CPG Compuprint SP 40 User manual

MAINTENANCE
MANUAL
SP 40

Maintenance Manual SP 40
Rev. 005 i.1Index
TABLE OF CONTENTS
Page
Preface 1
Chapter 1 General Information
1.1 Overview 3
1.2 Scope of the Product 3
1.3 Main Features 3
1.4 Printer Parts 4
1.5 Product Structure 6
1.5.1 Mechanism and Electromechanical devices 6
1.5.2 Electronics 7
1.6 Technical Specifications 10
1.7 Maintaining Parameters 12
Chapter 2 Removals
2.1 Overview 13
2.2 Covers 14
2.2.1 Top Cover 14
2.2.2 Main Cover 14
2.3 Print Head 16
2.4 Mechanical Assy 18
2.5 Electronic Boards 19
2.5.1 Optional (LAN or USB) and Backpanel Boards 19
2.5.2 Engine Board 19
2.5.3 Controller Board 20
2.5.4 Power Supply Assy 20
2.6 Operator Panel 23
2.7 Motors Assy 24
2.7.1 Carriage Motor Assy 24
2.7.2 Carriage Pulley 24
2.7.3 Selector Motor Assy 26
2.7.4 Paper Motor Assy 26
2.8 Home Sensor Assy 28
2.9 Ribbon Sensor Assy 29
2.10 Ribbon Drive Assy 30
2.11 Carriage Assy 32
2.12 Mylar Bar Assy 34
2.13 Rear Roller Assy 36
2.14 Front Roller Assy 38
2.15 Selector Cam 40
2.16 Lower Roller Assy (Rear Side) 42
2.17 Lower Roller Assy (Front Side) 43
2.18 Sensor Board and Sensor Cable 44
2.19 Platen Assy 46
2.20 Print Head Cables 48

Maintenance Manual SP 40
Rev. 005 i.2Index
TABLE OF CONTENTS cont’d
Page
Chapter 3 Operability and Configuration
3.1 Overview 49
3.2 Operability 49
3.2.1 Operator Panel 49
3.2.2 Function keys 50
3.2.3 Leds 50
3.3 Printer Set-up Mode by Operator Panel 51
3.3.1 Print of Self Test Page 52
3.3.2 Printer Configuration 53
3.3.2.1 Print of the Setup Forms 53
3.3.2.2 Filling in the Printer Setup Forms 54
3.3.2.3 Reading the Preprinted Forms 54
3.3.2.4 Setup Forms and Parameters 55
3.3.2.5 Offset Adjustments 61
3.4 Printer Set-Up Mode by Web Browser (NIC card) 63
3.5 Printer Set-Up Mode through the application SP40setup (via serial i/F) 68
3.5.1 Entering the printer Setup Mode 68
3.5.2 Install the SP40setup application 68
3.5.3 Run the SP40setup application 70
3.5.4 How to download to SP40 an existing configuration file 73
3.6 Print of NIC Configuration Page 74
Chapter 4 Service Maintenance
4.1 Overview 75
4.2 Initial Inspection and tools 75
4.3 Set-up 75
4.4 Cleaning 75
4.5 Lubrication 76
4.6 Paper Specifications 76
4.7 Consumables 76
4.8 Software Update 77
4.8.1 Basic Software update through parallel or serial interface 77
4.8.2 NIC Software update through parallel or serial interface 78
4.8.3 LAN Parameters Setup through parallel interface 79
4.8.4 Software update through LAN interface 80
4.8.4.1 Software update through LAN using FTP 80
4.9 Troubleshooting 81
4.9.1 Hexadecimal Dump 81
4.9.2 Printer Errors 81
4.9.2.1 Recoverable errors 81
4.9.2.2 Unrecoverable errors 82
4.10 Troubleshooting Tables 84
4.10.1 Power malfunction 84
4.10.2 Faulty probability guide 85
4.11 Reset the Consumable Parts 86

