 Operating Commands Y100250 4 Service Manual 2 1 2 1 POWER SWITCH The printer is equipped with a two pole power switch The switch on off commandis provided by means of a rod that crosses the printer longitudinally 2 2 CONSOLE The printer console has five LEDs and three buttons READY 2799 US grs ON ARENS Fig 2 2 Console Q The console is also equipped with a circuit breaker Dry reed that informs the board logics when the printer s top cover is opened During the machine set up section 4 3 or adjustment section 4 4 phases the buttons perform different functions according to the procedures in which they are used 2 2 Y100250 4 2 2 1 FUNCTIONS THE CONSOLE BUTTONS The buttons on the console perform the following functions STATION 1 STATION 2 LOCAL BREAK EJECT ST 1 EJECT ST 2 According to the selected emulation Reserves operator 1 Olivetti STD 12 14 or assigns the printer to operator
35. MULATION 6 23g BUTTON FUNCTIONS ER tees EM umet rU c 6 22 21 NEDINDICATIDNS ueri Cauet 6 Y100250 4 Service Manual V 24 BUTTON AND LED FUNCTIONS IN THE SNI 4915 4904 EMULATION 7 Dod BUTTON FUNCTIONS eere iade 7 TEDSINDIC ATION S cca hu pam Stm 7 25 BUTTON AND LED FUNCTIONS IN THE PROPRINTER 1 24 EPSON LQ 2550 EMULATION 8 BUTTON FUNCTIONS S cidit ipd 8 Bm NED INDICATIONS M LARUM tA E 8 2 6 UPPER MECHANICAL ASSEMBLY LIFTING LEVER 9 92 INSTALLATION Er 1 3 1 GENERAL INSTALLATION PRECAUTIONS 1 31 1 ELECTRICAL POWER SUPPLY tentent 1 3 1 2 ENVIRONMENTAL CONDITIONS 1 3 1 3 LOCATING THE MACHINE t 1 3 2 UNPACKING AND INSTALLING THE 2 3 2 21 UNPACKING THE MACHINE t 2 222 INSTALLING THE MACHINE acte cond tete unt 4 332 OFF LINE TESTS dite ia utut data 4 3 3 1 STARTING AND STOPPING THE PRINT TEST 4 2232 SDBINTTEST CONTENT S basti a s 5 3 4 CONNECTION TO THE SYSTEM eccssssssssssssssssessssssssvsesssssssssvesssnscssssssssesssiees 8 341 232C SERIAL INTERFACE 5
36. NG THE PAPER PATHS Clean all the document paths including the paper feed rollers of the front paper feeder making sure to remove any paper or ribbon residues that are deposited on the parts Also remove any foreign matter 7 1 3 CLEANING THE MAGNETIC READ HEAD Clean using the specific card code 751498E provided with the machines equipped with the horizontal magnetic MICR device Cleaning can be performed either automatically or manually by the field engineer AUTOMATIC CLEANING By means of a specific SW routine the system informs the operator that cleaning is necessary and engages in a dummy magnetic transaction If not provided by the system the cleaning instructions are indicated on the cleaning card The automatic cleaning procedure is usually performed directly by the operator Y100250 4 Service Manual 7 1 MANUAL PROCEDURE This cleaning procedure is performed by the field engineer and is not included in the programmed maintenance scheduled by the automatic procedure Also in this case you need to run a system command for a magnetic stripe read operation Insertthe cleaning card inthe front feed slot making sure to position it correctly the machine will attempt to read the card after which it expels the card and signals an error condition Power the machine off and then on again to resume its normal operating status Cleaning stripe side Back of card CLEANING STRIPE CHECK BOXES CLEANING PROCEDURE V
37. NTERFACE RS 232 1 OPTIONAL DUAL Determines the Draft mode that can activated via SW and by default Determines the LQ type that can be activated via SW and by default Determines document position width measurement position Activates deactivates acoustic signaling The optional interfaces are PARALLEL DUAL compatible RS 232 2 DUAL compatible USB when RS232C 1 EMULATION OLIVETTI Interface default emulation BAUD RATE 9600 4800 2400 1200 Data transmissione reception rate BIT CHAR 7 8 7 or 8 bit data format PARITY NONE ODD EVEN Type of parity checking STOP BIT 1 2 Number of stop bits DSR N Y Data Set Ready handled or not DCD N Y Data Carrier Detector handled or not Y100250 4 Service Manual 4 3 PAPER EDGE DETECTION N Y SPECIAL FORMS N Y SAVE PARAMETERS Y N When enabled Y inhibits the printing of lines that are wider than the sheet inserted Causes a paper jam ESC r 1 in the Olivetti environment For electronic HW reasons the width of the document is automatically measured only during the document insertion phase Therefore if the sheet of paper loaded has a variable width the different size will not be detected during the printing phase When enabled Y every paper movement is performed with the printhead positioned outside the margins of the sheet of paper This makes it possible to use the lightest forms indicated in the pape
38. Printer PR2 SERVICE MANUAL Code Y100250 4 PUBLICATION ISSUED BY Olivetti TECNOST S p A Documentazione 77 Mia Jervis 10015 Ivrea Italy Copyright 2001 Olivetti All rights reserved PREFACE This Service Manual provides you with all the technical information needed to install test and service the PR2 E specialized printer Consult this manual when the Operator Manual included in the printer packaging does not provide the information needed to correct a determined error condition SUMMARY This manual is divided into chapters where each chapter is organized in a way that the information can be accessed as simply and quickly as possible The first two chapters give an overview of the machine and describe its major functions Chapter 3 describes installation and testing procedures while the remaining chapters provide the information needed to effectively service the machine BIBLIOGRAPHY PR2 E Operator Manual PR2 E Programmer s Manual PR2 E Spare Parts Catalogue SECTOR PRODUCT RANGE Q2 PR2 DISTRIBUTION General G FIRST EDITION April 2001 NOTICE Olivetti TECNOST S p A reserves the right to make changes to the product described in this manual at any time and without notice Y100250 4 Service Manual iii TABLE CONTENTS 1 PRODUCT OVERVIEW 1 1 INTRODUCTION EF HERE PU A REM 1 134 1 2 FACTORY CONFIGURATION 2 1 2 GENERAL MACHINE CHARACTERIS
39. RDER PHOTOSENSOR gt FRONTPAPER DETECTION CARRIAGERESET PHOTOSENSOR gt PHOTOSENSOR SERVICES MOTOR 100250 4 Service Manual 1 11 1 10 FIRMWARE AND CHARACTER GENERATORS 1 10 1 MACHINE FIRMWARE Separate from the character generator and character set the printer management firmware is independently managed during the uploading operations so that all access to the character area for modification is rendered more flexible and immediate The printer s basic memory is provided by a 1 MB Flash EPROM The management FW the character generators and character sets reside in this memory and can be replaced on line A second Flash EPROM optional of the same capacity and capable of hosting complex character sets and considerable macro and logo volumes can be installed on the main board The machine firmware includes the following emulations Olivetti environment STD 12 14 controlled protocol with the PR2 E native environment 40 and PR2845 emulation Proprinter and Proprinter X24 industry standard emulation IBM environment 9068 protocol emulation covering also the model 4722 IBM Proprinter and Proprinter X24 industry standard emulation Wincor Nixdof environment SNI 4915 protocol emulation covering also the models 4905 EPSON LQ 2550 industry standard emulation 1 12 Y100250 4 1 10 2 CHARACTER SETS Compatibility at system level for each character set is extended to the environments l
40. T1 LOCAL ST2ON READY OFF gt lt v INSERT AN A4 SHEET OF PAPER MOVES THE TOF UPWARD TOP OF FORM PRINTED AND SHEET EXPELLED ST1 ST wovEsTHE DOWNWARD LOCAL TOP OF FORM OK PARAMETERS STORED Y100250 4 4 22 This calibration sets the distance between the form TOF and the first print line The adjustment can only be activated if the TOP MARGIN PR40 LIKE parameter in the PR40 emulation setup was set to N Proceed as follows to perform this calibration 1 Power on the printer with its cover open and while holding down the three buttons on the console 2 Wait for the audible signal indicating that the printer has switched into the calibration and adjustment procedures 3 Press the Local button and then wait for the printer to complete its reset 4 Pressthe Station 1 button the three console buttons are now active By pressing Station 1 you can reduce the TOF while by pressing Station 2 you can increase it 5 Insert an A4 sheet of paper into the front feed slot to check the status of the current TOF This check is made by printing a specific test If the current TOF value is too high printing may occur offthe sheet of paper 6 Press Station 1 and or Station 2 to decrease or increase the TOF 7 Repeate points 6 and 7 cyclically until the calibrations are complete 8 Press Lo
