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PR2 PLUS - Service Manual

1. ol D529 me z Rs22 gs23 054 USE 5 US8 E g RSA RS43 RS55 RS56 Sc F Bo AB 0 eeseewe 76 ee RS28 RS29 RS30 p oa RS32 S33 oo 5 3 5 RS44RS45 RS46 RS47 cm oo 5 RS57 RS58 RS59 RS60 Po a m T aod R5 R6 u2 4 RB R9 P g RS109 B o RL DL R2 4 D2 O usz9 oL R7 R10 i 10 9 8 Figure 1 8 Motherboard layout printer version with two serial interfaces and location of connectors Service Manual XZAC4219 05 1 Parallel interface connector 11 Services motor connector 2 Serial 1 interface connector 12 Carriage reset photosensor connector 3 Printhead connector 13 SBI signal connector of the card for MICR configuration 4 Printhead connector 14 Power unit connector Signal connector for cards for Horizontal Magnetic 5 Alignment device photosensors 15 and MICR configurations 6 G nsole connector 16 Power and signals connector for Horizontal Magnetic and MICR configuration cards 7 Carriage motor connector 21 USB port connector to host 8 Open close cover sensor connector 25 A ee d 9 Paper motor connector 26 Serial port 2 interface connector Analogue signal connector of the card 10 for MICR configuration XZAC4219 05
2. 5 Figure 1 10 Layout of interface card for MICR option and location of connectors Connector for power and motor signals from the 1 MICR head connector 5 motherboard Connector of photosensor for resetting 6 transport motor of MICR head Connector for signals from the motherboard 3 MICR motor connector 7 Connector for SBI signals from the motherboard Connector for analogue signal to the motherboard XZAC4219 05 Service Manual 1 15 SCANNER A fast color scanner with a resolution of 600 dpi is included The scanner features a fixed lower image acquisition element CIS and a mobile upper element that moves from the top down when activated This action makes it possible for the printer to maintain the same throughput in terms of documents managed as the standard PR2 plus When only the upper element is present a specific closing element replaces the shape of the lower scanning element The layout of the two scanners takes into account the fact that it must be possible to activate these at the same time eliminating optical disturbances shadow images that may occur with particular types of paper Scanner technical data e Type of scanner contact e Technology CIS e Resolution 600 dpi e llumination set of LEDs e Type of illumination red green blue RGB e Lighting method monochrome or color RGB factory alternative monochrome and infrared e Type of light co
3. Figure 6 4 Adjusting the print bar NOTE check the print quality with OFF LINE testing See the section Activating and deactivating the print test on page 2 10 XZAC4219 05 Service Manual 6 5 Adjusting the print bar parallelism and leaf spring load on the basic machine e MACHINE STATUS Printer switched off and without casing e CONDITIONS TO BE CHECKED Check print bar parallelism and leaf spring load e PROCEDURE The bar perpendicularity adjustment lever 1 can be pre regulated with tool code 9600303 according to drawing code 395130U For manual adjustment of head print bar parallelism back off the studs 2 and rotate in a counterclockwise direction to bring the bar close to the front part of the matrix rotate in a clockwise direction to bring the bar close to the rear part of the matrix The parallelism indicator 3 can be used to check whether the corrections have been made To modify the load of the leaf spring operate on the self locking adjustment nuts 4 Move the carriage completely to the left and using a comparator push the print bar close to the feeler roller with a dynamometer A load of 350 g 20 g must correspond to a movement of 0 35 0 45 mm Repeat the procedure on the right of the bar HOHE D H Is ao 20 20 20 0000 Do Oo 99 ete D a6 o6a5 ad 30 OQO 30 30 30 b Go 000000000000000000000000 OCGO Go 10101016151 0101
4. Figure 7 50 Disconnecting the CIS cable 5 Remove the snap ring 6 6 Slide the bush 7 in order to free the shaft from the rotation housing proceeding as shown in the figure XZAC4219 05 Figure 7 51 Removing the shaft from its rotation position Service Manual 7 35 il a Z 7 Press the clips 8 and remove the bush 9 proceeding as shown in the figure WS oo Z Ly GAY lt ag Figure 7 52 Removing the bushing 8 Remove the shaft 10 sliding it in the hole on the frame as shown in the figure Fp pe _ o ou i XE T Arry ca yi ef SZ cee F 10 Removing the CIS unit 12 from the bottom Figure 7 53 Removing the shaft 9 Turn over the lower mechanical assembly and unscrew the two screws 11 fastening the CIS unit 12 Service Manual XZAC4219 05 Figure 7 54 Removing the CIS unit NOTE for reassembly reverse the procedure paying attention to correct tensioning of the belt 13 NOTE clean CIS glass with a soft cloth After completing the reassembly procedure proceed to calibrate the scanner see the section Calibrating the scanner on page
5. TOOT Tit Figure 7 2 Disassembling the top cover XZAC 4219 05 Service Manual 7 3 Casing disassembly reassembly 1 Disassemble the upper cover See the section Top cover disassembly reassembly on page 7 3 2 Release the pins 1 of the sound absorbing material 2 and remove it 3 Extract the front slot 3 pulling it carefully upwards and towards the front of the printer Loosen the 4 screws that fix it to the case 4 Using a pointed tool exert pressure on the four points 4 of the casing as shown in the figure Figure 7 3 Disassembling the casing 5 Lift the casing and place it to the side of the machine as shown in the figure 6 Back off the two screws 5 of the cover open switch and remove it 7 4 Service Manual XZAC4219 05 Figure 7 4 Removing the casing plate 7 Working from the lower side of the machine back off the five lock screws 6 of the baseplate 8 Move the power supply switch 7 to the ON position 9 Remove the base plate as shown in the figure ii m AA mm mun Figure 7 5 Removing the casing bottom XZAC4219 05 Service Manual 7 5 Mechanical assy disassembly reassembly 1 Disassembling the casing See the section Casing disassembly reass
