IBM 1402 User manual

"7J//7 ~
Issued to: --FC>~..of4:-. .. -+; _' ~/;Ll~.(-.<·/::. • .JO:~·:::(,,;:-- ______ _
/1
Branch Office :------,ts-<'t'--'7""---.~~ ... ,l..-----------
Department: ________________ _
If this manual is misplaced, it should
be returned to the above address,
frl CjD)o l.\I.7
~d.E)~ Customer Engineering Instruction-Reference
1402 Card Read-Punch
© 1960, 1961, 1962 by International Business Machines Corporation

This manual, Form Number 231-0002-2, is a major reVISIOn of
the preceding Form 231-0002-1. Many minor changes and addi-
tions have been made. Major revisions include new punch feed,
transport, and brush timing procedures, the addition of solar cell
CB instructions and adjustments, and a more complete coverage
of belt replacement and retiming procedures.
This manual, Form 231-0002-2 makes obsolete Forms 231-0002-0
and 231-0002-1.
Address comments regarding this publication to:
IBM, Product Publications Department, Rochester, Minnesota
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . 1-1
FUNCTIONAL PRINCIPLES. . . . . . . . 1-1
OPERATING LIGHTS AND CONTROLS 1-2
FUNCTIONAL SWITCHES . . 1-3
SPECIFICATIONS .. 1-3
READ FEED. . . . . . . . . . 2-1
DRIVE MECHANISM. 2-1
Speed. . . . . . . 2-1
READ CLUTCH. . . . 2-1
Principles of Operation. 2-1
Clutch Adjustments. . . . 2-2
Clutch Timing. . . . . . . 2-4
Clutch Pulley Assembly Removal 2-4
Clutch Pulley Assembly Installation. 2-4
Clutch Drive Removal. . . 2-4
Clutch Drive Installation. 2-4
FILE FEED. . . . . . . . . . . . . 2-5
Principles of Operation. . 2-5
Clutch Adjustments. . . . . 2-6
Clutch Removal. . . . . . . 2-6
Service Checks . . . . . . . 2-7
Joggler Adjustments. . . . 2-7
HOPPER AND PICKER KNIVES 2-7
Principles of Operation. . 2-7
Adjustments 2-8
CARD GUIDES. . . . . 2-9
Adjustments ..
CARD LEVERS ...
Adjustments .
BRUSH ASSEMBLY
Adjustments .
Timing .....
TRANSPORT AND STACKERS
SELECTION MECHANISM ....
Principles of Operation ..
Chute Blade and Selector Magnet
Adjustment . . . . . . . . . ....
TRANSPORT ROLL ADJUSTMENTS
JAM BAR ADJUSTMENTS .. .
STACKERS ............... .
Principles of Operation. . . .
stacker Joggler Adjustments
Stacker Adjustments .
PUNCH FEED .......... .
DRIVE MECHANISM
....... .
PUNCH FEED CLUTCH ..... .
Principles of Operation ..
Clutch Adjustments. . .. .
Clutch Timing. . . ... .
Clutch Ratchet Removal.
GENEVA ............. .
Principles of Operation.
Adjustments . . . . . . . .
Timing ........ ' .... .
HOPPER AND PICKER KNIVES
Principles of Operation ..
Adjustments . . . . . .
CARD GUIDES ........... .
Adjustments . . . . . . . . . . . . . . . . .
FEED ROLLS AND ALIGNER STATIONS.
Principles of Operation. . . ... '.'
Timing Check of Punch Transport.
Adjustments of Punch Transport. .
2-9
2-9
2-9
2-10
2-10
2-10
3-1
3-1
3-1
3-1
3-2
3-2
3-2
3-2
3-3
3-3
4-1
4-1
4-1
4-1
4-1
4-3
4-3
4-3
4-3
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-4
4-4
4-5
4-7

Side Aligner Removal . . . . . . . . . . . . .
Forward Aligner Removal . . . ..
