Olivetti PR2 E User manual

PR2 E
Printer
SERVICE MANUAL
Code Y100250-4

PUBLICATIONISSUEDBY:
Olivetti TECNOST, S.p.A.
Documentazione
77, Via Jervis - 10015 Ivrea (Italy)
Copyright © 2001, Olivetti
Allrightsreserved

Service Manual
Y100250-4 iii.
PREFACE
This Service Manual provides you with all the technical information needed to install, test and service
the PR2 E specialized printer.
Consult this manual when the Operator Manual, included in the printer packaging, does not provide
the information needed to correct a determined error condition.
SUMMARY
This manual is divided into chapters, where each chapter is organized in a way that the information
can be accessed as simply and quickly as possible.
The first two chapters give an overview of the machine and describe its major functions; Chapter 3
describes installation and testing procedures while the remaining chapters provide the information
needed to effectively service the machine.
- BIBLIOGRAPHY: PR2 E Operator Manual
PR2 E Programmer's Manual
PR2 E Spare Parts Catalogue
- SECTOR/PRODUCT RANGE: Q2 PR2
- DISTRIBUTION: General (G)
- FIRST EDITION: April, 2001
NOTICENOTICE
NOTICENOTICE
NOTICE
Olivetti TECNOST S.p.A. reserves the right to make changes to the product described in this manual at any
time and without notice.

OOOOO

Service Manual
Y100250-4 v
TABLE OF CONTENTS
1. PRODUCT OVERVIEW
1.1 INTRODUCTION ................................................................................................ 1
1.1.1 PR2 E FACTORY CONFIGURATION............................................................... 2
1.2 GENERAL MACHINE CHARACTERISTICS ..................................................... 3
1.3 HORIZONTAL MAGNETIC DEVICE/MICR FEATURES.................................... 4
1.4 PRODUCT VARIABLES .................................................................................... 5
1.5 DOCUMENTS HANDLED BYTHE BASIC MACHINE ...................................... 6
1.5.1 SINGLE AND MULTI-COPY FORMS............................................................... 6
1.5.2 SAVINGS BOOKS ............................................................................................ 7
1.6 ACCESSORIES ................................................................................................. 8
1.7 LOCATINGTHE PRINTER'S MAJOR COMPONENTS .................................... 9
1.8 LOCATINGTHE PRINTER'S MAJOR INTERNAL COMPONENTS ............... 10
1.9 GENERAL BLOCK DIAGRAM ........................................................................ 11
1.9.1 BASIC MACHINE ........................................................................................... 11
1.10 FIRMWARE AND CHARACTER GENERATORS............................................ 12
1.10.1 MACHINE FIRMWARE................................................................................... 12
1.10.2 CHARACTER SETS ....................................................................................... 13
1.10.3 PRINT MODES AND CHARACTER FONTS.................................................. 13
2. OPERATING COMMANDS.......................................................................1
2.1 POWER SWITCH............................................................................................... 2
2.2 CONSOLE.......................................................................................................... 2
2.2.1 FUNCTIONS OF THE CONSOLE BUTTONS .................................................. 3
2.2.2 MEANING OF THE CONSOLE LEDS.............................................................. 4
2.2.3 ERROR MESSAGES........................................................................................ 4
2.3 BUTTON AND LED FUNCTIONS INTHE IBM 9068 (4722) EMULATION........ 6
2.3.1 BUTTON FUNCTIONS ..................................................................................... 6
2.3.2 LED INDICATIONS........................................................................................... 6

