Genicom 5180 User manual

GENICOMGENICOM
5180 Maintenance Manual
GEK-00046

GEK-00048 Preface
ii
Preface
FCC COMPLIANCE STATEMENT (USA)
This equipment complies with Part 15 of the FCC Rules. Operation is
subject to the following two conditions: (1) This device may not cause
harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation. If
this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on,
the user is encouraged to try to correct the interference by one or more of
the following measures:
•Reorient or relocate the receiving antenna.
•Increase the separation between the equipment and receiver.
•Connect the equipment to an outlet on a circuit different from that to
which the receiver is connected.
•Consult the dealer or an experienced radio/TV technician for help.
FCC warning: Changes or modifications not expressly approved by the
party responsible for compliance could void the user’s authority to
operate the equipment.
Note the following:
•The use of a non-shielded interface cable with the referenced device is
prohibited.
•The length of the parallel interface cable must be 3 meters (10 feet) or
less.
•The length of the serial interface cable must be 15 meters (50 feet) or
less.
•The length of the power cord must be 3 meters (10 feet) or less.
COMPLIANCE STATEMENT (CANADA)
This digital apparatus is in conformity with standard NMB-003 of
Canada.
Cet appareil numérique est conforme à la norme NMB-003 du Canada.
COMPLIANCE STATEMENT (GERMANY)
Bescheinigung des Herstellers/Importeurs
Hermit wird bescheinigt, daß der/die/das
Machinenlärminformationsverordnung 3. GSGV, 18.01.1991: Der
höchste
Schalldruckpegel beträgt 70 dB (A) oder weniger gemäß EN27779-1991.

5180 Maintenance Manual GEK-00048
iii
COMPLIANCE STATEMENT (EUROPE)
Warning: This product meets the interference requirements of EN55022.
In a domestic environment, this product may cause radio interference in
which case, the user may be required to take adequate measures.
Optional Interface Kits
If either Ethernet interface boards, Token Ring interface board, IBM
TX/CX interface board, or any variation of the Legacy Parallel board is
installed in either or both of the interface expansion slots, this
equipment may produce additional radio frequency interference in
compliance with FCC Class A emissions.
Si des panneaux d’interface d’Ethernet, panneau de token ring, panneau
d’IBM TX/CX, ou n’importe quelle variation des panneaux de parallèle de
legs est installé dans l’un ou l’autre ou tous les deux emplacements
d’interface, ce matérial peut produire l’interférence F.R. upplémentaire
conformément ICES-003 aux émissions de la classe A.
Falls Ethernet, Token ring, IBM TX/CX, Schnittstellenkarten oder eine
variation der herkoemmlicken Parallelscnittstellenkarten (interface) in
einer oder beiden steckbaren Erweiterungsschnittstellen installiert sind,
koennen moeglicherweise zusaetzliche Funkfrequenzstoerungen erzeugt
werden, unter Einhaltung der EN55022 Klasse A Stoerstrahlungswerte.
ENERGY STAR
As an ENERGY STAR ® Partner, GENICOM has determined that this
product meets the ENERGY STAR ® guidelines for energy efficiency. The
International ENERGY STAR ® Office Equipment Program is an
international program that promotes energy saving through the use of
computers and other office equipment. The program backs the
development and dissemination of products with functions that
effectively reduce energy consumption. It is an open system in which
business proprietors can participate voluntarily. The targeted products
are office equipment such as computers, displays, printers, facsimiles,
and copiers. Their standards and logos are uniform among participating
nations.
INTERNATIONAL COMPLIANCE
EN5008-1:1993 EN55022:1994
EN50082-1:1997 EN61000-4-2:1995
EN61000-4-3:1994
EN61000-4-4:1995
EN61000-4-5:1995
EN61000-4-6:1994

