Olivetti PR2 E User manual

Printer
SERVICE MANUAL
Code Y 100250-4

PUBLICATIONISSUEDBY:
Olivetti TECNOST,S.p.A.
Documentazione
77, Via Je~is - 1001 5 lvrea (Italy)
Copyright O 2001, Olivetti
Allrightsreserved

This Service Manual providesyou with allthe technical information neededto install, test and service
the PR2
E specialized printer.
Consultthis 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 ina 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
- SECTORIPRODUCT RANGE: Q2 PR2
- DISTRIBUTION: General (G)
- FIRST EDITION: April, 2001
NOTICE
OlivettiTECNOST S.p.A. reservesthe rightto make changes to the product described inthis manual at any
time andwithout notice.
Y 100250-4 Service Manual iii.

TABLE OF CONTENTS
l . PRODUCT OVERVIEW
l . 1 INTRODUCTION
.............................................................................................. 1
l . l . l PR2 E FACTORY CONFIGURATION ............................................................... 2
..................................................... 1.2 GENERAL MACHINE CHARACTERISTICS 3
....................................
1.3 HORIZONTALMAGNETIC DEVICE/MICR FEATURES 4
.................................................................................... 1.4 PRODUCT VARIABLES 5
...................................... 1.5 DOCUMENTSHANDLED BY THE BASIC MACHINE 6
1.5.l SINGLEAND MULTI-COPY FORMS ............................................................... 6
1.5.2 SAVINGSBOOKS ............................................................................................ 7
.................................................................................................
1.6 ACCESSORIES 8
.................................... 1.7 LOCATINGTHE PRINTER'S MAJOR COMPONENTS 9
............... 1.8 LOCATINGTHEPRINTER'SMAJOR INTERNAL COMPONENTS 10
1.9 GENERALBLOCK DIAGRAM
........................................................................ 11
1.9.l BASIC MACHINE ........................................................................................... 11
1 1 FIRMWARE AND CHARACTERGENERATORS ............................................ 12
l . 10.1 MACHINE FIRMWARE ................................................................................... 12
1.10.2 CHARACTERSETS ....................................................................................... 13
l
. 10.3 PRINT MODESAND CHARACTERFONTS .................................................. 13
2 . OPERATING COMMANDS ....................................................................... l
2.1 POWERSWITCH ............................................................................................... 2
2.2 CONSOLE
.......................................................................................................... 2
2.2.l FUNCTIONS OFTHE CONSOLE BUTTONS .................................................. 3
2.2.2
MEANING OFTHE CONSOLE LEDS .............................................................. 4
2.2.3 ERROR MESSAGES ........................................................................................ 4
2.3 BUTTONAND LED FUNCTIONS IN THEISM 9068 (4722) EMULATION
........ 6
2.3.l BUTTON FUNCTIONS ..................................................................................... 6
2.3.2 LEDINDICATIONS ........................................................................................... 6
Y 100250-4 Service Manual v

2.4 BUTTON AND LED FUNCTIONS IN THE SNI 4915 (4904) EMULATION
........ 7
2.4.1 BUTTON FUNCTIONS ................................................................................... 7
2.4.2
LED INDICATIONS ........................................................................................... 7
2.5 BUTTONAND LED FUNCTIONS IN THE
............................. ISM PROPRINTER ///X24 . EPSON LQ 2550 EMULATION 8
2.5.1 BUTTONFUNCTIONS .................................................................................... 8
2.6 UPPER MECHANICAL ASSEMBLY LIFTING LEVER ..................................... 9
.........................................................................................
3. INSTALLATION 1
3.1 GENERAL INSTALLATION PRECAUTIONS
............................................... 1
......................................................................
3.1. I ELECTRICALPOWER SUPPLY l
3.1.2 ENVIRONMENTAL CONDITIONS ................................................................... l
a
.............................................................................. 3.1.3 LOCATING THEMACHINE l
3.2 UNPACKINGAND INSTALLING THEMACHINE ............................................. 2
3.2. l UNPACKINGTHE MACHINE .......................................................................... 2
3.2.2
INSTALLINGTHEMACHINE ............................................................................ 4
3.3 OFF-LINETESTS ............................................................................................... 4
3.3.1
STARTINGAND STOPPINGTHE PRINT TEST .............................................. 4
3.3.2
PRINT TESTCONTENTS ................................................................................ 5
3.4 CONNECTIONTO THE SYSTEM
...................................................................... 8
3.4. l RE 232C SERIAL INTERFACE (STANDARD) .................................................. 8
3.4.2
OPTIONAL SERIAL INTERFACE + USB INTERFACE CARD ......................... 9
3.4.3 OPTIONALIEEE 1284 PARALLEL INTERFACE CARD ................................ l l
3.5 FINAL TESTING ............................................................................................... 13 4
3.6 INFORMATION FOR THE OPERATOR ......................................................... 13
3.7 OPERATINGPROCEDURES
..................................................................... 14
.....................
3.7. l INSERTINGA DOCUMENTWITHAUTOMATIC ALIGNMENT 14
3.7.2
INSERTINGA SAVINGS BOOK .................................................................... 15
3.7.3
INSERTINGA CHECKFOR HORIZONTALMAGNETIC
............................................................. DEVICE/MICR READ OPERATIONS 16
3.7.4
EXPULSION OFPROCESSEDDOCUMENTS ............................................. 17
3.7.5
REPLACINGTHE RIBBON CARTRIDGE ...................................................... 17
3.7.6
PAPERJAMS ................................................................................................. 20