First Stepped Feed Roll Removal
Fourth Upper Feed Roll Removal
Fifth Upper Feed Roll Removal. .
Second Stepped Feed Roll Removal ... .
ROLL OPENING DEVICE .............. .
Principles of Operation. . . . . . . . . . . .
BRUSH ASSEMBLIES ................ .
PUNCH UNIT ...................... .
Principles of Operation ... .
Punch Unit Removal ..... .
Punch Unit Installation ... .
Cam Follower Bearing Adjustments.
Cam Follower Assembly Removal. .
Cam Follow Assembly Timing . . ..
Interposer Setup Bail Adjustment . .
Interposer Setup Bail Removal . . . .
Magnet Bar Assembly Adjustment. . ...
Magnet Bar Assembly Removal .
Magnet Unit Adjustments ..
Magnet Unit Removal . . . . . . . .
Magnet Unit Installation . . . . . .
Interposer Guide Bar Adjustment
Interposer and Interposer Link
Removal .............. .
Stripper Assembly Removal. . . .
Stripper Assembly Installation . . . . .. .
Latch Removal. . . . . . . . . . . . . . . .. .
Punch Removal . . . . . . . . . . . . .... .
Punching Registration. . . . . . . . . . . . .
Punch Unit Timing . . . . . . . . . . . . . . .
TIMING DRIVE BELTS ................... .
PUNCH FEED INSTALLATION
PROCEDURES ................... .
Main Drive Belt ................ .
Drive Motor Belt ............... .
CR Idler Belt .................. .
Timer Index Belt. . . . . ..
PCCB Drive Belt ............... .
Idler Belt .................... .
PACB Drive Belt ............... .
Second Stepped Feed Roll Drive Belt .. .
PLCB Drive Belt ............... .
Punch Unit Drive Belt ............ .
First Stepped Feed Roll Drive Belt ... .
READ FEED BELT INSTALLATION.
Clutched Feed Roll Drive Belt .
Read Feed Belts . . . . . . .
ELECTRONIC COMPONENTS '" ..... .
SOLAR CELL CB ............. .
Introduction . . . . . . . . .
Principles of Operation ..
Timing Procedure . . . . .
Adjustment Procedure. . .
Removal and Replacement .
PERMISSIVE MAKE RELAYS .. .
Principles of Operation .. .
Contact Replacement . . . .
CIRCUIT BREAKERS ....
Open Strap Contacts . . . . .
4-9
4-9
4-9
4-9
4-9
4-10
4-10
4-10
4-10
4-10
4-10
4-12
4-12
4-12
4-12
4-13
4-13
4-14
4-14
4-14
4-14
4-14
4-14
4-15
4-15
4-15
4-15
4-15
4-16
4-16
4-17
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-3
5-3
5-3
5-3
5-3
5-4
5-4
5-4
6-1
6-1
6-1
6-1
6-2
6-3
6-3
6-3
6-3
6-4
6-4
6-5
SERVICE AIDS ....................... " 7-1
CUSTOMER ENGINEERING SERVICE
PANEL ....................... .
SPECIAL FEATURES .................... .
51-80 COLUMN DEVICE. . . . . . . ..... .
Mechanical Adjustments .......... .
PUNCH FEED READ ................. .
Principle of Operation ........... .
Card Guide Adjustments . . . . . . . . . . .
EARLY CARD READ ................. .
SERVICE HINTS ....................... .
INSTALLATION PROCEDURE .......... .
READ FEED ...................... .
Reader Stop Lights. . . . . . . . . . . . . . .
Reader Check Lights ............ .
Validity Lights ................ .
Picker Knife Timing Check . . . ..... .
Brush Timing . . . . . . . . . . . . . . . . . .
Circuit Breaker Timings .......... .
PUNCH FEED ..................... .
Punch stop Lights. . . . . . . . . . . . . .
Punch Check Lights . . . . . . . . . . .
Punch Check Brushes Out of Time ..