6. 004 5 8 Power onmessages 00 000 00 050s 5 8 Status messages running 5 10 Service messages 2 00 00 00 eee 5 12 MACHINE DIAGNOSTICS 2 244 044 4464 44 600242445 5 13 Operating condition analysis 5 13 Identifying the problem 040 5 13 Tracing the cause 020 5 14 Eliminating the fault 2 2 0 2 0 02 0040 5 14 Testing the machine 0 5 14 FAULT CLASSIFICATION gx euo4 4 oe 44se aust es s 5 15 Faults atpower on a 5 15 Faults during writing of the document 5 17 Faults with document handling 5 19 Chapter 6 MAINTENANCE 6 1 CLEANING aore Gee bo oS bud Oats Oe Seek 4 k ane 6 1 Cleaning the case ck ak bob ee a 6 1 Cleaning the paperpaths 6 1 LUBRICATION i 6 s heck 8 eG hw Ree eee ae OSS Gh wR Or 6 1 PROCEDURE FOR CLEANING REPLACING THE PHOTOSENSORS 4 4 44 4 amp Boa ed Heb Ae eee es 6 2 MECHANICAL ADJUSTMENTS 6 3 Adjusting the document drive belt 6 3 Adjusting the print bar where torsion bar present 6 4 Adjusting the print bar where torsion bar absent 6 5 Adjusting the print bar parallelism and leaf spring load on the basic machine 2 0 6 6 Adjusting parallelism of print bar without torsion bar 6 7
7. 5 6 Service Manual XZAC4219 05 Console LED Anomalies Possible solution ON Ready Station Local Station 2 Replace the motherboard See the NTC section Disassembling motherboard not reassembling the motherboard O O O 0 working printers with scanner or Anomaly on Disassembling reassembling the motherboard motherboard printers with serial number 8 xxx xxx and 1 XXX XXX E Start of CIS functional tests O Start of auto diagnostic cycle on powering on End of auto diagnostic cycle on powering on O LED ON LED OFF X LED FLASHING Number X indicates the number of flashes XZAC4219 05 Service Manual 5 7 DISPLAY MESSAGES The following table lists the messages of state warning and error that can be visualized on the display of the console when the printer is equipped with alphanumeric display Power on messages MESSAGE TIME OUT DESCRIPTION Olivetti PR2 PLUS No timeout Startup message Start Up l 7 COVER OPEN No timeout Startup condition Means please close cover for continue RS232 Error 1 second Serial channel parity framing overrun ERROR RFID Time Out 10 seconds RFID module SBI serial BUS vs MICR Option e Replace the MICR board See the section Horizontal ERROR id seconds magnetic MICR disassembly reassembly on page 7 28 SBI Time Out e Replace the MICR head See the se
8. Lever for lifting the upper part of the mechanism OPERATING PROCEDURE FOR INSERTING THE DOCUMENTS TOBE PRINTED Inserting the document with automatic alignment Inserting the passbook Inserting a document for horizontal magn MICR reading Ejection ofdocuments REPLACING THE RIBBON CARTRIDGE PAPERJAM mimado eu na rawun h Chapter 4 PROGRAMMING AND CALIBRATION CONFIGURING THE OPERATION PARAMETERS Set up activation 02 0 0 2 02 02 Modifying configuration parameters Exiting from the Configuration menu Description of configuration parameters CALIBRATING THE PHOTOSENSORS Printing photosensor calibration values Calibrating the top of form TOF Calibrating the left margin 00 Measuring document length MICR Calibration 02 202 0 002 0 0 Checking the JITTER 00 Calibrating the scanner 2 2 vi Index Chapter 5 MACHINE DIAGNOSTICS 5 1 POWER ON SELF TEST 0 4 044 444 4604404454404 5 1 ERROR MESSAGES ac 34 84 oud we de a 5 1 Printer anomalies with serial number 8 xxx xxx 5 1 Printer anomalies with serial number 1 xxx xxx 2 20 0 5 4 DISPLAY MESSAGES
9. Fault in the power supply unit Replace the power board See the section Power supply unit disassembly reassembly on page 7 26 Motherboard fault Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner on page 7 21 or Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 xxx xxx on page 7 23 Fault in the front photosensors Carry out the calibration procedure See the section CALIBRATING THE PHOTOSENSORS on page 4 18 Fault in the carriage photosensor Carry out the calibration procedure See the section CALIBRATING THE PHOTOSENSORS on page 4 18 Machine cover open Check that the cover is closed correctly Document jammed in machine Remove the document See the section PAPER JAM on page 3 11 XZAC4219 05 Service Manual 5 15 Fault n iS 3 o S S2 lt SS gt EG 23 a The machine does not connect with the system The self test indicates a fault on the Motherboard The self text indicates an error in the mechanics Possible cause Solution x lt Paper fragments left in the printer Perform cleaning of the printer See the section Cleaning the paper paths on page 6 1 Problems on interface connections Replace the motherboard See the section Disassembling reassembling the motherboar