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. l
ACTIVATING THESETUP ............................................................................... 2
4.3.2
SUPPORT SOFTWARE ................................................................................... 2
4.3.3
CONFIGURATIONPARAMETERS .................................................................. 3
4.4 SETTINGS ....................................................................................................... 14
4.4. l
PHOTOSENSORCALIBRATION ................................................................... 14
4.4.2
B/-DIRECTIONALPRINTALIGNMENT CALIBRATION ................................ 20
4.4.3
TOP OFFORM (TOF) CALIBRATION ............................................................ 22
4.4.4
LEFT PRINT MARGIN CALIBRATION ........................................................... 24
4.4.5
DOCUMENT LENGTH MEASUREMENT ...................................................... 26
4.4.6
SKEWANDSIGNALAMPLITUDE CONTROL .............................................. 28
4.4.7
SIGNAL AMPLITUDE CONTROL .................................................................. 28
5 . PRODUCT DIAGNOSIS ............................................................................ 1
5.1 SERVICINGMODES.......................................................................................... 1
5 . l . l FAULT DETECTIONANALYSIS .........................................................................
5.1.2 ANALYSIS OFTHE OPERATINGCONDITIONS ........................................ l
5.1.3
IDENTIFYING THEMALFUNCTION ................................................................ 2
5.1.4 FINDING THE CAUSE ...................................................................................... 2
5.1.5
SOLVING THEPROBLEM ............................................................................... 2
5.1.6 TESTINGTHEMACHINE .............................................................................. 2
5.2 FAULT CLASSIFICATION.................................................................................. 3
5.3 POWER ON FAULTS
......................................................................................... 4
............................................................................
5.4 DOCUMENT WRITEFAULTS 5
5.5 DOCUMENT HANDLING FAULTS
.................................................................... 6
5.6 MAGNETIC STRIPE READNVRITE FAILURES
.............................................. 7
Y 100250-4 Service Manual vii

.....................................................
6 . ELECTRICAL INTERCONNECTIONS l
6.1 GENERAL PRINTER INTERCONNECTIONDIAGRAM ................................... 1
6.2 BAPRZMAINBOARD
..................................................................................... 2
6.2.1MAIN BOARD VIEWANDLOCATION OF CONNECTORS .............................. 2
...................................................................................... 6.2.3 CONNECTOR PIN-OUT 3
............................................................................ 6.3 MAGNETIC OPTIONS CARD 5
6.3. l CARD LOCATION AND lDENTlFlCATlONOF CONNECTORS ...................... 5
6.3.2 VIEW OF THEPRZMAGN CARD
.................................................................... 6
6.4 SERIALAND US6INTERFACE CARD
........................................................ 8
6.4.7 CARD VIEWANDLOCATION OF CONNECTORS ......................................... 8
6.4.2 CONNECTORPIN-OUT ................................................................................... 9
6.5 PARALLEL INTERFACE CARD
.................................................................. 10
6.5. l CARD VIEWAND LOCATION OF CONNECTORS ....................................... 10
6.5.2 CONNECTORPIN-OUT ................................................................................ ll
6.6 CONSOLE ........................................................................................................ 12
6.7 ALIPRZE CARD
........................................................................................... 13
6.7.1 CARD VIEWAND LOCATION OFCONNECTORS ....................................... 13
6.7.2 CONNECTOR PIN-OUTAND FUSE
.............................................................. 13
............................................................... 7 . PREVENTIVE MAINTENANCE 1
.........................................................................................................
7.1 CLEANING 1
7.1. l CLEANINGTHECASE .................................................................................... I
7.1.2 CLEANINGTHEPAPER PATHS
...................................................................... l
7.1.3 CLEANINGTHEMAGNETICREAD HEAD ..................................................... l
7.2 MAINTENANCE ................................................................................................. 2
7.3 LUBRICATION
................................................................................................... 3
........................................ 7.3. l LUBRICATION POINTS ON THEBASIC MACHINE 3
...............
7.3.2 HORIZONTAL MAGNETICDEVICE/MICRLUBRICATION POINTS 4
viii Y 100250-4