41. TICS ceres ee eere einn 3 1 3 HORIZONTAL MAGNETIC DEVICE MICR FEATURES e 4 L4 PRODUCT VARIABLES aka Munch ME eanan rinier 5 1 5 DOCUMENTS HANDLED BY THE BASIC MACHINE 6 SINGLE AND MULTI COPY FORMS iot eta dtt ond nece 6 152 SAVINGS BOONS sit eint anode edita IDE D eR ah 7 1 67 ACCESSORIE S ciiin d Hr nice PI e FLU cU ee ADR MU MINE 8 1 7 LOCATING THE PRINTER S MAJOR COMPONENTS 9 1 8 LOCATING THE PRINTER S MAJOR INTERNAL COMPONENTS 10 1 9 GENERAL BLOCK DIAGRAM so viisssenetisiessertcsvasencossasstecrersstuesessotucnsdevaseuesivevece 11 191 BASIC MACHINE ue m i tt datei RE rd 11 1 10 FIRMWARE AND CHARACTER GENERATORS 12 1 10 1 MACHINE FIRMWARE pea t pet era un rad 12 1102 GHARAGTERI SETS IDs ea ape eee ee MM 13 1 10 3 PRINT MODES AND CHARACTER FONTS 13 2 OPERATING 65 2 2 2 42 2 0 1 1 nnne nnn 1 2 1 ET 2 22 CONSOLE iria mir seti uto e rv 2 221 FUNCTIONS OF THE CONSOLE BUTTONS itti aiti tae fett 3 222 MEANING OF THE CONSOLE LEDS ipte AR MR nt Ree 4 223 ERROR MESSAGES nc treten tdi mre tid 4 2 3 BUTTON AND LED FUNCTIONS IN THE 9068 4722 E
42. cal twice to permanently store the TOF and to automatically move on to the next calibration Y100250 4 Service Manual 4 23 4 4 4 LEFT PRINT MARGIN CALIBRATION Provided below is the left print margin calibration block diagram COVEROPEN ST1 LOCAL ST2 BUTTONS PRESSED WHILE POWERING ON THE MACHINE 4 v AUDIBLE SIGNALS LEDS ON ST2 v ST1 LED ON ST1 y LOCALLED ON v LOAD THE DOCUMENT TO BE MEASURED v THEDOCUMENTIS MEASURED AND EXPELLED v ST1 LED ON v PRESSST1 v DOCUMENT LENGTH IS STORED 4 24 Y100250 4 This calibration sets the distance between left edge of the and the first print character The left margin value will always be used without the need for set up configurations Proceed as follows to perform this calibration 1 2 Power on the printer with its cover open and while holding down the three buttons on the console Wait for an audible signal to indicate that the printer has switched to the calibration and adjustment mode Press Local and wait for the machine to complete its reset Press Station 2 Press the Station 1 button until hearing a prolonged dual tone signal different from the previous Insertan A4 sheet of paper and wait for the printed page Check that the left margin has the required measurement The minimum distance between the left edge of the do
43. cings automatically COVEROPEN ST1 LOCAL ST2 PRESSED WHILE POWERING ON THE PRINTER gt v ST2ON ST 1 ms ST 2 AUDIBLE SIGNAL AND LEDS ON ST 1 ST 2 LEDS ST1 AND lt ALLLEDS ON lt v INSERT AN A4 SHEET OFPAPER v TWO LINES PRINTED AND SHEETEXPELLED YES MOVES THE LEFT MARGIN TO THELEFT Y NO ST 1 ms ST2 MOVES THE LEFT MARGIN TO THE RIGHT 5 PARAMETERS STORED CALIBRATION ENDS NO MOVES TO THE PRINT MODE AND TO THE NEXT SPACING 4 20 Y100250 4 Alignment calibration corrects any bi directional printing misalignment possibly caused by the printer s mechanical tolerances Bi directional printing alignment can be optimized by means of a calibration procedure which must be performed for each of the following print modes High Speed Draft 10 cpi Draft 10 cpi Draft 12 cpi Near letter quality 10 cpi Letter quality 10 cpi Each print mode has two types of calibration One type of calibration is for the printing of lines without tabulation stops and the other is for the printing of lines with tabulation stops For this reason two specific texts will be printed one for each print mode to be calibrated Proceed as follows to calibrate the alignments 1 eO RO 5 Qo Power
44. code 751884Z into the front feed slot from the Jitter Ampl side Record the signal read when the printhead moves from rightto left If the signal recorded does not reach the value of 4V replace the printhead 4 4 7 SIGNAL AMPLITUDE CONTROL This control must be performed in the same way as the previous Insert a sample chart so that the jitter and amplitude of the sample stripe are read The printer will perform a read cycle before expelling the chart Using an oscilloscope with memory check the amplitude ofthe signal read which mustbe uniform and must have a value of no less than 4V peak to peak The check must be made when the printhead moves from right to left within the horizontal magnetic reader 4 28 Y100250 4 5 PRODUCT DIAGNOSIS 5 1 SERVICING MODES The following pages provide a technical approach to servicing that could be useful to less experienced field engineers 5 1 1 FAULT DETECTION ANALYSIS The user who detected product malfunction can give information regarding the operating mode the printer was in when the malfunction occurred and the related error indications that were provided The repetition of the fault when possible can help with its identification For fault diagnosis purposes it is important to establish whether the fault is repetitive or random 5 1 2 ANALYSIS OF THE OPERATING CONDITIONS WORK ENVIRONMENT An environment that is too cold hot or humid could be the cause of certain malfunctions The
45. cument and the beginning of the character must be a maximum of 0 5 mm with console calibration completely to the left If this condition is not met recalibrate the photosensor Check according to the requirements of step 6 By pressing Station 2 move the left margin rightward until reaching 6 95 0 55 mm defined by the DIMA code 473284Z check made by inserting an A4 sheet of paper 10 Press Local twice Y100250 4 Service Manual 4 25 4 4 5 DOCUMENT LENGTH MEASUREMENT Provided below is the document length measurement block diagram COVEROPEN ST1 LOCAL BUTTONS PRESSED WHILE POWERING ON THE MACHINE 4 Y AUDIBLE SIGNAL LEDS ON LOCAL v ST1 LED ON LOCAL v LOCALLED ON INSERT THE DOCUMENT TOBE MEASURED v THEDOCUMENTIS MEASURED AND EXPELLED v ST1LEDON v PRESSLOCAL v DOCUMENT LENGTH p VALUEIS STORED 4 26 Y100250 4 Form length measurement is necessary for a rapid handling of a savings book magnetic stripe By selecting the STRIPE HANDLING FAST set up option the value provided by the form measurement procedure will be used to determine the position of the magnetic stripe and to position the stripe above the magnetic head without needing to further measure the length of the savings book This entails greater time saving during savings book management For this feature to work correctly
46. e carriage at its reset position end of stroke at motor side and semi tie rod joining screw 1 loose OBJECTIVE ADJUSTMENT Coplanarity between the door and the front surface of the frame PROCEDURE Fitthe door 2 againstthe slot 3 working in the area between the leaf spring and the semi tie rod tooth 4 tighten the screw 3 ADJUSTMENT EIOS AREA Fig 8 10 100250 4 Service Manual 8 11 8 11 HORIZONTAL MAGNETIC DEVICE MICR PRESS POSITIONING MACHINE CONDITION Cam crank 4 against the shortest cam radius Position press 1 inside conveyor 2 with an indent of 0 5 1 mm and then phase cam 3 so as to move cam crank 4 against its shortest radius Secure the cam crank on the shaft with its screw 5 Make sure that the press is indented throughout the entire paper path OBJECTIVE ADJUSTMENT Press in ints working position PROCEDURE Rotate the cam until the cam crank 4 moves against its maximum radius then with the press resting on the paper feed surface check for a clearance in the joint at point A Fig 8 11 8 12 Y100250 4 8 12 POSITIONING THE ASSEMBLY THE HORIZONTAL MAGNETIC DEVICE MICR MACHINE CONDITION Unimportant OBJECTIVE ADJUSTMENT Coplanarity between the magnetic device door and the slot paper conveyor PROCEDURE Hook slots 1 on the sides of the magnetic device frame onto pins 2 on the sides of the machine Insert the securing screws 3 Pus
47. ead and ribbon cartridge Close the printer cover Power on the machine Y100250 4 Service Manual 3 19 3 7 5 2 REPLACING THE RIBBON CARTRIDGE WITH THE MACHINE POWERED OFF Theribbon cartridge can be changed with the machine powered on and by following the procedure listed below Open the printer cover printing stops automatically Liftthe upper mechanical assembly by using the appropriate lever Remove the used cartridge and replace it with a new as previously described Lower the upper machanical assembly by using the appropriate lever Close the printer cover Note DO NOT move the printhead manually 3 7 6 PAPER JAMS The paper could jam along its path inside the machine Jamming could be caused by one of the following Obstructed paper path for example residual pieces of paper Paper skew Paper weight or size non compliant with the specifications Crumpled folded or badly preserved paper Stapled paper or with paper clips this can seriously damage the machine Multicopy forms where the sheets are poorly glued together The areas where jams are more likely to occur are front document feed slot inside the printer rear document output slot 3 20 Y100250 4 3 7 6 1 PAPER JAMS THE FRONT DOCUMENT FEED SLOT To remove a jammed document from the front feed slot carefully pull the document from the printer to avoid ripping it Fig 3 21 Removing the Document from