Maintenance Manual SP 40
Rev. 005 i.3Index
TABLE OF CONTENTS cont’d
Page
Chapter 5 Test & Diagnostic
5.1 Overview 87
5.2 How to run T&D (with Standard Operator Panel) 87
5.3 General Rules for T&D Operations 87
5.4 T&D USER Tests Description 89
5.5 Step by Step T&D Mode Flow Chart 90
5.6 Step by Step T&D Mode Sequential Table 91
5.7 T&D Errors Handling 96
5.7.1 Led Meaning during T&D Error Condition 97
5.8 T&D Errors Codes 100
5.9 Requested Tools 102
5.9.1 Operator Panel with LCD 102
5.9.2 RS232 Serial Interface Loop-Back Connector 102
5.9.3 Parallel Interface Loop-Back Connector 103
5.10 Analysis of T&D Printouts 104
5.10.1 Printing Adjustment Printout (T&D 9) 104
5.10.2 Standard Pattern Printout (T&D 10) 105
5.11 Monitor Though Serial Interface 108
5.12 Log File Printout (T&D 12) 111
Chapter 6 Paper Specifications
6.1 Overview 113
6.2 Single Sheet 114
6.3 Passbook 115
6.3.1 Passbooks with horizontal fold 116
6.3.2 Passbooks with vertical fold 117
Chapter 7 Electromechanical Devices
7.1 Overview 119
7.2 Print Head 119
7.3 Carriage Motor 122
7.4 Paper Motor 123
7.5 Selector Motor 124
7.6 Sensors 125
Chapter 8 Adjustments
8.1 Overview 127
8.2 Print Head Gap Adjustment 128
8.3 Paper Belt Adjustment 130
8.4 Carriage Belt Adjustment 131
8.5 Selector Cam Adjustment 132

Maintenance Manual SP 40
Rev. 005 i.4Index
TABLES
Page
Table 1.1 Printer Specification Summary 10
Table 3.1 O.P. keys meaning 50
Table 3.2 O.P. Leds meaning 50
Table 3.3 Configuration Form Parameters description 56
Table 3.4 Program 1 (Program 2) Form Parameters description 59
Table 4.1 Not-recoverable leds errors code N° 82
Table 4.2 Not-recoverable errors error table 83
Table 4.3 Power malfunction Troubleshooting 84
Table 4.4 Faulty Probability Guide 85
Table 5.1 General Rules for T&D operations 88
Table 5.2 T&D USER Tests Description 89
Table 5.3 Step by Step USER Complete Sequential Actions 91
Table 5.4 T&D Error Phase Sequential Actions 96
Table 5.5 Led Status for N° of Test in error condition 97
Table 5.6 Led Status for O.R.U. in error 98
Table 5.7 Led Status for specific/common error codes 99
Table 5.8 T&D Error Codes 100
Table 5.9 T&D O.R.U. Codes 101
Table 5.10 T&D Common Errors (sensors) codes 101
Table 5.11 T&D Common Errors (mechanical) codes 101
Table 5.12 Serial Cable Connection for Remote T&D 108
Table 6.1 Single Sheet Dimensions 114
Table 6.2 Passbook Dimensions 115
Table 6.3 Horizontal Passbook Dimensions 116
Table 6.4 Vertical Passbook Dimensions 117
Table 7.1 Print Head Electrical pin-out 120
Table 7.2 Sensors Board pin-out 126

Maintenance Manual SP 40
Rev. 005 i.5Index
ILLUSTRATIONS
Page
Fig. 1.1 Front View 4
Fig. 1.2 Rear View (Standard model) 4
Fig. 1.4 Rear View (LAN model) 4
Fig. 1.3 Inside View 5
Fig. 1.5 Lay-out Electronic Parts 8
Fig. 1.6 Lay-out Electromechanical Parts 9
Fig. 2.1 Open Top Cover 15
Fig. 2.2 Cover removal 15
Fig. 2.3 Rise up Upper Mechanical Assy 16
Fig. 2.4 Ribbon Guide 17
Fig. 2.5 Print Head removal 17
Fig. 2.6 Mechanical Assy removal 18
Fig. 2.7 Boards removal 21
Fig. 2.8 Operator Panel removal 23
Fig. 2.9 Carriage Motor Assy removal 25
Fig. 2.10 Selector and Paper Motor removal 27
Fig. 2.11 Home Sensor Assy 28
Fig. 2.12 Ribbon Sensor Assy removal 29
Fig. 2.13 Ribbon Drive Assy removal 31
Fig. 2.14 Carriage Assy removal 33
Fig. 2.15 Mylar Bar Assy removal 35
Fig. 2.16 Rear Roller Assy removal 37
Fig. 2.17 Front Roller Assy removal 39
Fig. 2.18 Selector Cam removal 41
Fig. 2.19 Lower Roller Assy removal (Rear Side) 42
Fig.2.20 Lower Roller Assy removal (Front Side) 43
Fig. 2.21 Sensor Board and Sensor Cable removal 45
Fig. 2.22 Platen Assy removal 47
Fig. 2.23 Print Head Cable removal 48
Fig. 3.1 Operator Panel 49
Fig. 3.2 Set-up Mode Flow-Chart51
Fig. 3.3 Self Test Printout 52
Fig. 3.4 Leds meaning in Setup Mode 53
Fig. 3.5 Markers meaning in Setup Mode 54
Fig. 3.6 How to fill Markers in Setup Mode 54
Fig. 3.7 Configuration Setup Form 55
Fig. 3.8 Program 1 Setup Form 58
Fig. 3.9 Offset Tuning Setup Form 61
Fig. 3.10 Offset Tuning Example 62
Fig. 3.11a Home Page of SP40 using a web browser 63
Fig. 3.11b System Page of SP40 through web browser 64
Fig. 3.11c Security Setting (first time) 64
Fig. 3.11d Security Setting Page of SP40 through web browser 65
Fig. 3.11e Warning message of SP40 through web browser 65
Fig. 3.11f Reboot Page of SP40 through web browser 65
Fig. 3.11g Configuration Setup Page through web browser 66
Fig. 3.11h Program 1/2 Setup Page through web browser 66
Fig. 3.1i NIC Setup Page through web browser 67
Fig. 3.11j Printer Status Page through web browser 67

