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pr2 e
pr2 e
PR2 E
SERVICE MANUAL
Code Y100250-4
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.
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.
2.3 BUTTON AND LED FUNCTIONS IN THE IBM 9068 (4722) EMULATION........ 6
2.3.1 BUTTON FUNCTIONS ..................................................................................... 6
2.3.2 LED INDICATIONS ........................................................................................... 6
3. INSTALLATION ......................................................................................... 1
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7.1 CLEANING......................................................................................................... 1
7.1.1 CLEANING THE CASE .................................................................................... 1
7.1.2 CLEANING THE PAPER PATHS ...................................................................... 1
7.1.3 CLEANING THE MAGNETIC READ HEAD ..................................................... 1
7.2 MAINTENANCE ................................................................................................. 2
7.3 LUBRICATION ................................................................................................... 3
7.3.1 LUBRICATION POINTS ON THE BASIC MACHINE ........................................ 3
7.3.2 HORIZONTAL MAGNETIC DEVICE/MICR LUBRICATION POINTS ............... 4
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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 code 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 VAC + 10% 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.
Magnetic Device
Serial/Parallel
Serial Interface
Double Serial
MICR Reader
Horizontal
Interface
Interface
Commercial Name
PR2 E S10 X
PR2 E D10 X
PR2 E D12 X X
PR2 E D12 M X X
PR2 E S12 X X
PR2 E S12 M X X
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CONSOLE Located on the printer cover, it has three buttons and five LEDs
EMULATIONS PR40+, PR2 E and IBM PP II, X24, SNI 4915, IBM 9068
INTERFACE Standard RS 232C serial with the possibility of installing the following
interface cards:
- RS 232C serial + USB
- Centronics parallel.
The Horizontal magnetic device/MICR (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: In this 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.
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Minimum width 65 mm
Minimum length 70 mm
Maximum printable copies 1+5 with average paper weight and in the NLQ/LQ print mode
with chemical paper
Maximum printable copies 1+4 with average paper weight and in the NLQ/LQ print mode
with carbon paper
Maximum weight of
multicopy forms 320 g/m 2
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Book preparation Must be carefully flattened before being inserted into the machine
Minimum length 85 mm
This section describes the accessories available for the PR2 E printer.
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 if the printer is powered on or manual positioning if powered off, and lifting the print assembly
by using the appropriate lever.
The same as the BLACK NYLON SNUG CART but with indelible ink.
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COVER
CONSOLE
POWER SWITCH
CONNETTORE
CAVO RETE
PRINTHEAD
SERVICES MOTOR
CARRIAGE TRANSPORT MOTOR
MAIN BOARD
CONSOLE
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POWER SWITCH/
POWER CORD
POWER SUPPLY UNIT
BASIC MACHINE
USB
INTERFACE
SERIAL
INTERFACE
PARALLEL
INTERFACE
ROLLERS
MOTOR
CONSOLE
TRANSPORT PR2 E
MOTOR MAIN BOARD
PRINTHEAD
AUTOBORDER
PHOTOSENSOR
FRONT PAPER
DETECTION
PHOTOSENSOR
CARRIAGE RESET
PHOTOSENSOR
SERVICES
MOTOR
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.
• Olivetti environment: STD 12/14 controlled protocol with the PR2 E native environment, PR40+ and
PR2845 emulation. IBM Proprinter II and Proprinter X24 industry-standard emulation.
• IBM environment: 9068 protocol emulation covering also the model 4722. IBM Proprinter II and
Proprinter X24 industry-standard emulation.
• Wincor-Nixdof environment: SNI 4915 protocol emulation covering also the models 4905. EPSON
LQ 2550 industry-standard emulation.
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Compatibility at system level for each character set is extended to the environments listed below:
OLIVETTI STD 15
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:
The following table indicates the characteristics of the different print modes:
- H.S.D. (High Speed Draft) 350 cps 314 cps 327 cps
- N.L.Q. (Near Letter Quality) 130 cps 130 cps 130 cps
The reference standards for the optical characters are the following:
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• power switch
• console buttons
CONSOLE
BUTTONS
UPPER MECHANICAL
ASSEMBLY LIFTING LEVER POWER SWITCH
The printer is equipped with a two-pole power switch. The switch on/off command is provided by means
of a rod that crosses the printer longitudinally.