GEK-00048 Preface
iv
Trademark Acknowledgements
GENICOM is a registered trademark of GENICOM Corporation. The
following companies own the other trademarks used in this manual:
GENICOM Corporation: Centronics;
International Business Machines Corporation: IBM;
Operating Precautions
Read this section and remember these instructions to ensure user safety
and the printer’s correct performance. Follow the cautions and notices
labeled on the printer or marked with icons in the manual. Save this
manual for future reference.
•Use only the power cord furnished with the printer and a properly
grounded outlet. Do not use an extension power cord.
•Confirm that the rated voltage of the printer matches the voltage of
the power outlet where the printer will be connected.
•The maximum wattage of the 5180 printer is 1167 watts.
•Turn off the printer and disconnect the power cord before beginning
maintenance.
•Disconnect the power cord from the outlet when the printer is not
used over an extended period of time.
•Disconnect the power cord from the outlet whenever thunderstorms
are nearby. Leaving the power cord connected may damage the
printer or other property.
•Do not put the printer in direct sunlight, near a heater, or near
water. Leave adequate space around the printer.
•Use only a shielded interface cable 3 meters (10 feet) or less for the
parallel interface, 15 meters (50 feet) or less for the serial interface,
100 meters (328 feet) or less for Ethernet interface 10Base-T
connection, and 185 meters (607 fee) or less for the Ethernet
interface 10Base-2 connection.
•Be sure the printer is turned off before connecting any interface.
•Do not turn the printer off while it is printing.
•Do not disassemble or remove any components unless instructed in
the maintenance procedures.
•Keep the printer unit upright when removing or installing it.
•Do not drop small objects, such as paper clips, into the printer.
•Do not set page margins off the physically printable page area.
•Turn off the printer and disconnect the power cord immediately if an
abnormal condition occurs: for instance, if the printer emits smoke,
prints abnormally, or becomes wet. Consult the point of purchase for
additional information, if any of these conditions occur.

5180 Maintenance Manual GEK-00048
v
Table of Contents Page
Chapter 1. Printer Description........................................................................1
Introduction....................................................................................................1
Models............................................................................................................2
Description of the Operator Control Panel ......................................................3
Operation of the Control Panel........................................................................5
Basic Key Use...............................................................................................5
Power Supply...............................................................................................6
Protocols.......................................................................................................6
Horizontal and Vertical Tabulation...............................................................6
Paper Handling ............................................................................................6
Ribbon .........................................................................................................7
Print Head Characteristics ...........................................................................7
Functional descriptions..................................................................................7
Shuttle Motor...............................................................................................7
Character Formation and Timing.................................................................8
Heat Dissipation...........................................................................................8
Power-on, Print Time, and Head Life Readouts ............................................8
Chapter 2. Maintenance..................................................................................9
General...........................................................................................................9
Inspection Checklist.....................................................................................9
Cleaning Procedures..................................................................................10
Chapter 3. Diagnostics & Troubleshooting...................................................11
General.........................................................................................................11
Initializing the Printer...................................................................................12
Why Initialize the Printer?..........................................................................12
When to Initialize.......................................................................................12
Using the Keypad to Initialize .......................................................................13
Control Panel Initialization.........................................................................13
Using the Test Pattern as a Tool....................................................................14
Self-test Diagnostics......................................................................................15
LPCU Self-test............................................................................................15
Hardware Interface Controller Test – Machine Interface Board (TTMI)........16
Wire Driver/Actuator Test........................................................................16
Wire Driver/Actuator Failure Display.........................................................17
Self-test Error Messages.............................................................................17
Error Code Definitions...............................................................................18
Error Code Definitions (Continued)............................................................19
Soft Faults..................................................................................................20
Soft Faults (Continued)..............................................................................21
Miscellaneous Non-Fault Messages............................................................22

