Digital Equipment LA400 User manual

Service Manual
Order Number:ER-LA400-SV
1

Maintenance Manual Revision Record
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REVISION RECORD
Edition Date published Page Revised contents
001 June 1996 All First issue
Specification No. ER-LA400-SV
The contents of this manual may be revised without prior notice.
All Rights Reserved, Copyright 1996 Digital Equipment Corporation. Printed in Ireland.
No part of this manual may be reproduced in any form without permission.
Address your comments and inquiries on this manual to:
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Table of Contents
CHAPTER 1 GENERAL OVERVIEW
1.1 Introduction 1.2
1.1.1 Scope of the Products 1.2
1.1.2 Printers Features Summary 1.2
1.2 General Description 1.3
1.2.1 Physical Overview 1.3
1.2.2 Physical Dimension 1.5
1.2.3 Printer Structure 1.5
1.2.3.1 Mechanical Assy 1.6
1.2.3.1.1 Tractor Unit Assy 1.6
1.2.3.2 Print Head 1.6
1.2.3.3 Cabinet 1.6
1.2.3.4 Electronic Hardware 1.7
1.2.3.5 Inked Ribbon Cartridge 1.7
1.2.3.6 Mechanical Options 1.7
1.3 Printer Technical Specifications 1.8
CHAPTER 2 PAPER HANDLING OVERVIEW
2.1 Introduction 2.2
2.1.1 Paper Handling Architecture 2.2
2.1.2 Paper Path Configurations 2.5
2.1.2.1 Basic Configuration 2.5
2.1.2.2 Dual Fanfold Configurations 2.8
2.1.2.3 ASF Configuration 2.9
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Table of Contents cont'd
CHAPTER 3 ELECTRONIC HARDWARE OVERVIEW
3.1 Hardware General Overview 3.2
3.1.1 Electronic Architecture 3.3
3.1.2 Controller Overview 3.4
3.1.2.1 V55PI µProcessor 3.4
3.1.2.1.1 V55PI Internal Block Architecture 3.5
3.1.2.1.2 V55PI Block Features 3.6
3.1.2.2 ASIC 3.8
3.1.2.3 Memories 3.9
3.1.2.4 Operator Panel 3.9
3.1.2.5 Serial Interface Board 3.9
3.1.2.6 Expansion Bus 3.10
3.1.3 Mechanical Drivers 3.10
3.1.3.1 DOE Block Features 3.11
3.1.4 Power Supply Board 3.18
3.1.5 Controller SW Overview 3.20
CHAPTER 4 REMOVAL AND REPLACEMENT
4.1 Overview 4.2
4.2 Recommended Hand Tools and Equipment 4.2
4.3 ORU Order of Access 4.3
4.3.1 Front Push-Pull Tractor Group 4.4
4.3.2 Operator Panel Boards 4.5
4.3.3 Print Head 4.6
4.3.4 Front Cover Parts 4.7
4.3.5 Rear Cover Parts 4.8
4.3.6 Serial I/F Board 4.9
4.3.7 Main Board 4.10
4.3.8 Power Supply Board 4.11
4.3.9 Ribbon Motor 4.12
4.3.10 AGA Motor 4.13
4.3.11 AGA Support and T/F Lever 4.14
4.3.12 Carriage Motor 4.15
4.3.13 Bail Assy 4.16
4.3.14 Cut Sheet Assy 4.17
4.3.15 Upper Feeder Assy 4.18
4.3.16 Platen Assy 4.19
4.3.17 Lower Feeder Assy 4.20
4.3.18 Carriage Assy 4.22
4.3.19 Sensor Assy 4.23
4.3.20 Mechanical Assy 4.24
4.3.21 Paper Motor 4.25
4.3.22 Friction Bar Assy 4.26
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Table of Contents cont'd
CHAPTER 5 ADJUSTMENTS
5.1 Overview 5.2
5.1.1 Carriage Belt 5.2
5.1.2 Paper Belt 5.3
5.1.3 Print Head Gap 5.4
CHAPTER 6 SERVICE MAINTENANCE
6.1 Overview 6.2
6.2 Initial Ispection 6.2
6.2.1 Set-Up 6.2
6.2.2 Cleaning 6.3
6.2.3 Paper Specifications 6.3
6.2.4 Consumables 6.3
6.3 Troubleshooting Guide 6.4
6.3.1 Initializing Phase 6.4
6.3.2 Printer Errors 6.4
6.3.2.1 Status Errors 6.5
6.3.2.2 Recoverable Errors 6.5
6.3.2.3 Not Recoverable Errors 6.6
6.3.3 Power Malfunctions 6.8
6.3.3.1 P.S. Troubleshooting Guide 6.8
6.3.4 Self-Test 6.10
6.3.5 Hex-Dump 6.11
6.3.6 Faulty Probability Guide 6.12
6.4 Service Tests and Adjustments 6.16