.............................................................. 8 . MECHANICALADJUSTMENTS 1
.........................................................
8.1 DOCUMENT FEED BELT ADJUSTMENT 2
..............................................................................8.2 PRINT BARADJUSTMENT 3
8.3 PARALLELISMADJUSTMENT BETWEENTHEPRINT BARAND LEAF
........
SPRINGLOAD IN THEBASIC MACHINE.........................................................4
.......................................................................................... 8.4 TABADJUSTMENT 5
8.5 FRONT TAB OPENINGCHECK
........................................................................ 6
........................................................................
8.6 ROLLERGEARADJUSTMENT 7
.................................................
8.7 FRONT PRESSURE ROLLERADJUSTMENT 8
8.8 TABOPENINGADJUSTMENT
......................................................................... 9
... 8.9 HORIZONTAL MAGNETIC DEVICE/MICR OPTIONCARRIAGEFEED BELT
................................................................................
kr
TENSIONADJUSTMENT 10
8.10 HORIZONTALMAGNETIC DEVICE/MICRDOORADJUSTMENT
................ 11
................ 8.11 HORIZONTALMAGNETIC DEVICE/MICR PRESS POSITIONING 12
8.12 POSITIONINGTHEASSEMBLY ONTHE HORIZONTALMAGNETIC
..................................................................................................
DEVICE/MICR 13
.....................................
9 . DISASSEMBLYIREASSEMBLY PROCEDURES 1
9.1 GENERAL DISASSEMBLY/REASSEMBLYPRECAUTIONS
.......................... 2
9.2 DISASSEMBLY/REASSEMBLYOFTHEBASIC MACHINE
............................. 3
9.2. l CASEDISASSEMBLY/REASSEMBLY ............................................................. 3
9.2.2
CONSOLE DISASSEMBLY/REASSEMBLY ..................................................... 4
9.2.3
MECHANICALASSEMBLY DISASSEMBLY/REASSEMBLY ........................... 5
9.2.4 PRINTHEAD FLAT CABLEDISASSEMBLY/REASSEMBLY ............................ 6
9.2.5
PRINTHEAD DISASSEMBLY/REASSEMBLY .................................................. 8
9.2.6
PRINTHEAD PHOTOSENSORDISASSEMBLY/REASSEMBLY ..................... 9
9.2.7
SUPPER PART OF THEMECHANICALASSEMBLY
DISASSEMBLY/REASSEMBLY ...................................................................... 10
9.2.8
PAPER FEED MOTOR DISASSEMBLY/REASSEMBLY ................................ 11
9.2.9 PRINTHEAD MOVEMENT MOTOR DlSASSEMBLY/REASSEMBLY ............ 12
9.2.10 CARRIAGERESET PHOTOSENSORDISASSEMBLY/REASSEMBLY ........ 13
Y 1 00250-4 Service Manual ix

