Text preview for : MM_T_6180_Maintenance_Manual_Eng.pdf part of tallygenicom T6180 T6180 Maintenance Manual - English



Back to : MM_T_6180_Maintenance_Man | Home

T6180
Maintenance Manual Line Impact Printer
1010

Maintenance Manual Line Impact Printer

T6180

Table of Contents

Table of Contents

Table Of Contents

Subject Listing
Preface
About This Manual .................................................................................................................... Pref­1 Chapter 1. Technical Overview ................................................................................................ Pref­1 Chapter 2. Menu Operations .................................................................................................... Pref­1 Chapter 3. Faults and Troubleshooting ..................................................................................... Pref­1 Chapter 4. Removing and Replacing Components .................................................................... Pref­1 Appendix A. Schematics and Illustrated Parts Breakdowns ....................................................... Pref­1 Appendix B. Downloading Printer Firmware ............................................................................ Pref­1 Conventions .............................................................................................................................. Pref­1

Chapter 1: Technical Overview
Technical Overview ...................................................................................................................... 1­1 T6180 Electronic Hardware Architecture....................................................................................... 1­1 Engine Control Module ............................................................................................................ 1­1 Control Processor ............................................................................................................... 1­1 Sensor Inputs ................................................................................................................ 1­1 Shuttle Processor ................................................................................................................ 1­1 Hammer/Motor logic and drive .......................................................................................... 1­2 EEPROM ............................................................................................................................ 1­2 T6180 Personality Module ....................................................................................................... 1­2 Serial and Parallel Interfaces .................................................................................................... 1­3 Serial .................................................................................................................................. 1­3 Parallel ............................................................................................................................... 1­3 Motorola MC68340 ................................................................................................................. 1­3 Flash Memory .......................................................................................................................... 1­3 DRAM ..................................................................................................................................... 1­3 Altera EPM7064 ....................................................................................................................... 1­3 Specifications ................................................................................................................................ 1­4 Serial/Parallel Emulations ......................................................................................................... 1­4 Font Styles ............................................................................................................................... 1­4 Courier and Gothic ............................................................................................................ 1­4 Data Processing and Draft .................................................................................................. 1­4 OCR-A and OCR-B............................................................................................................. 1­4 Characters Per Inch .................................................................................................................. 1­4 Lines Per Inch .......................................................................................................................... 1­5 Dot Densities and Plot Speeds ................................................................................................. 1­6 Graphics Benchmarks .............................................................................................................. 1­6

i

T6180 Maintenance Manual
Paper Slew Speed .................................................................................................................... 1­7 Ribbons ................................................................................................................................... 1­7 Forms/Paper Description .......................................................................................................... 1­7 Acoustics ................................................................................................................................. 1­7 Power Supply .......................................................................................................................... 1­7 Cooling System ........................................................................................................................ 1­7 Safety ....................................................................................................................................... 1­8 Preventive Maintenance .......................................................................................................... 1­8 Environment ............................................................................................................................ 1­8 Operating ........................................................................................................................... 1­8 Nonoperating ..................................................................................................................... 1­8 Heat Load Contribution ........................................................................................................... 1­9 Physical Configurations ........................................................................................................... 1­9 Weight ............................................................................................................................... 1­9 Printer Dimensions ............................................................................................................. 1­9 Industry and Agency Standards ................................................................................................ 1­9 Electromagnetic Emissions ....................................................................................................... 1­9 Agency Approvals .................................................................................................................. 1­10

Chapter 2: Menu Operations
Introduction .................................................................................................................................. 2­1 Technical Access Mode ................................................................................................................. 2­1 Entering Tech Access Mode ..................................................................................................... 2­1 Exiting Tech Access Mode ........................................................................................................ 2­1 Testing, Troubleshooting, and Calibration ...................................................................................... 2­1 Printer Tests ............................................................................................................................. 2­1 Hex Dumps ............................................................................................................................. 2­2 Printer Information Printouts and Displays ............................................................................... 2­2 HELP Menu ........................................................................................................................ 2­2 Printing a HELP Menu In Tech Access Mode ................................................................. 2­2 Report Parameter (Menu Level 2) ....................................................................................... 2­3 Report selections (Menu Level 3) .................................................................................. 2­3 Selecting a Printer Report .............................................................................................. 2­3 TEST Menu .................................................................................................................................... 2­4 Pattern Category (Menu Level 1) .............................................................................................. 2­5 Print Parameter (Menu Level 2) .......................................................................................... 2­5 Print selections (Menu Level 3) ..................................................................................... 2­6 Print2 Parameter (Menu Level 2) ........................................................................................ 2­6 Print2 selections (Menu Level 3) ................................................................................... 2­6 Plot Parameter (Menu Level 2) ............................................................................................ 2­7 Plot selections (Menu Level 3) ....................................................................................... 2­7 Selecting And Running a Print Test ................................................................................ 2­7