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2.4 BUTTON AND LED FUNCTIONS INTHE SNI 4915 (4904) EMULATION ........ 7
2.4.1 BUTTON FUNCTIONS ..................................................................................... 7
2.4.2 LED INDICATIONS........................................................................................... 7
2.5 BUTTON AND LED FUNCTIONS INTHE
IBM PROPRINTER II/X24 - EPSON LQ 2550 EMULATION ............................. 8
2.5.1 BUTTON FUNCTIONS ..................................................................................... 8
2.5.2 LED INDICATIONS........................................................................................... 8
2.6 UPPER MECHANICAL ASSEMBLY LIFTING LEVER ..................................... 9
3. INSTALLATION.........................................................................................1
3.1 GENERAL INSTALLATION PRECAUTIONS .................................................... 1
3.1.1 ELECTRICAL POWER SUPPLY ...................................................................... 1
3.1.2 ENVIRONMENTAL CONDITIONS ................................................................... 1
3.1.3 LOCATING THE MACHINE .............................................................................. 1
3.2 UNPACKING AND INSTALLINGTHE MACHINE .............................................. 2
3.2.1 UNPACKINGTHE MACHINE ........................................................................... 2
3.2.2 INSTALLING THE MACHINE............................................................................ 4
3.3 OFF-LINETESTS............................................................................................... 4
3.3.1 STARTING AND STOPPING THE PRINT TEST .............................................. 4
3.3.2 PRINTTEST CONTENTS ................................................................................ 5
3.4 CONNECTION TO THE SYSTEM ...................................................................... 8
3.4.1 RE 232C SERIAL INTERFACE (STANDARD).................................................. 8
3.4.2 OPTIONAL SERIAL INTERFACE + USB INTERFACE CARD ......................... 9
3.4.3 OPTIONAL IEEE 1284 PARALLEL INTERFACE CARD ................................ 11
3.5 FINALTESTING............................................................................................... 13
3.6 INFORMATION FORTHE OPERATOR ........................................................... 13
3.7 OPERATING PROCEDURES .......................................................................... 14
3.7.1 INSERTING A DOCUMENTWITH AUTOMATIC ALIGNMENT ..................... 14
3.7.2 INSERTING A SAVINGS BOOK .................................................................... 15
3.7.3 INSERTING A CHECK FOR HORIZONTAL MAGNETIC
DEVICE/MICR READ OPERATIONS............................................................. 16
3.7.4 EXPULSION OF PROCESSED DOCUMENTS ............................................. 17
3.7.5 REPLACING THE RIBBON CARTRIDGE ...................................................... 17
3.7.6 PAPER JAMS ................................................................................................. 20

Service Manual
Y100250-4 vii
4. AUTODIAGNOSTICS, SET-UP AND ADJUSTMENTS .............................1
4.1 POWER-ON DIAGNOSTICS.............................................................................. 1
4.2 PRINTTEST....................................................................................................... 2
4.3 PRINTER SET-UP.............................................................................................. 2
4.3.1 ACTIVATING THE SET-UP ............................................................................... 2
4.3.2 SUPPORT SOFTWARE ................................................................................... 2
4.3.3 CONFIGURATION PARAMETERS .................................................................. 3
4.4 SETTINGS ....................................................................................................... 14
4.4.1 PHOTOSENSOR CALIBRATION ................................................................... 14
4.4.2 BI-DIRECTIONAL PRINT ALIGNMENT CALIBRATION ................................ 20
4.4.3 TOP OF FORM (TOF) CALIBRATION............................................................ 22
4.4.4 LEFT PRINT MARGIN CALIBRATION ........................................................... 24
4.4.5 DOCUMENT LENGTH MEASUREMENT ...................................................... 26
4.4.6 SKEW AND SIGNAL AMPLITUDE CONTROL.............................................. 28
4.4.7 SIGNAL AMPLITUDE CONTROL .................................................................. 28
5. PRODUCT DIAGNOSIS............................................................................1
5.1 SERVICING MODES.......................................................................................... 1
5.1.1 FAULT DETECTION ANALYSIS .........................................................................
5.1.2 ANALYSIS OFTHE OPERATING CONDITIONS............................................. 1
5.1.3 IDENTIFYING THE MALFUNCTION ................................................................ 2
5.1.4 FINDINGTHE CAUSE...................................................................................... 2
5.1.5 SOLVING THE PROBLEM ............................................................................... 2
5.1.6 TESTINGTHE MACHINE ................................................................................ 2
5.2 FAULT CLASSIFICATION.................................................................................. 3
5.3 POWER ON FAULTS ......................................................................................... 4
5.4 DOCUMENT WRITE FAULTS ............................................................................ 5
5.5 DOCUMENT HANDLING FAULTS .................................................................... 6
5.6 MAGNETIC STRIPE READ/WRITE FAILURES ................................................ 7