GEK-00048 Table of Contents
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Table of Contents Page
Chapter 3. Diagnostics & Troubleshooting (Continued)
Hard Faults................................................................................................23
Hard Faults (Continued).............................................................................24
Electrical Problems.....................................................................................25
Mechanical Problems .................................................................................26
Circuit Board Descriptions.........................................................................27
Common Control Unit Panel (CCUP) PWB..................................................28
Shuttle Switching Power Supply (SSPS) PWB.............................................28
Line Printer Control Unit (LPCU) PWB........................................................30
Machine Interface (TTMI) PWB....................................................................31
Shuttle Blower Motor Relay (SBMR) PWB...................................................33
Printer Interfaces..........................................................................................34
Parallel and Serial Interfaces......................................................................34
Parallel Interface ........................................................................................34
Interface Signal Path ...............................................................................34
Input Buffer Size........................................................................................34
CENTRONICS Interface Operation .............................................................35
Parallel Interface Pin Assignments.............................................................35
CENTRONICS Parallel Interface Signal Definitions.....................................36
Parallel Interface Control Options..............................................................39
Software Control......................................................................................39
I/F Settings................................................................................................39
Multisource .............................................................................................39
Parallel Setup..........................................................................................39
Serial.......................................................................................................39
Serial Type ....................................................................................................................... 40
Serial Setup...................................................................................................................... 40
IBM Host Status ......................................................................................40
Expansion 1 & Expansion 2.......................................................................41
Serial Interface Pin Assignments................................................................42
Serial Interface Signal Definitions..............................................................42
Serial Setup Menu Options........................................................................43
Protocol....................................................................................................43
XON/OFF......................................................................................................................... 43
CD (DTR_232) – Pin 20.................................................................................................... 43
CA (RTS_232) – Pin 4....................................................................................................... 44
SCA (SRTS_232) – Pin 11 & 19........................................................................................ 44
ETX/ACK.................................................................................................45
Inhibit Xmit.............................................................................................45
Lead Polarity............................................................................................45
Data Bits..................................................................................................45
Parity.......................................................................................................46
Stop Bits..................................................................................................46

5180 Maintenance Manual GEK-00048
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Table of Contents Page
Chapter 3. Diagnostics & Troubleshooting (Continued)
Baud Rate................................................................................................46
High Trip Pt % .........................................................................................47
Flash Upgrade Instructions........................................................................47
On Board Software to External Flash SIMM...............................................49
Chapter 4. Parts Removal, Replacement & Adjustments........................... 50
General.........................................................................................................50
Ribbon Cartridge Removal and Replacement................................................50
Ribbon Cartridge Removal..........................................................................50
Ribbon Cartridge Installation.....................................................................51
Ribbon Deck Assembly Removal and Replacement.......................................52
Ribbon Deck Removal and Replacement....................................................52
Print Actuator Module Removal and Replacement.....................................54
Resetting Print Head Counters...................................................................59
Outside Panels and Top Enclosure Removal .................................................60
55 dBa (Standard Model) Cabinet.................................................................60
Front Access Door Removal and Replacement............................................61
Side Panel Removal and Replacement........................................................62
Rear Access Panel Removal and Replacement............................................63
Top Enclosure Removal and Replacement..................................................64
At the Rear of the Printer:........................................................................64
At the Front of the Printer: ......................................................................65
Outside panels and Top Enclosure Removal .................................................66
52 dba (Quietized Model) Cabinet.................................................................66
Front and Rear Access Doors Removal and Replacement...........................66
Side Access Panel Removal and Replacement............................................67
Top Cover Removal and Replacement.........................................................68
Circuit Boards – 52 dba (Quietized Model) printer........................................69
Logic Control Unit (LPCU) Board Removal and Replacement......................70
Machine Interface (TTMI) Board Removal and Replacement.......................72
SSPS Board Removal and Replacement.....................................................73
SMAD Board (Actuator Driver) Removal and Replacement.........................75
Common Control Unit Panel (CCUP) Board Removal and Replacement.....77
Circuit Boards – 55 dba (standard Model) printer.........................................79
Logic Control Unit (LPCU) Board Removal and Replacement......................80
Machine Interface (TTMI) Board Removal and Replacement.......................81
SSPS Board Removal and Replacement.....................................................82
SMAD Board (Actuator Driver) Removal and Replacement.........................83
Common Control Unit Panel (CCUP) Board Removal and Replacement.....84
Drive Motors and cooling Fans – both models...............................................86
Ribbon Drive Motor, Belt, and Spindle Removal and Replacement.............86