6.4.1 Introduction 6.16
6.4.2 Loop-back Coonectors 6.16
6.4.3 Execution of the Service Adjustments 6.17
6.4.4 Execution of the Service Tests 6.19
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Table of Contents cont'd
CHAPTER 7 ELECTROMECHANICAL DEVICES
7.1 Overview 7.2
7.1.1 Print Head 7.2
7.1.2 Motors 7.4
7.1.2.1 Carriage Motor 7.4
7.1.2.2 Paper Motor 7.5
7.1.2.3 AGA Motor 7.6
7.1.2.4 Ribbon Motor 7.7
7.1.2.5 Alternance Motor 7.8
7.1.2.6 ASF Motor 7.9
7.1.2.7 Color Motor 7.9
7.1.2.8 Stacker Motor 7.11
7.1.3 Cables 7.12
7.1.3.1 Sensors Cable 7.12
7.1.3.2 Alternance Cable 7.13
7.1.3.3 Paper Stacker Cable 7.13
7.1.3.4 Operator Panel Cable 7.14
CHAPTER 8 OPTIONS
8.1 Overview 8.2
8.1.1 Automatic Sheet Feeder 8.2
8.1.2 Color Motor 8.6
CHAPTER 9 HW SETTING & FW INSTALLATION
9.1 Overview 9.2
9.1.1 Hardware Setting 9.2
9.1.2 Firmware Installation 9.2
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Figures
1.1 Basic Printer Parts Location (front view) 1.3
1.2 Basic Printer Parts Location (rear view) 1.4
1.3 Printer Internal Architecture 1.5
2.1 Paper Handling Architecture 2.4
2.2 Front Load Push-Mode 2.6
2.3 Rear Load Push-Mode 2.6
2.4 Rear (bottom) Load Pull-Mode 2.7
2.5 Front Load Push-mode and Rear Front Push-mode
with two tractors 2.7
2.6 Front Load Push-Pull with two tractors 2.8
2.7 Automatic Sheet Feeder 2.9
3.1 Electronics Structure 3.2
3.2 Electronics Architecture 3.3
3.3 Microprocessor Internal Block Diagram 3.5
3.4 DOE Blocks Diagram 3.10
3.5 Reset and Prefault Circuit 3.11
3.6 Reset and Prefault Waveforms 3.12
3.7 Color & Paper Stacker Motors Driving Circuit 3.12
3.8 Carriage and Paper Motors Driving Circuits 3.13
3.9 Ribbon and AGA Motors Driving Circuits 3.14
3.10 Color and Alternance Motors Driving Circuits 3.14
3.11 ASF Motor Driving Circuit 3.15
3.12 Sensors Driving Circuits 3.15
3.13a/b Print Head Behaviour 3.16
3.14 Print Head Needle Drivig Circuit 3.16
3.15 Print Head Needle Current Waveforms 3.17
3.16 Power Supply Major Block Diagram 3.19
3.17 Software Architecture 3.21
4.1 Front Push Tractor Group 4.4
4.2 Operator Panel Boards 4.5
4.3 Print Head 4.6
4.4 Front Cover Parts 4.7
4.5 Rear Cover Parts 4.8
4.6 Serial Interface Board 4.9
4.7 Main Board 4.10
4.8 Power Supply Board 4.11
4.9 Ribbon Motor 4.12
4.10 AGA Motor 4.13
4.11 AGA Support and T/F Lever 4.14
4.12 Carriage Motor 4.15
4.13 Bail Assy 4.16
4.14 Cut Sheet Assy 4.17
4.15 Upper Feeder Assy 4.18
4.16 Platen Assy 4.19
4.17 Lower Feeder Assy 4.21
4.18 Carriage Assy 4.22
4.19 Sensor Assy 4.23
4.20 Mechanical Assy 4.24
4.21 Paper Motor 4.25
4.22 Friction Bar Assy 4.26
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Figures cont'd
5.1 Carriage Assy Belt Adjustment 5.2
5.2 Paper Belt Adjustment 5.3
5.3 Print Head Adjustment 5.5
6.1 Power Supply Test Points 6.9
6.2 Self-Test Printout 6.10
6.3 Hex-Dump Printout 6.11
6.4 Serial Interface Loop-back Diagram 6.16
6.5 Parallel Interface Loop-back Diagram 6.16
6.6 Service Test Fanfold Printout 6.21
7.1 Print Head pinout 7.3
7.2 Carriage motor pin connector assignment 7.4
7.3 Paper Motor pin connector assignment 7.5
7.4 AGA Motor pin connector assignment 7.6
7.5 Ribbon Motor pin connector assignment 7.7
7.6 Color Motor pin connector assignment 7.10
7.7 Stacker Motor pin connector assignment 7.11
7.8 Sensors Cable 7.12
7.9 Alternance Cable 7.13
7.10 Paper Stacker Cable 7.13