ii

Table Of Contents
Diagnostic Category (Menu Level 1) ........................................................................................ 2­8 PrntCal (Print Calibration) Parameter (Menu Level 2) .......................................................... 2­8 Selecting And Running a Hammer Calibration Routine ................................................. 2­8 Selecting And Running a Hammer2 Calibration Routine ............................................... 2­9 Selecting And Running a BankPls Calibration Routine ................................................ 2­10 Selecting And Running a Current Calibration Routine ................................................. 2­11 Selecting And Running a Paper Out Calibration Routine ............................................. 2­11 Meter Parameter (Menu Level 2) ....................................................................................... 2­12 Accessing the Meter Measurement Tests: ..................................................................... 2­12 Motors Parameter (Menu Level 2) ..................................................................................... 2­13 Accessing the Motor Measurement Tests: .................................................................... 2­13 Motor selections (Menu Level 3) ................................................................................. 2­13 Sht Spd (Shuttle Speed) Parameter (Menu Level 2) ............................................................ 2­14 Shuttle Speed selections (Menu Level 3) ...................................................................... 2­14 Rbn Spd (Ribbon Speed) Parameter (Menu Level 2) .......................................................... 2­14 Speed selections (Menu Level 3) ................................................................................ 2­14 RibnThr (Ribbon Threshold) Parameter (Menu Level 2) ..................................................... 2­14 Threshold selections (Menu Level 3) ........................................................................... 2­14 POutThr (Paper Out Threshold) Parameter (Menu Level 2) ............................................... 2­14 Threshold selections (Menu Level 3) ........................................................................... 2­14 PMotThr (Paper Motion Threshold) Parameter (Menu Level 2) .......................................... 2­14 Threshold selections (Menu Level 3) ........................................................................... 2­14 Max T (Maximum Temperature) Parameter (Menu Level 2) ............................................... 2­14 EnStar (Energy Star) Parameter (Menu Level 2) .................................................................. 2­14 Energy Star selections (Menu Level 3) ......................................................................... 2­15 Bank Ena (Menu Level 2) .................................................................................................. 2­15 Clear selections (Menu Level 3) .................................................................................. 2­15 Clear Parameter (Menu Level 2) ....................................................................................... 2­15 Clear selections (Menu Level 3) ................................................................................. 2­15 Fault Override (FltOvrd) Category (Menu Level 1) .................................................................. 2­15 Pap Mot (Paper Motion) Parameter (Menu Level 2) ........................................................... 2­15 Pap Out (Paper Out) Parameter (Menu Level 2) ................................................................ 2­15 Rib Mot (Ribbon Motion) Parameter (Menu Level 2) ......................................................... 2­15 Shuttle Parameter (Menu Level 2) ..................................................................................... 2­15 Temp (Temperature) Parameter (Menu Level 2) ................................................................. 2­16 Platen Parameter (Menu Level 2) ...................................................................................... 2­16 Ctrl (Control Processor) Parameter (Menu Level 2) ............................................................ 2­16 Link Parameter (Menu Level 2) ......................................................................................... 2­16 Sync Parameter (Menu Level 2) ........................................................................................ 2­16 Control Panel Key Operations For Controlling Fault Reporting ............................................... 2­16 ALL Fault Reporting .......................................................................................................... 2­16 Four Faults Only ............................................................................................................... 2­16 Paper Out Only ................................................................................................................ 2­16

iii

T6180 Maintenance Manual

Chapter 3: Faults and Troubleshooting
Introduction .................................................................................................................................. 3­1 Messages ....................................................................................................................................... 3­1 Faults ....................................................................................................................................... 3­1 Fault Correction Procedure ................................................................................................. 3­1 Fault Override .................................................................................................................... 3­2 Dump Mode ....................................................................................................................... 3­2 Hardware Troubleshooting Guides .............................................................................................. 3­10 The printer does not power up when switched on ................................................................. 3­10 Troubleshooting Procedure ............................................................................................... 3­10 The Printer powers up but the Control Panel does not function. ............................................. 3­11 Troubleshooting Procedure ............................................................................................... 3­11 The Control Panel Display functions partially, nonsensically, or not at all. ............................. 3­11 Troubleshooting Procedure ............................................................................................... 3­11 There is no printed output but the printer appears to be operating normally. .......................... 3­12 Troubleshooting Procedure ............................................................................................... 3­12 Printed output appears light ................................................................................................... 3­12 Troubleshooting Procedure. .............................................................................................. 3­12 Printed output appears shaky or fuzzy ................................................................................... 3­13 Troubleshooting Procedure ............................................................................................... 3­13 Character columns not printing .............................................................................................. 3­14 Troubleshooting Procedure ............................................................................................... 3­14 The Printer is out of paper -- No Paper Out fault is reported ................................................. 3­15 No Paper Motion -- No Paper Motion fault is reported ......................................................... 3­15 Paper Handling Problems ............................................................................................................ 3­16 Troubleshooting The Hammer Driver Transistors ......................................................................... 3­17 T6180 Engine Controller To Hammer Bank CBA Cables .............................................................. 3­25

Chapter 4: Removing and Replacing Components
T6180 Service Procedures ............................................................................................................. 4­1 Introduction .................................................................................................................................. 4­2 Procedure 1: Top Cover Removal/Replacement ............................................................................. 4­2 Procedure 2: Control Panel Removal/Replacement ....................................................................... 4­4 Installing the Control Panel ...................................................................................................... 4­4 Procedure 3: Paper Guide Access ................................................................................................. 4­5 Procedure 4: Ribbon Platform Removal/Replacement ................................................................... 4­6 Reinstallation ........................................................................................................................... 4­8 Procedure 5: Ribbon Motor Removal/Replacement ....................................................................... 4­9 Reinstallation ........................................................................................................................... 4­9 Procedure 6: Upper Tractor Assembly Removal/Replacement ..................................................... 4­10 Reinstallation ......................................................................................................................... 4­11

iv

Table Of Contents
Procedure 7: Lower Tractor Assembly Removal/Replacement ...................................................... 4­12 Reinstallation ......................................................................................................................... 4­13 Procedure 8: Tractor Belt Phasing / Paper Drive Belt Adjustment ................................................. 4­14 Procedure 9: Fan Motor Removal / Replacement ......................................................................... 4­17 9a. Main Fan ........................................................................................................................ 4­17 9b. Paper Guide Fan ............................................................................................................. 4­17 Procedure 10: Hammer Bank and Shuttle Removal / Replacement .............................................. 4­18 Reinstallation ......................................................................................................................... 4­21 Procedure 11: Hammer Module Replacement ............................................................................. 4­22 Procedure 12: Installing The Hammer Module ............................................................................ 4­24 Procedure 13: Platen Removal / Replacement ............................................................................. 4­26 Reinstallation ......................................................................................................................... 4­28 Procedure 14: Platen Position Sensor / Disk Removal / Replacement .......................................... 4­29 Procedure 15: Platen Adjustment (Hammer Gap Adjustment) ..................................................... 4­30 Procedure 16: Shuttle Drive Belt Removal / Replacement ........................................................... 4­32 Reinstallation ......................................................................................................................... 4­32 Procedure 17: Shuttle Sensor Removal / Replacement ................................................................. 4­33 Reinstallation ......................................................................................................................... 4­33 Procedure 18: Adjusting the Shuttle Sensor ................................................................................. 4­34 Procedure 19: Shuttle Motor Removal / Replacement .................................................................. 4­35 Reinstallation ......................................................................................................................... 4­36 Procedure 20: Paper Drive Motor Assembly Removal / Replacement .......................................... 4­37 Reinstallation ......................................................................................................................... 4­38 Procedure 21: Personality Module (Interface) Removal / Replacement ........................................ 4­39 Reinstallation ......................................................................................................................... 4­39 Procedure 22: Engine Controller Removal / Replacement ............................................................ 4­40 Reinstallation ......................................................................................................................... 4­42 Procedure 23: Power Supply Removal / Replacement (500 watt) ................................................ 4­43 Reinstallation ......................................................................................................................... 4­45 Procedure 24: Power Supply Removal / Replacement (250 Watt) ............................................... 4­46 Reinstallation ......................................................................................................................... 4­47