GEK-00048 Table of Contents
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Table of Contents Page
Chapter 4. Parts Removal, Replacement & Adjustments (Continued)
Paper Drive Motor Removal and Replacement............................................87
Drive Belt Installation ................................................................................90
Cooling Fan Removal and Replacement.....................................................92
Rear (SMAD) Fan Removal and Replacement...........................................92
55 dBa (Standard Model).........................................................................92
Power Supply Fan Removal and Replacement.........................................92
Print Module Blower................................................................................95
Paper Handling Assemblies...........................................................................98
Upper Tractors, Shafts, and Bearings Removal and Replacement..............98
Upper Tractor Reassembly.....................................................................102
Checking for Proper Operation..............................................................106
Lower Tractors, Shafts, and Bearings.......................................................106
Lower Tractor Reassembly.....................................................................108
Checking for Proper Operation..............................................................112
Paper Tension Assembly...........................................................................112
Horizontal Vernier Timing Belt and Alignment.........................................115
Belt Removal..........................................................................................115
Replacement..........................................................................................116
Alignment..............................................................................................117
Shuttle Assembly........................................................................................118
Shuttle Motor ........................................................................................119
Shuttle Motor Assembly Removal and Replacement.................................120
Shuttle Motor Replacement......................................................................122
Balancing the Shuttle Mechanism.........................................................124
Shuttle Bar Assembly Removal.................................................................126
Shuttle Bar Installation.........................................................................130
Print Head to Striker Bar Gap ...............................................................131
To Increase Gap............................................................................................................. 133
To Decrease Gap............................................................................................................ 133
Striker Bar Assembly Removal .................................................................133
Striker Bar Switch Removal...................................................................134
Striker Bar Installation..........................................................................136
To Increase Gap............................................................................................................. 137
To Decrease Gap............................................................................................................ 137
Sensors.......................................................................................................139
Paper Motion Sensor................................................................................139
Paper Out Sensor.....................................................................................140
Ribbon Weld Sensor.................................................................................141
Top Access Door Interlock Switch ............................................................142
55 dBa (Standard Model) Printer Only .....................................................142
Switches......................................................................................................143
AC Receptacle ..........................................................................................143

5180 Maintenance Manual GEK-00048
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Table of Contents Page
Chapter 4. Parts Removal, Replacement & Adjustments (Continued)
Power Switch............................................................................................145
AC Line Filter...........................................................................................146
Fuse Holder..............................................................................................147
Miscellaneous Assemblies and Parts...........................................................148
Interface Data Connector Plate.................................................................148
Paper Chute/Top Access Door Gas Strut .................................................150
55 dBa (Standard Model) Only .................................................................150
Smudge Shield Removal/Replacement – Both Models..............................151
LVT (Linear Velocity Transducer) Coil......................................................152
Adjustments..........................................................................................154
Coil Bracket Adjustment............................................................................................... 154
Magnet Penetration Adjustment ................................................................................... 155
Mechanical Adjustments.............................................................................156
Print Head Intermodule Gap ....................................................................156
INCORRECT GAP SPACING...................................................................156
Electrical Adjustments................................................................................157
Amplitude Adjustment.............................................................................158
Adjustment............................................................................................158
SAMPLE TEST PATTERNS.....................................................................159
Horizontal Timing..................................................................................160
Vertical Timing ......................................................................................161
Chapter 5. Illustrated Parts List................................................................ 162
Introduction................................................................................................162
Catalog Number..........................................................................................162
Serial Number.............................................................................................163
Hardware ....................................................................................................163
Alphabetic Index of Parts ............................................................................164
Numerical Index of Parts.............................................................................170
Final Assembly (44E416594) ......................................................................176
Final Assembly (44E416594) – Continued..................................................177
Final Assembly (44E416594) – Continued..................................................178
Final Assembly (44E416594) – Continued..................................................179
Final Assembly (44E416594) – Continued..................................................180
Final Assembly (44E416594) – Continued..................................................181
Final Assembly Illustration ......................................................................182
Final Assembly Illustration (Continued)...................................................183
Final Assembly Illustration (Continued)...................................................184
Final Assembly Illustration (Continued)...................................................185
Final Assembly Illustration (Continued)...................................................186
Final Assembly Illustration (Continued)...................................................187