2.2 CONSOLE
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.
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LOCAL/BREAK: Toggles the printer between the on-line and off-line states
EJECT (ST. 1): Ejects the paper of operator 1 or ejects the paper present (*)
The following table provides the meaning of the console buttons in both cases.
X Print test
X X Set-up
STATION 1: When on: Waiting for a document from operator 1 (Oliveti STD 12/14) or machine
assigned to operator 1 or document present (*)
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
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.
(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.
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On-board failure:
- Eprom ON OFF OFF OFF OFF
- ROM
- Microprocessor
This section describes the button functions and LED indications of the PR2 E printer when in the IBM
4722 emulation.
LOCAL/BREAK Toggles the printer between the on-line and off-line states.
Pressing the STATION 2/EJECT button while powering on the printer prints the self-test.
READY Yellow LED, indicates that the printer is on-line and that a document is present.
Since the buttons and LEDs are managed via SW, their functions and usage may vary according to the
application SW being used.
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This section describes the button functions and LED indications of the PR2 E printer when in the SNI
4915 (4904) emulation.
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 the printer prints the self-test.
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.
This section describes the button functions and LED indications of the PR2 E printer when in the IBM
Proprinter II/X24, EPSON LQ 2550 emulation.
LOCAL/BREAK Toggles the printer between the on-line and off-line states
Pressing the STATION 2/EJECT button while powering on the printer prints the self-test.
STATION 1 Yellow LED; when flashing indicates that data are present in the buffer, when on
indicates that a document is present.
STATION 2 No indication.
A specific console different than the one used on the standard product is available for this PR2 E
version.
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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.
Pushing this lever as far as it goes lifts the upper part of the mechanical assembly thus granting you
access to the paper path.
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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.
Make sure that the electrical wall outlet to which the printer is connected has a valid ground and that
it is 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.
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 0C, relative humidity of 15/85%).
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.
Do not position the machine near air conditioning systems, heat sources or in direct sunlight.
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.
- PR2 E printer
- Power cord
- Operator Manual
- Ribbon cartridge
- Magnetic head cleaning card (not shown in the figure below) for models equipped with this option.
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- 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).
- Quickly check that the printer was not damaged during transportation.
Position the machine for operation, making sure that 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".
A print test can be run to make sure that the printer works correctly before actually connecting it to the
system.
- 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.
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- The release and version of the firmware and character generators installed
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.
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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 printer:
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.
Attach the serial cable to the interface located on the rear of the printer.
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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.
CONNECTOR J1 FOR
CONNECTION TO THE
MAIN BOARD
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 > 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 TAS01
9 TERRSE
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
of the 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.
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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 of the printer. It is suggested to use an interface
cable up to 1.5 meters long. The ECP data exchange protocol is used.
CENTRONICS
INTERFACE
CONNECTOR J1 FOR
CONNECTION TO
THE MAIN BOARD
STROBE 01 19 GROUND
DATA 0 02 20 GROUND
DATA 1 03 21 GROUND
DATA 2 04 22 GROUND
DATA 3 05 23 GROUND
DATA 4 06 24 GROUND
DATA 5 07 25 GROUND
DATA 6 08 26 GROUND
DATA 7 09 27 GROUND
ACKNOWLEDGE 10 28 GROUND
BUSY 11 29 GROUND
PAPER EMPTY 12 30 GROUND
ON LINE 13 31 INIT.
AUTOFEED XT 14 32 ERROR
NC 15 33 LOGIC GROUND
LOGIC GROUND 16 34 NC
FRAME GROUND 17 35 +5 V (PULL-UP; 3.3K ohm)
+5 V 18 36 INPUT / SELECT IN
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 a signal is received by any one of the two interfaces, the printer switches 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
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 of the reset routine, close the printer cover and insert an A4 sheet of paper (for the 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.
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 messages 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).
- 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.
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.
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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.
On the front of the machine cover there is a reference stripe to be used when inserting checks.
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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:
- are less than 100 mm long, they will be released from the feed rollers
- are 100 mm long or longer, they will remain gripped by the last set of rollers to avoid that the document
tails off the front shelf.
The ribbon cartridge must be changed when printing is incomplete 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
- 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.