Punching Registration .. .
Dropping Punches ..... .
Multiple Punches ..... .
Damaged Cards or Jams .
7-1
8-1
8-1
8-1
8-1
8-1
8-3
8-3
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-1
9-2
9-2
9-2
9-2
9-2
9-2
PREVENTIVE MAINTENANCE ....... .
..... 10-1
APPROACH TO PREVENTIVE
MAINTENANCE ................... 10-1
PREVENTIVE MAINTENANCE
PROCEDURE ..................... 10:"1
1402 CIRCUITS ........................ .
POWER SUPPLY AND INTERLOCK
CIRCUITS ....................... .
Power On Sequence .............. .
Power Off Sequence . . . . . . . . ..... .
READ FEED CIRCUITS ................ 11-1
Load Key Operation .............. 11-1
start Key Operation .............. 11-2
Card Reading (RLCB Machines) ...... 11-2
Reader Non-Process Run-Out ........ 11-2
Stop Key Operation ............... 11-2
Card Jam Circuits ............... 11-2
Clutch Check Circuit ............. 11-3
PUNCH FEED CIRCUITS ............... 11-3
Punch Motor Start and Run ......... 11-3
Punch Feed Cycles .............. ; 11-3
Punch Feed Read ................ 11-3
Card Punching .................. 11-3
Punch Check Brushes ............. 11-3
Punch Non-Process Run-Out ........ 11-4
Stop Key Operation. . . . . . . . .. 11-4
Card Jam Circuits ............... 11-4
Clutch Check Circuit. . . . . . . .... 11-4
Stacker Select Circuits. . . .... 11-4
1402 MODEL 2 ., ....................... 12-1
DESCRIPTION ...................... 12-1
VARIATIONS BETWEEN THE MODEL 1
AND
MODEL 2 ................... 12-1
Read Feed Roll Number 4 .......... 12-1
Punch Emitter .................. 12-1
Electrical Changes. . . . . . . . ....... 12-1
Operating Controls and Lights ....... 12-1

ffiM 1402 Card Read-Punch

INTRODUCTION
The IBM 1402 Card Read-Punch provides the 1401
data processing system with a punch card input and
output.
The read feed is a 20 cycle-point feed
equipped with a file feed which
has a capacity of 3600
cards. The read feed can process cards at a speed
of 800 cards per minute. The punch feed is a 16
cycle-point feed which can punch cards at 250 cards
per minute. Five radial stackers are used to accom-
plish stacking of the cards from both feeds. The
read feed and the punch feed are located at opposite
ends of the machine so that cards are fed from the
read feed and the punchfeed into a transport assembly
above the stackers. The card transport system is
driven by timing belts wherever possible to reduce
machine noise and maintenance. Power supplies for
other machines of the system are located in the 1402.
FUNCTIONAL PRINCIPLES
The 1402 Card Read-Punchcanreadcardsata maxi-
mum speed of 800 cards per minute. Actual card
speed is governed by the program routing. The read
feed is equipped with a 3600 card capacity file feed.
The
cards are fed through the read feed. 9 edge
first. face down. The card path is illustrated in the
feed schematic diagram (Figure 1-1). As the card
passes the read check brushes. 80 columns of the
card are read to condition the hole count check planes
in the 1401. It is then moved past the read brushes
where again 80 columns of the card are read and
entered into the read area of core storage. At the
same time the check planes are conditioned so that
a hole count check may be completed. Next. it is
transported past the stacker selection station and is
directed to the appropriate stacker under control of
programming. Three stackers are available to re-
ceive cards from the read feed. The NR (normal
read) stacker is used unless the cards are program-
directed to stacker 1 or stacker 2 (8/2).
