Tally T6215 User manual

T6215
Maintenance Manual

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© May 2000
Tally Printer Corporation
All rights reserved
Printed in the United States
Manual Reference #083644
Tally Printer Corporation
8301 South 180th Street
Kent, Washington 98032
This Manual is published by Tally Printer Corporation for use with the computer printer described herein.
Translations, reprinting or copying by any means of this manual, complete or in part, in any different form
requires our explicit approval. Tally Printer Corporation reserves the right to revise this manual without notice,
for any reason. This includes, but is not limited to, utilization of advances in the state-of-the-art and changes
in the equipment or configuration thereof. Liability for difficulties arising from unknown or unforeseen
technical limitations is disclaimed.
FCC Statement
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
Part 15, Subpart B of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates, uses,
and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual,
may cause harmful interference to radio communications. Operation of this equipment in a residential area
is likely to cause harmful interfe rence, in which case the user will be required to correct the interference at
his own expense.

Table of Contents
Table of Contents

i
Table Of Contents
Table of Contents
Preface
About This Manual.................................................................................................................................. Pref–1
Chapter 1. Technical Overview ........................................................................................................ Pref–1
Chapter 2. Menu Operations ............................................................................................................ Pref–1
Chapter 3. Faults and Troubleshooting ............................................................................................. Pref–1
Chapter 4. Removing and Replacing Components ............................................................................ Pref–1
Appendix A. Schematics and Illustrated Parts Breakdowns ............................................................... Pref–1
Appendix B. Downloading Printer Firmware .................................................................................... Pref–1
Conventions ...................................................................................................................................... Pref–1
Chapter 1: Technical Overview
Technical Overview .................................................................................................................................... 1–1
T6215 Electronic Hardware Architecture..................................................................................................... 1–1
Engine Control Module ......................................................................................................................... 1–1
Control Processor ............................................................................................................................ 1–1
Sensor Inputs ................................................................................................................................... 1–1
Motor logic and drive ...................................................................................................................... 1–2
EEPROM ......................................................................................................................................... 1–2
Serial and Parallel Interfaces ................................................................................................................. 1–2
Serial ............................................................................................................................................... 1–2
Parallel ............................................................................................................................................ 1–2
Main Processor ..................................................................................................................................... 1–2
Motorola Cold Fire 5307 ................................................................................................................. 1–2
Altera EPM7064 .............................................................................................................................. 1–2
Table 1–1. Host Interface Configurations ........................................................................................ 1–2
Hammer Drive Module ......................................................................................................................... 1–3
Specifications .............................................................................................................................................. 1–3
Serial/Parallel Emulations ...................................................................................................................... 1–3
Font Styles ............................................................................................................................................. 1–3
Courier and Gothic ......................................................................................................................... 1–3
Data Processing and Draft ............................................................................................................... 1–3
OCR-A and OCR-B.......................................................................................................................... 1–3
Characters Per Inch ............................................................................................................................... 1–3
Table 1–2. Type Style, Character Matrix, Dot Density, and CPI Combinations ................................. 1–4
Lines Per Inch ....................................................................................................................................... 1–4
Dot Densities and Plot Speeds ............................................................................................................... 1–5
Table 1–3. Plot Data Output Speed................................................................................................. 1–5
Graphics Benchmarks ........................................................................................................................... 1–5
Table 1–4. AIAG Label Benchmark Results ..................................................................................... 1–5
Table 1–5. POSTNET Label Benchmark Results .............................................................................. 1–5
Paper Slew Speed .................................................................................................................................. 1–6

T6215 Maintenance Manual
ii
Table 1–6. Slew Speed.................................................................................................................... 1–6
Ribbons ................................................................................................................................................. 1–6
Forms/Paper Description ....................................................................................................................... 1–6
Acoustics .............................................................................................................................................. 1–6
Power Supply ........................................................................................................................................ 1–6
Table 1–7. Power Requirements ..................................................................................................... 1–6
Cooling System ..................................................................................................................................... 1–6
Safety .................................................................................................................................................... 1–7
Preventive Maintenance ........................................................................................................................ 1–7
Environment .......................................................................................................................................... 1–7
Operating ........................................................................................................................................ 1–7
Nonoperating .................................................................................................................................. 1–7
Heat Load Contribution ......................................................................................................................... 1–7
Table 1–8. Heat Load Contribution ................................................................................................. 1–7
Physical Configuration .......................................................................................................................... 1–8
Weight ............................................................................................................................................ 1–8
Printer Dimensions ................................................................................................................................ 1–8
Table 1–9. Printer Dimensions ........................................................................................................ 1–8
Industry and Agency Standards.............................................................................................................. 1–8
Electromagnetic Emissions .................................................................................................................... 1–8
Agency Approvals ................................................................................................................................. 1–8
Chapter 2: Menu Operations
Introduction ................................................................................................................................................ 2–1
Technical Access Mode ............................................................................................................................... 2–1
How To Enter Tech Access Mode........................................................................................................... 2–1
How to Exit Tech Access Mode ............................................................................................................. 2–1
Testing, Troubleshooting and Calibration ..................................................................................................... 2–1
Printer Tests ........................................................................................................................................... 2–1
Hex Dumps ........................................................................................................................................... 2–2
Printer Information Printouts and Displays ............................................................................................ 2–2
Help Menu ...................................................................................................................................... 2–2
Printing a HELP Menu In Tech Access Mode.............................................................................. 2–2
Report ............................................................................................................................................. 2–3
Report selections ....................................................................................................................... 2–3
Selecting a Printer Report .......................................................................................................... 2–3
TEST Menu.................................................................................................................................................. 2–4
Table 2–1 Test Menu....................................................................................................................... 2–4
Pattern Category .................................................................................................................................... 2–6
Print ................................................................................................................................................ 2–6
Print selections .......................................................................................................................... 2–6
Print2 .............................................................................................................................................. 2–6
Print2 selections ........................................................................................................................ 2–6
Plot ................................................................................................................................................. 2–7
Plot selections ........................................................................................................................... 2–7
Selecting And Running a Print Test ............................................................................................ 2–8