3-18 Y100250-4
- Turn the carriage knob counterclockwise (2) until the ribbon is taut and then remove tab (3).
- Using the specific lever, completely lower the upper part of the mechanical assembly containing the
printhead and ribbon cartridge.
- Close the printer cover.
- Power on the machine.
The ribbon cartridge can be changed with the machine powered on and by following the procedure listed
below:
- Remove the used cartridge and replace it with a new one as previously described.
The paper could jam along its path inside the machine.
- Paper skew
- Stapled paper or with paper clips (this can seriously damage the machine)
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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 the Front Feed Slot
- Lift the upper mechanical assy by using the upper mechanical assy lifting lever.
1) Open the cover and power on the printer while pressing the STATION 1/EJECT button.
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.
To remove a document from the rear output slot, without opening the cover carefully pull the document
outward trying not to tear it.
3-22 Y100250-4 .
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).
The table below indicates the meaning of the LEDs according to the type of failure detected during the
autodiagnostic phase.
On-board failure:
- Eprom ON OFF OFF OFF OFF
- ROM
- Microprocessor
Failure with:
- Fuses ON ON ON ON ON
- Drivers
- Motors
Activation board
The motors do not perform any kind of movement
failure
The instructions to run this test are given in section 3.3, Off-line Testing.
The Set-up environment should only be accessed by the service engineer and programmer since some
of the 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.
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 different ways in which the various set-up
environments can be accessed.
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
4-2 Y100250-4
This section provides the description and possible values of the printer's different set-up parameters.
DRAFT SPEED: NORMAL - HIGH Determines the Draft mode that can
activated via SW and by default.
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(when) X24
AGM: N – Y Enables/disables the AGM function.
(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 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.
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.
BOTTOM MARGIN IBM-PP LIKE: N - Y Selects the form's bottom margin (BOF).
N - The Bottom of Form value is 4.23 mm.
Y - The Bottom of Form value is 13.7 mm.
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(when) PR40+
LINE BUFFER PR40 LIKE: N - Y Sets the reception buffer length like the PR40
(1K byte) or to 8 K byte.
TOP MARGIN PR40 LIKE: N - Y TOF management with fixed (PR40) or
adjustable mechanical header.
(when) PR2E
PASSBOOK: N - Y Enables the printer to handle savings books.
(when) Passbook Y
(when) IBM CHAR SET: PC - ISO IBM emulation PC or ISO character sets
regardless of the selection made.
4-8 Y100250-4
4-10 Y100250-4
DISPLACEMENT: STANDARD +10 +20 Defines the position of the magnetic stripe.
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.
LINE BUFFER PR2845 LIKE: N - Y Defines the reception buffer length like the
2845 (512 Bytes) or to 8 Kbytes.
NATION: INT
USA
D
P
E
E2
DK/N
F
I
S/SF
CH
UK
YU
IL
GR
CND
STD 31
SDC
TR
IS
4-12 Y100250-4
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.
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:
- 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
ACOUSTIC SIGNAL
AND LEDS ON
ST 1 ST 2
READ PHOTOSENSOR BUTTON
VALUES WITHOUT PAPER
LED ST2 ON
YES
4-16 Y100250-4
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 to the calibration and adjustment
procedures.
3. Manually position the printhead towards the left-hand side and then close the cover.
5. Upon the completion of this phase, the sensors have stored the electrical current ratings with the
printer in an out of paper condition.
6. Insert a sheet of 60 gr/m2 paper, in the landscape position, into the front insertion slot. During this
phase the motor continues to turn forcing the paper against the brush.
7. 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.
1 2
Parameters to be checked
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
Printing photosensor calibration values iis useful as reference between one calibration and the next.
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 to sound indicating that the printer has switched to the calibration and
adjustment phase, then close the printer cover.
6. The sheet is inserted, printed and automatically expelled. The printer automatically switches to the
next calibration phase.
COVER OPEN
ST1, LOCAL, ST2 PRESSED
WHILE POWERING ON THE
PRINTER
ST 1 ST 2
LEDS ST1 AND BUTTON
ST2 ON
ST 1 ST 2
BUTTON ALL LEDS ON
INSERT AN A4 SHEET
OF PAPER
YES
ALIGNMENT
OK
NO
ST 1 ST 2
MOVES THE MOVES THE
LEFT MARGIN BUTTON LEFT MARGIN
TO THE LEFT TO THE RIGHT
YES
PARAMETERS STORED CALIBRATION
ENDS
NO
4-20 Y100250-4
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.