Appendix A: Schematics and Illustrated Parts Breakdown
Cabinet Assembly Parts List ...........................................................................................................A­3 Basic Printer Assembly Parts List ...................................................................................................A­8 Print Mechanism Assembly Parts List ...........................................................................................A­12 Control Panel Assembly Parts List ................................................................................................A­14 Hammer Bank and Shuttle Assembly Parts List ............................................................................A­19 Ribbon Support Platform Assembly Parts List ...............................................................................A­21 Engine Controller Assembly Parts List (1 of 2) ..............................................................................A­30 Engine Controller Assembly Parts List (2 of 2) ..............................................................................A­31 Serial/Parallel CBA Personality Parts List......................................................................................A­38 LAN CBA Personality Parts List (1 of 2) ........................................................................................A­39 v

T6180 Maintenance Manual
LAN CBA Personality Parts List (2 of 2) ........................................................................................A­40 Fourplex CBA Personality Parts List (1 of 2) .................................................................................A­48 Fourplex CBA Personality Parts List (1 of 2) .................................................................................A­49 Data Products CBA Personality Parts List .....................................................................................A­56 Power Supplies and Cables Assembly Parts List ...........................................................................A­58

Appendix B: Downloading Printer Firmware
Firmware Update Procedure ......................................................................................................... B­1

Index

vi

Table Of Contents

Figure Listing
Chapter 2
Figure 2­1. Hammer Leadtime Calibration Printout Sample (partial) .......................................... 2­9

Chapter 3
Figure 3­1. Figure 3­1a. Figure 3­2. Figure 3­2a. Figure 3­2b. Figure 3­2c. Figure 3­2d. Power On Troubleshooting Sequence .................................................................... 3­18 Power On Troubleshooting Sequence, Continued .................................................. 3­19 Print Data Troubleshooting Sequence .................................................................... 3­20 Print Data Troubleshooting Sequence, Continued .................................................. 3­21 Print Data Troubleshooting Sequence, Continued .................................................. 3­22 Print Data Troubleshooting Sequence, Continued .................................................. 3­23 Print Data Troubleshooting Sequence, Continued .................................................. 3­24

Chapter 4
Figure 4­1. Figure 4­2. Figure 4­3. Figure 4­4. Figure 4­5. Figure 4­6. Figure 4­7. Figure 4­8. Figure 4­9. Figure 4­10. Figure 4­11. Figure 4­12. Figure 4­13. Figure 4­14. Figure 4­15. Figure 4­16. Figure 4­17. Figure 4­18. Figure 4­19. Figure 4­20. Figure 4­21. Figure 4­22. Figure 4­23. Figure 4­24. Open the Cover ....................................................................................................... 4­2 Disconnecting the Control Panel Cable ................................................................... 4­4 Removing the Paper Guide Assembly ...................................................................... 4­5 Removing the Ribbon Cartridge ............................................................................... 4­6 Disconnecting the Ribbon Motor Cable ................................................................... 4­7 Removing the Ribbon Platform ................................................................................ 4­8 Removing the Ribbon Motor mounting screws ........................................................ 4­9 Upper Tractor Assembly ........................................................................................ 4­10 Reinstalling the Upper Tractors .............................................................................. 4­11 Lower Tractor Assembly ......................................................................................... 4­12 Reinstalling the Lower Tractors .............................................................................. 4­13 Tractor Belt and Paper Drive Belt Assemblies ......................................................... 4­14 Using the Phasing Gauge ....................................................................................... 4­15 Adjusting the Paper Drive Motor Assembly ............................................................ 4­16 Removing the Fan .................................................................................................. 4­17 Removing the Ribbon Guide ................................................................................. 4­18 Unplugging the Hammerbank Cables .................................................................... 4­19 Removing the Screws from the Left Linear Bearing ................................................ 4­19 Removing the Screws from the Connecting Plate ................................................... 4­20 Removing the Screws from the Tie Blocks .............................................................. 4­20 Removing the Shuttle Assembly ............................................................................. 4­22 Protecting adjacent modules from damage ............................................................ 4­23 Hammer Ball Alignment Tool ................................................................................ 4­24 Platen Access, Left Side ......................................................................................... 4­26 vii

T6180 Maintenance Manual
Figure 4­25. Figure 4­26. Figure 4­27. Figure 4­28. Figure 4­29. Figure 4­30. Figure 4­31. Figure 4­32. Figure 4­33. Figure 4­34. Figure 4­35. Figure 4­36. Figure 4­37. Figure 4­38. Figure 4­39. Figure 4­40. Figure 4­41. Figure 4­42. Figure 4­43. Platen Access, Right Side ....................................................................................... 4­27 Platen Position Sensor Removal ............................................................................. 4­29 Platen Adjustment ................................................................................................. 4­30 Shuttle Drive Belt Removal .................................................................................... 4­32 Shuttle Sensor Removal ......................................................................................... 4­33 Shuttle Motor Removal .......................................................................................... 4­35 Aligning the Motor and Shuttle Pulleys .................................................................. 4­36 Removing the Paper Motor Drive Assembly ........................................................... 4­37 Installing the Pulley on the New Motor Drive Assembly ........................................ 4­38 Removing the Personality Module ......................................................................... 4­39 Unplugging the Connectors from the CBA ............................................................. 4­40 Removing the Mounting Screws ............................................................................ 4­41 Unscrewing the Engine Controller ......................................................................... 4­41 Unscrewing the Engine Controller from the ESD Shield ......................................... 4­42 Accessing the 500 Watt Power Supply ................................................................... 4­43 Removing the 500 Watt Power Supply ................................................................... 4­44 Removing the Cables from the 500 Watt Power Supply ......................................... 4­45 Removing the 250 Watt Power Supply ................................................................... 4­46 Removing the Cables from the 250 Watt Power Supply ......................................... 4­47