48. embly adjust its position on the frame section 8 12 9 22 Y100250 4 9 3 2 HORIZONTAL MAGNETIC DEVICE MICR MOTOR DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 Remove the horizontal magnetic device MICR assy section 9 3 1 Unplug the motor cable from the magnetic options card Loosen the two screws 1 and then remove the motor with its related protective shield Fig 9 24 Y100250 4 Service Manual 9 23 9 3 3 HORIZONTAL MAGNETIC DEVICE MICR HEAD ASSY DISASSEMBLY REASSEMBLY Remove the printer case section 9 3 1 Remove the horizontal magnetic device MICR section 9 3 1 Loosen screw 1 to free the signals cable Loosen screws 2 and remove the MICR head 3 Fig 9 25 9 24 Y100250 4 UPDATING STATUS DATE UPDATED PAGES CODE 04 2001 157 EDITION 100250 4
49. ement of 0 4 0 5 mm must correspond to a load of 280 gr 20 gr Repeat this procedure on the right hand side of the print bar When adjustment is complete secure using securing nuts 5 1 3 foo Ses ea ea Sar Ses ba tes Pita Seay Sa Sica eo a aS ea ee n n n n S Uu H 1 CM i can TA Q 603 FOR FOS 7 Qf fe XD Po 2 on OO OOOO fk OO Oo OO OO OO 7 OO OO OO OO OOOO OO 00 OO OO OOOO OO 00000 eoooo Ip LOADS DETECTED WITH THE COMPARATOR 280 gr 20 gr 280 gr 20 gr 280 gr 20 gr Fig 8 3 8 4 Y100250 4 8 4 TAB ADJUSTMENT MACHINE CONDITION The upper mechanical assembly must be raised OBJECTIVE ADJUSTMENT Tab 1
50. er is on line LOCAL Yellow LED indicates that the printer is off line STATION 1 Yellow LED when flashing indicates that data are present in the buffer when indicates that a document is present STATION 2 Noindication A specific console different than the one used on the standard product is available for this PR2 E version 2 8 Y100250 4 2 6 UPPER MECHANICAL ASSEMBLY LIFTING LEVER The upper mechanical assembly lifting lever 1 is located on the left hand side of the printer and is used to lift the upper part of the mechanical assembly so that you can access the internal paper path so that paper jams can be cleared without needing to power off the printer To access this lever lift the printer cover about 45 degrees until it stops Fig 2 3 Opening the Cover Y100250 4 Service Manual 2 9 Fig 2 4 Upper Mechanical Assembly Lifting Lever Pushing this lever as far as it goes lifts the upper part of the mechanical assembly thus granting you access to the paper path gr Fig 2 5 Removing a Jammed Sheet of Paper 2 10 100250 4 3 INSTALLATION 3 1 GENERAL INSTALLATION PRECAUTIONS To ensure optimim printer functionality and to avoid making service calls for problems that are not directly caused by the product itself bear in mind the information provided in the following sections 3 1 1 ELECTRICAL POWER SUPPLY Make sure that the electrical wall outlet to which the printer is connected has a valid
51. g it until you are able to reach the connectors on the main board Unplug the carriage reset photosensor cable from the main board and then release it from its plastic retaining clips the cable clips 1 and remove the photosensor by unscrewing screw 2 Fig 9 11 Note During reassembly replace the cable clips Y100250 4 Service Manual 9 13 9 2 11 ROLLER SUPPORT TRAY DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 and console section 9 2 2 Remove the mechanical assembly separating it from the base of the machine section 9 2 3 Free the carriage reset photosensor wires from their plastic retaining clips 1 Fig 9 12 Remove the upper part of the mechanical assembly section 9 2 7 Removethe four screws 2 and then extractthe tray being careful to avoid loosing the transmission joint 3 and the tray s soundproofing Fig 9 13 Note Duringreassembly make sure to correctly reposition the transmission joint and soundproofing before tightening the screws 9 14 Y100250 4 9 2 12 SERVICES MOTOR DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 Liftthe front part of the mechanical assembly off the base of the printer partly rotating it until you are able to reach the connectors on the main board Unplug the services motor connection cable from the main board Remove the two screws 1 that secure the motor
52. grafo 4 4 9 20 Y100250 4 9 2 16 POWER SUPPLY ASSY DISASSEMBLY REASSEMBLY Note Ifthe fuse inside the power supply has blown replace the entire power supply assy since some components on the power supply board may be damaged Remove the mechanical assy section 9 2 3 Unpiug the power supply cable 1 from the main board Unscrews the four screws 2 that secure the power supply and also remove the ground wires Loosen the two screws 3 that secure the switch Extract the power supply assy 3 Fig 9 22 Note During reassembly make sure that you correctly reposition the ground cables If you replace the assembly make sure that the replacement unit uses the correct voltage Y100250 4 Service Manual 9 21 9 3 BASIC MACHINE OPTIONS DISASSEMBLY REASSEMBLY 9 3 1 HORIZONTAL MAGNETIC DEVICE MICR DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 Liftthe front part of the mechanical assembly off the base of the printer partly rotating it until you are able to reach the connectors on the main board 1 Unplug the cables connected to the magnetic options card Remove the two screws 2 that secure the assembly to the machine frame and then remove this option EN ea O33 1 DONA 2107 SBR IRAQ n n 22034526 MA nmm ee C REGERE EEE EOE n 2 1212908 _ Fig 9 23 Note When refitting the ass
53. h the magnetic device frame upward untit it rests against the paper conveyor on both right and left hand sides Tighten the screws with a torque of 8 Kgcm Fig 8 12 Y100250 4 Service Manual 8 13 9 DISASSEMBLY REASSEMBLY PROCEDURES For easier consultation the disassembly procedures have been divided as follows 9 2 X disassembly of the basic machine with no option installed 9 3 X disassembly of the basic machine s horizontal magnetic device MICR Each individual disassembly procedure is described in the following way Wherever possible reference is made to previous disassembly procedures so as to give a backward glance at the disassembly that comes prior to the one described Operation steps described in sequence Notes recall adjustments that need to be made after reassembly precautions or warnings to be observed Y100250 4 Service Manual 9 1 9 1 GENERAL DISASSEMBLY REASSEMBLY PRECAUTIONS To ensure maximum safety before starting any disassembly operation power off the printer and unplug its power cord from the electrical outlet All operations should be performed in a clean and uncluttered area Follow the procedures carefully do not unscrew parts that are not to be disassembled Store the disassembled parts in a clean place where there is no danger of them getting lost After replacing the parts make sure that they have not been deformed during assembly restore the correct condi
54. he printer prints the self test 2 4 2 LED INDICATIONS When on the LEDs inform of the following machine states ON Green LED indicates that the machine is powered on READY Yellow LED indicates that the printer is on line LOCAL Yellow LED indicates that the printer is off line STATION 1 Yellow LED when flashing indicates that the printer is waiting for a document from operator 1 when on indicates that a document is present STATION 2 Yellow LED when flashing indicates that the printer is waiting for a document from operator 2 when on indicates that a document is present A specific console different than the one used on the standard product is available for this PR2 E version Y100250 4 Service Manual 2 7 2 5 BUTTON AND LED FUNCTIONS IN THE PROPRINTER 1 24 EPSON LQ 2550 EMULATION This section describes the button functions and LED indications of the PR2 E printer when in the IBM Proprinter 24 EPSON LQ 2550 emulation 2 5 1 BUTTON FUNCTIONS The buttons have the following functions LOCAL BREAK Toggles the printer between the on line and off line states STATION 1 EJECT the document present STATION 2 EJECT used Pressing the STATION 2 EJECT button while powering on the printer prints the self test 2 5 2 LED INDICATIONS When on the LEDs inform of the following machine states ON Green LED indicates that the machine is powered on READY Yellow LED indicates that the print