1. Power on the printer with its cover open and while holding down the three console buttons.
2. Wait for the audible signal indicating that the printer has switched to the calibration mode and then
close the printer cover.
3. Press the Station 1 button.
4. Press the Station 2 button.
5. The three console buttons are now active. The "Station 1" button activates printing ahead of time
while "Station 2" delays printing.
6. 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.
7. Insert an A4 sheet of paper into the front feed slot to check the print alignment status.
8. Press "Station 1" and/or "Station 2" to calibrate the alignments.
9. Repeat steps 7 and 8 cyclically until the calibrations are completed.
10. Press the "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 all the print modes are completed or by simultaneously pressing all three console
buttons. In both cases the printer will switch to the main menu.
COVER OPEN
ST1, LOCAL, ST2 BUTTONS
PRESSED WHILE POWERING
ON THE PRINTER
AUDIBLE SIGNAL,
LEDS ON
ST 1 ST 2
BUTTON
LOCAL
ST 1 ST 2
BUTTON
INSERT AN A4 SHEET OF
PAPER
ST 1 ST 2 MOVES THE
MOVES THE TOF
BUTTON
TOF UPWARD DOWNWARD
LOCAL
TOP OF FORM OK
PARAMETERS STORED
4-22 Y100250-4
The adjustment can only be activated if the "TOP MARGIN PR40 LIKE" parameter in the PR40+
emulation setup was set to "N".
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. Press the 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 off the 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 "Local" twice to permanently store the TOF and to automatically move on to the next
calibration.
COVER OPEN
ST1, LOCAL, ST2 BUTTONS
PRESSED WHILE POWERING
ON THE MACHINE
AUDIBLE SIGNALS
LEDS ON
ST 2
ST1 LED ON
ST 1
LOCAL LED ON
THE DOCUMENT IS
MEASURED AND EXPELLED
ST1 LED ON
PRESS ST1
DOCUMENT LENGTH
IS STORED
4-24 Y100250-4
The left margin value will always be used, without the need for set-up configurations.
1. Power on the printer with its cover open and while holding down the three buttons on the console.
2. Wait for an audible signal to indicate that the printer has switched to the calibration and adjustment
mode.
3. Press Local and wait for the machine to complete its reset.
4. Press Station 2.
5. Press the Station 1 button until hearing a prolonged dual-tone signal (different from the previous).
6. Insert an A4 sheet of paper and wait for the printed page. Check that the left margin has the required
measurement.
7. The minimum distance between the left edge of the document 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.
9. 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)
COVER OPEN
ST1, LOCAL, BUTTONS
PRESSED WHILE POWERING
ON THE MACHINE
AUDIBLE SIGNAL
LEDS ON
LOCAL
ST1 LED ON
LOCAL
LOCAL LED ON
THE DOCUMENT IS
MEASURED AND EXPELLED
ST1 LED ON
PRESS LOCAL
DOCUMENT LENGTH
VALUE IS STORED
4-26 Y100250-4
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.
This check must be performed with the machine completely assembled and after having configured and
specified, during set-up, the magnetic device installed on the printer.
- AMPLITUDE AND SKEW SAMPLE code 713483R for horizontal magnetic unit.
Fig. 4-2
- Insert the "Amplitude and Skew Sample" chart code 751884Z 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 code 751884Z into the front feed slot from the Jitter/
Ampl. side. Record the signal read when the printhead moves from right to left. If the signal recorded
does not reach the value of 4V, replace the printhead.
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 of the signal read which must be 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
The following pages provide a technical approach to servicing that could be useful to less experienced
field engineers.
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.
WORK ENVIRONMENT
An environment that is too cold, hot or humid could be the cause of certain malfunctions.
The 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.
Make sure that the accessories installed in the machine are originals and in good condition.
Check that the documents inserted in the printer comply with the machine specifications and are in good
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.
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.
At times a malfunction is generated by more than one cause: it is important in such cases to isolate the
faults and deal with them one at a time.