9.2. l l
ROLLER SUPPORT TRAYDISASSEMBLY/REASSEMBLY .......................... 14
9.2.12
SERVICESMOTOR DISASSEMBLY/REASSEMBLY ..................................... 15
9.2.13
FEEDER PHOTOSENSORSDISASSEMBLY/REASSEMBLY ............. ....... ... 16
9.2.14
PRINT BAR DISASSEMBLY/REASSEMBLY ................................................. 19
9.2.15 MAIN BOARD DISASSEMBLY/REASSEMBLY .............................................. 20
9.2.16
POWRERSUPPLYASSY DISASSEMBLY/REASSEMBLY ........ .. .... ....... .... .. 21
9.3 BASIC MACHINE OPTIONSDISASSEMBLY/REASSEMBLY ...................... 22
9.3. l
HORIZONTAL MAGNETICDEVICE/MICRDISASSEMBLY/REASSEMBLY .22
9.3.2
HORIZONTAL MAGNETICDEVICE/MICR MOTOR
DISASSEMBLY/REASSEMBLY ...................................................................... 23
9.3.3
HORIZONTAL MAGNETIC DEVICE/MICRHEADASSY
DISASSEMBLY/REASSEMBLY ...................................................................... 24

1. PRODUCT OVERVIEW
1 .l INTRODUCTION
The PR2 E is a specialized mid-rangebanking printer. It can handle ordinary stationary (singleand
multicopyforms) and savings booksfor depositlwithdrawltransactions.
Very versatile, this printercan also be usedin Public Administration front-office environments and in
Post offices. It can be equipped with a horizontal magnetic device for readinglwriting horizontal
magnetic bands, or with a horizontal magnetic device and MlCR (Magnetic Ink Character Reader)
readerfor readingthe code lines printedon checks. This printer model can also be configured with
different interfacesand emulations.
The PR2Enhancedrepresentsthe evolution intermsofqualityand performanceofthe PR2,towhich
it maintainscomplete compatibilityas far as the firmware and accessoriesare concerned.
With respectto the PR2, the PR2 E carries the following significant differences:
Updateddesign
Improvedprintingspeed
Interchangeablecommunicationportsthankstothe possibilityof installingsupplementarysnap-in
interface cards
Availability of support softwarefor on-linesetup, the designand loadirrgof user characterfonts,
design and storageof a user logoandthe on-lineloadingof charactergenerators
l00to 130and 200 to 240 VAC
+ 10% switching power supply unit
Optionalfan for delayingthe activationof the thermal protectionwhen printingcomplex graphics
Dual-interfacefunctionalityinall emulations
IBM9068 and IBMX24 emulations.
Y 100250-4 Service Manual 1-1

1.1.1 PR2 E FACTORY CONFIGURATION
The followitlg table indicatesthe different PR2 E factory configurations:
Commercial Name
PR2 E S12
PR2
E S12 M
X
X
X
X

1.2 GENERAL MACHINE CHARACTERISTICS
PRINTING MODULE Dot-matrixprintheadwith24diamond-shapedneedlesandovertemperature
protection
Printingcapability: 1original
+ 4 copies
Savingsbook handlingfeatures
PRINTING SPEED 86 cps
@ l0cpi in LQ
130cps
@ l0cpi in NLQ
260 cps
@ 10 cpi in DRAFT
350 cps
@ l0cpi in HSD
PRINT QUALITY H.S.D., DRAFT, N.L.Q., L.Q.
RIBBON CARTRIDGE Indeliblefabric, with a life span of 3.5 M characters
PAPER FEED Frontfeeder with automaticdocument alignment.
Ifthe mqgnetic device is present,the savings book must be aligned
manually.The machinewill generate an error message.
PAPER SIZE
CONSOLE
EMULATIONS
INTERFACE
DIMENSIONS
245
X 450 mm max.
70
X 65 mmmin.
Formore informationrefer to section 1.5.
Locatedon the printercover, it has three buttons and five LEDs
PR40+, PR2 E and IBM PP II,X24, SNI 4915, IBM9068
Standard RS 232C serial with the possibility of installingthe following
interface cards:
- RS 232C serial + USB
- Centronicsparallel.
Width: 384 mm
Depth:280 mm
Height: 195 mm
Weight: 10.5 Kg.
POWER CONSUMPTION Stand-by:
5 15W
Duringoperation: 170W max (worst case)
POWER SUPPLY Switching power supply:
100to 130VAC
5 10%
200 to 240VAC
+ 10%
Y 1002504 Service Manual 13

The followingfigure gives an overall view of the printer.
Fig. l-l PR2 E Printer
1.3 HORIZONTAL MAGNETIC DEVlCElMlCR FEATURES
The HorizontalmagneticdevicelMlCR(MagneticInkCharacterRecognition)devicereadscharacters
printedon checks with magnetic ink. Horizontal magneticdeviceIMICR applicationsare compatible
with the CMC7 and
E13B standards.
CMC7: Thisstandardusesacodingtechniquesimilartobarcodes. Inthiscasethecharacterconsists
of seven black bars of equalwidth and spaced by four narrowgaps and two wide gaps.
E13B: Inthiscasethecharactersarecontinuous(notbars)andhaveapreciseshape.Themagnetic
readermustalso interpretthe amplitude of the wave form andtherefore not only itsvariation
intime.