10. At the end of the self test phase if no errors have been detected the printer switches to READY status ON and READY LEDs on the console on Any FW or HW faults are highlighted by LEDs on the console ERROR MESSAGES READY ON O O O STATION1 LOCAL STATION2 J N J ke EJECT BREAK EJECT In the following are shown two tables indicating the meaning of the LEDs in relation to the type of error situation encountered during the auto diagnostics phase The first refers to printers with the serial number 8 xxx xxx the second to printers with the serial number 1 xxx xxx Faults are classified as follows 1 Non recoverable fault Blocks the machine and is eliminated only by switching off the printer and carrying out the necessary repairs 2 Fault that can be recovered by the operator eliminating the problem paper jam and then pressing the STATIONT1 key with the cover open 3 Anomaly recoverable by calibrating the printer for example calibrating photosensors Printer anomalies with serial number 8 xxx xxx Console LED Anomalies Possible solution ON Ready Station Local Station 2 See the section Faults at power on Power unit on page 5 15 Replace the motherboard See the section Disassembling reassembling CRC Error in the motherboard printers with 1x X O O O O BOOT sector of scanner or Disassembling flash reassembling the motherboard
11. aT SEs ee a 119 1 J6 Jo iota 6 33 READY ON e 0 O e e STATION 1 C LOCAL Garon 2 EJECT BREAK EJECT PR2 plus 1 Front CIS 2 Back CIS 1 4 Block Diagram Magnetic options interface Horizontal Magnetic or MICR Printhead Console Nn Oo Oo A XZAC 4219 05 Motherboard Version with scanner Printhead carriage motor 8 Paper feeder motor 9 Cover sensor 10 Paper presence alignment photosensors 11 Services motor 12 Power supply unit 13 Front paper present photosensor Service Manual 1 5 MOTHERBOARD Different motherboards have been used with the PR2 Plus printer as it has evolved on the basis of its configuration All the various versions are covered below Motherboard scanner version cod XYAB3468 and XYAB3871 QS1 Qs2 Q53 o o E Fonoti EH RS65 SS Sane HA pusu usa A a a bas us14 D532 cl D530 feeedng33 2535 D536 DS38 SS aca uUSI5 RS79 RS80 RS83 RS84 RS85 RS86 a O 16 CEE RS88 RS89 RS90 RS91 RS93 RS9 4 RS95 RS96 RS97 Rs98 Seeoa Ses E E a frs usi7 TE j 15 3 Sains RS111 L gt 0 20 Pore RS114 RS115 RS116 RS117 RS118RS119 E GS a RS128 RS129 RS130 RS131 RS132 RS133 0 2 20 a0 oo aS So
12. r File format i aa al Po z downloading Firmware Download ended corectly Bhck4 0 54K 4 pages Printer connected to USBOT GB PR2Plus Ready Begin page 4 End page 23 Pages A 6 Figure A 3 Firmware update display Service Manual XZA4219 05 8 Select the file containing the firmware to be transferred confirming this with the Open key 21x Cerca in Gy Fimware PR2 PLUS e 0ce wS 2 F Nomefile ReGQOEVert10bin Api a Tipo file Flash gt Anredla Risorse di rete I Aprin sola lettura 4 Figure A 4 Display for selecting file containing the firmware to be transferred 9 Select the Send key and wait until transfer of the firmware has been completed Rel330EVer110 bin r File format 1 4 Firmware J Tables Forts M Kes mecovioge scanmet celbreton I BOOT rPe g downloading Firmware Download ended conectly Blocks 0 64K 4 pages Printer connected to USBOT g PR2Plus Ready Begin page 4 End page 23 Pages ax as Figure A 5 Key to send the firmware transfer 10 Calibrate the photosensors See the section CALIBRATING THE PHOTOSENSORS on page 4 18 Calibrate the scanner See the section Calibrating the scanner on page 4 28 11 Print the Self Test again checking that the firmware release is that required Forced loading of firmware Before proceeding to force loading of the firmware
13. 4 Move the printhead manually to the centre of the carriage WARNING the printhead could be very hot therefore be very careful when handling it Only touch the parts in plastic Figure 3 8 Unhooking the ribbon guide 6 Remove the old cartridge pulling it outwards Figure 3 9 Removing the ribbon cartridge 3 8 Service Manual XZAC4219 05 7 Extract the new cartridge from its container and unhook the ribbon guide 1 pushing it to the back as illustrated in the following figure Figure 3 10 Unhooking the ribbon guide 8 Insert the new cartridge onto the feed pins fitting it laterally onto the two sides Figure 3 11 Attaching the cartridge to the structure 9 Insert the ribbon guide 1 from the front moving it upwards and applying sufficient force to fasten it onto the two flexible pins in the open slots 3 of the carriage 2 at the back of the printhead roller a click is heard Figure 3 12 Fitting the ribbon guide XZAC 4219 05 Sercice Manual 3 9 10 Turn the knob 1 of the cartridge in an anti clockwise direction until the ribbon is taut then remove the tab 2 Figure 3 13 Tightening the ribbon and removing the tab 11 Actioning the lever lower fully the upper part of the printer 12 Close again the cover of the printer 3 10 Service Manual XZAC4219 05 PAPER JAM The paper may jam along t
14. AFF USA Selects the width of the print line LINE BUFFER PR2845 hi LIKE y If the SIDE gt R parameter has been selected sets the width of the reception buffer to 2845 512 Byte or 8 K bytes INT NATION If the SIDE gt R parameter has been selected sets up the character generator for the country specified LQ CHAR DEFINITION DRAFT Selection of print definition 10 CPI 12 Selection of printing pitch END OF PAPER WARNING PHOTO SENSORTOP Selection of paper out or cover photosensor message 1 TOP OF FORM 2 Selects the first or second printable line NO WAIT WAIT STATUS REQUEST This parameter determines the timing of the status reply to an ESC j command Selecting NO WAIT the reply will be provided as soon as possible and in parallel with printing or paper movements Selecting WAIT the status reply will be provided at the end of printing XZAC 4219 05 Service Manual 4 15 If the horizontal magnetic option is present OPTION HOR MSRW Message indicating that the option has been installed There is no selection and the next selection is printed after this title If the hor magn MICR option is present MICR is shown beside MSRW Parameter Values possible Description DIN ISO Sets the magnetic standard See page 4 17 STANDARD ANSI See page 4 17 IBM 3604 See page 4 16 If the IBM 3604 S