Using experience togethe with the information given in this section 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.
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
To make the search easier, the faults have been classified as follows:
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.
Autogiagnostics indicate a
mechanical failure
main board failure
FAULT
power on
POSSIBLE CAUSE
5-4 Y100250-4
Incomplete printing
Unaligned printing
FAILURE
irregular spacing
Stained printing
Faided printing
POSSIBLE CAUSE
crookedly
line feeds
POSSIBLE CAUSE
5-6 Y100250-4
read/write errors
POSSIBLE CAUSE
Incorrect set-up X
Ruined savings book X
Incorrect savings book insertion X
Dirty magnetic head X
Faulty magnetic head X
Faulty paper feed motor X
Faulty magnetic device card X
Faulty main board X
Faulty magnetic head movement motor X
TO LINE VOLTAGE
ALIPR2E TRANSFORMER
CARD
J10
J3
CONSOLE
TRANSPORT J9
MOTOR
J15
PRINTHEAD AND
PAPER J16
PHOTOSENSOR BAPR2E
OPTIONS J12 MAIN
INTERFACE
BOARD
J11
OPTIONS
INTERFACE
J14 J1
J1
MAGNETIC
ROLLER MOTOR OPTIONS
J4 CARD
CARRIAGE RESET
PHOTOSENSOR
PAPER FEED J2
MOTOR
FRONT J5
PHOTOSENSORS
The BAPR2 main board has an onboard serial interface. The printer can be configured with one of the
following two interface cards:
J18
J16
J15
J7
J10 J9
J4
J1
J5 J3 J2
6-2 Y100250-4
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 J10
(RS 232 INTERFACE) (CONSOLE) (POWER SUPPLY)
J9 J15 J16
(TRANSPORT MOTOR) (PRINTHEAD CONNECTOR) (PRINTHEAD CONNECTOR)
1 FASEA
1 TESTE 1 R0818
2 FASEB 2 LEBCA 2 SPL(8)
3 FASEC 3 FOBCA 3 R1016
4 FASED 4 VCCTES 4 SPL(10)
5 R0224 5 R1214
6 SPL(2) 6 SPL(14)
7 R0422 7 R0818
8 SPL(4) 8 SPL(18)
9 R0620 9 R1016
10 SPL(6) 10 SPL(16)
11 R1214 11 R0915
12 SPL(12) 12 SPL(15)
13 R0717 13 R0915
14 SPL(17) 14 SPL(9)
15 R1113 15 R0717
16 SPL(13) 16 SPL(7)
17 R1113 17 R0321
18 SPL(11) 18 SPL(3)
19 R0519 19 R0123
20 SPL(5) 20 SPL(1)
21 R0422 21 R0620
22 SPL(22) 22 SPL(20)
23 R0123 23 R0224
24 SPL(23) 24 SPL(24)
25 R0519 25 R0321
26 SPL(19) 26 SPL(21)
J12 J6 J99
(OPTIONS) (OPTIONS) (FRONT PHOTOSENSORS)
J11 J1
(OPTIONS) (INTERFACE)
6-4 Y100250-4
The following magnetic options card can be installed on the BAPR2 main board:
The option installed is controlled by the FW according to the parameters defined during machine setup.
J6
J2
J1
J5
J4
J3
6-6 Y100250-4
J1 J2
(CONNECTION TO THE MAIN BOARD) (CONNECTION TO THE MAIN BOARD)
1 MAC21 1 VCC
2 MAC20 2 DAWRM
3 MAC11 3 DACOM
4 MAC10 4 FAZMA
5 MAPH2 5 GND
6 MAPH1 6 VERMA
7 PIU35 7 RESE0
8 PIU35 8 F2FDA
9 GND 9 PIU12
10 GND 10 GND
J3 J4 J5
(MAGNETIC DEVICE MOTOR) (MAGNETIC RESET PHOTO.) (MAGNETIC HEAD)
J6
(CALIBRATIONS)
1 OUT1
2 GND
The installation of this interface card provides the printer with an additional serial RS232 and USB
interface.
