AMT Datasouth XL300 Maintenance Manual
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AMT Datasouth XL300 Maintenance Manual

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XL300
MAINTENANCE MANUAL
Part No. 105880
Rev. A

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Summary of Contents for AMT Datasouth XL300

  • Page 1 XL300 MAINTENANCE MANUAL Part No. 105880 Rev. A...
  • Page 2 INTRODUCTION The Maintenance Manual is a two-part document. The first part is an introduction to the printer systems and sub-assemblies and theory of operation. The second part provides troubleshooting and scheduled maintenance procedures, including corrective maintenance (removal and replacement) procedures.

  • Page 3: Table Of Contents

    Table of Contents GENERAL INFORMATION ......……………………. 1-1 Introduction …..…........……………………. Functional Description ......……………………. Printer Initialization ......………………………… Printhead Assembly ......……………………… Paper Feeding .........………………………… Paper-Out Detection ......……………………… Bell Operation ........……………………….. Operator Control Panel .......………………………… 1-3 Non-Volatile Memory ......……………………… 1-4 1.10 Ribbon Drive System ......……………………….
  • Page 4 4.5.3 Operator Panel Removal and Replacement - Figure 4.1 ..… 4-5 4.5.4 Electronic Chassis Removal and Replacement - Figure 4.2 ..… 4-5 4.5.5 Controller Board Removal and Replacement - Figure 4.2..… 4-6 4.5.6 Fan Removal and Replacement - Figure 4.2 ....………...
  • Page 5 List of Illustrations Figure 1.1 Spacial Requirements ..........………. 1-11 Figure 2.1 Functional Block Diagram ...........…… Figure 2.2 Printhead Solenoid Current Waveform ......… Figure 2.3 Paper Motor Current Waveforms ........Figure 2.4 Carriage Motor Current ..........……… Figure 3.1 Controller Schematic Diagram - Sheet 1 of 8 ......Figure 3.2 Controller Finished Assembly - Sheet 1 of 2 ......

  • Page 6: General Information

    Chapter 1: GENERAL INFORMATION 1.1: INTRODUCTION The printer is a serial matrix printer capable of producing highly legible copy on forms containing as many as six parts. It is well suited to a variety of applications. The standard ASCII code is employed, and communications may be performed over a serial interface at BAUD rates ranging from 110 to 19,200.

  • Page 7: Printer Initialization

    1.3: PRINTER INITIALIZATION At power-on, the printhead is moved slowly left until the carriage reaches the left margin. This is accomplished when a small tab on the carriage engages a photosensor mounted on the left endplate. This position is referred to as the true left margin and all future printhead motion is referenced to this point.

  • Page 8: Paper-Out Detection

    1.6: PAPER-OUT DETECTION A photoelectric sensor is employed to detect the absence of paper. It is attached to the lower-paper guide which is mounted to the bottom side of the platen. The sensor is constructed with an infrared light-emitting diode (ILED) mounted adjacent to a phototransistor.

  • Page 9: Non-Volatile Memory

    1.9: NON-VOLATILE MEMORY A non-volatile memory (NVM) is used to store all programmable printer parameters. Included are such things as forms length, BAUD rate, tab position, communications status, etc. The forms line number is saved in the NVM so that top-of-form position is maintained at all times unless the form is manually moved by the operator.

  • Page 10: Universal Power Supply

    The NMU relies on the inherent stepper motor operation for position control. It is assumed that the motor faithfully steps once each time it is commanded to do so. This method of control differs from most printers which employ closed loop servo motors and encoder devices.

  • Page 11: Controller Board

    1.13: CONTROLLER BOARD A single printed circuit board (PCB) contains all the digital and analog circuitry required to operate the printer subsystems and to control the operational protocol. Interface correctors are mounted to the PCB and are accessible via the rear of the printer. Connectors are also provided for the motors, printhead, and sensors.

  • Page 12: Current Loop Interface Option

    ASSIGNMENT 1. Chassis Ground 2. Serial Data Out Asynchronous output data line 3. Serial Data In Asynchronous input data line 7. Signal Ground 11. Data Terminal Indicates the printer is open for communication and can accept Ready (DTR) or transmit data. 20.