Y100250-4viii
6. ELECTRICAL INTERCONNECTIONS .....................................................1
6.1 GENERAL PRINTER INTERCONNECTION DIAGRAM ................................... 1
6.2 BAPR2 MAIN BOARD ....................................................................................... 2
6.2.1 MAIN BOARD VIEW AND LOCATION OF CONNECTORS.................................. 2
6.2.3 CONNECTOR PIN-OUT...................................................................................... 3
6.3 MAGNETIC OPTIONS CARD............................................................................ 5
6.3.1 CARD LOCATION AND IDENTIFICATION OF CONNECTORS ...................... 5
6.3.2 VIEW OF THE PR2MAGN CARD.................................................................... 6
6.4 SERIAL AND USB INTERFACE CARD ........................................................... 8
6.4.1 CARDVIEW AND LOCATION OF CONNECTORS ......................................... 8
6.4.2 CONNECTOR PIN-OUT................................................................................... 9
6.5 PARALLEL INTERFACE CARD ...................................................................... 10
6.5.1 CARDVIEW AND LOCATION OF CONNECTORS ....................................... 10
6.5.2 CONNECTOR PIN-OUT................................................................................ 11
6.6 CONSOLE........................................................................................................ 12
6.7 ALIPR2E CARD............................................................................................... 13
6.7.1 CARDVIEW AND LOCATION OF CONNECTORS ....................................... 13
6.7.2 CONNECTOR PIN-OUT AND FUSE.............................................................. 13
7. PREVENTIVE MAINTENANCE ...............................................................1
7.1 CLEANING......................................................................................................... 1
7.1.1 CLEANING THE CASE .................................................................................... 1
7.1.2 CLEANING THE PAPER PATHS ...................................................................... 1
7.1.3 CLEANINGTHE MAGNETIC READ HEAD ..................................................... 1
7.2 MAINTENANCE................................................................................................. 2
7.3 LUBRICATION ................................................................................................... 3
7.3.1 LUBRICATION POINTS ON THE BASIC MACHINE........................................ 3
7.3.2 HORIZONTAL MAGNETIC DEVICE/MICR LUBRICATION POINTS ............... 4

Service Manual
Y100250-4 ix
8. MECHANICAL ADJUSTMENTS ..............................................................1
8.1 DOCUMENT FEED BELT ADJUSTMENT......................................................... 2
8.2 PRINT BAR ADJUSTMENT .............................................................................. 3
8.3 PARALLELISM ADJUSTMENT BETWEENTHE PRINT BAR AND LEAF ........
SPRING LOAD INTHE BASIC MACHINE......................................................... 4
8.4 TAB ADJUSTMENT .......................................................................................... 5
8.5 FRONTTAB OPENING CHECK ........................................................................ 6
8.6 ROLLER GEAR ADJUSTMENT........................................................................ 7
8.7 FRONT PRESSURE ROLLER ADJUSTMENT ................................................. 8
8.8 TAB OPENING ADJUSTMENT ......................................................................... 9
8.9 HORIZONTAL MAGNETIC DEVICE/MICR OPTIONCARRIAGE FEED BELT ...
TENSION ADJUSTMENT ................................................................................ 10
8.10 HORIZONTAL MAGNETIC DEVICE/MICR DOOR ADJUSTMENT................ 11
8.11 HORIZONTAL MAGNETIC DEVICE/MICR PRESS POSITIONING ................ 12
8.12 POSITIONINGTHE ASSEMBLY ONTHE HORIZONTAL MAGNETIC
DEVICE/MICR.................................................................................................. 13
9. DISASSEMBLY/REASSEMBLY PROCEDURES .....................................1
9.1 GENERAL DISASSEMBLY/REASSEMBLY PRECAUTIONS.......................... 2
9.2 DISASSEMBLY/REASSEMBLY OF THE BASIC MACHINE............................. 3
9.2.1 CASE DISASSEMBLY/REASSEMBLY ............................................................. 3
9.2.2 CONSOLE DISASSEMBLY/REASSEMBLY ..................................................... 4
9.2.3 MECHANICAL ASSEMBLY DISASSEMBLY/REASSEMBLY ........................... 5
9.2.4 PRINTHEAD FLAT CABLE DISASSEMBLY/REASSEMBLY ............................ 6
9.2.5 PRINTHEADDISASSEMBLY/REASSEMBLY .................................................. 8
9.2.6 PRINTHEAD PHOTOSENSOR DISASSEMBLY/REASSEMBLY ..................... 9
9.2.7 SUPPER PART OF THE MECHANICAL ASSEMBLY
DISASSEMBLY/REASSEMBLY...................................................................... 10
9.2.8 PAPER FEED MOTOR DISASSEMBLY/REASSEMBLY ................................ 11
9.2.9 PRINTHEAD MOVEMENT MOTOR DISASSEMBLY/REASSEMBLY ............ 12
9.2.10 CARRIAGE RESET PHOTOSENSOR DISASSEMBLY/REASSEMBLY ........ 13