GEK-00048 Table of Contents
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Table of Contents Page
Chapter 5. Illustrated Parts List (Continued)
Final Assembly Illustration (Continued)...................................................188
Final Assembly Illustration (Continued)...................................................189
Final Assembly Illustration (Continued)...................................................190
Lower Enclosure Assembly (44D430657-G05) – Standard Model................191
Lower Encl. Asm. Illustration – Standard Model (Cont’d).........................192
Lower Encl. Asm. Illustration – Standard Model (Cont’d).........................193
Lower Enclosure Assembly (4D1253G03) – Quiet Model.............................194
Lower Enclosure Illustration – Quiet Model..............................................195
Lower Enclosure Illustration – Quiet Model (Continued)..........................196
Lower Enclosure Illustration – Quiet Model (Continued)..........................197
Lower Enclosure Illustration – Quiet Model (Continued)..........................198
Drive Mechanism Assembly (44D430354-G05)...........................................199
Drive Mechanism Assembly Illustration...................................................200
Drive Mechanism Assembly Illustration (Continued)................................201
Drive Mechanism Assembly Illustration (Continued)................................202
Mechanism Sub-Assembly (44D430353-G03).............................................203
Mechanical Sub–Assembly Illustration.....................................................204
Mechanical Sub–Assembly Illustration (Continued).................................205
Paper Handling Assembly (44E416581-G06) ..............................................206
Paper Handling Assembly (44E416581-G106) ............................................207
Paper Handling Assembly Illustration......................................................208
Paper Handling Assembly Illustration (Continued)...................................209
Paper Handling Assembly Illustration (Continued)...................................210
Idler Bracket ASM (44B505526-G01)..........................................................211
Idler Plate ASM (44B508382-G01) ..............................................................211
Tractor ASM – PAP. Out Det. (4D0697G01).................................................212
Tractor Asm – Paper Out Det. Illustration (Continued).............................213
Paper Tension Assembly (44D416313-G01) ................................................214
Top Enclosure (44D416382-G59) – Standard Model ...................................215
Top Enclosure Illustration........................................................................216
Top Enclosure Illustration (Continued)....................................................217
Top Enclosure Illustration (Continued)....................................................218
Top Enclosure Illustration (Continued)....................................................219
Top Enclosure Illustration (Continued)....................................................220
AC-DR Asm w/55 DBa (44D416383-G19) – Standard Model......................220
AC-DR Asm W/55 DBa Illustration (Continued) ......................................222
AC-DR Asm W/55 DBa Illustration (Continued) ......................................223
AC – DR – AST W/55DB (44D416383-G106) – Standard Model..................224
Strike Plate ASM (44A505246-G01) – Standard Model................................225
Paper Chute ASM (44D430416-G04) – Standard Model..............................226
Paper Chute Asm - Illustration.................................................................227

5180 Maintenance Manual GEK-00048
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Table of Contents Page
Chapter 5. Illustrated Parts List (Continued)
Ribbon Cart Pack (44A509160-G02) – Standard Model ..............................228
Ribbon Drive Assembly (44D430355-G02)..................................................229
Ribbon Drive Assembly Illustration (Continued).......................................230
Wire Driver Mount Assembly (44C510391-G02) – Standard Model.............231
Wire Driver Mount Assembly (44C510392-G02) – Standard Model.............232
Removable Cover RH (44C510132-G99) – Standard Model .........................233
Removable Cover LH (44C510133-G99) – Standard Model..........................234
Front Cover Assembly (44C510151-G99) – Standard Model .......................235
Rear Cover Assembly (44C510385-G00) – Standard Model.........................236
Strike Plate Assembly (44A505246-G01) – Standard Model........................237
PWA TTMI/11 (4C0299G11)........................................................................238
PWA SMAD/12 (44C510006-G12) ..............................................................239
Paper Rack/Ext (44C506666-G01) – Standard Model.................................240
Kit – Paper Handling Aids (4A0885G02) – Standard Model .........................241
Belt Guard Assembly (44C510155-G02).....................................................242
CCU Module-4490 (4D2222G01) ................................................................243
PWA SSPS/1 (44C510010-G01)..................................................................244
AC SW Assembly (44D430495-G01) – Standard Model...............................245
AC SW Assembly Illustration....................................................................246
AC SW Assembly Illustration (Continued)................................................247
AC SW Assembly Illustration (Continued)................................................248
Fan Assembly (44A507008-G03).................................................................249
Control Panel Assembly (4D2154G01) – Standard Model............................250
Control Panel Assembly Illustration (Continued)......................................251
Control Panel Assembly (4D1832G01) – Quiet Model..................................252
Control Panel Assembly Illustration (Continued)......................................253
Duct – Horiz. Assembly (44B508617-G01) – Standard Model .....................254
Duct – Vert. Assembly (44B508618-G01) – Standard Model .......................255
Air Filter (44A507798-001) .........................................................................256
Blower Assembly (44B508725-G02) – Standard Model...............................257
Plenum – Lower Assembly (44C430251-G02)..............................................258
Plenum Assembly – PH (44C430255-G025) ................................................259
Printer Pack 4000 (44A509184-G01) – Standard Model..............................260
PWA SBMR/1 (44B502478-G015)...............................................................261
Recommended Spare Parts List (RSPL).......................................................262
Appendix A. Strapping Options..................................................................263
Legacy Parallel Hardware Strap Definitions................................................263
I/F Hardware Straps ................................................................................264
Legacy Parallel Software Strap Definitions..................................................265
I/F Software Straps..................................................................................265

