Kerning KDS 300 User manual
ii
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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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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2.3 Configuration
Perform the following procedures to configure the interface protocol:
A. Power up the printer, the unit is in the offline state.
B. Depress the PROG key to enter the program mode.
C. Use the NEXT key to advance to the program menu to the Select Interface
Routine. Press the ENTER key to access the sub-menu. The NEXT key
sequences the selection between Centronics parallel, Dataproducts parallel, and
RS232 Serial. Use the ENTER key to select the desired interface. The interface
information is stored in non-volatile memory.
D. Exit the program mode (CLEAR), and return to the on line state for normal
operation (ONLINE).
2.4 Interface Cable Requirements
Centronics Parallel
Pin Signal Description
1 Strobe*
2 Data 1
3 Data 2
4 Data 3
5 Data 4
6 Data 5
7 Data 6
8 Data 7
9 Data 8
10 ACK*
11 BUSY
12 PE
17 Chassis ground
19-30 Signal ground
31 Input Prime*
32 Fault*
* Indicates low true signal
The mating connector is a 36 pin male "Centronics".
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Dataproducts Parallel
DB50
Pin Signal Description
38 Strobe
19 Data 1
20 Data 2
1 Data 3
41 Data 4
34 Data 5
43 Data 6
36 Data 7
28 Data 8
23 Demand
21 On Line
22 Ready
30 Paper Instruction
12 +5 V
37 Strobe rtn
3 Data 1 rtn
4 Data 2 rtn
2 Data 3 rtn
40 Data 4 rtn
18 Data 5 rtn
42 Data 6 rtn
35 Data 7 rtn
44 Data 8 rtn
7 Demand rtn
6 Ready rtn
5 On Line rtn
14 Paper Instruction rtn
46 Interface Verify
45 Interface Verify rtn
The required mating connector is a DB50P (male).
Serial Interface
Pin Signal Description
2 Transmitted Data (TxD)
3 Received Data (RxD)
7 Signal Ground
20 Data Terminal Ready (DTR)
The serial interface is configured to respond to either XON/XOFF or DTR
handshaking. The character data format is eight bits, no parity, and one stop
bit. The required mating connector is a DB25P (male).
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III. THEORY OF OPERATION
3.1 System Block Diagram
The printer is divided into four major blocks. They are: AC/DC power distribution,
microprocessor subsystem, paperfeed, and hammer subsystem.
3.2 Electronics
3.2.1 AC/DC Power Distribution
The applied AC power is filtered and then distributed to the power supply, drum
motor, and paperfeed system. The power supply outputs four DC voltages which
are combined to drive all logic, hammer, and relay functions. The drum motor is
a geared induction motor controlled by a solid state relay. The paperfeed system
is a self-contained power supply, amplifier, and servo driver.
The main power supply has four DC outputs: +5 V, +24 V, +24 V, and +12 V.
These voltages are combined on the DC Distribution board to generate +5 V, +36
V, and +48 V. The +5 V drives all of the digital logic and relays. The incremental
ribbon circuit uses the +36 V to drive a stepper motor. The +48 V is stored in
large capacitors and provides power and high current for the hammer subsystem.
An auxiliary +12 V power supply drives the ribbon take-up motor.
3.2.2 DC Distribution Board
The DC Distribution board configures the primary and secondary +24 V inputs into
+48 V for the hammers, and the primary +24 V and the +12 V into +36 V for the
ribbon motor. These two voltages and the +5 V are then fused and distributed to
the printer. The +48 V is initially isolated from the hammers by a relay. The relay
prevents the hammers from firing prior to the completion of the logic initialization
routine. After the initialization is complete, the relay is engaged and each hammer
is individually tested.