Y100250-4x
9.2.11 ROLLER SUPPORT TRAY DISASSEMBLY/REASSEMBLY .......................... 14
9.2.12 SERVICES MOTOR DISASSEMBLY/REASSEMBLY..................................... 15
9.2.13 FEEDER PHOTOSENSORS DISASSEMBLY/REASSEMBLY ....................... 16
9.2.14 PRINT BAR DISASSEMBLY/REASSEMBLY.................................................. 19
9.2.15 MAIN BOARD DISASSEMBLY/REASSEMBLY .............................................. 20
9.2.16 POWRER SUPPLY ASSY DISASSEMBLY/REASSEMBLY ........................... 21
9.3 BASIC MACHINE OPTIONS DISASSEMBLY/REASSEMBLY........................ 22
9.3.1 HORIZONTAL MAGNETIC DEVICE/MICR DISASSEMBLY/REASSEMBLY . 22
9.3.2 HORIZONTAL MAGNETIC DEVICE/MICR MOTOR
DISASSEMBLY/REASSEMBLY...................................................................... 23
9.3.3 HORIZONTAL MAGNETIC DEVICE/MICR HEAD ASSY
DISASSEMBLY/REASSEMBLY...................................................................... 24

ServiceManualY100250-4 1-1
1. PRODUCT OVERVIEW
1.1 INTRODUCTION
The PR2 E is a specialized mid-range banking printer. It can handle ordinary stationary (single and
multicopy forms) and savings books for deposit/withdrawl transactions.
Very versatile, this printer can also be used in Public Administration front-office environments and in
Post offices. It can be equipped with a horizontal magnetic device for reading/writing horizontal
magnetic bands, or with a horizontal magnetic device and MICR (Magnetic Ink Character Reader)
reader for reading the code lines printed on checks. This printer model can also be configured with
different interfaces and emulations.
The PR2 Enhanced represents the evolution in terms of quality and performance of the PR2, to which
it maintains complete compatibility as far as the firmware and accessories are concerned.
With respect to the PR2, the PR2 E carries the following significant differences:
• Updated design
• Improved printing speed
• Interchangeable communication ports thanks to the possibility of installing supplementary snap-in
interface cards
• Availability of support software for on-line setup, the design and loading of user character fonts,
design and storage of a user logo and the on-line loading of character generators
• 100 to 130 and 200 to 240 VAC + 10% switching power supply unit
• Optional fan for delaying the activation of the thermal protection when printing complex graphics
• Dual-interface functionality in all emulations
• IBM 9068 and IBM X24 emulations.

Y100250-41-2
1.1.1 PR2 E FACTORY CONFIGURATION
The following table indicates the different PR2 E factory configurations:
Commercial Name
PR2 E S10 X
PR2 E D10 X
PR2 E D12 X X
PR2 E D12 M X X
PR2 E D10 DSP X
PR2 E S12 X X
PR2 E S12 M X X
Serial Interface
Double Serial
Interface
Horizontal
Magnetic Device
MICR Reader
Serial/Parallel
Interface

ServiceManualY100250-4 1-3
1.2 GENERAL MACHINE CHARACTERISTICS
PRINTING MODULE Dot-matrixprintheadwith24diamond-shapedneedlesandovertemperature
protection
Printing capability: 1 original + 4 copies
Savings book handling features
PRINTING SPEED 86 cps @ 10 cpi in LQ
130 cps @ 10 cpi in NLQ
260 cps @ 10 cpi in DRAFT
350 cps @ 10 cpi in HSD
PRINT QUALITY H.S.D., DRAFT, N.L.Q., L.Q.
RIBBON CARTRIDGE Indelible fabric, with a life span of 3.5 M characters
PAPER FEED Front feeder with automatic document alignment.
If the magnetic device is present, the savings book must be aligned
manually. The machine will generate an error message.
PAPER SIZE 245 x 450 mm max.
70 x 65 mm min.
For more information refer to section 1.5.
CONSOLE Located on the printer cover, it has three buttons and five LEDs
EMULATIONS PR40+, PR2 E and IBM PP II, X24, SNI 4915, IBM 9068
INTERFACE Standard RS 232C serial with the possibility of installing the following
interface cards:
-RS 232C serial + USB
-Centronics parallel.
DIMENSIONS Width: 384 mm
Depth: 280 mm
Height: 195 mm
Weight: 10.5 Kg.
POWER CONSUMPTION Stand-by: < 15 W
During operation: 170 W max (worst case)
POWER SUPPLY Switching power supply:
100 to 130 VAC + 10%
200 to 240 VAC + 10%

Y100250-41-4
Fig. 1-1 PR2 E Printer
1.3 HORIZONTAL MAGNETIC DEVICE/MICR FEATURES
TheHorizontalmagneticdevice/MICR(Magnetic Ink Character Recognition) device reads characters
printed on checks with magnetic ink. Horizontal magnetic device/MICR applications are compatible
with the CMC7 and E13B standards.
CMC7: Thisstandardusesacodingtechniquesimilartobarcodes.Inthiscasethecharacterconsists
of seven black bars of equal width and spaced by four narrow gaps and two wide gaps.
E13B: Inthiscasethecharactersarecontinuous(notbars)andhaveapreciseshape.Themagnetic
reader must also interpret the amplitude of the wave form and therefore not only its variation
intime.
The following figure gives an overall view of the printer.