  • Page 13: Current Loop Installation

    1.16: Current Loop Installation For a passive loop, install the following jumpers: W15, W17, W19, W27 For an active loop, install the following jumpers: W29, W18, W16, W28, W26, W20 The following jumpers should be removed when installing an active loop: W15, W17, W19, W27...

  • Page 14: Ttl Parallel Interface

    1.17: TTL PARALLEL INTERFACE A TTL parallel interface is standard and is mounted on the logic board. It is compatible with most systems which have been designed to operate with Centronics printers. Certain signals found on early Centronics printers are not provided. Should any problems with compatibility arise, contact place of purchase.
  • Page 15 1-10...

  • Page 16: Physical Characteristics

    1.18: PHYSICAL CHARACTERISTICS The printer is packaged in a compact enclosure suitable for use on a desktop, or for mounting to an optional free-standing pedestal. Dimensions for the printer and the pedestal Figure 1.1: Spacial Requirements 1-11...
  • Page 17 This page intentionally left blank. 1-12...

  • Page 18: Theory Of Operation

    Chapter 2: THEORY OF OPERATION 2.1: INTRODUCTION All printer electronic subassemblies, with the exception of the power supply, are contained on one printed circuit board (the controller board). This chapter provides the technician with descriptions of the various circuits contained on the controller board, ie. printhead driver circuit, carriage drive circuit, and an overview of the microprocessor system.

  • Page 19: Character Printing

    2.3: CHARACTER PRINTING Incoming characters are taken from the communications interface (either serial or parallel) and placed into a FIFO buffer. The characters are then placed into a print buffer to construct the next line to be printed. No printing occurs until all data for that line of print has been received and the printer receives a line terminator (e.g.

  • Page 20: Paper Motor

    T1 is the current rise period, during which the fun power supply voltage is applied to the solenoid to build the current up as quickly as possible. T2 is the slow decay or “free wheeling” period. The supply voltage is removed and current is allowed to re-circulate through the solenoid.

  • Page 21: Carriage Drive

    2.6: CARRIAGE DRIVE Carriage motion is controlled by a stepper motor. The motor is a 1.5 degree two-phase type. The carriage is driven by the motor through a capstan and set of wire cables. The capstan is sized so that one step of the motor corresponds to 1/100 of an inch (the separation of sub-columns at 10 characters per inch).

  • Page 22: System Clamp

    Figure 2.4 Carriage Motor Current 2.7: SYSTEM CLAMP The system clamp allows the processor to energize or de-energize the motors by toggling a 1/0 bit. Any time a motor is moved, the 1/0 bit “system ready” must be enabled. This allows step data to be converted to motor current.

  • Page 23: Troubleshooting

    Chapter 3: Troubleshooting 3.1: Introduction This chapter provides the technician with procedures for troubleshooting the printer. The following table summarized some of the more common problems which may be encountered with the printer. A brief description of the problem is provided with one or more possible causes for each.
  • Page 29 Figure 3.1: Controller Schematic Part No. 105947 (Sheets 1 – 8) PC Board 105601...
  • Page 33 3-10...
  • Page 34 3-11...
  • Page 35 3-12...
  • Page 36 3-13...
  • Page 37 3-14...
  • Page 38 Figure 3.2: Controller Finished Assembly Component Layout Part No. 105535 (Sheets 1 and 2) PC Board 105601 3-15...
  • Page 39 3-16...
  • Page 40 3-17...
  • Page 41 Figure 3.3: Power Supply PCB Schematic Part No. 105623 PC Board 105622 3-18...
  • Page 42 3-19...
  • Page 43 Figure 3.4: Power Supply PCB Assembly Part No. 105621 PC Board 105622 3-20...
  • Page 44 3-20...
  • Page 45 Figure 3.5: Operator Panel PCB Schematics Part No. 105815 PC Board 105800 3-21...
  • Page 46 3-22...
  • Page 47 Figure 3.6: Operator Panel PCB Assembly Part No. 105801 PC Board 105800 3-23...
  • Page 48 3-24...

