Kaypro 2 Use and care manual

KAYPRO TECHNICAL MANUAL
DECEMBER 1984
Part Number 1484-D

1.0
1.1
1.2
2.0
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.0
5.0
5.1
5.2
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
7.0
7.1
7.2
7.3
7.4
7.5
8.0
8.1
8.2
8.3
Introduction
Purp::lse of Technical Manual
Scope of Technical Manual
FCC Infonnation
M::x1el Specifications
KAYPRO 2
KAYPRO 2/84 and 2X
KAYPR04
KAYPRO 4/84
KAYPRO 4X
KAYPRO 10
KAYPRO ROBIE
RCM Revisions - CP/M canpatibi1ity
O1assis
Raroval/Replacement of !bod (Exc. ROBIE)
'Ibuch-up Infonnation
Mainboards-Troub1eshooting Tips
KAYPRO 2 (81-110-n)
KAYPRO 2/4 (81-240-n)
KAYPRO 10 (81-180-n)
KAYPRO 2/84 and 2X (81-294-n)
KAYPRO 4/84 (81-184)
KAYPRO ROBIE (81-296-n)
Rarova1/Installation Instructions
CRI' Assemblies
Descriptions and Adjustments
Video Alignment
Video Signals on KAYPRO Mainboard
ALIGN.MAC Diagrx:>stic Listing
Raroval/lnsta11ation Instructions
Power SUW1ies
Introduction
Description and 220V Configuration
Raroval/lnstal1ation Instructions
PAGE
1-1
1-2
2-1
3-1
3-2
3-3
3--4
3-5
3-6
3-7
4-1
5-1
5-2
6-1
6-2
6-8
6-16
6-26
6-35
6-44
6-53
7-1
7-3
7-4
7-5
7-8
8-1
8-2
8-5

<Dll'ftll'S (<:mtinued)
~m
9.0
Diskette Drives
9.1
Introduction/Disk Drive Cleaning
9-1
9.2 Which Brand of Drive Is It?
9-2
9.3
Jumpering Diagrams
9-5
9.4
High-Density (Drivetec) Drives
9-9
9.5
Removal/Installation Instructions
9-10
10.0
Hard Disk Drives (KAYPRO 10)
10.1
Introduction
10-1
10.2
Description
10-2
10.3
Hard Drive Configuration
10-3
10.4
Hard Drive or FloR'}" Drive Rsroval/
Installation Instructions (KAYPRO 10)
10--4
11.0
Hard Drive Controller Board
(KAYPRO 10)
11.1
Description
11-1
11.2
Removal/Installation Instructions
11-2
12.0
Interface Board (KAYPRO 10)
12.1
Description
12-1
12.2
Removal/Installation Instructions 12-2
13.0 Keyboards
13-1
14.0
ROBIE Removal/Installation Instructions
14.1
Chassis Covers
14-1
14.2
Diskette Drives
14-2
15.0 Troubleshooting
15.1
Introduction
15-1
15.2 KAYPRO 2 and 4 Symptan-Fix Guides
15-2
15.3
KAYPRO 10 Symptan-Fix Guide 15-8
15.4 ROBIE Symptan-Fix Guide
15-15
15.5
KAYPRO 2/84 and 2X Sympt.cm--Fix Guide 15-21
15.6 KAYPRO 4/84 and 4X Symptan-Fix Guide
15-22