Appendix A
Cabinet Assembly .........................................................................................................................A­2 Basic Printer Assembly I ................................................................................................................A­4 Basic Printer Assembly II ...............................................................................................................A­5 Basic Printer Assembly III ..............................................................................................................A­6 Basic Printer Assembly IV ..............................................................................................................A­7 Print Mechanism Assembly I .........................................................................................................A­9 Print Mechanism Assembly II ......................................................................................................A­10 Print Mechanism Assembly III ..................................................................................................... A­11 Control Panel Assembly ..............................................................................................................A­13 Control Panel PCA Diagram ........................................................................................................A­15 Control Panel PCA Schematics ....................................................................................................A­16 Control Panel PCA Assembly ......................................................................................................A­17 Hammer Bank and Shuttle Assembly ...........................................................................................A­18 Ribbon Support Platform Assembly .............................................................................................A­20 Engine Controller Assembly ........................................................................................................A­22 Engine Controller Assembly Schematic I .....................................................................................A­24 Engine Controller Assembly Schematic II ....................................................................................A­25 Engine Controller Assembly Schematic III ...................................................................................A­26 Engine Controller Assembly Schematic IV ...................................................................................A­27 Engine Controller Assembly Schematic V ....................................................................................A­28 Engine Controller Assembly Schematic VI ...................................................................................A­29

viii

Table Of Contents
Serial/Parallel/LAN CBA Personality Diagram ..............................................................................A­32 Serial/Parallel/LAN CBA Personality Module End Panels .............................................................A­34 Serial/Parallel/LAN CBA Personality Schematic I .........................................................................A­35 Serial/Parallel/LAN CBA Personality Schematic II ........................................................................A­36 Serial/Parallel/LAN CBA Personality Schematic III .......................................................................A­37 Fourplex CBA Personality Diagram .............................................................................................A­41 Fourplex CBA Personality Module End Panel ..............................................................................A­43 Fourplex CBA Personality Schematic I .........................................................................................A­44 Fourplex CBA Personality Schematic II ........................................................................................A­45 Fourplex CBA Personality Schematic III .......................................................................................A­46 Fourplex CBA Personality Schematic IV ......................................................................................A­47 Data Products CBA Personality Diagram .....................................................................................A­50 Data Products CBA Personality Module End Panel ......................................................................A­51 Data Products CBA Personality Schematic I.................................................................................A­52 Data Products CBA Personality Schematic II................................................................................A­53 Data Products CBA Personality Schematic III...............................................................................A­54 Data Products CBA Personality Schematic IV ..............................................................................A­55 Power Supplies and Cables Assembly .........................................................................................A­57

ix

T6180 Maintenance Manual

Table Listing
Chapter 1
Table 1­1. Table 1­2. Table 1­3. Table 1­4. Table 1­5. Table 1­6. Table 1­7. Table 1­8. Table 1­9. Personality Module Configurations............................................................................ 1--2 Type Style, Character Matrix, Dot Density, and CPI Combinations ............................ 1--5 Plot Data Output Speed ............................................................................................ 1--6 Graphics Benchmarks ............................................................................................... 1--6 POSTNET Label Speeds............................................................................................. 1--6 Slew Speed ............................................................................................................... 1--7 Power Requirements ................................................................................................. 1--7 Heat Load Contributions ........................................................................................... 1--9 Printer Dimensions.................................................................................................... 1--9

Chapter 2
Table 2­1 Test Menu .................................................................................................................... 2­4

Chapter 3
Table 3­1. Display Messages ........................................................................................................ 3­3 Table 3­2. Paper/Printing Corrective Action ............................................................................... 3­16 Table 3­3. Connector Pinouts..................................................................................................... 3­25

Appendix A
Control Panel PCA X-reference....................................................................................................A­15 Engine Controller Assembly X-reference ......................................................................................A­23 Serial/Parallel/LAN CBA Personality X-reference .........................................................................A­33 Fourplex CBA Personality X-reference .........................................................................................A­42 Data Products CBA Personality X-reference .................................................................................A­50

x

Preface

Preface

Preface

About This Manual
This manual presents maintenance, alignment, and troubleshooting procedures for the T6180 printer. Also included are all schematics and diagrams necessary for repair and maintenance. The following chapter and appendix summaries will provide you with a survey of the manual contents.

Chapter 1. Technical Overview
In Chapter 1, you will find detailed descriptions of the technical aspects of your printer. In addition, design and operational specifications are discussed.

Chapter 2. Menu Operations
In Chapter 2, you will find the Menu Operations concerned with troubleshooting and maintaining your printer.

Chapter 3. Faults and Troubleshooting
This chapter contains a listing of the error and fault messages that may appear on the Control Panel Display and various troubleshooting procedures and problem fixes.

Chapter 4. Removing and Replacing Components
This chapter presents instructions for removing and replacing/reinstalling various printer components.

Appendix A. Schematics and Illustrated Parts Breakdowns
In appendix A schematics are given to assist you in troubleshooting problems and locating components that control your printer operations. Also included are exploded views of all printer components along with detailed parts listings.

Appendix B. Downloading Printer Firmware
In this appendix, instructions are given on downloading firmware for your printer.

Conventions
We use the following conventions throughout this manual. Notes may be considered as supplementary information.

This symbol marks information about actions that may damage the equipment or injure the user.