15. VERSION CONFIGURATION Basic model with RS232 Parallel and USB ports PR2 plus 10 Basic Model Passport version PR2 plus SC Model PR2 plus 10 with scanner PR2 plus 12 PR2 plus 10 with horizontal magnetic unit PR2 plus 12 M PR2 plus 12 with horizontal magnetic unit and MICR reader Figure 1 1 PR2 Plus Printer XZAC 4219 05 Service Manual 1 1 TECHNICAL SPECIFICATIONS Technology Impact needle matrix Needle diameter 0 25 mm Frequency 2295 Hz CHARACTERISTICS OF THE PRINTHEAD Max nominal speed 560 cps a 10cpi Thermal protection PTC Overheating safety sensor If the critical temperature threshold is exceeded printing is interrupted Mode Cps Copies Matrix VxH Definition VxH VHSD 560 1 1 24 x 4 3 1 1 80 H 1 180 V HSD 510 1 2 24 x 4 3 2 1 90 H 1 180 V PRINT SPEED AND Draft 370 1 4 24 x 5 4 3 1 120 H 1 180 V DEFINITION NLQ 185 1 5 24x 1846 1 240 H 1 180 V LQ 125 1 6 24 x 36 1 360 H 1 180 V BIM min 2000 dps 1 120 H 1 180 V BIM max 2000 dps 1 360 H 1 180 V Type Indelible in carbon free pigmentation tissue PRINT RIBBON Color Black Duration About 10 Million characters FONT AND CHARACTER Optical reading OCR A B SET Alphanumeric Roman Sans Serif Italic Courier PAPER INSERTION Via front slot with automatic document alignment DOCUMENT DIMENSION Module Width 65 min 247 max
16. Printer PR2 PLUS Code XZAC4219 05 PUBLICATION ISSUED BY Olivetti S p A Gruppo Telecom Italia Via Jervis 77 10015 Ivrea TO Copyright 2010 Olivetti All rights reserved PREFACE This manual for Service engineers supplies all the technical information required for installing testing and carrying out maintenance interventions on the specialised PR2 PLUS printer This manual can help you resolve a printer malfunctioning problem when the solutions proposed in the Operating Manual provided in the printer kit are not successful SUMMARY The manual is subdivided into 8 chapters and an Appendix Chapter 1 Introduction provides information of a general nature on the printer Chapter 2 Installation describes the procedures and standards to follow for installing the printer Chapter 3 Operating the Printer examines the operating procedures to follow to operate the printer correctly Chapter 4 Programming and Calibration describes the procedures for programming the printer and calibrating it Chapter 5 Diagnostics all the defects that can be detected by the printer s diagnostics system are listed here Chapter 6 Maintenance an illustrated procedure describes the cleaning lubrication and mechanical adjustments that may be necessary for the printer Chapter 7 Disassembling and Reassembling Parts describes the procedures for disassembling and reassembling again the main components of the printer Chapte
17. printers with serial number 8 XXX XXX and 1 XXX XXX 2x X o o o o Firmware Proceed with forced loading of the not present firmware Replace the motherboard See the section Disassembling reassembling Programming the motherboard printers with 3x X O O O O scanner or Disassembling error reassembling the motherboard printers with serial number 8 XXX XXX and 1 XXX XXxX XZAC4219 05 Service Manual 5 1 Console LED ON Ready Station1 Local Station 2 Anomalies Possible solution 4x X O Write error on FPGA registers Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner or Disassembling reassembling the motherboard printers with serial number 8 XXX XXX and 1 XXX XXX 5x X O External SRAM Test failed Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner or Disassembling reassembling the motherboard printers with serial number 8 XXX XXX and 1 XXX XXX EEPROM SW setup e Reconfigure the printer e Proceed with forced loading of the firmware e Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner or Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 XXX XXX EEPROM HW setup e Perform all the printer calibrations See the chapter PROGRAMMING AND C
18. 29 Failure None lt Led Dac Peak DutyS top MixPeak MixDutyStop green 147 24 27 82 12 red LA 249 28 166 14 blue 147 740 20 241 11 REAR Temp ref 29 Failure None lt Led Dac Peak DutvS tory MaxPealk MixDutyStop areen 142 248 24 85 11 red 142 246 28 165 14 blue 142 242 L 247 12 KK SCANNER CALIB Ner 3 1 200 dpi monochr ome speed Lom sec ES 52 FRONT Temp ref 29 Failure None lt Led Dac Peak DutyvS top MixPeak MixDutySton green 157 242 20 23 13 red LS 244 30 158 14 blue 157 243 22 241 12 REAR Temp ref 29 Failure None lt led Dac Peak DutyS top MixPeak MaxDutbyStopo areen 151 247 26 79 11 red 151 241 30 L62 15 blue 151 247 21 247 2 k SCANNER CALIB Ver 3 300 dpi color sneed cm sec l 8 5 FRONT Temp ref 29 Failure None lt REAR Temp ref 29 Failure None g k SCANNER CALIB Ver 600 doi color speed om s ec Dicks FRONT Temp ref 29 Failure None lt REAR Temp ref 29 Failure None g OK SCANNER CALIB ver 3 1200 dpi color speed lLon sec J 12 2 FRONT Temp ref 29 Failure None REAR Temp ref 29 Failure None g Figure 4 6 Scanner calibration parameters XZAC4219 05 Service Manual 4 29 4 30 Page left intentionally blank Service Manual XZAC4219 05 Chapter 5 MACHINE DIAGNOSTICS POWER ON SELF TEST The PR2 plus features a set of diagnostic tests that are activated automatically at power on