<XIftmill'S
(cmtinued)
~<E
16.0
System I/O
16.1
Video Catmand Protocol
16-1
16.2
Keyboard Codes arrl FUnctions 16-2
16.3
Connector Pin-outs
16-3
16.4
Port Addresses
16-10
17.0
Reference Section
17.1
ASCII Chart
17-1
17.2 Mercory Maps 17-2
17.3
Vendor Addresses
17-6
18.0
Suggested References
18-1
19.0
KAYPRO 16
19.1
O1assis
19-3
19.2
System Boards
19-4
19.23
Board Assembly Rem:>val
19-16
19.24
card Rem:>val 19-18
19.25
Mainboard Rem:>val
19-21
19.26
Disk Controller Board Ratoval
19-22
19.3
CRI' Assembly 19-23
19.33 CRI' Rem:>val
19-24
19.4
Power SU£:ply 19-26
19.43
Power Supply Rem:>val
19-29
19.5
Diskette Drives 19--31
19.53 Diskette Drive Ratoval
19-32
19.6
Hard Disk Drive 19-37
19.63 Hard Disk Drive Raroval
19--38
19.7
Keyboard 19-41
19.8 System I/O
19-42
19.81
Parallel Printer Cable
19--42
19.84 Serial Printer Cable
19-44
19.86
~em Cable
19-45
19.92
I/O Port Addresses
19-48
19.93
Mercory Map 19-49
19.94 Switch settings
19-50
19.95
Mercory Expansion 19-52

1.1 PURl?<:SE <F 'IK.HfiCAL MANUAL
'!his publication is intended to be a technical re ference guide to be used by
trained rePair technicians. It will attempt to COller all dealer-serviceable
sections of Kaypro computers. '!his manual replaces previous manuals on the
subject.
'The procedures and infurmation contained in this manual assume technical
expertise on the part of the reader. 'Ib avoid personal injury, do not perfurm
any servicing unless you are a qualified service technician.
It is our desire to provide dealers with the infurmation and stlJ?fX)rt needed to
expedite rePairs am provide the users with the service they deserve. We
encourage your comments am suggestions regarding this manual.
1-1

1.2 SCCPE <F 'lHR\IICAL Ml\NUAL
'!he infbrmation and procedures covered by this manual assume some technical
kn<:Mledge on the part of the reader. '\
'!he policy 0fKaypro Corporation is to repair computers to the modular level
only. Even Kaypro's repair technicians do not rePair switching power
supplies, CRI' assemblies, or disk drives. Repairs to modular comPonents not
manufactured by Kaypro Corporation (power supplies, CRI' assemblies, disk
drives) are Nor covered by this manual.
Ibwever, we do rot discourage dealers and technicians who have the knowledge
and the tcx:::>ls to repair to the component level from doing so, on out~f
warranty Kaypro computers.
'!he adjustment and rerroval/replacement infbrmation in this manual is organized
by module type, with the exception of removal/replacement infbrrnation :fOr the
KAYFRO RCBIE, which is placed in a seParate section due to the di fferences in
chassis design and hardware module placement in that machine.
\
1-2

5.e IWUiARE M<DRES
-> CCLOOED TAB HERE: HARIWARE

\
2." F<X:: INFCIMATI<N
As Kaypro keeps in step with romputer technology, the models have changes
which affect FCC ratings. The proPer rating is affixed to the back of each
romputer. Contact the Kaypro Engineering Department if you need further
infunnation •
2-1

3.8 H<IEL SPECll'ICATIQ1S
3.1 KAYPRO 2SPOCll'ICATIOlS
CPU
RAM
MAINBCARD
DISK STORAGE
KEYBCARD
VIDEO SCREEN
I/O CCNNECl'ICNS
Z-80 2.5 MHz
64K bytes
81-110-n or 81-240-n series.
Two 5-1/4 indh, double-density, single-
sided, floppy disk drives, providing
19lK bytes of storage per diskette.
Detachable, 72 key typewriter style
keyboard with 18 progranmable keys.
Non-glare, 9-indh, green Phosphor
screen with a25 row x 80 column
display.
(he "Centronics"-type parallel
port, one RS-232C serial port.
3-1

3.2 KAYPRO 2/84 aId 2X SPFCIEilCATI~
CPU
RAM
DISK STORAGE
(Kaypro 2/84)
DISK STORAGE
(Kaypro 2X)
KEYBQt\RD
VIDEO SCREEN
I/O C<::NNECI'ICNS
Z80-A 4.0 MHz
64K bytes
81-294-n series.
Two 5-1/4 inch double-density, single-
sided, floppy disk drives, providing
191K bytes of storage per diskette.
Two 5-1/4 inch double-density, double-
sided, floppy disk drives, providing
3901< bytes 0f storage per diskette.
Detachable, 72 key typewriter style
keyboard with 18 programnable keys.
Non-glare, 9-inch, green phosIilor
screen with a25 row x 80 column
display.
Che "Centronics"-type parallel port,
t'WO RS- 232C serial ports.
3-2