These statements list special instructions, warnings, or reminders about printer operations.

Pref­1

T6180 Maintenance Manual

Blank Page

Pref­2

Chapter 1:
Technical Overview

Technical Overview

Chapter 1. Technical Overview

Technical Overview
The T6180 is a medium speed, line impact dot matrix printer. It has a maximum speed of 1800 lines per minute in uppercase draft text mode. The T6180 is designed for long term operations, supporting a workload of 315,000 pages per month with minimal maintenance.

T6180 Electronic Hardware Architecture
The electronic design of the T6180 is implemented in two basic modules. These are the Engine Control and the Personality Module.

Engine Control Module
The primary components of the Engine Control Module are: · · · · · Control Processor ­ Intel 87C196KB Shuttle Processor­ Philips/Signetics 87C750 Sensor Inputs Hammer/Motor logic and drive EEPROM ­ X24C08

Control Processor
· · · · 12.288 MHz clock High speed outputs for driving the paper motor and hammer firing High speed inputs for synchronizing timing of the shuttle position 8 channel 10 bit Analog to Digital Converter for sensor readings (paper out, paper motion, shuttle motion, ribbon motion, platen gap, hammer current, power supply voltage, ambient temperature) Serial channel for communication (19.2K bps) with Main CPU Port control of Shuttle/Ribbon microcontroller Port control of control panel, ribbon clock, and hammer loading

· · ·

Sensor Inputs
· · · · · · Paper motion sensor ­ optical Paper out sensor ­ optical Platen gap sensor ­ optical Shuttle motion/capture sensor ­ optical Ambient temperature ­ thermistor Power supply voltage ­ resistor divider

Shuttle Processor
· · 12.288 MHz clock Drives stepping phases to the Shuttle and Ribbon motors

1­1

T6180 Maintenance Manual

Hammer/Motor logic and drive
· · · · 4 hammer driver ASICs ­ each of the 136 outputs drives a transistor 34 quad Hammer drive transistor arrayss ­ SMA4032 34 Zener Diodes for absorbing coil drive energy­ 1N5347B 6 H-bridge Motor drive chips (2 for ribbon, 2 for shuttle and 2 for paper) ­ Allegro 3952

EEPROM
The EEPROM stores engine calibration and printer configuration settings.

T6180 Personality Module
Interface control is provided by the Personality Module. There are four Personality Modules available, two of which have optional configurations. The configurations vary in terms of host interface, memory configuration, and installed software. The primary components of the Personality Module are: · · · · · Main processor ­ Motorola MC68340 Flash EPROM ­ comprised of 4M-bit and/or 2M-bit parts (determined by the type of interface) DRAM ­ .5 Meg, 1 Meg, or 2 Meg (determined by the type of interface) EPLD ­ Altera EPM7064 Parts specific to the type of interface (Serial/Parallel, Lan, Twinax/Coax and Dataproducts). (See Table 1-1.)

The following table shows the modules and optional configurations:

Table 1­1. Personality Module Configurations Personality Module
Host I/Os

Standard Ser/Par
IEEE 1284 RS-232-C

Extended Ser/Par
IEEE 1284 RS-232-C Dataproducts1 IG, Code V, PGL, & MTPL Dataproducts Standard or Longlines 768 K 512 K

LANPlex
IEEE 1284 RS-232-C Ethernet IG, Code V, PGL, & MTPL

FourPlex
IEEE 1284 RS-232-C Twinax Coax Code V, PGL, IPDS2 Graphics 1 Meg 512 K 3

Standard Graphics Languages Optional Configurations Flash ROM RAM

IG, Code V, PGL, & MTPL

768 K 512 K
1 2 3

1.5 meg 2 Meg

Dataproducts may be set up for Standard or Longlines operation. With IPDS Option, Code V and PGL are not included. With IPDS Option, 512 K RAM is upgraded to 1 Meg.

1­2

Chapter 1. Technical Overview

Serial and Parallel Interfaces
Serial
· · · · MC145406 (+/- 12V) chip is used for the RS-232 drivers and receivers Internal programmable bps generator (300 bps to 38.4K bps) Both DTR/Busy and XON/XOFF is supported Standard secondary RTS on pins 11 and 19. Primary RTS is capable of being jumpered to pin 4 Altera EPM7064 and 74LS374/74LS244 ­ supports IEEE-1284 compatibility and nibble modes 25MHz clock 16-bit CPU bus Two direct Memory Access (DMA) channels ­ One for hammer loading, and one for the IEEE-1284 parallel Interface Two serial channels ­ One for the control CPU communication, and one for the external serial interface

Parallel
·

Motorola MC68340
· · · ·

Flash Memory
The amount of Flash Memory depends on the configuration of the personality module.

DRAM
The amount of DRAM depends on the configuration of the personality module.

Altera EPM7064
· · · Dynamic random access memory (DRAM) control Logic for IEEE-1284 Parallel interface Glue logic (chip selects, hammer data and clock, row and column selection for DRAM)

1­3

T6180 Maintenance Manual

Specifications
Serial/Parallel Emulations
Nine emulations are available on the T6180: MT660, Genicom ANSI, HP2564C, Printronix P600, Printronix P6000, IBM Proprinter III XL, Epson FX-100+, DEC LG01, and MTPL.

Font Styles
There are 6 resident type styles available on your printer. They include: Courier, Data Processing, Draft, Gothic, OCR-A, and OCR-B. All font styles and the two output modes (Enhanced and Constant Density Fonts for Draft and DP) are selected through the printer control panel.

Courier and Gothic
These two font styles provide near letter quality (NLQ) printing on your printer. They print at higher dot densities and use denser character matrixes. NLQ type styles provide greater readability for reports and other text output.

Data Processing and Draft
Data Processing and Draft styles appear in two modes: Constant Density (CDF) and Enhanced. Constant Density Fonts print at the same dot density regardless of the CPI. This produces consistent print speed even when changing from one CPI to another. Enhanced Mode provides higher resolution and a greater range of CPI's than CDF Mode. Because Enhanced Mode uses a variety of dot densities, you should expect a change in print speed of text when switching from one CPI to another.