  • Page 49: Introduction

    Chapter 4: MAINTENANCE 4.1: INTRODUCTION This chapter provides the technician with scheduled maintenance, corrective maintenance and adjustment and alignment procedures needed to service the printer. 4.2: Recommended Tools and Materials Only a small number of tools are required to perform the maintenance and alignment procedures provided in this chapter.

  • Page 50: Scheduled Maintenance

    A complete back-up machine for the first 1-25 units installed is recommended beyond the initial 25 units, recommended quantities of spares are as follows: 4.4: Scheduled Maintenance WARNING Make certain printer is disconnected from A.C. power supply before reaching into the printer to perform any cleaning task.

  • Page 51: Printhead

    4.4.1: Printhead The printhead should be removed and cleaned approximately every 4-6 months depending on usage. Deterioration of print quality between scheduled cleanings would indicate a need for more frequent cleaning. To remove and clean the printhead proceed as follows: Remove top cover (see Paragraph 4.5.1).

  • Page 52: Top Cover Removal And Replacement - Figure 4.1

    Figure 4.1: Coverset Removal 4.5.1: Top Cover Removal and Replacement - Figure 4.1 Raise the access cover (window assembly) (3) to a vertical position and remove it by pulling straight up. Using a long shank Phillips screwdriver, remove the two front comer screws (7) in the bosses.

  • Page 53: Bottom Cover Removal And Replacements - Figure 4.1

    WARNING Do not operate the printer with the top cover removed. Replace in reverse order. 4.5.2: Bottom Cover Removal and Replacements - Figure 4.1 Remove top cover. (See Paragraph 4.5.1). Remove the four screws (15, 16, 17) that secure the printer mechanism to the bottom cover.

  • Page 54: Controller Board Removal And Replacement - Figure 4.2

    Remove electronic chassis (62) from frame. Replace in reverse order. 4.5.5: Controller Board Removal and Replacement - Figure 4.2 Remove top cover (see Paragraph 4.5.1). Remove electronic chassis (see Paragraph 4.5.4). Remove ground screw (61). CAUTION Do not over-flex the controller board when removing from standoffs. Do not reach under the controller board with any object and attempt to pry it free from standoffs.

  • Page 55: Power Supply Pcb Removal And Replacement - Figure 4.2

    4.5.7: Power Supply PCB Removal and Replacement - Figure 4.2. Remove top cover (see Paragraph 4.5.1). Remove electronic chassis (see Paragraph 4.5.4). Remove all connectors from power supply PCB (45) Remove two Phillips screws (46) securing power supply PCB (45) to electronic chassis (62).

  • Page 56: Figure 4.2 Electronic Module

    Figure 4.2: Electronic Module...

  • Page 57: Line Filter Removal And Replacement – Figure 4.2

    4.5.8: Line Filter Removal and Replacement - Figure 4.2. Remove top cover (see Paragraph 4.5.1). Remove electronic chassis (see Paragraph 4.5.4). Tag line filter leads (32) to ensure correct reconnection then remove leads from transformer (44) and fuse holder (54). Remove two screws (51) securing line filter (32) to electronic chassis and remove line filter.

  • Page 58: Voltage Switch Removal And Replacement - Figure 4.2

    The locking tabs which hold the power switch into the electronic chassis must be removed in order to remove the switch. Use a screwdriver to pry the tabs away from the switch, then use diagonal cutters to cut each tab. A new switch ma then be installed into the electronic chassis by simply pressing it Install leads onto replacement switch and replace transformer (44) and line filter (32).

  • Page 59: Operator Panel Cable Removal And Replacement -Figure 4.2

    Disconnect printhead cable (29) from printhead (172). Remove cable (29) from cable clamps, The cable (29) passes through an opening under the left side of the plate. Pull the cable (29) toward the front of the printer until free of the printer. Replace in reverse order.

  • Page 60: Figure 4.3 Ribbon Advance Cable

    Figure 4.3: Ribbon Advance Cable 4.5.16: Ribbon Advance Mechanism Removal and Replacement - Figure 4.4. Remove top cover (see Paragraph 4.5.1). Remove operator panel (see Paragraph 4.5.3). Remove ribbon advance cables (see Paragraph 4.5.15). Remove two screws (175) securing ribbon advance mechanism (161) to carriage (160) and remove mechanism.

