Kerning KDS 300 User manual

MAINTENANCE MANUAL
For The
MODEL 300/600
HIGH SPEED MICR PRINTER
Kerning Data Systems Inc.
Copyright 1998 P/N 301982-001
All Rights Reserved June 1998
Printed in U.S.A. Rev. A
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All rights reserved. No part of this document shall be published or reproduced in whole or
in part except with written permission of Kerning Data Systems, Inc.
The material in this document is for information purposes and is subject to change without
notice.
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TABLE OF CONTENTS
I. GENERALINFORMATION ........................................ 1
1.1 Specifications ............................................. 2
1.2 Options .................................................. 2
II. INSTALLATION ................................................. 3
2.1 SpaceRequirements........................................ 3
2.2 Unpacking ................................................ 5
2.3 Configuration.............................................. 8
2.4 InterfaceCableRequirements ................................ 8
III. THEORYOFOPERATION ....................................... 10
3.1 SystemBlockDiagram ..................................... 10
3.2 Electronics............................................... 10
3.2.1 AC/DCPowerDistribution ................................... 10
3.2.2 DCDistributionBoard ...................................... 10
3.2.3 BusBoard ............................................... 11
3.2.4 MicroprocessorBoard ...................................... 11
3.2.4.1 MicroprocessorDesign .................................. 11
3.2.4.2 InterfaceData ......................................... 11
3.2.4.3 PaperfeedSystem ...................................... 11
3.2.4.4 Interlocks ............................................. 11
3.2.4.5 DrapeSensor.......................................... 12
3.2.4.6 RibbonDrive .......................................... 12
3.2.4.7 AnalogDesign ......................................... 12
3.2.4.8 HammerProtectionCircuit................................ 13
3.2.5 HammerDriverBoard ...................................... 13
3.2.5.1 HammerCircuitDesign .................................. 13
3.2.5.2 HammerTestRoutine ................................... 13
3.2.5.3 HammerFlightTimeRoutine .............................. 13
3.2.6 Operator'sPanel .......................................... 14
3.2.7 PaperPullerBoard ........................................ 14
3.3 Mechanics ............................................... 14
3.3.1 PaperfeedSystem......................................... 14
3.3.2 RibbonSystem ........................................... 14
3.3.3 PaperPuller ............................................. 14
3.4 CharacterandControlCodes ................................ 15
3.4.1 CharacterSetCodes....................................... 15
3.4.2 FormatControlCodes...................................... 15
IV. REPLACEMENTPROCEDURES .................................. 17
4.0 TOOLSREQUIRED ....................................... 17
4.1 HammerModule .......................................... 18
4.2 Hammerbackstopscrew.................................... 19
4.3 Drummotor .............................................. 20
4.4 PaperFeedmotor ......................................... 21
4.5 Ribbonincrementmotor .................................... 22
4.6 Ribbontakeupmotor....................................... 23
4.7 Paperpullermotor......................................... 24
4.8 DrumBelt ............................................... 25
4.9 Paperfeedbelts .......................................... 26
4.10 Ribbonincrementbelt ...................................... 27
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4.11 Ribbondrivebelt .......................................... 27
4.12 HorizontaltractorAdjustbelt ................................. 28
4.13 Paperpullerbelt .......................................... 29
4.14 Paperfeedtractor ......................................... 29
4.15 ControlPanelswitcharray .................................. 31
4.16 PowerSupply ............................................ 32
4.17 PaperFeedBooster ....................................... 33
4.18 PaperOutSensor ......................................... 33
4.19 Papermotionsensor ....................................... 34
4.20 Drumgateinterlock ........................................ 35
4.21 Transducer .............................................. 36
4.22 Drumrelay............................................... 36
4.23 Cabinetcoolingfans ....................................... 37
4.24 Hammerbankcoolingfan(s) ................................. 38
4.25 MicroprocessorCCA ....................................... 48
4.26 I/OInterfaceAssembly ..................................... 49
4.27 DCDistributionCCA ....................................... 40
4.28 Busboard ............................................... 40
4.29 SensordistributionCCA .................................... 41
4.30 HammerdriverCCA ....................................... 42
4.31 ControlpanelCCA ........................................ 43
4.32 PaperpullerCCA ......................................... 44
4.33 InputSplineshaft ......................................... 44
4.34 OutputSplineshaft ........................................ 46
4.35 RibbonIncrementcapstan .................................. 47
4.36 Paperpullero-rings........................................ 48
4.37 Ribbon Increment idler o-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
V. PRINTERADJUSTMENTS ....................................... 50
5.1 HammerFlightTime ....................................... 50
5.2 Transducer .............................................. 53
5.3 PaperOutSensor ......................................... 54
5.4 PaperMotionSensor ...................................... 54
5.5 TractorPhasing........................................... 55
5.6 RibbonDriveBelt ......................................... 55
5.7 RibbonTake-Upbelt ....................................... 55
5.8 RibbonBufferArm......................................... 56
5.9 RibbonPressureRoller ..................................... 56
5.10 PaperFeedBelt .......................................... 56
5.11 Paperpullerbelt .......................................... 57
VI. TROUBLESHOOTING .......................................... 58
CharacterClockFault ........................................... 59
DrumFault .................................................... 60
HammerError ................................................. 62
PaperJam .................................................... 64
PaperOut .................................................... 66
PowerFault ................................................... 68
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The Model 300/600 MICR Printer
I. GENERAL INFORMATION
The throughput of the printers are rated up to 600 documents per minute. The
print format is 8 characters per inch and 120 columns per line. Line density is
either six or eight lines per inch. Print drums with either E13B or CMC7 MICR
(Magnetic Ink Character Recognition) font are available. Special total-
transfer ribbons with ferrous particles mixed in the ink are used to generate the
characters.