OCR-A and OCR-B
These font styles print at 10 CPI only. They are used mainly for Optical Character Recognition.

Characters Per Inch
The T6180 offers a variety of CPI's for use in printer output. Available CPI's are dictated by the font style selected. Each CPI is based on one of twelve character matrixes and twelve dot densities. Each matrix uses a specific number of dot columns for character composition and intercharacter gap. CPI's are grouped in any given type style by the base CPI matrix used for the group. These base CPI's are 10, 12, and 15.

1­4

Chapter 1. Technical Overview

Table 1­2. Type Style, Character Matrix, Dot Density, and CPI Combinations
Print Modes Constant Density Type Styles Draft 10 CPI Group Base Matrix: 9 x 8 Dot Density: 60 x 48 CPIs: 5 and 10 Base Matrix: 9 x 12 Dot Density: 60 x 72 CPIs: 5 & 10 Base Matrix: 9 x 8 Dot Density: 60 x 48 CPIs: 5 &10 Base Matrix: 9 x 12 Dot Density: 60 x 72 CPIs: 5 & 10 Base Matrix: 19 x 16 Dot Density: 80 x 96 CPIs: 5 &10 Courier Base Matrix: 19 x 16 Dot Density: 80 x 96 CPIs: 5 & 10 Base Matrix: 9 x 16 Dot Density: 60 x 96 CPIs: 10 Base Matrix: 19 x 24 Dot Density: 80 x 144 CPIs: 10 12 CPI Group Base Matrix: 7 x 8 Dot Density: 60 x 48 CPIs: 6, 6.67, 12, & 13.33 Base Matrix: 7 x 12 Dot Density: 60 x 72 CPIs: 12 & 13.33 Base Matrix: 13 x 8 Dot Density: 80 x 48 CPIs: 6, 6.67, 12, & 13.33 Base Matrix: 13 x 12 Dot Density: 80 x 72 CPIs: 6, 6.67, 12, & 13.33 Base Matrix: 13 x 16 Dot Density: 80 x 96 CPIs: 6, 6.67, 12, & 13.33 Base Matrix: 13 x 16 Dot Density: 80 x 96 CPIs: 6, 6.67, 12, & 13.33 15 CPI Group Base Matrix: 5 x 8 Dot Density: 60 x 48 CPIs: 15 & 17.14 Base Matrix: 5 x 12 Dot Density: 60 x 72 CPIs: 15 & 17.14 Base Matrix: 9 x 8 Dot Density: 120 x 48 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20 Base Matrix: 9 x 12 Dot Density: 120 x 72 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20 Base Matrix: 9 x 16 Dot Density: 120 x 96 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20 Base Matrix: 9 x 16 Dot Density: 120 x 96 CPIs: 7.5, 8.33, 8.57, 15, 16.67, 17.14, & 20

Data Processing

Enhanced

Draft

Data Processing

Near Letter Quality

Gothic

Optical Character OCR-A Recognition OCR-B

Lines Per Inch
Ten lines per inch (LPI) settings are available through the control panel. They include 1.5, 2, 3, 4, 5, 6, 8, 9, 10, and 12 LPI. In some emulations the availability of certain LPI's are restricted.

1­5

T6180 Maintenance Manual

Dot Densities and Plot Speeds
The T6180 printer supports Horizontal row plots (single and multiple row), Vertical column plots, and specialized Graphic plots. Your printer supports the following horizontal DPI's: 40, 48, 60, 80, 90, 120, 180, and 240. Scaled densities available on your printer are 50, 72, 75, 96, 100, 144, 150, 160, and 200. All other selections will be approximated by conversion to the next higher density. Your printer supports the following vertical DPI's: 48, 72, 96,144, and 288. All other selections are emulated through the use of scaling techniques.

Table 1­3. Plot Data Output Speed Dot Plot Hor./Vert. 60 x 48 60 x 72 120 x 72 240 x 288 Print Speed Inches Per Min. 180 120 60 25

Graphics Benchmarks
Two benchmark tests were used to rate graphics output on the T6180 printer. The first was an AIAG label containing bar codes and block characters inside a box. The second was a POSTNET label with one line of POSTNET bar code and four lines of text. The AIAG test consisted of a series of labels printed two across repeated vertically with a 0.1" vertical space. The test was performed in two variations: Normal AIAG printed with 60 DPI bar codes and Dark AIAG printed with 120 DPI bar codes. The POSTNET test consisted of rows of labels printed four across with one blank line between each row. In addition, the POSTNET test was run with 4 variations: Draft and Data Processing (DP) type styles for text/bar codes printed at 6 and 8 LPI. Tests were timed, then results were converted into labels per hour.

Table 1­4. Graphics Benchmarks AIAG Label Benchmark Results Graphics Dots Per In. Language 60 120
Code V PGL 3540 LPH 3540 LPH 2280 LPH 2280 LPH

Table 1­5. POSTNET Label Speeds
POSTNET Label Benchmark Results Lines Type Style Per Inch Draft Data Processing 6 LPI 8 LPI 48000 LPH 49000 LPH 39000 LPH 40000 LPH

1­6

Chapter 1. Technical Overview

Paper Slew Speed
Table 1­6. Slew Speed
Print Mode Normal Heavy Forms Maximum Slew Speed 20 Inches Per Second 12 Inches Per Second

Ribbons
The T6180 is designed to operate optimally with Tally ribbon cartridges. These cartridges are designed for easy access and loading.

Forms/Paper Description
The T6180 is designed to use continuous, sprocket feed type paper, 4 to 16 inches in width, and variable (according to user needs) in length. One to six part paper may be used with a maximum thickness of .025 inches. (Reference specifications: ISO 2784, DIN 9771, and DIN 6721.)

Acoustics
The noise generated by the T6180 printer is 6.6 bels (Sound Power per ISO 7779-C at 51 dBA (Sound Pressure Level--9 position average).

Power Supply
The printer requires single phase, 47 to 63 Hz. 90 to 264 VAC input power. The printer's universal power supply automatically adjusts to the correct values. A fuse is provided to interrupt power to the power supply. The following table gives typical current values.