The 1402 Card Read-Punch will punch cards and
check card punching at a maximum speed of250 cards
per minute. Cards are placed in the 1200 card ca-
pacity hopper. 12 edge first. face down. Card feeding
is illustrated in the feed schematic diagram (Figure
1-1). As the card passes the Punch Feed Read
(optional feature). 80 columns of the card are read
into the read areas of core storage of the 1401 if
PFR is called for. Before the card is punched. it is
aligned at the aligner station both vertically and
horizontally to insure correct punching registration.
Punching is done by a high-speed punch unit. As
the card passes the punch station. circuits are set up
in the 1401 which allows the card to be punched with
information contained in the punch area of core
storage. At the same time the check plane cores are
conditioned so that a hole count check may be per-
formed. After the card is punched. it is read at the
80 column punch-check brushes to condition the check
plane cores so that a hole count check may be com-
pleted. It is then moved past the stacker selection
station and is directed to the appropriate stacker
under program control. Three stackers are available
to receive cards from the punchfeed. The NP (Normal
Punch) stacker is used unless the cards are program-
directed to stacker 4 or stacker 8 (8/2). The 8/2
stacker cannot be used for collating between the punch
and
read feeds.
The card transport assembly located between the
punch feed and the read feed has a set of six feed
rolls along with two select magnets and chute blades
for the read feed as well as two select magnets and
chute blades for the punchfeed. A jam bar is located
in the transport assembly to provide an indication of a
jam and stops the machine when a card jam occurs
(Figure 1-2).
All stackers are the non-stop unloading radial
type stackers with a capacity of 1000 cards each.
Cards can be removed from the stackers without
PUNCH FEED
TRANSPORT
READ m='D
FI RST STEPPED
FEED ROLLS
PUNCH FEED
READ STATtON
Figure 1-1. 1402 Feed Schematic
NP
STACKERS
NR
READ STATION
NOTE
DARKENED FEED ROLLS ARE UNDER
CONTROL OF THE FEED CLUTCHES
1-1

JAM STOP
SWITCH
Figure 1-2. Transport Mechanism
stopping the machine . Two stackers are assigned
exclusi vely to the punch fe ed . The center (8 / 2)
stacker can be used by either unit, but it must be
assigned by the program to one or the other, in any
one
run (Figure 1-3).
Both feeds are equipped with jam and misfeed
detention devices .
OPERATING LIGHTS AND CONTROLS (Figure 1-4)
Read Switch: Controls the read section of the
machine . When this switch is off, the read feed is
inoperative.
Figur e 1-3 . Radial Stacker
1-2
STAC KER SE L EC TMA GN ETS
rpU NC H
Punch Switch: Controls the punch section of the
machine. When this switch is off, the punch feed is
inoperative by program control. Cards can be run
into the punch feed with the punch switch off by use
of the non-process runout punch switch .
Start Switch: Causes the read feed motor to start
when the read switch is on. Punch motor will start
if punch switch is on.
Stop Switch: Used to stop the system. If a pro-
gram instruction is in process, it is completed before
the stop occurs.
Non- Process Runout- Read Switch: Used to run
cards out of the read feed. The last two cards run
out will not be processed. The read hopper must be
empty to make this switch effective.
Non- Process Runout- Punch Switch: Used to run
cards out of the punch feed. The last two cards will
not be punched. When the punch switch is on, the
hopper must be empty to make this switch effective.
Load Switch: Used to start loading instruction
cards. PreSSing the load key causes the read feed
to operate until a card has passed the read brushes.
After the card is read at the read brushes, the pro-
gram can start and execute the instruction that is
punched in the card . Continued operation is under
control of programming. When the punch switch is
on, pressing the load key causes the punch drive
motor to run.
Check Reset Switch: Must be pressed to reset an
error indication before the start key can become
operative . This switch is operative only when the
feed, in error, is empty of all cards.
Power Light: When power is supplied to the read-
punch unit, this light is on.
Reader stop Light: A feed failure or a card jam
in the read-feed causes the machine to stop and the
reader-stop light to come on.