55. hes to the receiving interface and maintains this condition until the end of the print job Dual port functionality is configured during printer set up in particular active emulation can be set on each of the two interfaces and can be changed in run time mode by means of a specific command 3 12 Y100250 4 3 5 FINAL TESTING After connecting the printer to the system test its interface parameters The PR2 E ha a resident run in test which is useful to check the outcome of the ordinary maintenance intervention Proceed as follows to perform this test Power on the PR2 E by pressing the STATION 2 EJECT button with the printer cover open Upon completion ofthe reset routine close the printer cover and insert an A4 sheet of paper forthe printing of the self test When the sheet of paper is expelled press the LOCAL BREAK and STATION 2 EJECT buttons simultaneously RUN IN test The test lasts about 45 and vertical bars are printed In this test mode the efficiency of the machine s mechanics and electronics is tested just like at the factory Power off the printer to exit from the run in test mode 3 6 INFORMATION FOR THE OPERATOR After installation the field engineer has the responsibility of informing the operator on how to use the printer how to replace the cartridge and how to clear paper jams It is suggested that a practical demonstration be given for the following operations Using the console interpreting the error message
56. idge roller 473074Z X Hole of the contact bushing between roller shaft 473170A X and strap shaft 473171X X Center pressure device in shaft contact area 473167T X Bushings in the shaft contact area 473087P X 474953Y X Motor gear 473069C X gear 473071W X and cam teeth 473072X X assembly gear 4731745 X 473180V X Pulley toothing 473017Q X Hooking area leaf spring 473182K X Ribbon feed rotation pin hole 473159B X with support pin Belt tightener pin with return pulley 473149H X Alignment rollers shaft assy 474987K X in torsion bar contact area 473091K in conveyor assy guideway area 473186P 474951W Rubber in the damper assembly hole 475871K X Grease Code 150337 M MAGNALUBE E Oil Code 757283 C FOMBLIN Y 06 oil perfluorate polyether Supplier Ausimont a Montedison group company Y100250 4 Service Manual 7 3 DESCRIPTION CODE GREASE Print crosspiece in the following areas 3951158 X Left pin and ballast 473049G X Guide hole center pin X Pin contact left bracket X Inside the crosspiece adjustment screw holes X 7 3 2 HORIZONTAL MAGNETIC DEVICE MICR LUBRICATION POINTS DESCRIPTION CODE GREASE Upper carriage slide shaft with moderation placing a drop at the sides of the shaft X Return pulley between pin and roller cage X Door on rotation pins X Sector gear on its own pin X Sector door conical copling gear X Inclined plane of the carriage in the door closing lever contro
57. ifferent ways in which the various set up environments can be accessed 4 3 2 SUPPORT SOFTWARE The software tools include all tools and languages that the product needs for the environments in which it will be used Promotional demo The program features an appropriate product presentation format and exploits all the operating modes and options available It highlights the features and performance offered by the printer in every configuration and optimizes the operational cycle so as to reach the maximum performance obtainable Drivers Based on the Olivetti native protocol they integrate the entire range of features handled by industry standard applications Reference command sets STD 12 14 PR2E DLL driver provided WIN NT 4 x 2000 WIN 95 98 Environment DLL WOSA Set up management software A specific program developed for set up management on line It displays the product s set up parameters and makes it possible to change them handshaking included Font and logo management software A program used to create unusual graphical representations or special fonts 4 2 Y100250 4 4 3 3 CONFIGURATION PARAMETERS This section provides the description and possible values of the printer s different set up parameters The default value is indicated in bold 4 3 3 1 CONFIGURATION MODE MENU PARAMETERS DRAFT SPEED NORMAL HIGH TYPE 02 LQ2 PAPER WIDTH FIRST LINE PROGRAMMABLE BUZZER N Y I
58. isted below ENVIRONMENT CHARACTER SETS PC DOS WINDOWS 2 X 3 0 OS 2 UNIX WINDOWS 3 1 OLIVETTI ISO 8859 X CP SET STD 15 CP SET CODE PAGE Each emulation in the machine has one or more associated character sets The character sets that are available with each emulation are listed in the following table EMULATION CHARACTER SETS OLIVETTI IBM CP SET ISO CP SET STD 15 Olivetti ISO 1 10 3 PRINT MODES AND CHARACTER FONTS The following table indicates the characteristics of the different print modes 10 cpi 12 cpi 15 cpi H S D High Speed Draft 350 cps 314 cps 327 cps DRAFT 260 cps 260 cps 260 cps N L Q Near Letter Quality 130 cps 130 cps 130 cps L Q Letter Quality 86 cps 104 cps 131 cps The reference standards for the optical characters are the following Font Code Standard 519 Dimensions Shape Print Specifications OCR A EUROBANKING ISO 1073 1 ISO 1831 OCR B EUROBANKING ISO 1073 2 ISO 1831 Y100250 4 Service Manual 1 13 Relationship between write cycles and emulation environment Emulation Print Styles Selection PR50 PR2845 HSD DRAFT NLQ1 FROM SET UP NLQ2 LQ2 OCRA OCRB DRAFT NLQ1 FROM THE LINE PR50 PR40 HSD DRAFT NLQ1 FROM SET UP NLQ2 LQ2 OCRA OCRB DRAFT NLQ1 OCRA OCRB FROM THE LINE PR2E HSD DRAFT NLQ1 FROM SET UP NLQ2 LQ2 OCRA OCRB HSD DRAFT NLQ1 N
59. l area X Inside the pressure control cam X Grease gt Code 150337 M MAGNALUBE E Oil Code 757283 FOMBLIN Y 06 oil perfluorate polyether Supplier Ausimont a Montedison group company 7 4 Y100250 4 8 MECHANICAL ADJUSTMENTS For easier consultation purposes the mechanical adjustments have been divided into Machine condition Describes the condition that the printer must be in in order to be able to perform a successful adjustment Objective adjustment Indicates the points values and tolerances to be observed to ensure good kinematic operation Procedure Describes the operations to be performed for the adjustment Notes Indicates any reference to adjustment sequences or to tests to be performed once the adjustment is made Y100250 4 Service Manual 8 1 8 1 DOCUMENT FEED BELT ADJUSTMENT MACHINE CONDITION Unimportant OBJECTIVE ADJUSTMENT The tension of timing belt 1 must sag 2 9 2 mm when applying 200 gr 2 gr at the center of the lower span PROCEDURE Loosen the motor securing nuts 2 tighten the belt accordingly and then tighten nuts 1 again 200 g 10 g 2 9 0 2 Fig 8 1 8 2 Y100250 4 8 2 PRINT BAR ADJUSTMENT MACHINE CONDITION Testina di stampa posizionata coassiale con l asse della vite su cui si compie la regolazione OBJECTIVE ADJUSTMENT A distance of 0 4 0 5 mm must be measured between the frame s lower shie
60. ld 1 and the head of screw 2 PROCEDURE While holding the printhead carriage on the axis adjust screw 2 until measuring the required distance Repeat this procedure on the other screw located on the opposite side of the frame PRINTHEAD EEUU NINE ETIN Pee Se a WERE i 0 4 0 5 Fig 8 2 100250 4 Service Manual 8 3 8 3 PARALLELISM ADJUSTMENT BETWEEN THE PRINT BAR AND LEAF SPRING LOAD IN THE BASIC MACHINE MACHINE CONDITION Machine powered off and with the case removed OBJECTIVE ADJUSTMENT Parallelism between the print bar and leaf spring load PROCEDURE The print bar perpendicularity adjustment lever must be previously adjusted using tool code 9600303 according to drawing code 395130U To manually adjust the parallelism between the printhead and print bar loosen studs 2 and turn counterclockwise to move the print bar closer to the front of the matrix turn clockwise instead to move the bar closer to the rear of the matrix You can use parallelism indicator 3 to check whether corrections have been made To change the load of the spring leaf turn adjustment nuts 4 Move the carriage all the way to the left and using a comparator with a dynamometer push the print bar near the probe roller A displac
61. ms 245 mm 65 mm 297 mm 450 mm 70 60 to 160 g m 0 1 to 0 28 mm Up to 25926 and uniform 40 to 60 g m 20 to 34 g m 1 5 with average paper weight and in the NLQ LQ print mode 1 4 with average paper weight and in the NLQ LQ print mode Original 50 g m last copy 60 g m At head or on the side 320 g m NLQ or LQ Y100250 4 1 5 2 SAVINGS BOOKS Max thickness with book open Max difference in level between pages Cover thickness Type of binding Book preparation Book with Vertical Seam Open book width Maximum length Minimum length Union of external corners Book with Horizontal Seam Open book width 1 8mm 1 2 mm 0 2 to 0 5 mm Thread sewn without metal staples or clips Mustbe carefully flattened before being inserted into the machine 241 3 mm 9 5 max 150 mm 5 9 min 220 mm 85 mm 3 to 14 mm radius 241 3 mm 9 5 max 150 mm 5 9 min Maximum length 220 mm Minimum length 165 mm Y100250 4 Service Manual 1 7 1 6 ACCESSORIES This section describes the accessories available for the PR2 E printer BLACK NYLON SNUG CART RIBBON CARTRIDGE Ribbon cartridge specific for the needle printhead with a life span of more than 3 5 million characters The cartridge is installed in the machine by opening the printer cover with automatic printhead positioning ifthe printer is powered on or manual positioning if powered off and lifting the printassembly by using the ap