iii
Table Of Contents
Hammer .......................................................................................................................................... 2–8
Fault Override Category ........................................................................................................................ 2–8
Paper Motion .................................................................................................................................. 2–8
Paper Out........................................................................................................................................ 2–8
Ribbon Motion ................................................................................................................................ 2–9
Shuttle ............................................................................................................................................. 2–9
Temp ............................................................................................................................................... 2–9
Platen .............................................................................................................................................. 2–9
Control ............................................................................................................................................ 2–9
Link ................................................................................................................................................. 2–9
Sync ................................................................................................................................................ 2–9
Diagnostic Category .............................................................................................................................. 2–9
Calibrations ..................................................................................................................................... 2–9
Selecting And Running a Hammer Calibration Routine.............................................................. 2–9
Figure 2–1. Hammer Leadtime Calibration Printout Sample (partial) ............................................. 2–11
Selecting And Running a Platen Gap Calibration Routine ........................................................ 2–11
Meter ............................................................................................................................................ 2–12
Accessing the Meter Measurement Tests: ................................................................................. 2–12
Motors........................................................................................................................................... 2–13
Accessing the Motor Tests: ....................................................................................................... 2–13
Motor selections ...................................................................................................................... 2–13
Shuttle Speed ................................................................................................................................ 2–13
Shuttle Speed selections: ......................................................................................................... 2–13
Ribbon Speed ................................................................................................................................ 2–13
Speed selections: .................................................................................................................... 2–13
Ribbon Threshld ............................................................................................................................ 2–14
Threshold selections: ............................................................................................................... 2–14
Paper Out Thold............................................................................................................................ 2–14
Energy Star .................................................................................................................................... 2–14
Clear ............................................................................................................................................. 2–14
Clear selections ....................................................................................................................... 2–14
Shuttle Off ..................................................................................................................................... 2–14
Shuttle Change .............................................................................................................................. 2–14
Ribbon Ink, Dots per Pump ........................................................................................................... 2–14
Serial Dump .................................................................................................................................. 2–14
Control Panel Key Operations For Controlling Fault Reporting ............................................................ 2–15
ALL Fault Reporting ....................................................................................................................... 2–15
Four Faults Only............................................................................................................................ 2–15
Paper Out Only ............................................................................................................................. 2–15

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iv
Chapter 3: Faults and Troubleshooting
Faults .................................................................................................................................................... 3–1
Table 3–1. Display Messages .......................................................................................................... 3–3
The printer does not power up when switched on ............................................................................... 3–10
The Printer powers up but the Control Panel does not function. .......................................................... 3–11
The Control Panel Display functions partially, nonsensically, or not at all. .......................................... 3–11
There is no printed output but the printer appears to be operating normally. ....................................... 3–12
Printed output appears light ................................................................................................................ 3–12
Printed output appears shaky or fuzzy ................................................................................................. 3–13
Character columns not printing ........................................................................................................... 3–13
The Printer is out of paper — No Paper Out fault is reported ............................................................... 3–15
No Paper Motion — No Paper Motion fault is reported ....................................................................... 3–15
Table 3–2. Paper/Printing Corrective Action ................................................................................. 3–16
Figure 3–1. Power On Troubleshooting Sequence........................................................................ 3–18
Figure 3–1a. Power On Troubleshooting Sequence, Continued .................................................... 3–19
Figure 3–2. Print Data Troubleshooting Sequence ........................................................................ 3–20
Figure 3–2a. Print Data Troubleshooting Sequence, Continued .................................................... 3–21
Figure 3–2b. Print Data Troubleshooting Sequence, Continued .................................................... 3–22
Figure 3–2c. Print Data Troubleshooting Sequence, Continued .................................................... 3–23
Figure 3–2d. Print Data Troubleshooting Sequence, Continued .................................................... 3–24
Chapter 4: Removing and Replacing Components
Introduction ................................................................................................................................................ 4–1
Required Tools ...................................................................................................................................... 4–1
Service Procedures ...................................................................................................................................... 4–2
Procedure 1: Ribbon Platform Removal....................................................................................................... 4–3
Figure 1. Loosening screws on Ribbon Platform. ............................................................................ 4–3
Figure 2. Unplugging Ribbon Drive Motor cable. .......................................................................... 4–3
Procedure 2: Ribbon Motor Removal .............................................................................................. 4–4
Figure 3. Removing motor screws. ................................................................................................. 4–4
Figure 4. Unplugging Ribbon Motor cables. .................................................................................. 4–4
Procedure 3: Ribbon Motion Sensor PCA Removal...................................................................................... 4–5
Figure 5. Removing PCA screws. ................................................................................................... 4–5
Procedure 4: Control Panel Removal........................................................................................................... 4–6
Figure 6. Unplugging Control Panel cable. .................................................................................... 4–6
Procedure 4a: Control Panel Circuit Board removal ............................................................................. 4–7
Figure 7. Removing circuit board screws. ...................................................................................... 4–7
Procedure 5: Hammer Bank Removal.......................................................................................................... 4–8
Figure 8. Removing plastic cable cage. .......................................................................................... 4–8
Figure 9. Unplugging Hammer Bank ribbon cables........................................................................ 4–8
Figure 10. Removing screws on retainer clips. ............................................................................... 4–9
Figure 11. Removing nuts from underneath Hammer Bank. ........................................................... 4–9
Figure 12. Lifting Hammer Bank from printer............................................................................... 4–10
Figure 13. Replacing Shuttle Drive belt. .......................................................................................4–10
Procedure 6: Ribbon Shield Removal ........................................................................................................ 4–11
Figure 14. Removing the Ribbon Shield. ...................................................................................... 4–11