g
=
PUNCH
STOP
CHIPS
STACKER
Figure 1-4. Operating Controls
CHECK
RESET
Punch stop Light: A feed failure or a card jam
in the punch feed causes the machine to stop and the
Punch Stop light to come on.
Validity Light: This light comes on if an invalid
character is detected during read operation.
Reader Check Light: This light comes on under
control of the data processing system when anerror
is detected during card reading.
Punch Check Light: This light comes on under
control of the data processing system when an error
is detected during the punching of a card.
Stacker Light: If any of the five stackers become
full, the stacker light goes on and the machine stops.
The light may come on shortly before the machine
stops.
Transport Light: This light is turned on by the
jam contact. It indicates that a card has jammed in
the transport feed roll area.
FUNCTIONAL SWITCHES
Cover Interlocks: When a cover is opened, the
respective interlock switch will open the circuit to
the punch and reader, motor and run circuits.
Punch Magazine Interlock: When the magazine
locking lever is opened, this switch opens the circuit
to the punch motor and motor start relays.
Die Lift Interlock: This switch provides the same
function as the magazine interlock when the lowering
frame is lowered.
Crank Interlock: This is a manually operated
switch which must be turned off to insert the hand
crank. It provides the same function as the magazine
POWER REAOER
CHECK
TRANSPORT
BB
interlock while using the hand crank.
g
~
Die Interlock: This switch provides the same
function as the magazine interlock when the die is
removed or improperly located.
Stacker Switch: This switch operates whenanyof
the 5 stackers are filled. When transferred, it opens
the circuit to the punch and reader, start and run
circuits. It also closes the circuit to the stacker
indicating light when transferred.
Jam Bar Switch: When a jam occurs, this switch
provides the same function as the stacker switch
except that it completes a circuit to the transport
light when transferred.
Joggle Switch: This switch is operated when the
hinged front joggler assembly is opened. Itopens the
circuit to the reader motor control relay.
Chips 1 and 2 Switches: These switches operate
when the chip box is full or removed from the ma-
chine. Operation of either switch willopen the punch
motor and run circuits as well as light up the "chips"
indicating lamp.
SPECIFICATIONS
Dimensions:
57 1/2" wide
29 3/4" deep
45 1/4" high (plus read file feed 14 5/8")
Weight:
1300 lbs
BTU Rating:
3,500 BTU
1-3

READ FEED
DRIVE MECHANISM (Figure 1-1)
A 1/ 4 hp motor drives the input pulle y on the read
feed . The following are kept continuously running:
1. Timer index
2. Clutch ratchet
3. Two contact rolls
4. First feed roll after each contact roll
5. Continuously running CB/ s (RC)
6. File feed drive shaft
7. Three transport feed rolls
8. Stacker jogglers for NR, 1 and 8/ 2 pockets.
When the read clutch engages, power is transmitted
to the following:
1. Picker knife cam shaft
2. Feed knives
3. First feed roll before each contact roll
4. Clutch controlled CB's (RL) and solar cell
CB (if installed)
GENEVA ---fi
CHIP BOX--tlI--- .....
PMT (PUNCH MAGNET TERMINALS)
HD RELAYS AND MAIN CONTACTOR _ _ J
(BEHI ND FUSE PANEL)
BRUSH IMPULSE TRANSISTORS
(REAR OF RELAY GATE)
Figure 2-1. 1402 Front View
Adjust the motor pulley to feed cards 800+ 3- 20 cards
per minute.
READ CLUTCH
Principles of Operation
The clutch ratchet is continuously running and makes
one-half revolution each machine cycle. This ratchet
is engaged by a drive dog and detent, which are
controlled by the action of the drive arm and inter-
mediate arm.
The dog and detent are spring-loaded to engage
the ratchet. They pivot on studs that are part of the
drive arm and are controlled by studs that are part
of the intermediate arm. The intermediate arm pivots
on a sleeve that is the hub of the drive arm (Figure
2-3).
RLCB UNIT
GT (GATE TERMINALS)
2-1