  • Page 61: Ribbon Cartridge Spring Clips Removal And Replacement Figure 4.4

    4.5.17: Ribbon Cartridge Spring Clips Removal and Replacement - Figure 4.4. Lift access cover (3). Remove ribbon cartridge. Remove screw (163) securing spring clip (164) to carriage. Replace in reverse order. 4-13...

  • Page 62: Figure 4.4 Ribbon Advance Mechanism

    Figure 4.4: Ribbon Advance Mechanism 4-14...

  • Page 63: Figure 4.5 Push Pulley Towards Endplate

    4.5.18: Carriage Drive Cables Removal and Replacement - Figure 4.7 Remove top cover. As shown in Figure 4.5, depress the spring idler arm (156) and insert a screwdriver between the lower portion of the arm and the left endplate. This relieves the tension in the carriage drive system and makes it much easier to remove the drive cables.

  • Page 64: Figure 4.6 Carriage Cables

    Prior to installation of new drive cables, carefully inspect the new pair of cables for damage to either the cable jacket or attached hardware. If any detectable defect is found in the replacement cable jackets, discard the damaged cable and procure an undamaged replacement.

  • Page 65: Figure 4.7 Carriage Cable -Replacement

    Figure 4.7: Figure 4.7: Carriage Cable Replacement Carriage Cable Replacement 4-17...
  • Page 66 While holding a slight tension against the cable going onto the drive spool with one hand, use the other hand to rotate the motor shaft in a clockwise direction and wind the cable onto the spool until the carriage rests against the left endplate and all stack is taken up.

  • Page 67: Figure 4.8 Spring Loaded Idler

    4.5.19: Spring-loaded Idler Pulley Removal and Replacement - Figure 4.8. Remove top cover (see Paragraph 4.5.1). Remove left carriage drive cable (117) (see Paragraph 4.5.18). Rotate, spool (pulley) (119) on carriage motor clockwise until carriage rests against the right endplate (82). Remove brace from idler arm and allow spring to contract.

  • Page 68: Figure 4.9 Fixed Idler

    Remove the idler shaft (141) from the remaining right angle bracket (139) and unhook the tensioning spring (129) from the spring bracket (128). Remove spring bracket (128) (if it is to be replaced) by removing two screws (130) securing it to the left endplate (144). Apply a light grease to the shaft prior to installation.

  • Page 69: Figure 4. 10 Left Margin Sensor

    4.5.21: Left Margin Sensor Removal and Replacement - Figure 4.10 The left margin sensor is an electronic “photo-interrupter.” It contains a light emitting diode (LED) on one side as a light source and a photo-transistor on the other side which acts as an on/off switch.
  • Page 70 Remove the screws (153) that attach the two cable clamps (149) to the left endplate. Slip the clamps off the cable. Remove the two screws (145) that attach the margin sensor (150) to the left endplate (144). Pull the cable and connector through the sensor opening in the endplate.

  • Page 71: Figure 4.11 Carriage Drive Motor

    Figure 4.11: Carriage Drive Motor 4.5.23: Carriage Drive Spool Removal and Replacement - Figure 4.11 It is possible to replace a damaged or defective drive spool without removal of the carriage motor from the print mechanism. To replace the drive spool: Remove carriage drive cables (see Paragraph 4.5.18).
  • Page 72 Move the carriage (160) to the center of the carriage rails and disconnect the printhead cable connector (29) from the printhead (172). Load paper into the printer to prevent damage to the platen surface or printwires in the event the printhead comes in contact with the platen. Support the printhead (172) while loosening two screws (173) securing the printhead to the carriage (160).
  • Page 73 Insert a soft cloth through the left endplate hole and under the carriage rail (124). Slide the rail (124) out through the left endplate (144). Remove the Phillips screw (166) and loosen the set screw securing the printhead adjustment lever (167) to the carriage rail (124). Make sure the cloth is still inserted through the left endplate hole.