J3 J2
J1
6-8 Y100250-4
J2 J2
(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 TAS01
9 TERRSE
J1
(INTERFACE)
AD (15) 32 1 GND
AD (13) 33 2 AD (14)
AD (11) 34 3 AD (10)
AD (9) 35 4 AD (12)
AD (7) 36 5 AD (8)
AD (5) 37 6 AD (6)
AD (3) 38 7 AD (4)
AD (1) 39 8 AD (2)
DA (7) 40 9 AD (0)
DA (5) 41 10 DA (6)
DA (3) 42 11 DA (4)
DA (1) 43 12 DA (2)
ASTB0 44 13 DA (0)
WRITE 45 14 WAITO
INTCX 46 15 READO
RDOSP 47 16 CKMOT
CSEXP 48 17 WROSP
GPI00T 49 18
STROB 50 19 BUSY1
DACX (7) 51 20 ACK00
DACX (5) 52 21 DACX (6)
DACX (3) 53 22 DACX (4)
DACX (1) 54 23 DACX (2)
IMPRA 55 24 RESUSB
ESTR2 56 25 SELRSUS
ESTR1 57 26 SUSPUSB
GND 58 27 PESTR
VCC 59 28 RESEO
VCC 60 29 MEN12
GND 61 30 PIU12
PIU35 62 31 GND
The installation of this interface card provides the printer with a Centronics parallel interface.
J2
J1
6-10 Y100250-4
J2 J1
(PARALLEL INTERFACE) (MAIN BOARD INTERFACE)
AD (15) 32 1 GND
19 GND AD (13) 33 2 AD (14)
STROBX 1 20 GND AD (11) 34 3 AD (10)
DACXX(0) 2 21 GND AD (9) 35 4 AD (12)
DACXX(1) 3 22 GND AD (7) 36 5 AD (8)
DACXX(2) 4 23 GND AD (5) 37 6 AD (6)
DACXX(3) 5 24 GND AD (3) 38 7 AD (4)
DACXX(4) 6 25 GND AD (1) 39 8 AD (2)
DACXX(5) 7 26 GND DA (7) 40 9 AD (0)
DACXX(6) 8 27 GND DA (5) 41 10 DA (6)
DACXX(7) 9 28 GND DA (3) 42 11 DA (4)
ACKX 10 29 GND DA (1) 43 12 DA (2)
BUSYX 11 30 GND ASTB0 44 13 DA (0)
PAPEMP 12 31 IMPRAX WRITE 45 14 WAITO
SELOUT 13 32 FAULTCX INTCX 46 15 READO
AUTOLF 14 33 GND RDOSP 47 16 CKMOT
- 15 34 - CSEXP 48 17 WROSP
GND 16 35 TIR00 GPI00T 49 18
TERRCX 17 36 SELINP STROB 50 19 BUSY1
VCC 18 37 TERRCX DACX (7) 51 20 ACK00
38 GND DACX (5) 52 21 DACX (6)
DACX (3) 53 22 DACX (4)
DACX (1) 54 23 DACX (2)
IMPRA 55 24 RESUSB
ESTR2 56 25 SELRSUS
ESTR1 57 26 SUSPUSB
GND 58 27 PESTR
VCC 59 28 RESEO
VCC 60 29 MEN12
GND 61 30 PIU12
PIU35 62 31 GND
YELLOW LED 5
YELLOW LED 4
YELLOW LED 3
YELLOW LED 2
GREEN LED 1
BUTTON 3
BUTTON 2
BUTTON 1
6-12 Y100250-4
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.
J1
J1
F1
F1
S1
S1
J2
J2
J1 J2
(EXTERNAL POWER SUPPLY) (MAIN BOARD POWER SUPPLY)
1 VAC
1 ROUT
2 GND
3 VAC 2 -12V
3 +12V
4 +5V
5 GND
F1 Fuse: 250V 3.15A 6 GND
7 GND
8 35V
9 35V
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.
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.
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.
Clean using the specific card (code 751498E) provided with the machines equipped with the horizontal
magnetic + MICR device.
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.
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.
Insert the cleaning card in the 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.
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 life 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
Although machine lubrication is not scheduled throughout its entire life span, during each service call
you are expected to check the lubrication of the differnet parts by referring to the lubrication points table
indicated below.
7-4 Y100250-4
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.
- Notes. Indicates any reference to adjustment sequences or to tests to be performed once the
adjustment is made.