7.11 Operator Panel Cable 7.14
8.1 1st ASF Components 8.2
8.2 ASF and Stacker Blocks Diagram 8.3
8.3 ASF Installation (rear view) 8.4
8.4 Second Bin ASF Installation 8.5
8.5 Color Motor Installation 8.6
8.6 Color Ribbon Installation 8.7
Tables
2.1 Printer Path Configurations 2.4
4.1 ORU Order of Access 4.3
6.1 Unrecoverable Error Display Messages 6.7
7.1 Print Head Resistance/Temperature Characteristics 7.2
7.2 Print Head Pin assignment 7.3
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Chapter 1
General Overview
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LA400 Multiprinter 1. 1 ER-LA400-SV

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1.1 Introduction
This Manual describes the features and the maintenance procedures for the new Digital
LA400 Multiprinter and its options.
1.1.1 Scope of the Products
This printer is an advanced impact printer which give real and efficient solutions to the
actual and future printer needs.
It is designed to be extremely flexible in paper handling and capable to manage different
paper types and formats, able to print on thick and multipart forms, specialized on dual
fanfold management in non-attended mode.
In the same time, these printers are intended to support EDP, Office and "Administrative"
environments applications requiring very high throughput, high level print quality and
graphic capabilities, either in black or in colors, in order to print listing, invoicing & billing,
spread sheets, diagrams, business or technical graphics and machine readable texts.
This printer enters the top segment of the SIDM pinter market and can be a valide and
convenient alternative to the low end line-printers.
1.1.2 Printers Features Summary
•24 wire print head.
•Draft print at 400 cps and LQ print at 133 cps
•High resolution Graphics Printing at 360x360 dpi
•DEC ANSI Conformance Level 2, IBM Proprinter XL24E and Epson
LQ2550/LQ1170 (ESC P2) resident emulations
•Paper path switching selected by operator panel or SW commands.
•Easy print function selection and printer configuration via the operator panel or with
SW commands.
•Centronics Compatible Bidirectional (IEEE-1284) parallel interface
and Moduar 6-pin DECconnect type serial interface.
•Font styles in multiple international character sets.
•Optional second tractor assembly for dual fanfold operation.
•Optional Automatic Sheet Feeder that handles cut sheets, multicopies & envelopes.
•Optional color motor for color feature printing.
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1.2 General Description
1.2.1 Physical Overview
A sketch of the resulting appearance is reported on figures 1.1 and 1.2.
1. Top Cover 4. Single Sheet Support
2. Operator Panel 5. Paper Knob
3. Power Switch 6. Front Tractor Unit Cover
Fig. 1.1 Basic Printer Parts Location (front view)
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1. Interface Cover 4. ASF Location Cover
2. Rear Tractor Unit Cover 5. AC Power Inlet
3. Paper Stacker Covers
Fig. 1.2 Basic Printer Parts Location (rear view)
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1.2.2 Physical Dimension
Basic printer without options
Dimensions
- HEIGHT 12.1" (310 mm)
- WIDTH 26.2" (665 mm)
- DEPTH 13.3" (390 mm)
- WEIGHT (unpacked) 38 lbs (18 Kg)
1.2.3 Printer Structure
The printer can be described as the complex of the following parts.