62. n non standard products 8 8 Y100250 4 8 8 TAB OPENING ADJUSTMENT MACHINE CONDITION With the upper mechanical assembly in its working position and with the printhead carriage against the left side position and secure lever 1 on the shaft with a clearance of 1 5 mm between the knob and balancer with respect to the profile of the carriage Upper mechanical assembly lifted and lever 1 against the lifting lever control pin 2 OBJECTIVE ADJUSTMENT A distance of between 5 and 8 mm between the edge of the tab 3 and the center of the print bar PROCEDURE Turn screw 4 that secures lever 1 on the tab shaft PRINTHEAD CARRIAGE Fig 8 8 Note This adjustment must be performed after the platen and tab adjustments Y100250 4 Service Manual 8 9 8 9 HORIZONTAL DEVICE MICR OPTION CARRIAGE FEED BELT TENSION ADJUSTMENT MACHINE CONDITION Read write carriage in its reset position end of stroke at the motor side OBJECTIVE ADJUSTMENT The tension of timing belt 1 so thata5 mm sagis obtained when a force of 60 gr is applied at the center of the carriage Measure with the carriage in its reset position left hand end of stroke motor end PROCEDURE Loosen the securing screws and then move motor 2 until the objective adjustment is reached tighten the screws again Fig 8 9 8 10 Y100250 4 8 10 HORIZONTAL MAGNETIC DEVICE MICR DOOR ADJUSTMENT MACHINE CONDITION Read writ
63. ode lines printed on checks This printer model can also be configured with different interfaces and emulations The PR2 Enhanced represents the evolution in terms of quality and performance of the PR2 to which it maintains complete compatibility as far as the firmware and accessories are concerned With respect to the PR2 the PR2 E carries the following significant differences Updated design Improved printing speed Interchangeable communication ports thanks to the possibility of installing supplementary snap in interface cards Availability of support software for on line setup the design and loading of user character fonts design and storage of a user logo and the on line loading of character generators 100 to 130 and 200 to 240 1096 switching power supply unit Optional fan for delaying the activation of the thermal protection when printing complex graphics Dual interface functionality in all emulations IBM 9068 and IBM X24 emulations Y100250 4 Service Manual 1 1 1 1 1 PR2 E FACTORY CONFIGURATION The following table indicates the different PR2 E factory configurations 2 8 g s 18 3 2 amp a z 9 o D tc 58 58 52 295 58 Commercial PR2 E S10 X PR2 E D10 X PR2 E D12 X X PR2 D12M X X PR2 E D10 DSP X PR2 E S12 X X PR2 E 12 X X 1 2 Y100250 4 1 2 GENERAL MACHINE CHARACTERISTICS
64. omplete or faded or when there are frequent optical read errors on the printed documents This procedure is to be performed with the machine powered off if necessary however it can even be performed with the machine powered off 3 7 5 1 REPLACING THE RIBBON CARTRIDGE WITH THE MACHINE POWERED OFF Proceed as follows to change the ribbon cartridge Power off the machine Open the printer top cover Liftthe upper mechanical assembly by pushing the appropriate lever Fig 3 16 Lifting the Upper Mechanical Assembly Y100250 4 Service Manual 3 17 Push the ribbon guide downwards until it releases from the print carriage Remove the old cartridge by pulling it outwards Fig 3 17 Removing the Ribbon Cartridge Insert the cartridge into the feed gears hooking it on the two sides and making sure to insert pin 1 into the related hole of the ribbon feed knob Fig 3 18 Inserting the Ribbon Cartridge 3 18 Y100250 4 Insert the ribbon guide frontwards and then lift it until it hooks on to the two eleastic pins on carriage s open slots behind behind the printhead platen a clack sound is heard Fig 3 19 Hooking the Ribbon Guide Turn the carriage knob counterclockwise 2 until the ribbon is taut and then remove tab 3 Fig 3 20 Removing the Tab Usingthe specific lever completely lower the upper part of the mechanical assembly containing the printh
65. on as a guide take a logical path to find the fault starting from the most probable cause throught to the most remote possibility until faulty part is found 5 1 5 SOLVING THE PROBLEM Repair the machine so that it correctly resumes to operate as normal The information provided in Chapters 6 7 8 and 9 can be of help 5 1 6 TESTING THE MACHINE When the repair is completed give the machine a general cleaning and then run a complete test on the machine section 3 5 possibly with the Operator present to make sure that the malfunction has been corrected and that no others have occurred in the mean time 5 2 Y100250 4 5 2 FAULT CLASSIFICATION To make the search easier the faults have been classified as follows 53 54 5 5 5 6 Power on faults Document write faults Document handling faults Magnetic stripe read write faults Each fault classification lists the more probable failures and their possible causes The classification provided in this chapter cannot cover all the faults that could occur on the machine if the fault detected is not described herein refer to the description of a similar fault Y100250 4 Service Manual 5 3 5 3 POWER FAULTS t ot 9 9 25 B BEES ies FAULT m 50 5 5 u d u 9 8 bz 2 OG 50 O 59 os
66. on the printer with its cover open and while holding down the three console buttons Wait for the audible signal indicating that the printer has switched to the calibration mode and then close the printer cover Press the Station 1 button Press the Station 2 button The three console buttons are now active The Station 1 button activates printing ahead of time while Station 2 delays printing Pressing the Station 1 and Station 2 buttons before step 5 stores approximate default values very close to the correct ones for all the print modes Insert an A4 sheet of paper into the front feed slot to check the print alignment status Press Station 1 and or Station 2 to calibrate the alignments Repeat steps 7 and 8 cyclically until the calibrations are completed Pressthe Local button twice to permanently store the alignment setting for the current print mode and to automatically switch to the next adjustment Calibration ends when allthe print modes are completed or by simultaneously pressing all three console buttons In both cases the printer will switch to the main menu Y100250 4 Service Manual 4 21 4 4 3 OF FORM TOF CALIBRATION Provided below is the Top Of Form TOF calibration block diagram COVEROPEN ST1 LOCAL ST2 BUTTONS PRESSED WHILE POWERING ON THE PRINTER y AUDIBLE SIGNAL LEDS ON ST2 LOCAL LEDS ST1 AND ST2 ON ST1 ms ST2 v LEDS S
67. oning systems heat sources or in direct sunlight Do not obstruct the printer s ventilation slots If the printer is installed in a cabinet make sure that it has good ventilation so as to avoid overheating Install the printer in a position so that paper jams can be cleared easily Y100250 4 Service Manual 3 1 3 2 UNPACKING AND INSTALLING THE MACHINE 3 2 1 UNPACKING THE MACHINE Checking the box contents The following items should be contained in the packaging PR2E printer Power cord Operator Manual Ribbon cartridge Magnetic head cleaning card not shown in the figure below for models equipped with this option Fig 3 1 Package Contents 3 2 Y100250 4 Unpacking and Setting Up the Printer Remove the machine from its protective bag Open the printer s top cover completely forcing it to a horizontal position Push forward the two red plastic retainers that lock the print carriage illustration 1 in the following figure Lift the upper part of the mechanical assembly illustration 2 in the following figure and then remove the two retainers illustration 3 in the following figure Fig 3 2 Removing the Transportation Retainers Quickly check that the printer was not damaged during transportation Install the ribbon cartridge section 3 7 5 Close the machine Y100250 4 Service Manual 3 3 3 2 2 INSTALLING THE MACHINE Position the machine for operation making sure tha
68. propriate lever INDELIBLE NYLON SNUG CART RIBBON CARTRIDGE The same as the BLACK NYLON SNUG CART but with indelible ink Fig 1 2 SNUG CART Ribbon Cartridge 1 8 Y100250 4 1 7 LOCATING THE PRINTER S MAJOR COMPONENTS COVER CONSOLE FRONTINSERTIONSLOT POWERSWITCH REAROUTPUTSLOT CONNETTORE CAVO RETE BREAKABLE SLOT COVER FOR THE INSTALLATION OF THEOPTIONAL STANDARDSERIALINTERFACE INTERFACE CARD SERIAL USB OR CONNECTOR CENTRONICS PARALLEL OPENCOVERSENSOR PRINTHEAD AND CARRIAGE UPPERMECHANICAL ASSEMBLY LIFTINGLEVER Fig 1 3 Locating the Printer s Major Components Y100250 4 Service Manual 1 9 1 8 LOCATING THE PRINTER S MAJOR INTERNAL COMPONENTS PRINTHEAD FLAT CABLE PRINTHEAD SERVICESMOTOR CARRIAGE TRANSPORT MOTOR PAPER FEED MOTOR PINION FRONT PAPER FEED SLOT POWER SUPPLY UNIT OPTIONALINTERFACE CARD MAGNETIC OPTIONS CARD INSTALLATION PINS POWER SWITCH MAIN BOARD CONSOLE Fig 1 4 Locating the Printer s Major Internal Components 1 10 Y100250 4 1 9 GENERAL BLOCK DIAGRAM 1 9 1 BASIC MACHINE POWER SWITCH POWER POWER SUPPLY UNIT BASIC MACHINE USB INTERFACE gt SERIAL INTERFACE gt INTERFACE ROLLERS MOTOR CONSOLE TRANSPORT 4 PR2E MOTOR MAIN BOARD PRINTHEAD 4 AUTOBO