GEK-00048 Table of Contents
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Table of Contents Page
Appendix B. General Printer Options (GenPtrOpts)..................................266
Setup Menu: GenPtrOpts............................................................................266
Group 1....................................................................................................266
Group 2....................................................................................................267
Appendix C. Printer Emul Settings Options..............................................268
ANSI (4800)..............................................................................................268
ANSI (4410)..............................................................................................268
Proprinter III XL.......................................................................................269
EPSON FX286e ........................................................................................270
ESC P2.....................................................................................................270
Printronix Pseries.....................................................................................271
Printronix P300/600................................................................................271
Dec LG Plus .............................................................................................271
Dec PPL3..................................................................................................271
Appendix D. Interface Emul Setting Compatibility Charts......................272
Printer Emul Settings vs. Filter Settings..................................................272
Filter Setting Combinations......................................................................272
Interface Port and Filter Setting Compatibility .........................................273
Appendix E. LCD Menu Maps....................................................................274
Appendix F. Wiring Schematic................................................................... 281
Appendix G. 5180 Printer Optional Interface Kits ...................................283

5180 Maintenance Manual GEK-00048
1
CHAPTER 1. PRINTER DESCRIPTION
INTRODUCTION
These products are heavy duty cycle line matrix printers. Some of the
advanced features of these printers are:
•High speed of 1800-lpm
•Industry’s only lifetime warranty on shuttle mechanism
•IBM-compatible models
•High reliability, ideal for manufacturing pick lists and shipping
documents
•Remote network printing
•Auto interface switching
•Industrial graphics, bar codes, and labels
Other characteristics include:
•Input voltage: switch-selectable 115V or 230V
•Hardware interfaces: menu selectable IEEE 1284 parallel and
RS-232/422 serial
•Standard emulations: menu- or host-selectable ANSI X3.64, IBM
Proprinter III XL, and Epson FX286e.
•Standard fonts: menu- or host-selectable Gothic NLQ, Courier NLQ,
Italic NLQ, OCR-A, OCR-B and Oversize.
•Available in either the 52 dBa (Quietized) cabinet or the 55 dBa
(Standard) cabinet.
Reference usage:
•Warning: Warning is used to alert a user of a hazard that could
cause personal injury or severe damage to the equipment.
•Caution: Caution is used where there is a risk of damaging the
equipment, parts or supplies.
•Note: Indicates that additional information is available.

GEK-00048 Chapter 1. Printer Description
2
MODELS
This guide covers the 52 dBa (Quietized) cabinet model and the 55 dBa
(Standard) cabinet model.
The printers are illustrated in the following:
52 dBa (Quietized Model) 55 dBa (Standard Model)