Other functions maintained by the DC Distribution board include the starting and
stopping of the drum and ribbon take-up motors. The driver for the drum motor
relay is located on the board. This signal is shared by the take-up motor. When
the drum motor is turned off for a ribbon out, gate interlock open, or printer reset,
the ribbon take-up motor is also turned off. This prevents the take-up motor from
turning while the operator is changing a ribbon or wasting unused ribbon when the
drum gate is open. The fan turn-on circuit is located on the board. After a brief
delay to allow the power supplies to settle, a relay switches +24 V to the fans.
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3.2.3 Bus Board
The Bus Board distributes isolated 5 V and Ground to the Microprocessor board.
This reduces noise from crossing between the digital, analog, and ribbon driver
circuits. The Bus board provides a location to collect: sensor inputs, hammer
driver control signals, paperfeed control and status lines, ribbon incremental motor
drive lines, and relay control lines.
3.2.4 Microprocessor Board
3.2.4.1 Microprocessor Design
Controlling all functions of the printer is the Microprocessor board with an 8-bit
microprocessor, 16 k-bytes of programming, and 2 k-bytes of non-volatile ram.
The microprocessor utilizes programmable devices to control the relays, the
motors, and the control panel. These devices known as Programmable Peripheral
Interfaces (PPI) have three ports each having eight bit output latch/buffers or eight
bit input/buffers. Each port can be configured to send or receive data, act as
control lines, or receive sensor information. Another device assisting the
microprocessor is a Programmable Timer which uses the system clock, CPUCLK,
to create hammer timing.
3.2.4.2 Interface Data
Interface data directed to the microprocessor is first captured by a data latch and
then clocked into a PPI. An interrupt is sent to the microprocessor which then
transfers the data to the print buffer in the non-volatile ram until a paperfeed
control character is received. The printer scans the data buffer and matches the
buffer to the drum. When true compares are made, the Hammer Driver cards are
preset and hammer fire strobes are sent until the data buffer is printed. The
microprocessor completes the operation by stepping the ribbon and sending the
appropriate move command to the paperfeed controller.
3.2.4.3 Paperfeed System
The paperfeed system is controlled by the microprocessor with the PAP_DIR and
PAPCLK* signals. PAP_DIR determines the direction of paper motion, and PAPCLK*
drives the paperfeed motor the appropriate number of steps. Should the
microprocessor need to stop the system due to a drape sensor input, the PAPCLK*
signal is suspended during the drape short condition. Units configured with a
paper puller use the signal, PAP_DIR, to activate the paper puller during forward
movement.
3.2.4.4 Interlocks
Prior to printing, the microprocessor monitors all the faults/sensors: paper out,
paper motion, ribbon out, drum gate interlock, power monitor, paper drape, and
the character clock transducer. All faults/sensor signals are sent to the
microprocessor through the PPI's. Each sensor must be in the ready state for the
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printer to be in an ONLINE condition. The character clock transducer signal, CHAR
CLK, links the spinning drum to the microprocessor. CHAR CLK informs the
microprocessor of an indexing position from which the program can synchronize
itself to drum's character pattern. After the index mark, each CHAR CLK pulse
indicates the availability of the next print character.
PAPER OUT fault indicates the front tractor has run out of paper. A PAPER JAM error
results when the paper motion sensor not seen a significant number of pinfeed
holes at the rear tractor. DRUM GATE FAULTs occur when the gate opens while the
printer is in the ONLINE state. Opening the drum gate while the printer is offline
or during a ribbon out condition will not create a gate fault. POWER FAULTs are the
result of the power monitor signal sensing the +48 V RELAY_ON signal going to an
off state. Errors related to the character clock transducer are DRUM FAULT and
CHAR CLK FAULT. The DRUM FAULT indicates that no clock pulses were received,
while CHAR CLK FAULT means that too many or too few clocks were sensed.