3.3 KAYP{«) 4SPFX:.lFlCATIQIS
CPU
RAM
DISK STORAGE
VIDEO SCREEN
I/O Cc:NNECI'ICNS
Z-80 2.5 MHz
64K bytes
81-240-n series.
Two 5-1/4 inch double-densi ty, double-
sided, floppy disk drives, providing
3901< bytes 0f storage Per diskette.
Detachable, 72 key typewriter style
keyboard with 18 programnable keys.
Non-glare, 9-inch, green PhosPhor
screen with a25 row x 80 column
display.
Cb.e "Centronics"-type Parallel port,
one RS-232C serial port.
3-3

3.4 KAYPRO 4/84 SPJ£IFlCATICNS
CPU
RAM
DISK STORAGE
KEYBmRD
VIDEO SCREEN
I/O C~ICNS
MmEM
REAL-TIME CLOCK
Z-80A 4.0 MHz
64K bytes
8l-l84-n series.
Two double-densi ty, double-sided,
floH¥di~~ives, provMmg 39~
bytes 0f storage per diskette.
Detachable, 72 key typewriter style
keyOOa.rd with 18 progranmable keys.
Non-glare, 9-inch green phosphor
screen with a25 row x 80 column
display.
(he "Centronics"-type parallel port,
two RS-232C serial ports, one RJllC
rrcdular telephone jack.
Built-m, 300-0000 rrcdem, with Bell
System 103 crnpatibility. Uses Texas
Instruments TMS99531/TMS99532.
Built-m real-time clock. Uses National
r-M58167.
3-4

3.5 KAYPRO 4X SPJ£IFICATIQ1S
CPU
MAINBCARD
DISK srOOAGE
KEYBCARD
VIDEO SCREEN
I/O C~ICNS
MffiEM
~TIME CLOCK
Z-80A 4.0 MHz
641< bytes
81-296-n series.
Two 5-1/4 inch, high-density, double-
sided, floppy disk drives providing
2.6M bytes of storage per diskette.
Detachable, 72 key typewriter style
keyboard with 18 programna.ble keys.
Non-glare, 9-inch, green phosrnor
screen with a 25 row x 80 coltnnn
display.
(be "Centronics"-type parallel
port, two RS-232C serial ports, one
RJIIC rrodular telephone jack.
Built-in, 300-0000 modem, with Bell
System 103 compatibility. Uses Texas
Instruments TMS99531/TMS99532.
Built-in real-time clock. Uses National
r.M58167.
3-5

3.6 IQ\YPRO 19 SPJ£IFICATIQIS
CPU
RAM
DISK STORAGE
VIDEO SCREEN
I/O CCNNECI'ICNS
Z80A, 4.0 MHz
64K bytes
81-18l2J-n series.
(he 5-1/4 inch double-density, double-
sided, :fl.oFPY disk drive providing
39l2JK bytes of storage per diskette.
(he hard disk drive providing 10M
bytes 0f storage.
Detachable, 72 key typewriter style
keyboard with 18 progranmable keys.
Non-glare, 9-inch, green Phosphor screen
with a25 row x 80 colurm display.
(he "Centronics"-type parallel port,
t.v.Q RS-232C· serial ports.
3-6

3.7 KAYPRO RCBIE SPEClFlCATI<NS
-----,
CPU
RAM
DISK STCRAGE
KEYBCNID
VIDEO SCREEN
I/O CCNNECTICNS
MCDEM
REAL-TIME CLCCK
Z80A, 4.0 MHz
64K bytes
81-296-n series.
Two 5-1/4 inch, high-density, double-
sided, flowy disk drives providing
2.6M bytes of storage per diskette.
Detachable, 72 key typewriter style
keyboard with 18 progranmable keys.
Non-glare, 9-inch, green phosphor screen
with a25 reM x 80 column display.
(he "Centronics"type parallel port,
two RS232C serial ports, one RJllC
m:xiular telephone jack.
Built-in, 300-baud modem, with Bell
System 103 compatibility. Uses Texas
Instruments TMS9953l/TMS99532.
Built-in real-time clock. Uses National
~8167.
3-7