The printer is connected to either a Centronics, Dataproducts or Serial interface.
ASCII or Dataproducts character codes can be used for character selection. Print
images are transmitted a line at a time, and stored in a non-volatile memory on the
Microprocessor board. Timing marks on the drum are used to generate image
scans which the Microprocessor uses to match characters from the print image.
Vertical format is maintained with control codes which follow every line of data.
These codes determine if the printer will advance paper from zero to 15 lines or
the remainder of the form after printing the current image. Multiple line movement
is processed by a vertical format unit which monitors paper positioning and vertical
tab (channel) stops. Paper is transported by four pin-feed tractors under the
control of a closed loop servo system.
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1.1 Specifications
Print columns
Model 300 56
Model 600 120
Character density 8 per inch
Font E13B or CMC7 MICR
Line density 6 or 8 lines per inch
Triple Interface Centronics Parallel
Dataproducts Parallel
RS 232 Serial
Ribbon Total-transfer MICR
Model 600 standard 190 yards x 16 inches, two-wide checks
Checks/ribbon 100,000 approximately
Optional 2500 feet 7.5 inches, one-wide checks
Checks/ribbon 230,000 approximately
Paper MICR bond check stock
Thickness .004 - .007 inches
Weight 24 lb. to 90 lb.
Max. width 21.5" sprocket hole centers
Power requirements
Single phase 115 VAC +/- 10%, 15 A, 60 Hz
Weight Printer alone Shipping
Model 300/600 530 lb. 660 lb.
Dimensions
Height 48 inches 60 inches
Width 36 inches 42 inches
Depth 40 inches 53 inches
Operating environment 10EC to 30EC, 30 to 70% humidity
(non-condensing)
1.2 Options
230 VAC, 50 or 60 Hz, Single Phase
Split ribbon kit (Model 600)
Bar Code Reader
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II. INSTALLATION
This section provides the installation and configuration procedures for the
document printer. Included in the procedures are:
Space requirements
Unpacking/repackaging
Interface connection and configuration
2.1 Space Requirements
The following figures illustrate the space requirements for the printer. Additional
space around the printer for operating and maintenance personnel should be
considered.
Figure 2.1 Printer Side View
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Figure 2.2 Printer Front View
Figure 2.3 Printer Top View, Door Open
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2.2 Unpacking
Save all major packing materials for repackaging should re-shipment be required.
The following tools are required to unpack the printer:
Diagonal cutters
2.5 mm ball hex key wrench
3 mm ball hex key wrench
Adjustable open end wrench, or
3/4" open end wrench
9/16" open end wrench
WARNING
This procedure requires three people to properly
unpack the printer.
1. Locate the pallet in a location with sufficient room to vertically remove the carton
and to roll the printer down the loading ramps.
2. While holding the ramps against the packing carton, cut the shipping straps and
lower the ramps to the floor.
3. Cut the remaining shipping straps.
4. Vertically remove the shipping carton and the protective vinyl bag.
5. Open the paper compartment and remove the ramp supports, mounting hardware,
lifting levers, and rachet wrench.
6. With the ratchet wrench install the ramp supports to the underside of the ramps
with the mounting hardware.
7. From under the pallet, loosen the nuts securing the four J-hooks and disengage
the hooks from the corners of the printer cabinet.
8. Raise the ramps and remove the three lag bolts securing the printer shipping
support. Return the ramps to the lowered position.
9. Place the two lifting levers across the pivot board at position 1 with three inches
of the lever under the printer (mark A).
10. While two people step on the levers to raise the printer, a third person can remove
the shipping support.
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11. Slowly lower the printer onto the pallet.
CAUTION
To prevent injury or damage to the printer, care should be
taken to prevent the printer from sliding off the second shipping
support.
12. Remove the three lag bolts securing the second printer shipping support.
13. Place the two lifting levers across the pivot board at position 2 with three inches
of the lever under the printer (mark A).
14. While two people step on the levers to raise the printer, a third person can remove
the shipping support.
15. Slowly lower the printer onto the pallet.
16. To remove the printer, it is recommended that two people guide the printer down
the ramps.
CAUTION
To prevent injury or damage to the printer, care should be
taken to prevent the printer from sliding off the ramps.
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