19. 8 Free the cable clip 1 on the right hand side of the structure unclipping it from the inside 2 of the structure Remove the sound proofing material 3 Loosen the lock screw 4 of the rear cable clip rotate the cable clip and free the flat cable Rotate the flat cable support connected to the printhead 5 upwards to its stopping point Slide out the mylar 6 from the lower part of the flat cable support then free the flat cable from the clips of the support Np np ow 9 9 o0 YAO QO A O O_O Figure 7 9 Removing the cable retainers 8 Remove the printhead unscrewing the two screws 1 7 8 Service Manual XZAC4219 05 9 Slide out the two flat cables from the respective connectors 2 on the printhead WARNING when reassembling the flat cable on the printhead check that the path indicated in the figure has been restored and that it does not interfere with the ribbon rewind gears which could cause irreparable damage to this during machine operation XZAC4219 05 Service Manual Printhead disassembly reassembly 1 Open the top cover and lift the upper mechanical assy 2 Removing the ribbon cartridge from the printer See the section REPLACING THE RIBBON CARTRIDGE on page 3 8 3 Back off the two lock screws 1 of the printhead 4 Partially slide out the printhead from the carriage and disconnect the two flat cables 2 from the connectors o
20. A S139 i us23 a 30 20 Ss TrA a 3 R5168 RS169 RS170 RS171 RS172 gt S S 8 BA RS175 RS176 RS177 RS178 RS179 FR 13 8 Se ee a Je osi7 us32 J ia Do Joo C348 C 5 C541 CS37 CS32 C528 C523 RS74 RS75 5 amp f s us20 QS12 Q513 10 Figure 1 5 Motherboard layout scanner version identifying the location of the connectors Service Manual XZAC4219 05 1 Parallel interface connector 2 Serial interface connector 3 Printhead connector 4 Printhead connector 5 Alignment device photosensors 6 Console connector 7 Carriage motor connector 8 Open close cover sensor connector 9 Paper motor connector Analogue signal connector of the card for 10 MICR configuration 11 Services motor connector XZAC4219 05 12 Carriage reset photosensor connector 13 SBI signal connector of the card for MICR configuration 14 Power unit connector 15 Signal connector for cards for Horizontal Magnetic and MICR configurations 16 Power and signals connector for Horizontal Magnetic and MICR configuration cards 17 Front CIS scanner connector 18 Rear CIS scanner connector 19 Connector for USB ports two at rear from HUB to peripherals only for code XYAB3871 20 USB port connector on front from HUB to peripheral only for code XYAB3871 21 USB port connector to host Service Manual 1 7 Motherboard machines with serial
21. Adjusting Paper Photosensor 6 8 Adjusting the roller gears 000 6 9 Adjusting the front pressure rollers 6 10 Adjusting the horizontal magnetic MICR drive belt tension 6 11 Adjusting the horizontal magnetic MICR closing flap 6 12 Positioning the horizontal magnetic MICR pressure roller 6 13 Positioning the assy on the horizontal magnetic MICR structure 6 14 Replacement and adjustment of belt for carriage movement 6 15 Index vii viii Index chapter 7 DISASSEMBLY REASSEMBLY OF PARTS PRELIMINARY WARNINGS 00 BASIC MACHINE DISASSEMBLY REASSEMBLY PROCEDURES Console disassembly reassembly Top cover disassembly reassembly Casing disassembly reassembly Mechanical assy disassembly reassembly Printhead flat cable disassembly reassembly Printhead disassembly reassembly Upper mechanical assy disassembly reassembly Paper feed motor disassembly reassembly Printhead drive motor disassembly reassembly Services motor disassembly reassembly Feeder photosensors disassembly reassembly Disassembling reassembling the print bar printers with torsion bar Disassembling reassembling the print bar printers without torsion bar Disassembling reassembling pres
22. Length 70 mm min x 297 mm min Located on the printer cover and composed of three keys and five LEDs CONSOLE Optionally an alphanumerical LCD display can be integrated Olivetti standard aaar IBM PP amp X24 EMULATIONS IBM 4722 9068 Optional WINCOR 4915 P EPSON LQ 2550 UNISYS EFP series Serial RS 232C INTERFACES Parallel IEEE 1284 Nibble BYTE ECP USB 1 0 e 2 0 Service Manual XZAC4219 05 Width 384 mm Depth 296 mm DIMENSIONS Height 204 mm Weight 10 5 Kg Stand by lt 15 W The product conforms with the requirements of the Energy POWER CONSUMPTION Star trademark During printing 170 W max worst performance 230 Vac 10 POWER SUPPLY 50 60 Hz DOCUMENTS THAT CAN BE HANDLED BY THE BASIC MACHINE e SINGLE FORM e Width 65 x 245 mm e Length 297 x 70 e Single sheet thickness 0 07 0 28 mm e Single sheet weight 60 160 gr m e Chemical paper copies n 1 4 medium weight LQ n 1 6 e Carbon paper copies n 1 4 medium weight LQ n 1 6 e PASSBOOK WITH VERTICAL BINDING e Width max open 241 mm e Width min open 150 mm e Length max 220 mm e Length min 85 mm e PASSBOOK WITH HORIZONTAL BINDING e Width max 241 mm e Width min 150 mm e Length max open 220 mm e Length min open 165 mm e OTHER CHARACTERISTICS e Max thickness open in the passport version the maximum thickness is 5 mm e Max diff In thickness between pages1 2 mm e Cover thick
23. ON Waiting for document from operator 2 STATION 2 Flashing Waiting for document from operator 2 ON ON Printer on READY ON Printer online with a document present IBM 9068 4722 LOCAL ON Machine in LOCAL mode off line STATION 1 ON Machine assigned to operator 1 STATION 2 ON Machine assigned to operator 2 ON ON Printer on READY ON Printer on line LOCAL ON Machine in LOCAL mode off line SNI 4915 4904 ON Document present in the printer STATION 1 Flashing Waiting for document from operator 1 ON Document present in the printer STATION 2 Flashing Waiting for document from operator 2 ON ON Printer on READY ON Printer on line Machine in LOCAL ff li BM PROPRINTER Il LOCAL ON achine in LOCAL mode off line X24 EPSON LQ 2 SON LQ 2550 ON Document present in the printer STATION 1 Flashing Data is present in the printer buffer STATION 2 No signal NOTE the ON LED is always illuminated when the printer is powered on however if any of the other 4 LEDs lights while the printer is on it indicates an anomalous situation Refer to section ERROR MESSAGES on page 5 1 XZAC 4219 05 Sercice Manual 3 3 Key functions during powering on and resetting phases During the procedures for configuring the printer or during calibration see the chapter PROGRAMMING AND CALIBRATION on page 4 1 the console keys have different uses with respect to normal operation which depend on the type of activity in course The following t