Table 1­7. Power Requirements
External Power Supply AC Volts (RMS) 110 110 220 Frequency (Hz) 50 60 50 Average Operating 3.00 A/314 W 3.00 A/313 W 1.60 A/310 W Current/Wattage Requirements @ Nominal Voltage Peak Operating 8.00 A/820 W 8.00 A/816 W 4.40 A/824 W Average Idle (<5 min.) 0.72 A/75 W 0.72 A/74 W 0.55 A/81 W Average Idle (>5 min.) 0.54 A/48 W 0.54 A/48 W 0.44 A/55 W

Cooling System
Cooling system malfunctions are detected and a failure will result in shuttle motion, paper motion, and printing functions being inhibited. The malfunction will be reported on the control panel display.

1­7

T6180 Maintenance Manual

Safety
Personnel hazard areas have restricted access with appropriate warning labels. Catastrophic equipment failures are inhibited with protective functions in major areas of overload potential.

Preventive Maintenance
The T6180 is designed to eliminate the requirement of scheduled maintenance procedures, such as alignment, adjustment, or lubrication. Preventive maintenance is limited to periodic cleaning. Dust and paper fibers should be removed periodically with a soft cloth and brush or a vacuum cleaner. Clean the printer case with a damp cloth and soapy water. DO NOT use any abrasive cleaners or solvents, as they will damage the case.

Environment
Operating
Temperature Dry Bulb: Humidity: 50°F to 104°F (10°C to 40°C) 10 to 90% noncondensing with a maximum wet bulb temperature of 82°F (28°C) and a minimum dew point of 36°F (2°C ) To 8,000 ft. (2438 meters) Half sine wave shock pulse of 10 g peak and 10 +/- 3 ms duration, three times in the vertical direction. Applied to each of the three axes: · 5 ­ 22 Hz 0.010 in. double amp. · 22 ­ 500 Hz 0.25 g peak · 500 ­ 22 Hz 0.25 g peak · 22 ­ 500 Hz 0.010 in. peak Sweep rate of 1 octave/min.

Altitude: Mechanical Shock:

Vibration:

Nonoperating
Temperature: Boxed: Unboxed: Humidity: Altitude: Thermal Shock: Vibration: - 40°F to 151°F (-40°C to 66°C) 14°F to 122°F (-10°C to 50°C) 5 to 95% noncondensing To 10,000 ft. (3048 meters) 29°F (16°C) per minute Units meet NSTA (National Safe Transit Association) requirements.

The printer must be allowed to reach room temperature before operating. Three hours out of the shipping container is usually enough time for stabilization. Complies with NSTA Program 1 & 2.

1­8

Chapter 1. Technical Overview

Heat Load Contribution
The average heat load contribution to the environment is approximately 1075 BTUs per hour (315 Watts) with a maximum potential of 3000 BTUs per hour (880 Watts) under continuous full-load printing conditions.

Table 1­8. Heat Load Contributions Printing Conditions (110 VAC/60 Hz)
Power On, not printing 100% Uppercase Rolling ASCII Black Page Plot

Current/Wattage
0.64 A/42 W (>5 min.) 2.57 A/268 W 6.29 A/491 W

BTU/Hr
143 915 1677

Physical Configuration
The T6180 printer is only available in the Quietized Cabinet.

Weight
The printer has an actual weight of 252 lbs and a shipping weight of 308 lbs.

Printer Dimensions
Table 1­9. Printer Dimensions
Dimension Parameter Height Height/Lid Open Width Depth Door Opening (paper loading) Printer Measurement 42.5" 60.5" 32.35" 32.0 " 21.5"

Industry and Agency Standards
The T6180 is designed to meet the requirements of several industry and Government agency standards.

Electromagnetic Emissions
EMI: ESD: RF: FCC part 15, subpart J, Class A and EN5022 Class B EN 61000-4-2 (REF. Q1012) EN 61000-4-3

Power Line: 61000-4-4 Transients: RF: 61000-4-5 61000-4-6

Energy Star Compliant

1­9

T6180 Maintenance Manual

Agency Approvals
United States
The T6180 complies with UL 1950, C22.2 No. 950-M89, and IEC 950(TUV) via EN 60950 (cb scheme) safety requirements. The T6180 printer is Energy Star compliant.

Europe
IEC 950 (1986) plus Amendment 1 (1988) and 2 (1990) and National Deviations CA, DE, FI, GB, NL, NO, SE, US (CAN/CSA-C22.2 No. 950-M89 and CSA TIL F-18 (May 19, 1992) (UL Std no. 1950-1989)

1­10

Chapter 2:
Menu Operations

Menu Operations

Chapter 2. Menu Operations

Introduction
This line printer uses a unique approach to calibration procedures and troubleshooting aids. The TEST Mode contains a number of procedures for calibrating sensors, turning motors on and off, changing hammer lead time, running various printer tests, and many other adjustments. They are located in the CONFIGuration and TEST menus and can be accessed through the Printer Control Panel. These procedures are integral to the printer's firmware. No tools of any kind are required.

Technical Access Mode
Technical (Tech) Access Mode is provided for the repair technician. It allows him access to additional tests, calibration, and diagnostic procedures for use in troubleshooting and correcting problems with the printer. These features do not appear on the display or in any printout until you turn on Tech Access. They can then be accessed through the control panel and will appear on the Control Panel Selections Printout (the HELP printout) as long as Tech Access is enabled. Once Tech Access is disabled, the additional features will revert to being "hidden" again.

Entering Tech Access Mode
Place the printer Offline. Depress the LINE FEED Key and ENTER Key simultaneously and hold them depressed for approximately 3 seconds. When the printer enters Tech Access Mode, the printer alarm sounds and the display flashes, "Tech Access On." Release the keys immediately when the alarm sounds. At this point, the printer will default to the POWERUP Configuration.

Exiting Tech Access Mode
There are two methods for leaving Tech Access. Upon leaving Tech Access, the printer will again default to the POWERUP Configuration. 1. Place the printer Offline. Depress the LINE FEED Key and ENTER Key simultaneously. Release the keys immediately when the alarm sounds. 2. Cycle power on the printer.