  • Page 74: Figure 4.12 Carriage Removal

    Figure 4.12: Carriage Removal 4-27...
  • Page 75 With the carriage (160) approximately in the center of the mechanism the right end of the upper carriage rail (121) with one hand and the right endplate (82) with the other hand. Pull the shoulder of the rail (121) from the hole in the endplate (82) and continue to pull it up and back in the normal carriage plane until it clears the endplate.
  • Page 76 Locate the drive motor cable (28) and cut any wire ties needed to free the cable from the printer harness. Loosen the three screws (195) which attach the motor (194) to the right endplate (82). Slide the motor (194) toward the platen and remove the drive belt (89). Completely remove the three motor attachment screws (195) and the motor (194) may be removed and set aside.

  • Page 77: Figure 4.13 Drive Belt Tension

    Figure 4.13: Drive Belt Tension 4.5.30: Paper Drive Shaft Removal and Replacement - Figure 4.14. Remove top cover (see Paragraph 4.5.1). Loosen set screws in drive shaft pulley (90) and motor pulley (78) an, simultaneously remove both pulleys and drive belt (89). Remove the bearing retainer (83) from the right endplate (82).
  • Page 78 Slide the shaft (188) through the right endplate (82) and through both tractors. Be sure that the alignment marks on each tractor are matched on the same side of the square drive shaft (188). See Figure 4.14. Complete the installation by reversing steps 1 through 3 above. Set proper tension in drive belt as shown in Figure 4.13.
  • Page 79 The idler shaft (187) may now be slipped from the tractors and set aside. To install the replacement shaft, reverse steps 1 through 5 above. Be sure to install new push-on retainers (80) in step 2. 4-32...

  • Page 80: Figure 4.14 Paper Drive/Idler Shaft

    Figure 4.14: Paper Drive/Idler Shaft 4-33...
  • Page 81 4.5.33: Platen Removal and Replacement - Figure 4.16. Remove top cover (see Paragraph 4.5.1) Remove electronic chassis (see Paragraph 4.5.4). Remove printhead (see Paragraph 4.5.23). Remove absorber panel retainers (180, 189). Remove absorber panel (186). Remove three screws (184) securing platen (I 85) to lower paper guide (190). Remove four screws (15, 16, 17) securing left and right endplate (144, 82) to enclosure base.
  • Page 82 4.5.34: Printhead to Platen Gap Alignment – Figure - 4.15. Platen alignment must be done with great care to achieve maximum print quality and printhead performance. Care must be exercised to avoid damage to the platen surface and printwires while setting the printhead-to-platen gap. Push the printhead adjustment lever toward the platen into the first detent position.

  • Page 83: Figure 4.15 Printhead To Platen Gap Alignment

    Figure 4.15: Printhead to Platen Gap Alignment 4.5.35: Lower Paper Guide/Paper Out Sensor Removal a Replacement - Figure 4.16 Remove top cover (see Paragraph 4.5.1). Remove electronic chassis (see Paragraph 4.5.4). Remove three screws (184) securing lower paper guide (190) to platen (185). Remove four screws (15, 16, 17) securing printer mechanism to bottom cover (2) and lift rear of printer mechanism enough to remove lower paper guide (190).

  • Page 84: Figure 4.16 Lower Paper Guide

    Figure 4.16: Lower Paper Guide 4-37...

  • Page 85: Figure 4.17 Lower Paper Guide/Platen Alignment

    Figure 4.17:Lower Paper Guide/Platen Alignment 4-38...
  • Page 86 4-39...
  • Page 87 4-40...
  • Page 88 4-41...
  • Page 89 4-42...
  • Page 90 4-43...
  • Page 91 4-44...
  • Page 92 4-45...
  • Page 93 4-45...

  • Page 94: Figure 4.18 Illustrated Parts Breakdown

    Figure 4.18: Illustrated Parts Breakdown 4-46...
  • Page 95 4-47...
  • Page 96 4-48...
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  • Page 98 4-50...
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  • Page 104: Figure 4.19 Illustrated Parts Breakdown Dd

    Figure 4.19: Illustrated Parts Breakdown DD 4-56...
  • Page 105 APPENDIX A This section provides updated schematics for the Main Controller Board (Figure A-1) Part No.: 105766 (Sheets 1 – 8) PC Board: 105767...
  • Page 115 Figure A.2: Controller Board Assembly Part No. 105768 (Sheet 1 and 2) PC Board 105767...
  • Page 117 A-10...

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