24. READY ON O O O Q n r N ri STATION LOCAL STATION2 ri A hee EJECT BREAK EJECT READY ON O O C O O 9 fr NK i STATION LOCAL STATION2 7 Wig B ja EJECT BREAK EJECT READY ol O O O O ee x 2 STATION toca staTion2 X a es NS EJECT BREAK EJECT READY ON O O O O O A S a STATION LOCAL STATION2 EJECT BREAK EJECT READY ON i O O O O 7 N a N a STATION1 LOCAL STATION2 A A S EJECT BREAK EJECT READY ON O O O 7 O S pe So STATION1 LOCAL 4 STATION2 A Xe 7 Nes EJECT BREAK EJECT NOTE mode and spacing changes occur automatically Service Manual 4 21 Calibrating the top of form TOF This calibration makes it possible to set the distance between the left hand edge of the document and the first character printed 1 2 4 22 Open the printer cover Power on the printer with the cover open keeping the three console keys pressed Wait for the acoustic signal that indicates access to the calibration and adjustment procedure then close the cover Press the LOCAL button and wait until the end of the machine reset procedure Press the STATION1 button Insert an A4 sheet in the front slot to check the status of the current TOF This check is made printing a specific text If the current TOF is too high printing may be carried out off the sheet Press the STATION1 and or STATIONZ2 keys to ca
25. gt N A Figure 3 2 Console WARNING the meaning of the keys and LEDs on the console varies according to the emulation configured for the printer as indicated in the following tables Emulation Keys Meaning STATION1 Books operator 1 EJECT Ejects the document of operator 1 Olivetti Standard STATION2 EJECT Books operator 2 Ejects the document of operator 2 LOCAL BREAK Switches the printer between on line and off line status eee i Assigns the printer to operator 1 IBM 9068 4722 STATION2 EJECT Assigns the printer to operator 2 LOCAL BREAK Switches the printer between on line and off line status STATION Assigns the printer to operator 1 EJECT Ejects the document of operator 1 SNI 4915 4904 STATION2 EJECT Assigns the printer to operator 2 E Ejects the document of operator 2 LOCAL BREAK Switches the printer between on line and off line status STATION EJECT Ejects the document present IBM PROPRINTER II X24 EPSON LQ 2550 STATION2 EJECT Not used LOCAL BREAK Switches the printer between on line and off line status 3 2 Service Manual XZAC4219 05 Emulation LED Status Meaning ON ON Printer on READY ON Printer on line LOCAL ON Machine in LOCAL mode off line Olivetti Standard ON Waiting for document from operator 1 STATION 1 Flashing Waiting for document from operator 1
26. 0101010101016 0101 0101010181 01618 ooo ao ooooc oooceoooooo0eceoo0000000ccacs 30000 oceco 350 g 20g Loads recorded with comparator 350g 20g Figure 6 5 Adjusting the print bar parallelism 6 6 Service Manual XZAC4219 05 Adjusting parallelism of print bar without torsion bar e MACHINE STATUS Printer switched off and without casing e CONDITIONS TO BE CHECKED Check print bar parallelism e PROCEDURE The bar perpendicularity adjustment lever 1 can be pre regulated with tool code 9600303 according to drawing code 395130U For manual adjustment of the parallelism between the head and the print bar rotate studs 2 counter clockwise to move the bar close to the front of the matrix rotate clockwise to move the bar to the rear of the matrix The parallelism indicator 3 can be used to check whether the corrections have been made Move the carriage completely to the left and using a comparator push the print bar close to the feeler roller with a dynamometer A load of 350 g 20 g must correspond to a movement of 0 35 0 45 mm Repeat the procedure on the right of the bar Repeat the procedure for every adjustment screw of the bar J 4 Wu i ielelelelelelelslelelelelelelelelelelelelelelelelele 9000 Jp 9900090009000090000900090406 o000 IF 300g 20g 300g 20g 300g 20g 300g 20g Figure 6 6 Adjusting parallelism of print bar XZAC4219 05 Service Manual 6
27. 2 up by 0 35 0 45 mm operating on the screw 1 and checking movement with a comparator 5 positioned on the axis of the screw Repeat the operation on the other screw from the opposite side of the structure Figure 6 3 Adjusting the print bar NOTE check the print quality with OFF LINE testing See the section Activating and deactivating the print test on page 2 10 6 4 Service Manual XZAC4219 05 Adjusting the print bar where torsion bar absent e MACHINE STATUS Printer switched off and without casing Printhead positioned co axially with the axis of the screw used to make the adjustment e CONDITIONS TO BE CHECKED Distance of 0 4 0 5 mm between print bar 2 and feeler roller 3 e PROCEDURE Disassemble the mechanical unit See the section Mechanical assy disassembly reassembly on page 7 6 Bring the print unit to the writing position then using the four screws 1 adjust the print bar 2 in contact with the feeler roller 3 positioning the head 4 in axis with the screw Lift the print unit and move the print bar 2 up by 0 35 0 45 mm operating on the two screws 1 and checking movement with a comparator 5 positioned on the axis of the screw Repeat the operation on the other two screws from the opposite side of the structure