3.2.4.5 Drape Sensor
When two printing units are running a common form in series (tandem), a length
of paper is required to span the distance between the two units. This additional
length of paper is known as a "drape." Care must be observed when running in
the tandem mode with a drape. If the second unit prints faster than the first unit
it can break the paper spanning between the two printers. One method of
protection is specialized software and the other is a sensing device to monitor the
physical length of paper between the two units. When the MICR printer is the
second unit of this two printer system, a drape sensor can be used to maintain a
minimum length. The drape sensor sends a signal via a PPI to the
microprocessor which in turn interrupts the paperfeed system and prevents any
paper movement until the sensor indicates the paper drape is longer. There is no
visible notice that the printer is stalled due to the drape sensor.
3.2.4.6 Ribbon Drive
The ribbon drive circuit is initialized with MOTOR_RST(and enabled with the signals
MOTOR_EN(and RIBEN(. To drive the motor, a series of pulses, RIBCLK(, are sent
to the ribbon motor controller chip and output driver.
3.2.4.7 Analog Design
The analog portion of the microprocessor board generates the initial hardware
reset, converts the hammer and character clock waveforms into a digital signals
for input to the microprocessor, monitors the hammer drivers for errors, and
controls the driver for the +48 V relay. The hardware reset, CPU_RST, is directed
to the microprocessor to place the microprocessor in a known state and to inhibit
operation while the power supplies are stabilizing. The hammer and character
clock signals are digitized for use by the microprocessor. The hammer signal is
used to determine the hammer flight time, the time required for the hammer to
strike the drum after receiving the fire pulse. The character clock signal generates
the timing for the character scans when preparing to print.0
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3.2.4.8 Hammer Protection Circuit
The +48 V relay control is operated by both software and by hardware. Software
can turn on and off the relay with PWRON(and PWROFF. PWRON(is used during
the initial power up sequence and both functions are used when the printer is
forced into the initialization routine with reset operation from the control panel.
The hardware operation is utilized as an emergency control. The input signal
PWRSEN images the current status of the hammers. When the hammers are idle
PWRSEN is approximately 4.0 V. When hammer fires or has an open coil, the
signal will drop below the 3.8 V threshold voltage. When the transition occurs the
operational amplifier (op amp) turns on. When the printer is idle, the 7406 open
collector device will complete the circuit with a ground to the transistor allowing the
op amp signal to pass through the transistor and turn off the +48 V relay. During
printing operations, the signal PWRSEN is switching and the 7406 is held inactive,
thus preventing any signals from releasing the + 48 V relay.
3.2.5 Hammer Driver Board
3.2.5.1 Hammer Circuit Design
The hammer circuit based on the latching of pre-drivers with compares made
between the drum and the data buffer, followed by a fire strobe which triggers the
hammer movement. Timing marks on the drum clock a drum pattern generator,
which the microprocessor uses when scanning the data buffer. Whenever the
microprocessor has a compare, the corresponding hammer latch is set, and
awaits the strobe pulse to fire the hammer. The strobe HFIRE is sent by the
microprocessor through a PPI to all the pre-drivers. All latched pre-drivers
activate their hammer drive pulses. The pre-driver circuits turn off the drive pulse
after receiving 128 HCLK's from the Microprocessor.
3.2.5.2 Hammer Test Routine
During the printer initialization routine, each hammer is tested. The test consists
of individually firing all the hammers and monitoring the common feedback signal,
FLIGHT, during each hammer's activation. After the verification of each hammer's
flight signal, the microprocessor initializes the hammer with the clear signal, HCLR,
and continues with the next sequential hammer. Any hammers that fail are
immediately identified to the operator with the display HAMR ## ERROR. By
depressing the CLEAR key, the hammer test routine continues until all hammers
are tested.
3.2.5.3 Hammer Flight Time Routine
The verification and adjusting of the hammers is accomplished using the same
circuitry as in the initial hammer test routine, except that the flight time routine
allows the hammer to impact the drum. The microprocessor determines the time
each hammer flies until impact, and displays a number on the control panel that
represents the flying time. Maintenance personnel can use this number to assist
in the adjustment of each hammer flight time.