5180 Maintenance Manual GEK-00048
3
DESCRIPTION OF THE OPERATOR CONTROL PANEL
The control panel is mounted on the top of the printer and is accessible
with the top cover either open or closed. The control panel utilizes a
display panel composed of two rows of 16 characters each.
The 52 dBa (Quietized Model) has a rectangular design while the 55 dBa
(Standard Model) has a vertical design. With the top cover open, the
control panel will move around slightly to the touch (52 dBa Quietized
Model). This is normal. The floating mount allows the panel to align itself
when the top cover is closed. The mount is also hinged so that it may be
tilted forward to remove the ribbon deck for service. The 55 dBa
(Standard Model) is affixed to a stationary platform.
The four     keys are to navigate the menu tree structure. The
Clear and Select keys are used in conjunction with the menu navigation
key for data entry to set up the printer. The On Line/Off Line key is at
the upper left (52 dBa Quietized Model) and to the lower left side of the
display (55 dBa Standard Model). The three keys (TOF, , ) are used to
set Top of Form. The Format key is used (in conjunction with the Select
key) to select one of ten stored setup formats. The FF, Tear Off, and View
keys are additional paper positioning functions.
52 dBa (Quietized Model) Operator Control Panel
55 dBa (Standard Model) Operator Control Panel

GEK-00048 Chapter 1. Printer Description
4
Note
The locations of the keys and display on the two cabinet models are
different, however the functionality of each is the same.
When the the printer is On Line, only the FF, On Line/Off Line, Tear Off
& View keys and limited functionality of the Clear, Select, and  arrow
navigation keys are active. Depressing any other key causes only a
“beep.” The “Processing” LED indicator is lit whenever data is being
received and/or being processed/printed. In multisource I/O mode, the
“Processing” LED indicator will blink for the duration of the timeout
period.

5180 Maintenance Manual GEK-00048
5
OPERATION OF THE CONTROL PANEL
The primary use of each key is printed beside each key.
Basic Key Use
The On Line/Off Line key, causes the printer to toggle between online and
offline operation. Offline operation allows access to the menu functions.
Online operation allows printing of data sent from the data source.
The ↑↑ key moves paper up incrementally.
The ↓↓ key moves paper down incrementally.
The TOF (Top of Form) key sets the top of form position on the printer.
The Format key allows the operator to select from up to ten stored
formats. The key is repeatedly depressed until the desired format is
displayed, then the Select key is depressed to activate the selected
format. Only formats stored during printer setup will be displayed.
The FF key moves paper to next top of form according to the current top
of form set for the printer and the form length setting.
The Tear Off key advances the paper to the tear position and will auto
retract to the retract position after 15 seconds. Depressing the tear off
key any time within the 15 second wait period will retract the paper to
the retract position.
The View key advances the paper such that the last printed line is visible
in the top cover window. Depressing the View key a second time will
return the paper to the last print position. Receipt of any data will also
retract the paper to the print position.
The Clear key allows the operator to exit the current function; backspace
through characters being entered into the display, and backup through
the menu tree.
The Select key allows the operator to select an entry or data currently on
the control panel display.
The left or right menu key allows navigation through menu selections
laterally within a level.
The up or down menu browse key allows navigation through menu
selections up or down a level.

GEK-00048 Chapter 1. Printer Description
6
Power Supply
The power supply is switch selectable for an input voltage level (120 or
240V).
The power switch, power cord receptacle, voltage selection switch, and
line fuse are located at the left rear of the printer.
Protocols
These printers emulate ANSI 4800 & 4410, Proprinter III XL, FX-286e,
P300/600, DEC LG+, Pseries, DEC PPL/3 and ESC P2. Selection is made
through the operator menu using the control panel.
Horizontal and Vertical Tabulation
Tab stops and margins can be changed through the control panel or by
using control sequences sent from the data source.
Paper Handling
Two sets of synchronized six-pin tractors handle continuous forms from
3 inches (76.2 mm) to 16.54 inches (420.1 mm) wide and up to six parts.
A dedicated paper drive stepper motor moves the paper forward and
backward as needed.
Paper is stored in the lower cabinet in both cabinet models (55 dBa and
52 dBa).
In the 55 dBa (Standard Model), the paper is fed up through the tractors
and out the rear of the printer. A static-grounded paper rack and paper
shelf is used to handle the printed forms. A “V”-shaped stacking aid is
used to form the paper stack when large amounts (1000+) of forms are
expected.
In the 52 dBa (Quietized Model), the paper is fed up through the tractors
and into the rear internal cabinet area.
A paper-out switch is located in the lower left tractor in both cabinet
models (55 dBa and 52 dBa). A photoelectric sensor, located in the upper
left tractor, monitors paper motion in both cabinet models (55 dBa and
52 dBa).