69. r YL E ul o 054 053 gt 2 it Be 0 Fig 6 4 SERIAL and USB Interface 6 8 Y100250 4 6 4 2 CONNECTOR PIN OUT Provided below is the pinout of the connectors on this interface card J2 J2 RS232 SERIAL INTERFACE USB INTERFACE DCD1 VBUS REXD1 DMENO TXD1 DPIU DTR1 GND GND DSR1 CTS1 501 TERRSE o o001m0 0n J1 INTERFACE gt gt gt gt gt gt gt gt DACX 7 DACX 5 DACX 3 DACX 1 IMPRA ESTR2 ESTR1 GND GND PIU35 Y100250 4 Service Manual 6 5 PARALLEL INTERFACE CARD The installation of this interface card provides the printer with a Centronics parallel interface 6 5 1 CARD VIEW AND LOCATION OF CONNECTORS J2 1 Lj Lj Fig 6 5 Parallel Interface Card N J1 6 10 Y100250 4 6 5 2 CONNECTOR PIN OUT Provided below is the pinout of the connectors on this interface card J2 PARALLEL INTERFACE GND STROBX GND DACXX 0 GND DACXX 1 GND DACXX 2 GND DACXX 3 GND DACXX 4 GND DACXX 5 GND DACXX 6 GND DACXX 7 GND ACKX GND BUSYX GND PAPEMP IMPRAX SELOUT FAULTCX AUTOLF 14 33 GND 15 34 GND 16 35 TIROO T
70. r against the brush Press the Station 2 button Wait for the sheet feed and expulsion movement to be completed If no failure is detected after the expulsion of the sheet of paper the console LEDs will remain off the reloading of an A4 sheet of paper will allow you to print the values read and selected for each single photosensor Y100250 4 Service Manual 4 17 If calibration does not end successfully the faulty photosensor is identified through specific LED configurations Pressing one of the console buttons allows you to identify any other faulty photosensor In this case the other calibrations or measurements may not be performed If instead calibration was successful load an A4 sheet of paper in order to print the calibration values The following table indicates the parameters that need to be checked 119 710 ERE ae M S Mo Olivetti JECV ERENG 1 2 Photosensor No paper is Aver value Current mV mV mV mV Photos 1 front paper alignment XXXX XXXX XX Photos 2 front paper alignment XXXX XXXX XXXX XX Photos 3 front paper alignment XXXX XXXX XXXX XX Photos 4 front paper alignment XXXX XXXX XXXX XX Photos 1 front paper presence XXXX XXXX XXXX XX Photos 2 front paper presence XXXX XXXX XXXX XX Rear paper detection photos 0 0 0 0 Paper edge printhead photos XXXX XXXX XXXX XX 3
71. r front alignment photosensors check the alignment of the document before it reaches the printhead The assembly consists of four LEDs and four photoreceivers all connected via fibre optics Autoborder photosensor Fitted on the printhead it detects the paper so as to measure the position of the first print column If selected from Set up with this sensor it is also possible to control printing interruption in cases when the paper is narrower than the line being printed and sent from the system The location of the individual photosensors in the machine is shown in the figure on the following page 4 14 Y100250 4 Rear ofthe printer Printhead reset photosensor does not require calibration Impact printhead carriage Paper edge detection photosensor p Fibre optics Fibre optics ia qo dor Photo 1 Photo2 Photo3 Photo4 Frontpaper alignment photosensors Fibre optics Fibre optics Photo N 1 Front paper detection Photo N 2 Frontpaper detection Frontofthe printer Fig 4 1 Locating Machine Photosensors Y100250 4 Service Manual 4 15 Provided below is the photosensor calibration block diagram COVER OPEN ST1 LOCAL ST2 PRESSED WHILE POWERING ON THE MACHINE gt READ PHOTOSENSOR VALUES WITHOUT PAPER v LED ST2ON v INSERT A WHITE SHEET OFA4PAPER v READ PHOTOS VALUES WIT
72. r not the settings made Y100250 4 Service Manual 4 7 Olivetti Menu EMULATION PR2E PR40 Selects the OLIVETTI emulation when PR40 LINE BUFFER PR40 LIKE N Y TOP MARGIN PR40 LIKE N Y Sets the reception buffer length like the PR40 1K byte or to 8 byte TOF management with fixed 40 adjustable mechanical header when PR2E PASSBOOK N Y Enables the printer to handle savings books when Passbook Y BINDING VERTICAL HORIZONTAL Used when the PASSBOOK Y setting is made Selects the type of savings book binding horizontal or vertical If horizontal binding is selected during the printing on a savings book the printhead is positioned outside the margin of the savings book so as to improve the feed of the book itself SIDE L R Selecting R Right ensures SW compatibility with the PR50 with right hand alignment Selecting L Left ensures SW compatibility with the PR50 with left hand alignment CHAR GENERATOR OLIVETTI Selects the character generator when IBM CHAR SET PC ISO IBM emulation PC or ISO character sets regardless of the selection made 4 8 Y100250 4 when PC CHAR SET DK N DK 210 220 437 INT 850 LATIN 1 851 GREEK 852 LATIN 2 855 CYRILLIC 857 LATIN 5 858 LATIN EURO 860 P 862 IL 863 CANADIAN FRENCH 864 ARABIC 865 NORDIC 866 CYRILL
73. r specifications thus avoiding the forms to crumple Stores or not the settings made 4 4 Y100250 4 EMULATION Il 24 Selects the IBM emulation wanted when X24 AGM N Y Enables disables the AGM function PASSBOOK N Y Indicates whether the printer is enabled or not to handle savings books when Passbook Y BINDING VERTICAL HORIZONTAL SIDE L R Used when the PASSBOOK Y setting is made Selects the type of savings book binding horizontal or vertical If horizontal binding is selected during a savings book print job the printhead will move outside the margins of the savings book so as to improve the feed of the savings book itself Selecting R Right ensures SW compatibility with the PR50 with right hand alignment Selecting L ensures SW compatibility with the PR50 with left hand alignment CHAR SET PC ISO Character generator selection when PC CHAR SET DK N DK 210 GR 220 E 437 INT 850 LATIN 1 851 GREEK 852 LATIN 2 855 CYRILLIC 857 LATIN 5 858 LATIN EURO 860 P 862 IL 863 CANADIAN FRENCH 864 ARABIC 865 NORDIC 866 CYRILLIC 1250 PC WIN Latin2 1252 PC WIN Latin Y100250 4 Service Manual 4 5 when ISO SET OLI UNIX ISO 8859 1 ISO 8859 2 ISO 8859 5 ISO 8859 6 ISO 8859 7 ISO 8859 8 ISO 8859 9 ISO 8859 15 TABLE TABLE 1 TABLE 2 Selects the charac
74. resent When flashing Waiting for a document from operator 1 or data present in the buffer STATION 2 When on Waiting for a document from operator 2 Oliveti STD 12 14 or machine assigned to operator 2 or document present When flashing Waiting for a document from operator 2 According to the selected emulation 2 2 3 ERROR MESSAGES The table on the next page shows the different LED configurations with the exception of the ON LED which is always on and their meaning The faults are classified as follows 1 Fatal error This error locks the machine and can only be cleared by powering off the printer and proceeding with all necessary repairs 2 Operator correctable error paper jam that can be cleared by removing the cause and then pressing the ST1 key with the cover open 2 4 Y100250 4 2 2 3 1 FAULT IDENTIFICATION CHART LED FAULT ON READY 511 LOCAL ST2 Power supply unit OFF OFF OFF OFF OFF failure On board failure Eprom ON OFF OFF OFF OFF ROM Microprocessor Failure caused by Fuse ON ON ON ON ON Driver Motors Activation board failure The motors are not working Y100250 4 Service Manual 2 5 2 3 BUTTON AND LED FUNCTIONS IN THE 9068 4722 EMULATION This section describes the button functions and LED indications of the PR2 E printer when in the IBM 4722emulation 2 3 1 BUTTON FUNCTIONS The buttons have the following func
75. rinter RS 232C serial interface USB interface card Centronics parallel interface card In its dual port configuration and therefore configured with the standard serial interface and serial interface USB interface card or with the standard serial interface and parallel interface card the printer can operate in run time mode on the available interfaces so as to satisfy specific application requirements 3 4 1 RS 232C SERIAL INTERFACE STANDARD Attach the serial cable to the interface located on the rear of the printer Via Set up Section 4 3 2 program the following interface parameters BAUD RATE BIT CHAR PARITY STOP BIT DSR and DCD 10 2 4 RECEIVED DATA 3 Q TRANSMITTED DATA 4 DATA TERMINAL READY 50 PROTECTIVE GROUND 6 O H 4 DATA SET READY 70 80 9 O H 9 SIGNAL GROUND I ux c a i A e Fig 3 5 Standard 5232 C Serial Interface 3 8 Y100250 4 3 4 2 OPTIONAL SERIAL INTERFACE USB INTERFACE CARD The optional serial interface Universal Serial Bus USB interface card hosts both interfaces and is installed in the specific slot alongside the standard first serial interface on the rear of the printer This interface card is shown in the following figure USB CONNECTOR SERIAL CONNECTOR Ele 42 J3 CIE ISI ILS Is SE c 515 O CS14 518 51