In the next figure it is possible to see the internal printer architecture and where the
major blocks described below are located.
•• MECHANICAL ASSY
•• PRINT HEAD
•• CABINET
•• ELECTRONIC HARDWARE
•• INKED RIBBON
Fig. 1.3 Printer Internal Architecture
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1.2.3.1 Mechanical Assy
This block is composed of a rubber platen roller with a carriage carrying a print head with
24 needles in front of the platen.
This movement is obtained via a step-motor (providing 1/120" movement per step) and a
minipitch belt.
The movement of the rubber drum for paper traslation is obtained via a specific step
motor providing a minimum movement of 1/180" and a couple of minipitch belts.
The motion of the ribbon cartridge is obtained through a specific step-motor
indipendently from the actual carriage speed, movement, direction and width.
In this way in front of the print head there is a continuously renewing well inked ribbon.
The ribbon speed is optimized to reduce conflicts with ribbon and graphic printout
appearance when ribbon and print head are moving in the same direction.
The color ribbon and the extended life black cartridges are moved up and down through
a linear actuator (step motor) with a plastic coupler that transmits the axial movement to
the plastic print head mask installed on the color ribbon cartridge.
Another step motors is used for the A.G.A. (automatic gap adjustment) of the print head
movement to have the best perfomance on the paper in use.
1.2.3.1.1 Tractor Unit Assy
A removable push tractor unit is installed on the printer.
Inside of it, a DC motor switches to engage/disengage the gear to allow the fanfold or
the single sheet to be fed.
The tractor unit can be installed in two different positions depending on the type of
fanfold management (front - rear - both).
In the next chapter all the paper handling possibilities of this mechanism are detailed.
1.2.3.2 Print Head
The core of the printer is the print head, which is an electromagnetic non- ballistic type
with a life of 400 MChrs.
See chapter 3.1.3.1 and 7.1.1 for major hardware and mechanical details.
1.2.3.3 Cabinet
The cabinet allows safety-proof lifting of frontal part for ribbon substitution and paper
path check.
It is composed of various parts to allow an easy access to all the printer internal parts.
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1.2.3.4 Electronic Hardware
See chapter 3 for major details.
This section is composed of the following boards:
MAIN BOARD located in the bottom right side of the printer which controls the motors
movement, the various input sensors, the parallel interface and the print head needles.
It also provides the management of the asynchronous host serial interface, external
synchronous serial interface for mechanical options and fonts cartridge.
POWER SUPPLY BOARD located in the bottom left side of the printer which provides
specific voltages for logical area, printhead needles and drive motors.
There are two power supply boards: 120 and 220/240 Vac respectively.
OPERATOR PANEL BOARD placed on the front side of the printer driving 9 push
buttons and 8 leds (3 for printer status and 5 for paper path selection).
This board also drives a 16 Digit LCD Alphanumeric display to easily interact with
parameters setting for menu operation.
SERIAL INTERFACE board located on the rear right side and plugged to the main board
which drives the proper drivers for serial interface.
1.2.3.5 Inked Ribbon Cartridge
The ribbon cartridge is installed in different ways according to the ribbon types.
In case of the black ribbon, the cartridge is fixed on both sides on four points.
Its position is obliquous to the print line to automatically show the complete height of the
ribbon in front of print head while printing on the full print line.
The inked ribbon inside of these cartridges is a continuous loop.
In case a color ribbon is installed, the cartridge is fixed on both sides only on the two rear
points, so that is is free to move its frontal part upward and downward.
Its installation is parallel to the print line to assure the correct color band selection.
A specific step motor is used to move the ribbon band up and down for color selection.
1.2.3.6 Mechanical Options
This printer can provide some mechanical options :
AUTOMATIC SHEET FEEDER (up to 3 bins).
Each bin has a DC motor inside it to automatically load the single sheet paper.