5180 Maintenance Manual GEK-00048
7
Ribbon
The cartridge-type ribbon mounts on the deck assembly containing the
ribbon drive mechanism. Continuous loop ribbons are available with or
without a re-inker.
A ribbon weld sensor, located near the left side of the deck, prevents
printing on the weld (the seam where the ends of the ribbon are joined)
and senses when the ribbon cartridge is missing.
Print Head Characteristics
The printers have six interchangeable print modules. Each module has
two tiers of 11 print wire actuators. The print wires are spaced 0.4 inches
apart horizontally and the two tiers are spaced .5 inches vertically.
Each module contains a thermistor to sense high temperature
conditions.
FUNCTIONAL DESCRIPTIONS
Shuttle Motor
The shuttle mechanism is powered by a linear motor consisting of a
stationary coil and a magnet. The motor has no bearings or rotor and
requires no lubrication. A hollow coil is mounted on the right side of the
printer frame and a tube-shaped magnet inside the coil is mounted on
the end of the shuttle bar. Since the magnet is suspended in air by the
shuttle, it never touches the coil. There is no friction or wear and the
only resistance for the motor is in flexing the cantilevered springs
supporting the shuttle bar and shuttle motor coil.
The shuttle bar carries the print modules and is suspended by the leaf
springs. The motor’s magnet is mounted on the right end of the shuttle
bar and moves back and forth inside the motor coil as the shuttle bar
oscillates.
Sinusoidal current is applied to the coil with the direction of current flow
changing approximately 80 times a second. As a result, the shuttle bar is
pulled toward the right side frame and then pushed away by the
changing current. The motor consumes only 6-10 watts of power since
the springs help reverse the direction of motion.
The speed of the shuttle and distance of travel (amplitude of the swing)
are crucial to the timing of the printer. A magnet mounted on the left end
of the shuttle bar travels back and forth inside a separate stationary coil.
This linear velocity transducer (LVT) coil sends feedback signals to the
printer electronics to regulate the amount of current applied to the
motor.

GEK-00048 Chapter 1. Printer Description
8
Character Formation and Timing
Dots are printed during each swing of the shuttle as it sweeps across the
print surface. Individual print wires are actuated at each position where
a dot is required to form the character. After the first horizontal row is
printed, the shuttle reverses direction, while the paper is advanced to the
next print row (typically 1/72-inch).
The character formation process continues through a total of 9 swings
(data process font), with rows 8 and 9 used for the formation of lowercase
descenders and underlining. After a character row is completed, the
paper is advanced to the next line.
Each tier simultaneously prints a ½ inch vertical area (three lines of text)
on the paper. After the six lines (three lines for each tier) are printed by
the upper and lower tier, the paper skips forward ½ inch. The ½ inch
skip prevents the top tier from overprinting on the text printed by the
lower tier.
Heat Dissipation
Two axial-flow fans and one blower cool the 55 dBa (Standard Model)
printer. All are located inside the rear access panel. One fan is located
just below the top enclosure at the rear of the printer and forces air up
through the actuator driver circuit (SMAD) boards. The second fan is
located on the rear wall and forces air up past the power supply. The
blower is located inside an air baffle to the left of the LPCU logic board.
The 52 dBa (Quietized Model) contains one axial-flow fan, located inside
the left rear access panel just above and slightly to the rear of the LPCU
board. The air baffle and blower are contained in the front right access
panel located just inside the front door. Air is pulled in through the right
side air filter, through the blower, and routed up through the print
actuator modules.
The fans in both models run continuously. The blower runs when power
is applied to the shuttle motor.
Power-on, Print Time, and Head Life Readouts
The printer has a built-in timer that is used to maintain a record of print
duty cycle in hours, minutes, and seconds. The timer records the
amount of time the printer has had power applied and the amount of
time the shuttle motor has run.
This information is available on the status printout and can be displayed
on the control panel LCD via the Maintenance menu.
Power-on Time Display: HHHHH:MM:SS
Print Time Display: HHHHH:MM:SS
A graph, showing the number of times each print head has fired, can be
printed by accessing the Maintenance menu, HeadService, Print Chart.