76. s and unlocking the machine whenever necessary Inserting a savings book and sheets of paper into the front insertion slot stressing the importance of avoiding the use of crumpled or torn paper or savings books with jutting spines Show how to insert the sheet of paper automatic alignment and the savings book manual alignment Replacing the ribbon cartridge Removing a jammed document from the printer by using the lever for lifting the upper mechanical assembly Inserting a check or tab in the optional check reader making sure to avoid using documents that are torn wrinkled folded stapled or hel together with paper clips Stress the importance of good internal ventilation and therefore the need to keep the printer vents unobstructed from forms or other types of paper Make it clear to the operator that observing these simple precautions ensures good printer operation in time If failures should arise however the operator should promptly call the field engineering service Y100250 4 Service Manual 3 13 3 7 OPERATING PROCEDURES 3 7 1 INSERTING A DOCUMENT WITH AUTOMATIC ALIGNMENT The front shelf on the case helps to insert the document in the printer With the printer powered on place the document at the center of the front slot and then insert it into the feed slot Release the document as soon as the automatic alignment system is activated Fig 3 12 Automatic Document Insertion 3 14 Y100250 4
77. s to detach the upper part of the mechanical assembly Fig 9 8 Note Duringreassembly make sure to route the cables through the appropriate slots and check the adjustment of the roller gears section 8 1 7 9 10 Y100250 4 9 2 8 PAPER FEED MOTOR DISASSEMBLY REASSEMBLY Remove the mechanical assembly section 9 2 3 Loosen the two nuts 1 that secure the motor and then release the document feed belt Remove the nuts and extract the motor Fig 9 9 Note After reassembly adjust the tension of the document feed belt section 8 6 Y100250 4 Service Manual 9 11 9 2 9 PRINTHEAD MOVEMENT MOTOR DISASSEMBLY REASSEMBLY Remove the upper part of the mechanical assembly section 9 2 7 Loosen the screw 1 that secures the return pulley support slide and then release the carriage movement belt from the motor pinion Releasethe printhead flat cable by loosening screw 2 and then unscrew the three special securing screws 3 and then remove the printhead movement motor being careful to avoid damaging the ribbon feed gears Fig 9 10 Note Afterreassembly correctly reposition ground spring 4 and then adjust the carriage feed belt section 8 9 9 12 Y100250 4 9 2 10 CARRIAGE RESET PHOTOSENSOR DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 and console section 9 2 2 Liftthe frontpartof the mechanical assembly off the base of the printer partly rotatin
78. scoscensonscoesandsdesriaradssoiseesccassonre 4 5 4 DOCUMENT WRITE FAULTS uuu ccesccccceccenccceccencenccnscnnscenscensenscencanscnsceansensseneenes 5 5 5 DOCUMENT HANDLING FAULTS c1ccosccecconscenccnccenccnccenscenscnscnnsenecessnenscneeenss 6 5 6 MAGNETIC STRIPE READ WRITE FAILURES 7 Y100250 4 Service Manual vii 6 ELECTRICAL INTERCONNECTIONS eene 1 6 1 GENERAL PRINTER INTERCONNECTION DIAGRAM 1 62 gt 2 MAIN BOARD ient eda eh aita ty 2 6 2 1 MAIN BOARD VIEW AND LOCATION OF 2 623 CONNECTOR PIN QUT pe ix ul ende 3 6 3 MAGNETIC OPTIONS 5 6 3 1 CARD LOCATION AND IDENTIFICATION OF CONNECTORS 5 632 VIEW OF THE PR2MAGN citet ttu techn ia nets 6 6 4 SERIAL AND USB INTERFACE 8 6 4 44 CARD VIEW AND LOCATION OF CONNECTORS 8 642 CONNECTOR PIN OLHT ua tue te tab t terra tite fv pe ha espe Pra tpa 9 6 5 PARALLEL INTERFACE CARD tro orta rank atia pra aya you apo pEa aka kay eaa o 10 6 5 1 CARD VIEW AND LOCATION OF CONNECTORS 10 5652 CGCONNEGIORPIN OUT uico tio a RU
79. section 9 2 1 Liftthe front part ofthe mechanical assembly off the base of the printer partly rotating it until you are able to reach the connectors on the main board Unpiug all the cables with the exception of the printhead cables Unscrew the two nuts 1 that secure the print bar and then slide it off from the top Fig 9 20 Note After reassembly adjust the distance between the printhead and print bar section 8 2 Y100250 4 Service Manual 9 19 9 2 15 MAIN BOARD DISASSEMBLY REASSEMBLY Power off the machine and unplug the power cord from the electrical outlet Remove the mechanical assembly section 9 2 3 Unplug the power supply cable 1 that connects the main board to the power supply assy Remove the optional interface card 2 if installed Remove the five screws 3 that secure the main board to the base Unscrew the two connection screws 4 of the standard serial port Remove shield 5 Extract the main board from the base of the printer Fig 9 21 Nota Durante il rimontaggio del lamierino 4 bloccarlo dall esterno della lamiera di supporto della piastra base In caso di sostituzione della piastra aggiornare il firmware secondo l ultima release paragrafo 1 11 1 effettuare il set up di installazione paragrafo 4 3 e la taratura dei fotosensori para
80. sembly is released Remove screw 2 that secures the ground wires Liftthe entire mechanical assembly from the base of the printer Fig 9 3 Y100250 4 Service Manual 9 5 9 2 4 PRINTHEAD FLAT CABLE DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 Freethe cable clip 1 located on the right hand side of the frame by unhooking it from the inside 2 of the frame itself Remove the soundproofing 3 Loosen screw 4 that secures the rear cable fastener rotate the fastener and then free the flat cables Rotate the flat cable support 5 connected to the printhead upwards as far as it goes Removethe mylar sheet 6 from underneath the flat cable support then free the flat cables from their securing tabs on the support Fig 9 4 9 6 Y100250 4 Remove the printhead by unscrewing two screws 7 Unplug the two flat cables from their connectors 8 on the printhead Fig 9 5 Warning When reconnecting the flat cables to the printhead make sure to restore the correct cable route 9 as indicated in the figure so thatthe cables do not interfere with the ribbon rewind gears if the correct route is not restored the cables could become seriously damaged during machine operation Y100250 4 Service Manual 9 7 9 2 5 PRINTHEAD DISASSEMBLY REASSEMBLY Open the printer cover and lift the mechanical assembly Remove the ribbon cartridge Unscrew the two screws 1
81. sthe console through the flat cable passage slot and remove the case from the machine Fig 9 1 Note Duringthe reassembly ofthe case secure the console flat cable with the guide tabs 5 located at the rear of the console panel Y100250 4 Service Manual 9 3 9 2 2 CONSOLE DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 Loosen screws 1 and turn sideways the securing plates of the mechanical assembly rubber stops So as to release the front of the mechanical assembly from their slots Liftthe front part of the mechanical assembly off the base of the printer partly rotating it until you are able to reach console connector 2 on the main board Remove the board s protection Remove the console by unplugging its flat cable connector from the main board 2 and then releasing the flat cable from its securing tabs 3 on the base Fig 9 2 9 4 Y100250 4 9 2 3 MECHANICAL ASSEMBLY DISASSEMBLY REASSEMBLY Remove the printer case section 9 2 1 and console section 9 2 2 Liftthe front part ofthe mechanical assembly off the base of the printer partly rotating it until you are able to reach the connectors on the main board Unplug all the cables connecting the mechanical assembly to the main board with the exception of the main board to power supply unit connection cable Loosen screws 1 of the plates that secure the assembly s rear rubber stoppers so that the entire mechanical as
82. t it complies with the information provided in section 3 1 Make sure that the voltage rating indicated on the electrical data plate corresponds to the local mains Plug the power cord into the electrical wall outlet and then power on the printer Make sure that the printer powers on by checking the mechanical reset and the lighting of the ON LED on the console If other LEDs other than the ON LED remain lit refer to section 2 2 3 Error Messages 3 3 OFF LINE TESTS A print test can be run to make sure that the printer works correctly before actually connecting it to the system 3 3 1 STARTING AND STOPPING THE PRINT TEST Proceed as follows to activate the print test Power off the printer Power on the printer while pressing the STATION 2 EJECT button on the console After printer initialization insert an A4 sheet of paper into the front feed slot until triggering the paper alignment photosensor The machine will automatically feed the sheet of paper and start printing the test The sheet of paper is automatically expelled at the end of the test To repeat the test simply insert a new sheet of paper To stop the print test power off the machine 3 4 Y100250 4 3 3 2 PRINT TEST CONTENTS The print test provides the following information The release and version of the firmware and character generators installed Agraphical represetnation of 24 needle functionality Needles test The configuration of the printer