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.
P=200 g +10 g
2.9 + 0.2 mm
1
2
Fig. 8-1
8-2 Y100250-4
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 shield (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
0,4/0,5
1 2
Fig. 8-2
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 displacement 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
5 4
Fig. 8-3
8-4 Y100250-4
MACHINE CONDITION:
The upper mechanical assembly must be raised.
OBJECTIVE ADJUSTMENT:
Tab (1) 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
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.
8-11
Fig. 8-5
8-6 Y100250-4
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.
0,2
< 0.2
Post-adjustment
clearance
Fig. 8-6
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.
2 3
0,5
4
5
Fig. 8-7
Note: The adjustment value can vary for certain non-standard products.
8-8 Y100250-4
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.
2
2
1
1
4
5-8
1,5 PRINTHEAD
CARRIAGE
Fig. 8-8
Note: This adjustment must be performed after the platen and tab adjustments.
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 that a 5 mm sag is 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.
P = 60 gr
f = 5 mm
1
2
Fig. 8-9
8-10 Y100250-4
MACHINE CONDITION:
Read/write 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:
Fit the door (2) against the slot (3), working in the area between the leaf spring and the semi-tie rod tooth
(4); tighten the screw.
1 4 3
ADJUSTMENT
AREA
Fig. 8-10
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".
A
2
1
0.5-1
Fig. 8-11
8-12 Y100250-4
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).
Push 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.
2
1
3
Fig. 8-12
For easier consultation, the disassembly procedures have been divided as follows:
- Notes: recall adjustments that need to be made after reassembly, precautions or warnings to
be observed.
- To ensure maximum safety, before starting any disassembly operation power off the printer
and unplug its power cord from the electrical outlet.
- 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 conditions if necessary.
- Before disconnecting the cables make sure to take note of their connections for reassembly.
- 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.
- At the end of the service call, run an overall check on the printer to make sure that all failures
are corrected.
9-2 Y100250-4
3 2
Fig. 9-1
Note: During the reassembly of the case, secure the console flat cable with the guide tabs (5) located
at the rear of the console panel.
Fig. 9-2
9-4 Y100250-4
- Remove the printer case (section 9.2.1) and console (section 9.2.2).
- Lift the 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 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 assembly is released.
- Remove screw (2) that secures the ground wires.
- Lift the entire mechanical assembly from the base of the printer.
Fig. 9-3
6 5
Fig. 9-4
9-6 Y100250-4
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 that the 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.
Fig. 9-6
9-8 Y100250-4
Fig. 9-7
Note: The printhead photosensor must be calibrated whenever the printhead is replaced.
- Remove the printer case (section 9.2.1) and console (section 9.2.2).
- Lift the 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 as to detach the upper part of the mechanical assembly.
Fig. 9-8
Note: During reassembly, 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
Fig. 9-9
Note: After reassembly, adjust the tension of the document feed belt (section 8.6).
Fig. 9-10
Note: After reassembly, correctly reposition ground spring (4) and then adjust the carriage feed belt
(section 8.9).
9-12 Y100250-4
- Remove the printer case (section 9.2.1) and console (section 9.2.2).
- Lift the 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 carriage reset photosensor cable from the main board and then release it from its plastic
retaining clips.
- Cut the cable clips (1) and remove the photosensor by unscrewing screw (2).
Fig. 9-11
- 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
2 3
Fig. 9-13
Note: During reassembly, make sure to correctly reposition the transmission joint and soundproofing
before tightening the screws.
9-14 Y100250-4
Fig. 9-14
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.
Fig. 9-16
9-16 Y100250-4
4
6
Fig. 9-17
- Remove the six screws (7) that secure the conveyor assembly (8).
Fig. 9-18
10
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
Fig. 9-20
Note: After reassembly, adjust the distance between the printhead and print bar (section 8.2).
- 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.
4 5
2
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
(paragrafo 4.4).
9-20 Y100250-4
Note: If the fuse inside the power supply has blown, replace the entire power supply assy since some
components on the power supply board may be damaged.
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.
Fig. 9-23
Note: When refitting the assembly, adjust its position on the frame (section 8.12).
9-22 Y100250-4
Fig. 9-24
2 3 2
Fig. 9-25
9-24 Y100250-4