ServiceManualY100250-4 1-5
1.4 PRODUCT VARIABLES
VOLTAGE AND FREQUENCY TEN 023 110/120V 50/60 Hz
TEN 204 220/240V 50/60 Hz
POWER CORD COR 005 Europe
COR 041 Switzerland
COR 042 Great Britain
COR 043 Australia
COR 050 USA
COR 080 South Africa
CRT FIRMWARE Olivetti standard + IBM X24
IBM 9068 + IBM X24
SNI 4915 + EPSON LQ 2550

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1.5 DOCUMENTS HANDLED BY THE BASIC MACHINE
1.5.1 SINGLE AND MULTI-COPY FORMS
Maximum width 245 mm
Minimumwidth 65 mm
Maximum recommended length 297 mm
Maximum accepted length 450 mm
Minimumlength 70 mm
Single sheet weight 60 to 160 g/m2
Single sheet thickness 0.1 to 0.28 mm
Transparency Up to 25% and uniform
Multicopy weight (chemical) 40 to 60 g/m2
Carbon paper weight 20 to 34 g/m2
Maximum printable copies 1+5 with average paper weight and in the NLQ/LQ print mode
with chemical paper
Maximum printable copies 1+4 with average paper weight and in the NLQ/LQ print mode
with carbon paper
Recommended weight Original 50 g/m2, last copy 60 g/m2
Multicopyglueing At head or on the side
Maximum weight of
multicopy forms 320 g/m2
Print quality (with multicopy
forms) NLQ or LQ

ServiceManualY100250-4 1-7
1.5.2 SAVINGS BOOKS
Max. thickness with book open 1.8 mm
Max. difference in level between
pages 1.2 mm
Cover thickness 0.2 to 0.5 mm
Type of binding Thread-sewn, without metal staples or clips
Book preparation Mustbecarefullyflattenedbeforebeinginsertedintothemachine
Book with Vertical Seam
Open book width 241.3 mm/9.5" max.; 150 mm/5.9" min.
Maximumlength 220 mm
Minimumlength 85 mm
Union of external corners 3 to 14 mm radius
Book with Horizontal Seam
Open book width 241.3 mm/9.5" max.; 150 mm/5.9" min.
Maximumlength 220 mm
Minimumlength 165 mm

Y100250-41-8
1.6 ACCESSORIES
This section describes the accessories available for the PR2 E printer.
BLACK NYLON SNUG CART RIBBON CARTRIDGE
Ribboncartridge specific forthe needle printhead, witha life-span of morethan 3.5 millioncharacters.
The cartridge is installed in the machine by opening the printer cover, with automatic printhead
positioningiftheprinterispoweredonormanualpositioningifpoweredoff,andliftingtheprintassembly
by using the appropriate lever.
INDELIBLE NYLON SNUG CART RIBBON CARTRIDGE
The same as the BLACK NYLON SNUG CART but with indelible ink.
Fig. 1-2 SNUG CART Ribbon Cartridge

ServiceManualY100250-4 1-9
1.7 LOCATING THE PRINTER'S MAJOR COMPONENTS
COVER
CONSOLE
POWERSWITCH
BREAKABLESLOTCOVERFORTHE
INSTALLATIONOFTHEOPTIONAL
INTERFACECARD;SERIAL+USBOR
CENTRONICSPARALLEL
CONNETTORE
CAVO RETE
REAROUTPUTSLOT
STANDARDSERIALINTERFACE
CONNECTOR
Fig. 1-3 Locating the Printer's Major Components
PRINTHEADANDCARRIAGE
UPPERMECHANICALASSEMBLY
LIFTINGLEVER
OPENCOVERSENSOR
FRONTINSERTIONSLOT

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1.8 LOCATING THE PRINTER'S MAJOR INTERNAL COMPONENTS
PRINTHEAD
CARRIAGETRANSPORTMOTOR
PRINTHEADFLATCABLE
PAPERFEEDMOTOR
PINION
SERVICESMOTOR
Fig. 1-4 Locating the Printer's Major Internal Components
MAGNETICOPTIONSCARD
INSTALLATIONPINS
POWERSWITCH
POWERSUPPLYUNIT
MAINBOARD
FRONTPAPERFEEDSLOT
OPTIONALINTERFACECARD
CONSOLE