Internally on the bin a series of gears takes the movement of the motor to the rubber
roller shaft.
Together with the first bin a PAPER STACKER is provided to collect the output printed
paper.
Also this part has an internal step motor to select the path where the paper should be
output.
See chapter 9 for more details.
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1.3 Printers Technical Specifications
The following features refer mainly to intrinsic characteristics and can change without notice.
•• PRINT HEAD
N. of Needles 24
Life (MChrs draft) 400
H. Pitch 1/120"
V. Pitch 1/180"
Needle Diameter 0.2 mm (0.0078")
•• PRINT SPEED
CPI= characters per inch
DPI= dots per inch
CPS= characters per second
DPS= dots per second
CPI DPI CPS DPS
Draft mode: 10 60 400
12 60 480
15 60 600
17 120 343
20 120 400
24 120 400
Letter Quality mode: 10 180 133
12 180 160
15 180 200
17 180 229
20 180 267
24 180 320
Dot Graphic Mode: - 60 - 2100
- 80 - 1660
- 90 - 1245
- 120 - 2100
- 180 - 2100
- 240 - 2100
- 360 - 2100
•• THROUGHPUT PPH ECMA 132
PPH= pages per hour
PPH Fanfold ASF
Letter Draft: 402 330
Letter Quality: 208 150
Graphic: 75 95
Spread 17: 226 170
Spead 10: 246 -
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•• CHARACTER PITCH
Basic: 10, 12, 15
Compressed: 16.7, 17.14, 20, 24
Double-Wide: 5, 6, 7.5, 8.33, 8.5
Other: Proportional
Intercharacter spacing n/120
n/180
n/360
n/720
•• CHARACTER FORMATION
DPC= dots per character
H S H Res (V)
Draft (text 10 cpi): 9 3 1/120" (24)
Draft (text 12 cpi): 7 3 1/120" (24)
Draft (text 15 cpi): 7 1 1/120" (16)
Draft (graphic char): 12 0 1/120" (30)
LQ (text 10 cpi): 31 5 1/360" (24)
LQ (text 12 cpi): 27 3 1/360" (24)
LQ (text 15 cpi): 21 3 1/360" (24)
LQ (proportional): 42 0 1/360" (24)
LQ (graphic char): 36 0 1/360" (30)
•• VERTICAL SPACING
LPI= lines per inch
Basic: 2, 3, 4, 6, 8, 12
Incremental n/60
n/72
n/180
n/216
n/360
•• BIT IMAGE (DOT GRAPHICS)
Horizontal: 60, 80, 90, 120,
180, 240, 360
Vertical: 60, 72, 144, 180
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•• MEDIA HANDLING
BACKWARD PAPER MOVEMENT
The reverse paper movement is always allowed except:
- When NO TEAR option is selected in Set-up.
- When PULL TRACTOR option is installed and PULL ONLY mode is selected.
•• MEDIA CHARACTERISTIC
The basic printers can manage a manual single sheet front insertion and up to
3 fanfold modules formats in 4 different paths.