28. 4 28 XZAC4219 05 Service Manual 7 37 7 38 Page left intentionally blank Service Manual XZAC4219 05 Chapter 8 INSTALLING THE OPTIONS This chapter looks at how to install the expansion kit for the printer INSTALLING THE ETHERNET LAN CARD WARNING this option can be installed exclusively on the models PR2 Plus printer 10 PR2 Plus 12 and PR2 Plus 12 M with firmware version 4 06 Vers 126 or later Installation kit contents The package contains 1 Ethernet LAN Card 2 Mounting Screws 3 Instruction references Figure 8 1 Contents of package WARNING preserve the original packagings XZAC 4219 05 Service Manual 8 1 Installation procedure 1 Disconnect all printer s cables including power cable safety first 2 Use a screwdriver or a punch to break the metal shield on back of the printer as indicated in the following figure Figure 8 2 Removing the metal shield on back of the printer 3 Insert the LAN card in the hole with circuit board on bottom 4 When card touch the bottom of the hole push on both sides until the Ethernet LAN Card lock in position 5 Tighten both screws to fix the Ethernet LAN Card Figure 8 3 Inserting the Ethernet LAN Card 6 Install the Ethernet LAN Card drivers following instructions supplied with software drivers 7 If necessary configure the Ethernet LAN Card NOTE the Eth
29. 4219 05 Service Manual 7 25 Fan power supply unit disassembly reassembly 1 2 3 4 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 Remove the upper mechanical assy See the section Mechanical assy disassembly reassembly on page 7 6 Back off the two lock screws 1 of the fan Disconnect the power cord 2 and extract the power supply unit fan Figure 7 34 Disassembling the fan power supply unit Power supply unit disassembly reassembly NOTE If the fuse inside the power supply unit has blown replace the entire unit as some of the components on the power supply unit board could be faulty Disassembling the casing See the section Casing disassembly reassembly on page 7 4 Disassembling the mechanical assy See the section Mechanical assy disassembly reassembly on page 7 6 Detach all the connections to the motherboard and disassemble the mechanical assy See the Figure 7 25 for the printers with scanner or see the Figure 7 29 for the printers with serial number 8 xxx xxx and 1 XXX XXX Loosen the 2 lock screws 1 of the switch Figure 7 35 Fastening screws for switch 7 26 Service Manual XZAC4219 05 5 Back off the four lock screws 2 of the power supply unit also removing the ground cables loos ololoroxorololove SSSSSSSOSSSSSS SSSSSOSDSCCOSSOGOGS SOSCSCDCOOCOOOGOO6 JonoRoRoRonononononoto
30. 7 Adjusting Paper Photosensor e MACHINE STATUS Printer switched off and without casing e CONDITIONS TO BE CHECKED Correct positioning of the paper photosensor on the printhead e PROCEDURE Using the screw 1 fix the photosensor 2 onto the printhead maintaining it against the reference profile on the ribbon protection flap Make sure that the component rests on the whole width of the reference profile Figure 6 7 Adjusting Paper Photosensor NOTE make sure that the component rests on the whole width of the reference profile Carry out this operation after adjusting the print bar See the previous section When replacing the photosensor perform the calibration See the section CALIBRATING THE PHOTOSENSORS on page 4 18 6 8 Service Manual XZAC4219 05 Adjusting the roller gears e MACHINE STATUS Printer switched off and without casing Upper part of the mechanism closed e CONDITIONS TO BE CHECKED Gearing between the sprocket wheels 1 and 2 with a maximum radial play between the teeth of 0 2 mm Check for full rotation of wheels Adjust the two couplings present on the right side of the printer e PROCEDURE Work on the bushing blocking screws 3 tightening with a torque of 6 0 5 Kgcm lt 0 2 mm Figure 6 8 Adjusting the roller gears NOTE make this adjustment on both the gear pairs present on printer XZAC4219 05 Service Manual 6 9 Adjusti
31. C Loca d station2 paper is absent JON JP N EJECT BREAK EJECT 6 Into the front slot insert a sheet in Mylar code 473245H01 READY ON and press the STATION2 key The sheet is inserted O O O O O y completely in a way that it covers all the photosensors At the rere ET eur same time the printer logic will perform a reading of the ee e JO N currents and voltages present on the photosensors for the EJECT EREAK EJECT paper present status 7 Press the STATION2 button Wait for the end of the movement that introduces and ejects the sheet 8 If after ejection of the sheet there are no faults the console LEDs will remain off subsequent re insertion of a sheet of A4 paper will permit printing of the values read and selected for each individual photosensor 9 Verify that the values printed for every photosensor are included within the limits indicated in the following figure If the values respect the limits the sensors are functioning correctly On the other hand if any value is anomalous outside or very near to the limit it means that the photosensor is either dirty or very near breakage point 1 Minimum value acceptable greater than or equal to 3500 2 Maximum value acceptable less than or equal to 1500 3 The difference between the acceptable values for B and the acceptable values for A must be at least 3000 1 2 Average Photosensors Paper No Paper Yes val Current mV mV mV mA q all Photosens 1 fro