v
Table Of Contents
Procedure 7. 13-pack Hammer Replacement ........................................................................................... 4–12
Figure 15. Measuring old hammer for replacement size ............................................................... 4–12
Figure 16. Aligning the new hammer pack................................................................................... 4–13
Procedure 8: Coil Board Replacement...................................................................................................... 4–14
Figure 17. Coil board replacement. ............................................................................................. 4–14
Procedure 9: Shuttle Removal ................................................................................................................... 4–15
Figure 18. Removing Shuttle screws. ........................................................................................... 4–15
Figure 19. Removing screws from inside shuttle. ......................................................................... 4–15
Procedure 10: Platen Removal .................................................................................................................. 4–16
Figure 20. Location of circuit board. ............................................................................................ 4–16
Figure 21. Removing the Platen Springs. ...................................................................................... 4–17
Figure 22. Removing screws from the platen stop. ....................................................................... 4–18
Figure 23. Transferring components from old to new platen. ........................................................ 4–19
Figure 24. Adding grease. ............................................................................................................ 4–20
Procedure 11: Platen Gap Adjustment ...................................................................................................... 4–22
Figure 25. Platen Adjustment screws and use of shim. ................................................................. 4–23
Procedure 12: Print Mechanism Access (Tilting) ....................................................................................... 4–24
Figure 26. Unplugging the Power Supply cable. .......................................................................... 4–24
Figure 27. Print Mechanism tilted and held by strut. .................................................................... 4–25
Procedure 13: Distribution PCA Removal ................................................................................................. 4–26
Figure 28. Removing screws on mounting bracket. ...................................................................... 4–26
Procedure 14: Lower Tractor Removal ...................................................................................................... 4–27
Figure 29. Location of Paper Out sensor cables. .......................................................................... 4–27
Figure 30. Removing Retaining (Snap) rings. ................................................................................ 4–27
Figure 31. Ground spring. ............................................................................................................. 4–28
Figure 32. Round and square shafts. ............................................................................................. 4–28
Procedure 15: Upper Tractor Removal ..................................................................................................... 4–30
Procedure 16: Tractor Phasing/Paper Drive Belt Tension Adjustment ........................................................ 4–31
Figure 33. Tractor phasing and paper drive belt. .......................................................................... 4–31
Figure 34. Paper Tension Lever in middle position. ...................................................................... 4–32
Figure 35. Placing the Phasing Gauge .......................................................................................... 4–32
Figure 36. Placing Tension Gauge ................................................................................................ 4–33
Figure 37. Placing Paper Tension Gauge. ..................................................................................... 4–34
Procedure 17: Paper Drive Motor Removal .............................................................................................. 4–35
Figure 38. Paper Drive Motor location. ........................................................................................ 4–35
Procedure 18: Shuttle Motor Removal ...................................................................................................... 4–36
Figure 39. Shuttle Motor .............................................................................................................. 4–36
Procedure 19: Control PCA Assembly Removal ........................................................................................ 4–37
Figure 40. Front of Control PCA assembly after cover has been removed. .................................... 4–37
Procedure 20: Power Supply Assembly Removal...................................................................................... 4–38
Figure 41. Power Supply Assembly. ............................................................................................. 4–38

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vi
Appendix A: Illustrated Parts Breakdowns and Schematics
Illustrated Parts Breakdowns and Schematics .............................................................................................. A–1
Appendix B:
Firmware Update Procedure ....................................................................................................................... B–1