Maintenance Manual SP 40
Rev. 005 i.6Index
ILLUSTRATIONS
Page
Fig. 3.12a Initial mask for SP40setup installation 68
Fig. 3.12b Other mask for SP40setup installation 68
Fig. 3.12c Other mask for SP40setup installation 69
Fig. 3.12d Other mask for SP40setup installation 69
Fig. 3.12e Other mask for SP40setup installation 69
Fig. 3.12f Other mask for SP40setup installation 70
Fig. 3.12g Other mask for SP40setup installation 70
Fig. 3.13 Initial mask for SP40setup application 70
Fig. 3.14a Read NVM mask of the SP40setup application 71
Fig. 3.14b Read NVM mask of the SP40setup application 71
Fig. 3.15 Write NVM mask of the SP40setup application 72
Fig. 3.16 Button to print NIC Configuration 74
Fig. 3.17 Network Interface Configuration 74
Fig. 4.1 Basic FW steps through LAN using FTP 80
Fig. 4.2 Power Supply pin-out 84
Fig. 5.1 Operator Panel Sketch 87
Fig. 5.2 Schematic flow-chart of the T&D USER in Step by Step mode 90
Fig. 5.3 Operator Panel with Display for T&D activities 102
Fig. 5.4 Serial I/F loop-back 102
Fig. 5.5 Parallel I/F bi-directional loop-back 103
Fig. 5.6 Pattern for Printout T&D9 of standard model (reduced) 104
Fig. 5.7 Pattern for Printout T&D9+T&D10 of Standard model (reduced) 107
Fig. 5.8 Remoter mode display (Hyper Terminal under W98) 108
Fig. 5.9 Remote mode display (Sensor 2 error during T&D9) 109
Fig. 5.10 Remote mode display (Sensor 4 error during T&D9) 110
Fig. 5.11 Remote mode display (Sensor 8 error during T&D9) 110
Fig. 5.12 Example of T&D12 Log File (without errors) 112
Fig. 5.13 Example of T&D12 Log File (with maximum N° of errors) 112
Fig. 6.1 Single Sheet dimensions 114
Fig. 6.2 Passbook Dimensions 115
Fig. 6.3 Horizontal Passbook 116
Fig. 6.4Vertical Passbook 117
Fig. 7.1 Print Head Architecture 119
Fig. 7.2 Print Head Connection (rear view) 120
Fig. 7.3 Needles Position (rear view) 121
Fig. 7.4a P.H. Operation 121
Fig. 7.4b P.H. Operation 121
Fig. 7.5 Carriage Motor Layout 122
Fig. 7.6 Paper Motor Layout 123
Fig. 7.7 Selector Motor Layout 124
Fig. 7.8 Home Position Sensor 125
Fig. 7.9 Edge Sensor 126
Fig. 7.10 Ribbon Sensor 126
Fig. 7.11 Sensor Board and Optical Fibre 127

Maintenance Manual SP 40
Rev. 005 i.7Index
ILLUSTRATIONS
Page
Fig. 8.1 Gap Adjustment 129
Fig. 8.2 Print Head Gap versus Platen 129
Fig. 8.3 Paper Belt Adjustment 130
Fig. 8.4 Carriage Belt Adjustment 131
Fig. 8.4Selector Cam Adjustment 132

Maintenance Manual SP 40
Rev. 005 i.8Index
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