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3.2.6 Operator's Panel
The operator's control panel consists of a 16 column display, a 23 key switch
array, and two indicator LED's. One microprocessor board PPI is dedicated to the
control of the display and keypad. Communication to the display requires an eight
bit parallel port plus control lines, and the keypad passes through a keyboard
decoder to another port. The online LED is driven from a PPI and the fault LED
is a clocked output from the programmable timer.
3.2.7 Paper Puller Board
The Paper Puller board turns on the paper puller whenever a forward paperfeed
command is generated from either the interface data or the control panel. The
circuit enables an optocoupler which enables a ground potential to the 24 V paper
puller motor. The circuit will time out and the motor stop unless another enable
signal (PAP_DIR) is received.
3.3 Mechanics
3.3.1 Paperfeed System
The paperfeed motor is controlled by the microprocessor. The stepper motor
receives amplified steps from the printer's microprocessor. The paper direction
signal determines the appropriate clock sequence.
3.3.2 Ribbon System
The ribbon system is driven by a controller and driver on the microprocessor
board. The drive motor increments a urethane coated capstan which steps the
ribbon after each print cycle. The ribbon is held in place against the capstan by
a shaft with idler rollers. The amount of ribbon movement is controlled by the
operator. A range of 22 to 32 increment steps is available with the default at 27.
3.3.3 Paper Puller
The paperpuller consists of a series of urethane rollers driven by a 24 VDC motor
whenever a forward paperfeed command is sent by the microprocessor. The
signal PAP_DIR is sent to the paperpuller motor control board which in turn
activates the motor and turns it off if subsequent commands are not received.
...........
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3.4 Character and Control Codes
3.4.1 Character Set Codes
E13B CMC7 ASCII Mode Symbol Dataproducts
Mode Symbol
Hex Dec Hex Dec
Space Space 20 32 <sp> 20 32 <sp>
0 0 30 48 0 21 33 !
1 1 31 49 1 22 34 "
2 2 32 50 2 23 35 #
3 3 33 51 3 24 36 $
4 4 34 52 4 25 37 %
5 5 35 53 5 26 38 &
6 6 36 54 6 27 39 '
7 7 37 55 7 28 40 (
8 8 38 56 8 29 41 )
9 9 39 57 9 2A 42 *
Trans S1 26 38 & 2B 43 +
Amount S2 24 36 $ 2C 44 ,
On-Us S3 2F 47 / 2D 45 -
Dash S4 2D 45 - 2E 46 .
S5 21 33 ! 2F 47 /
3.4.2 Format Control Codes
Channel Hex Dec Symbol Step Hex Dec
1 80 128 Ç 0 90 144
2 81 129 ü 1 91 145
3 82 130 é 2 92 146
4 83 131 â 3 93 147
5 84 132 ä 4 94 148
6 85 133 à 5 95 149
7 86 134 å 6 96 150
8 87 135 ç 7 97 151
9 88 136 ê 8 98 152
10 89 137 ë 9 99 153
11 8A 138 è 10 9A 154
12 8B 139 ï 11 9B 155
12 9C 156
13 9D 157
14 9E 158
15 9F 159
Paper motion is accomplished by using the channel codes listed above. There are
12 channels that can be used as vertical tab stops. The channel code slews the
paper to the next stop and each channel can have multiple stops.
NOTE
Executing a command to an unloaded channel
will result in no paper movement, the same as
issuing a Carriage Return.
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To permit non-standard data spacing, three small-increment skip codes are
available. These codes position forms at fractions of the normal 1/6 inch or 1/8
inch line spacing.
B0 = 1/24 inch
B1 = 2/24 inch
B2 = 3/24 inch
Codes are available to buffer the MICR printer when used with a text printer
which runs at a slower rate. This buffering helps to maintain the paper drape
length by adding a delay after paper motion. Multiple codes can be sent to the
printer to accumulate the appropriate delay.
10 = 20 msec
11 = 120 msec
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This manual suits for next models
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