1.4 PRODUCT VARIABLES
VOLTAGE AND FREQUENCY TEN 023 1101120V 50160 Hz
TEN 204 2201240V 50160 Hz
POWER CORD
CRT FIRMWARE
COR 005 Europe
COR 041 Switzerland
COR 042 Great Britain
COR 043 Australia
COR 050 USA
COR 080 SouthAfrica
Olivettistandard + IBMX24
IBM9068
+ IBMX24
SNI 4915
+ EPSON LQ 2550
Y 1002504 Service Manual 1-5

1.5 DOCUMENTS HANDLED BY THE BASIC MACHINE
1.5.1 SINGLE AND MULTI-COPY FORMS
lblaximumwidth
1 245mm
Minimumwidth
1 65mm
Maximumrecommendedlength
1 297mm
Maximumacceptedlength
1 450mm
Minimumlength
1 70mm
Singlesheet weight
I 60 to g/m2
Single sheet thickness
I O.l to 0.28 mm
Transparency I Upto 25% and uniform
Multicopy weight (chemical)
1 40 to60g/m2
Carbon paper weight
I 20 to 34 g/m2
Maximumprintablecopies
with chemicalpaper
Maximumprintablecopies
with carbon paper
1+5 with average paperweight and in the NLQILQ print mode
1
+4 with average paperweight and in the NLQlLQ print mode
Multicopyglueing
1 At heador on the side
Recommendedweight
Maximumweight of
multicopy forms
Original 50 g/m2,last copy 60 g/m2
Print quality(with multicopy
forms) NLQ or LQ

1.5.2 SAVINGS BOOKS
Max. thickness with book open
Max. difference in level between
pages
Cover thickness
Type of binding
Book preparation
Book with VerticalSeam
Open book width
Maximumlength
Minimumleugth
Unionof external corners
Book with Horizontal Seam
Open book width
Maximurnlength
Minimumlength
1.2mm
0.2 to 0.5 mm
Thread-sewn, without metal staples or clips
Must
becarefullyflattenedbeforebeinginsertedintothemachine
241.3 mm19.5" max.; 150mm15.9" min.
220 mm
85 mm
3to 14mm radius
241.3 mm19.5" max.; 150mm15.9" min.
220 mm
165mm
Y 1002504 Service Manual 1 -7

1.6 ACCESSORIES
This section describes the accessories available for the PR2 E printer.
BLACK NYLON SNUG CART RIBBON CARTRIDGE
Ribboncartridgespecificfor the needleprinthead,with a life-spanof morethan 3.5 millioncharacters.
The cartridge is installed in the machine by opening the printer cover, with automatic printhead
positioningiftheprinterispoweredonormanualpositioningifpoweredoff,andliftingtheprintassembly
by usingthe appropriate lever.
INDELIBLE NYLON SNUG CART RIBBON CARTRIDGE
The same as the BLACK NYLON SNUG CART butwith indelible ink.
Fig. 1-2 SNUG CART Ribbon Cartridge

1.7 LOCATING THE PRINTER'S MAJOR COMPONENTS
CONSOLE
FRONTINSERTIONSLOT
POWERSWITCH
- REAROUTPUTSLOT
STANDARDSERIALINTERFACE
-
CONNECTOR
OPENCOVERSENSO
LIFTINGLEVER
INTERFACECARD;SERlAL+USBOR
CENTRONICSPARALLEL
Fig. 1-3 LocatingthePrinter's Major Components
Y 1 00250-4 Service Manual 1-9

1.8 LOCATING THE PRINTER'S MAJOR INTERNAL COMPONENTS
PRINTHEADFLATCABLE
FRONTPAPERFEEDSLOT
POWERSUPPLYUNIT
POWERSWI
MAGNETICOPTIONSCARD
INSTALLATIONPINS
MAINBOARD
CONSOLE
Fig. 1-4 Locating the Printer'sMajor InternalComponents