SINGLE SHEET
Front insertion and straight path
The printer can accept these formats:
•A5, A4, A3, portrait and landscape
•A2 portrait
•LETTER, LEGAL and EXECUTIVE
WIDTH minimum 114.3mm 4.5"
maximum 444.5 mm 17.5"
LENGTH minimum 101.6 mm 4"
maximum 558.8 mm 22"
THICKNESS maximum 0.635 mm 0.025"
COPIES 1 + 5 (1 + 7 with High Impact Draft selected)
WEIGHT (original) minimum 50 gr/M² 12.5 lbs
maximum 120 gr/M² 30.0 lbs
WEIGHT (Multicopy)
first sheet minimum 55 gr/M²
maximum 75 gr/M² 18.75 lbs
other minimum 45 gr/M² 11.25 lbs
maximum 75 gr/M² 18.75 lbs
carbon minimum 14 gr/M² 3.5 lbs
maximum 35 gr/M² 8.75 lbs
FRONT PUSH FANFOLD
Frontal push fanfold feeding and straigh path
WIDTH minimum 76.2 mm 3.0"
maximum 431.8 mm 17.0"
LENGTH minimum 76.2 mm 3.0"
maximum 609.6 mm 24"
THICKNESS maximum 0.635mm 0.025"
COPIES 1 + 5
WEIGHT (original) minimum 55 gr/M² 13.75 lbs
maximum 150 gr/M² 37.5 lbs
WEIGHT (Multicopy)
copies minimum 45 gr/M² 11.25 lbs
maximum 75 gr/M² 18.75 lbs
carbon maximum 35 gr/M² 8.75 lbs
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PULL TRACTOR OPTION
Same as Front Push Fanfold
REAR PUSH FANFOLD
Rear push fanfold feeding
WIDTH minimum 76.2 mm 3.0"
maximum 431.8 mm 17.0"
LENGTH minimum 76.2 mm 3.0"
maximum 609.6 mm 24"
THICKNESS maximum 0.35mm 0.0138"
COPIES 1 + 3
WEIGHT (original) minimum 55 gr/M² 13.75 lbs
maximum 80 gr/M² 20 lbs
WEIGHT (Multicopy)
copies minimum 45 gr/M² 11.25 lbs
maximum 75 gr/M² 18.75 lbs
carbon maximum 35 gr/M² 8.75 lbs
The printer can accept also the Automatic Sheet Feeder option with these paper limitations:
ASF ALL BINS
Capacity Bin of 120 sheets
LENGTH maximum 355 mm 14"
THICKNESS maximum 0.35mm 0.0138"
COPIES 1 + 2
WIDTH minimum 88.9 mm 6"
maximum 304.8 mm 12"
WEIGHT (original) minimum 60 gr/M² 15 lbs
maximum 150 gr/M² 37.5 lbs
WEIGHT (Multicopy with carbon)
first/last sheet minimum 70 gr/M² 17.5 lbs
maximum 80 gr/M² 20.0 lbs
other minimum 35 gr/M² 8.75 lbs
maximum 40 gr/M² 10.0 lbs
carbon approx. 25 gr/M² 6.25 lbs
WEIGHT (Multicopy sensitive)
first/last sheet minimum 70 gr/M² 17.5 lbs
maximum 80 gr/M² 20.0 lbs
other minimum 40 gr/M² 10.0 lbs
maximum 60 gr/M² 15.0 lbs
ENVELOPES
Capacity of 30 envelopes max., Size US 6, US 10
ASF 1 BIN
LENGTH minimum 114 mm 4.5"
ASF 2 BIN
LENGTH minimum 216 mm 8.5"
ASF 3 BIN
LENGTH minimum 267 mm 10.5"
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•• INTERFACES
There are two interfaces with automatic protocol and I/F switching on SW commands.
- Parallel interface
Centronics Compatible Bidirectional (IEEE-1284) nibble and byte modes
36 pin Amphenol connector with ESD protection
- Serial interface
Modular 6-pin DECconnect type
Baud Rate:300 to 19200 bps
Character Format: 1 Start bit + 7 or 8 data bits, + optional parity bit + 1 stop bit
•• DEVICE PROTOCOLS
Emulation: Printer Names
EPSON ESC P/2
IBM Proprinter X24E/XL24E
ANSI DEC PPL2
•• ELECTRICAL CHARACTERISTICS
JA/US Specification : 120 V +10% -15%, 50/60Hz ±2Hz
EU/UK Specification : 220/240 V +10% -15%, 50/60Hz ±2Hz
AC Consumption : Idle less than 80 VA
Printing less than 200 VA
•• ENVIRONMENTAL CONDITIONS
The storage and transit environment (1 year) of the device and the related
expansion module and supplies is:
Temperature Range - 20 °C to + 60 °C (-4 °F to 140 °F)
Humidity Range 5% RH to 90% RH (not condensing)
The operating environment is :
Temperature Range + 10 °C to + 40 °C (41 °F to 104 °F)
Humidity Range 20% RH to 80% RH (not condensing)
Additional resctrictions are introduced by the paper.
The ECMA standard suggestions are :
Temperature Range + T16 °C to + 24 °C
Humidity Range 40% RH to 60% RH (not condensing)
•• NOISE
Sound Pressure level bystander position according to ISO 7779:
Printing: less than 56 dBA
Stand-by: less than 45 dBA
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