4.f2J I<AYPRO RCM REVISICN-CP!M VERSI<N CCMPM'IBn..rIY
2/83
4/83
4/83
+88
2/84
4/84
4/84 +88
2 X
4X
RCBlE
CP/M VERSI<N KAYP.RO PARr J
(:fOr CP/M disk)
2.2F 0777
2.2F 1475
2.2F 1475
2.2G 2619
2.2G 2622
2.2G 2622
2.2G 2470
2.2G 2340
2.2G 2340
4-1
RCM VERSI<N
81-149-C or 81-232-A
81-232-A
81-232-A
81-292-A
81-292-A
81-292-A
81-292-A
81-326-E
81-326-E

--> CCLORED TAB: TRClJBLESHoorING

5.0 aJASSIS
5.1 aJASSIS H<XD ImDlAL (EX.CEPT KAYPRO RffiIE)
1. Turn 0 ff the machine.
2. Disconnect AC power by unplugging the power cord from wall outlet.
3. Remove the ten screws from the chassis haJdi there are two on top
and fuur on each side.
4. Renove the haJd fran the chassis.
aJASSIS H<XD ~
1. lDwer the hood onto the unit.
2. Align the two holes on top 0f the hood with those on top 0f the
chassis.
3. Insert the two flat-head screws into the holes on the top of the
chassis and start them, but do rot tighten them yet.
4. Insert the eight round-head screws, fuur on each side, and start
them.
5. Tighten each screw securely.
5-1

5.2 TaXH-UP:J:NF(H4AT1<N
Kaypro Corp::>ration has small amO\IDts 0f touch-up paint fur Kaypro hcx:x1s and
chassis available to the dealers. Contact the Hardware Technical Support
personnel to obtain this paint.
O=casionally a customer's computer will have scratches on the hcx:x1 or chassis.
A small amo\IDt of rubbing com];X)und, when carefully applied, will often smooth
out very small scratches on a hcx:x1 or chassis. Should painting be necessary,
there are two sizes of sable paintbrushes to have on hand: size 00 and size
000. 'Ihese brushes are available at any art supply store.
5-2

The fOllowing sections contain schematics, chip layout diagrams, and IC lists
(by U-number) fOr Kaypro mainboards. This is not intended to be a theory of
operation, but rather an aid to locating possible problems on a.mai.nl::x>ard.
; ,.
Consult an appropriate databJok (TrL, Zilog, etc.) if you need to find out the
internal v.orkings of a particular IC.
MAINBQl\RD .TRaJBLEsHoorING TIPS:
A blank EPRCM can be used to help troubleshoot Kaypro mainlx:>ards of series
81-110, 81-240, and 81-180. The appropriate model of EPRCM (2732, 2716, etc)
allows a quick check of the 1:x:lard. It will usually fOrce the data and
address lines to toggle at approximately the same amplitude, allowing the
technician to use a scope to spot affected lines.
If the video display does not show a screen filled with alternating "9'''s
and apostrophes, you have a problem in the video RAM or associated
circuitry.
You can check the main RAM and associated circuitry quickly with a scope by
looking at pin 14 on each of the RAM chips. There should be a pattern of
signals like this:
For th~ 81-240 1:x:lard:
U20 (D7)
U21 (06)
U22 (D5)
U23 (D4)
U24 (D3)
U25 (D2)
U26
(Dl)
U27 (00)
ION
ION
toggle
toggle
toggle
ION
ION
toggle
The U-numbers 0f the main RAM chips will vary depending on which mai.nl::x>ard
you have, but the pattern will be the same.
6-1