83. ter generator table CHAR DEFINITION LQ DRAFT Selects the character definition 10 12 17 1 Selects the print pitch expressed in number of characters per inch CR N Y Selects or not the execution of an automatic carriage return each time a line feed command is received CR N Y Selects or not the execution of an automatic line feed each time a carriage return command is received ZERO SLASH N Y Enables disables slashed zero printing LINE LENGTH 80 90 Selects maximum print line length expressed in number of character at 10 cpi FORM LENGTH 11 12 Selects the maximum form length expressed in inches BOTTOM MARGIN IBM PP LIKE Selects the form s bottom margin N The Bottom of Form value is 4 23 mm Y The Bottom of Form value is 13 7 mm 4 6 Y100250 4 MARGIN IBM PP LIKE PNS SELECTION N Y Selects the form s top margin TOF N The Top Of Form value will be included between 4 23 mm defined by the adjustment for documents and 7 4 mm per savings books Y The Top Of Form value will be 4 23 mm for documents and 7 4 for passbooks Selecting Y grants access to the PNS selection menu in the IBM environment when PNS SELECTION Y PNS 4192 5 4501 SAVE PARAMETERS Y N If enabled upon reception of a Form Feed command the document is expelled regardless of the form length selected Selects a 1 5 spacing value Stores o
84. the Front Feed Slot 3 7 6 2 PAPER JAMS INSIDE THE PRINTER Proceed as follows to remove a document from inside the printer Open the cover without powering off the machine Lift the upper mechanical assy by using the upper mechanical assy lifting lever Remove the jammed document by carefully pulling it from the printer Fig 3 22 Removing a Document from Inside the Printer Y100250 4 Service Manual 3 21 If pieces of paper jammed in unaccessible areas inside the machine proceed as follows to remove them 1 Open the cover and power on the printer while pressing the STATION 1 EJECT button 2 Wait for an audible signal to sound 3 Press STATION 1 EJECT and or STATION 2 EJECT to move the paper forward backward so that the jam can be cleared 4 Power off the machine and close the cover before powering it back on again 3 7 6 3 PAPER JAMS AT THE REAR OUTPUT SLOT remove a document from the rear output slot without opening the cover carefully pull the document outward trying not to tear it Fig 3 23 Removing a Document from the Rear Output Slot 3 22 100250 4 4 AUTODIAGNOSTICS SETUP AND ADJUSTMENTS 4 1 POWER ON DIAGNOSTICS At power on besides a general reset the printer runs an autodiagnostic routine that checks the efficiency of all machine components Upon the successful completion of the autodiagnostic routine the printer switches to the READY state ON and READY LEDs lit
85. the same savings books measured must be used Proceed as follows to make this calibration 1 Power on the printer with its cover open and while holding down the three buttons on the console 2 Wait for the audible signal indicating that the printer has switched into the calibration and adjustment mode 3 Press the Local button and wait for the completion of machine reset 4 Insert an A4 sheet of paper into the front insertion slot and then press Station 1 The sheet will be inserted and expelled automatically 5 If necessary repeat step 5 6 Press Local twice to permanently store the form length value measured and to automatically switch to the next calibration Y100250 4 Service Manual 4 27 4 4 6 SKEW AND SIGNAL AMPLITUDE CONTROL This check mustbe performed with the machine completely assembled and after having configured and specified during set up the magnetic device installed on the printer The signal source must be exclusively the following card AMPLITUDE AND SKEW SAMPLE code 713483R for horizontal magnetic unit SKEW JITTER Fig 4 2 Using an oscilloscope with memory proceed as follows Insert the Amplitude and Skew Sample chart code 7518847 into the front feed slot from the Skew Control side Record the signal read when the printhead moves from right to left The signal recorded must not have a spread greater than 0 4V No action is required Insert the Amplitude and Skew Sample chart
86. tions LOCAL BREAK Toggles the printer between the on line and off line states STATION 1 EJECT Assigns the printer to operator 1 SW monitored button STATION 2 EJECT Assigns the printer to operator 2 SW monitored button Pressing the STATION 2 EJECT button while powering on the printer prints the self test 2 3 2 LED INDICATIONS When on the LEDs inform of the following machine states ON Green LED indicates that the machine is powered on READY Yellow LED indicates that the printer is on line and that a document is present LOCAL Yellow LED indicates that the printer is off line STATION 1 Yellow LED indicates that the printer is assigned to operator 1 STATION 2 Yellow LED indicates that the printer is assigned to operator 2 Since the buttons and LEDs are managed via SW their functions and usage may vary according to the application SW being used 2 6 Y100250 4 2 4 BUTTON AND LED FUNCTIONS THE 4915 4904 EMULATION This section describes the button functions and LED indications of the PR2 E printer when in the SNI 4915 4904 emulation 2 4 1 BUTTON FUNCTIONS The buttons have the following functions LOCAL BREAK Toggles the printer between the on line and off line states STATION 1 EJECT Assigns the printer to operator 1 and ejects the document of operator 1 STATION 2 EJECT Assigns the printer to operator 2 and ejects the document of operator 2 Pressing the STATION 2 EJECT button while powering on t
87. tions if necessary Reassembly must be performed by following the disassembly procedures in reverse order Before disconnecting the cables make sure to take note of their connections for reassembly After servicing lubricate where specified When replacing the main board update the firmware to the latest release section 1 9 1 run the installation set up Chapter 4 and then perform the electromechanical adjustments from the console Chapter 4 When replacing the power supply assembly make sure that the line voltage rating of the replacement module corresponds to the value indicated on the printer s electrical data plate Atthe end of the service call run an overall check on the printer to make sure that all failures are corrected 9 2 Y100250 4 9 2 DISASSEMBLY REASSEMBLY OF THE BASIC MACHINE 9 2 1 CASE DISASSEMBLY REASSEMBLY Open the printer s top cover Removethe two securing screws 1 from the front ofthe case 2 Remove this front part ofthe case from the machine by pulling it in the direction of the arrows in the figure below Using a flat blade screwdriver release the case s two front snap features 3 Insert a pointed object in the holes at the rear right and left sides of the case and then release the two rear snap features 4 partly lift the case off the base Release the console from the case by pressing gently in the points indicated by the arrows in the figure below and lifting it upward Pas
88. to the left hand side of the frame and remove the motor from the machine Fig 9 14 Y100250 4 Service Manual 9 15 9 2 13 FEEDER PHOTOSENSORS DISASSEMBLY REASSEMBLY Remove the mechanical assembly 9 2 3 Remove the upper part of the mechanical assembly 9 2 7 Remove the roller shield after remov ing its M3 securing screws 1 Fig 9 15 Unhook the two springs 2 straighten the document stop bar slide proof fins 3 and then slide the stop bar from its guideways 3 9 16 Y100250 4 Remove bushing 4 from alignment pressure roller shaft 5 and then remove the entire assembly 6 Fig 9 17 Remove the six screws 7 that secure the conveyor assembly 8 Fig 9 18 Y100250 4 Service Manual 9 17 Remove the two screws 9 that secure photosensor support 10 and then remove support Fig 9 19 Note When refitting the conveyor assy make sure that you refit the related bushing before refitting the pressure roller assy During reassembly do not secure the photosensor support until the conveyor assy is properly fitted since the conveyor assy has two reference pins for the photosensor support After reassembly adjust the tab section 8 4 the front pressure rollers section 8 7 the opening of the tab section 8 8 and then calibrate the photosensors section 4 4 1 9 18 Y100250 4 9 2 14 PRINT DISASSEMBLY REASSEMBLY Remove the printer case

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