Testing, Troubleshooting, and Calibration
The printer is equipped with the following types of Print Tests, Hex Dumps, and Printer Information Printouts.

Printer Tests
Print tests appear in both normal menu operations and in the Technical Access Mode of the printer. These tests consist of the following patterns and types. · · · · ASCII print patterns Plot Mode patterns Calibration routines Electronic hardware tests

Detailed explanations of the print tests follow in the TEST Menu Section of this chapter. 2­1

T6180 Maintenance Manual
Hex Dumps
Hex Dumps can be used to check printer functions and data processing operations and are also used to help solve problems that can affect printer performance. These dumps are located in the Configuration Menu, Printer Category, under the Dmp Mod (Dump Mode) Parameter in normal menu operations. There are three styles of Dump Modes on the printer. Style 1 Text, spaces, and control codes are printed out in hexadecimal format.

Make sure that wide paper (136 columns -- 13+ inches of printable width) is loaded on the printer before running a Style 1 Hex Dump. Style 2 Style 3 Control codes are printed out in hexadecimal format while text and spaces are printed out in their original form. Control codes and spaces are printed out in hexadecimal format, while text is printed out in its original form.

Printer Information Printouts and Displays
There are five printouts and displays that you can access through the printer control panel. The first printout is the HELP Menu and the remaining four are Printer Reports (Configs, CalData, LastFlt, and Version). These reports can be accessed via the Configuration Menu, Printer Category, under the Report Parameter. HELP Menu The HELP Menu is a printout that lists selections that are available for each parameter in the multilevel menus on the printer and indicates with an asterisk (*) which ones are currently active. Before printing out the HELP Menu, make sure that there is at least 13 inches of printable width on the installed paper. Printing a HELP Menu In Tech Access Mode STEP 1. Place the printer Offline. STEP 2. Depress the LINE FEED Key and ENTER Key simultaneously until the printer alarm sounds, then release them immediately to place the printer in Tech Access Mode. STEP 3. Depress the MODE Key to enter the multilevel menu system, then scroll (v Key) to the HELP selection. STEP 4. Depress the ENTER Key to begin printing the HELP Menu. This printout will end when the entire HELP Menu is printed out.

2­2

Chapter 2. Menu Operations
Report Parameter (Menu Level 2) This parameter has four selections. Two of the selections, Configs and CalData, generate printouts. The second pair of reports (LastFlt and Version) are displays. The Report Parameter is located in the CONFIGuration Menu, under the Printer Category. Report selections (Menu Level 3) Configs Prints a report showing the setups of the configurations. CalData Prints a report showing the current values of the Paper Out and Paper Motion sensors and the hammer lead time and shuttle amplitude. LastFlt The Control Panel Display shows the Last Fault that occurred. Version The Control Panel Display shows the version number of the currently installed firmware. To clear the displays, depress any key on the printer control panel. Selecting a Printer Report STEP 1. Take the printer Offline. STEP 2. Depress the MODE Key to enter the multilevel menu system, then scroll (v Key) to the CONFIG selection. STEP 3. Depress the FORMS/1 Key to access the CONFIG Menu categories, then scroll (v Key) until the Printer Category is displayed. STEP 4. Depress the CPI/2 Key to access the Printer Category parameters, then scroll (v Key) until the Report Parameter is displayed. STEP 5. Depress the LPI/3 Key to access the Report selections, then scroll (v Key) to the desired selection. STEP 6. Depress the ENTER Key to begin the Report printout or display.

2­3

T6180 Maintenance Manual

TEST Menu
The TEST Menu contains the parameters for testing printer operation, adjusting print quality, and controlling fault reporting. There are three categories in this menu: Pattern, Diagnostics, and Fault Override. The table that follows presents the categories, parameters, and parameter selections that will appear in the TEST Menu while the printer is in Tech Access Mode. Table 2­1 Test Menu To access ¦ Depress this key ¦ Categories
FORMS 1

Parameters
CPI

Selections
LPI

Level 1

2

Level 2

3

Level 3

Pattern Use the v Key to scroll to the desired selection.

Print

Upper All Chrs 63/69 ECMA Columns PaperSv ThermCy Lower 1 Line All H's All E's All #'s All +'s Parens Rubout Ribbon Grid Cross Gray Black Block Hammer Hammer2 Bank Pls Current Pap Out Pap Out Pap Mot Sht Sen Rib Mot Tmp Sen Power Platen Current Keypad Ribbon Shuttle 23­48

Print2

Use the ENTER Key to select a value or option. Plot

Diag

PrntCal

Meter

Motors Sht Spd

2­4

Chapter 2. Menu Operations
Table 2­1, Continued To access ¦ Depress this key ¦ Categories
FORMS 1

Parameters
CPI

Selections
LPI

Level 1

2

Level 2

3

Level 3

Rbn Spd RibnThr POutThr Use the v Key to scroll to the desired selection. PMotThr Max T En Star BankEna

1­250 1­255 0­255 0­255 1­255 On Off Upper Lower Both CalData Counts NVRAM OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON

Clear Use the ENTER Key to select a value or option.

FltOvrd

Pap Mot Rib Mot Pap Out Shuttle Temp Platen Ctrl Link Sync

Pattern Category (Menu Level 1)
The Pattern Category contains several predefined print patterns used to test basic printer functionality. There are three parameters in this category: Print, Print2, and Plot. Print Parameter (Menu Level 2) This parameter is also available in normal menu operations. It has five selections.

2­5

T6180 Maintenance Manual
Print selections (Menu Level 3) Upper Prints a rolling pattern of 63 UPPERCASE ASCII characters. All Chrs 63/69 ECMA Columns Prints all Character Sets available on your printer. Prints rolling ASCII with spaces. Prints a pattern designed to produce a specific audible noise pattern specified by European Computer Manufacturers Association used for acoustics testing. This test labels each column in the current print line. The line length used is based on the current margin settings.

To stop any of the ab