32. ON e O O O K7 N VY ses ee a OF STATION LOCAL STATION2 po XK ah Ng EJECT BREAK EJECT Breakdown of photosensor n 1 Front paper present READY ON D O J e lv Sete ee n N w fr STATION LOCAL STATION2 sd S J K EJECT BREAK EJECT Breakdown of photosensor n 2 Front paper present READY ON O VU esa 7 STATION LOCAL C STATION2 EJECT BREAK EJECT Breakdown of printhead photosensor with carriage reset function READY ON O N m D a STATION LOCAL STATION2 EJECT BREAK EJECT Breakdown of printhead photosensor with paper border reading READY ON function O G O Sf Y STATION LOCAL _ STATION2 a Oe aot _ EJECT BREAK EJECT Ay WARNING if calibration is not completed correctly it will not be possible to make the other 2 calibrations or measurements In this case switch off the printer and retry the operation vi If calibration continues to give problems carry out the procedure for cleaning or replacing the defective photosensor s as indicated in the section PROCEDURE FOR CLEANING REPLACING THE PHOTOSENSORS on page 6 2 4 20 Service Manual XZAC4219 05 Printing photosensor calibration values Bi directional printing speeds up the writing of the printer but it could reduce printing quality if a misalignment occurs between the lines written from left to right and
33. for horizontal magn MICR reading A reference stripe for insertion of the check is provided on the front part of the cover Figure 3 7 References for check insertion for horizontal magn MICR reading 3 6 Service Manual XZAC4219 05 Ejection of documents According to the application program documents may be ejected as follows e Returning these to where they were introduced manually feed slot The documents ejected from the front feed slot lf less than 100 mm in length are abandoned by the drive rollers lf they are 100 mm or more long they remain grasped by the last pair of rollers so that sheet does not slip off the front resting surface e From the rear slot of the machine starting from the front feed slot NOTE if the document processed is not output by the printer consult the section refer to section PAPER JAM on page 3 11 XZAC 4219 05 Sercice Manual 3 7 REPLACING THE RIBBON CARTRIDGE WARNING the ribbon cartridge must be replaced when printing is faded or incomplete or in the case of frequent optical reading errors of printed documents This procedure must be carried out with the machine off Switch off the printer 2 Open the upper cover of the printer lifting it up 3 Actioning the lever raise the upper part of the printer mechanical assembly to access the printhead Refer to section Lever for lifting the upper part of the mechanism on page 3 4
34. functions if the paper is narrower than the print line sent by the system The position in the machine of the individual photosensors is shown in the following figure Back of the printer Paper edge Impact head detection photosensor carriage O Optical fibers Optical fibers Sadh bA Photo N 1 Photo N 2 Photo N 3 Photo N 4 Paper alignement photosensor Optical fibers Optical fibers Photo N 1 Paper present Photo N 2 Paper present Front of the printer Figure 4 2 Locating the machine photosensors 4 18 Service Manual XZAC4219 05 To carry out the photosensor calibration procedure proceed as follows 1 Open the printer cover Check that the printhead is positioned on the left end of carriage 2 Power on the printer with the cover open keeping the three READY ON console keys pressed O O O y O O y STATION A LOCAL N STATION2 SE nN A Sa EJECT BREAK EJECT 3 Wait for the acoustic signal that indicates access to the calibration and adjustment procedure 4 Close the printer cover READY ON 4 LEDs are illuminated while the READY LED flashes ee o o STATION D LOCAL D STATION2 EJECT BREAK EJECT 5 Press the STATION1 key twice and wait until the LED insert ON paper STATION 2 illuminates The printer logic will read the O O O current and voltages present on the photosensors when STATION
35. indications provided in section GENERAL INFORMATION FOR INSTALLATION on page 2 1 Connect the mains cable and switch on the printer Check power on through the mechanism reset phase and READY lighting up of the ON led on the console O O O O 4 If other LEDs apart from the ON LED remain on refer to STATION a LocaL STATION2 section ERROR MESSAGES on page 5 1 EJECT o S BREAK AOR EJECT OFF LINE TEST A print test can be carried out to check functioning of the printer before connecting it to the system Activating and deactivating the print test To activate the test proceed as follows 1 Switch off the printer 2 Switch on the printer holding down the STATION 2 key READY ON of the console O O O O O 3 Atthe end of the initialization phase insert an A4 sheet in the station C LocaL STATION2 introduction slot until the paper alignment photosensor is EJECT An SREAK a EJECT activated 4 The machine automatically feeds the sheet and prints the test The sheet is ejected automatically at the end of the test To repeat printing simply insert a new sheet The print test provides the following information e The release and version of the firmware e The presence and type of scanner installed e The presence and type of magnetic options used e A visual check of the operation of the 24 printhead needles e The parameter settings for the emulations used e The configur
36. kinematics Procedure Lists the operations to be carried out to make the adjustment Notes Provide any references to adjustment sequences or checks Adjusting the document drive belt MACHINE STATUS Printer switched off and without casing CONDITIONS TO BE CHECKED Cogged belt 1 tensioned so as to obtain a deflection of 2 9 mm with a force of 200 g applied at the center of the span PROCEDURE Disassemble the mechanical unit See the section Mechanical assy disassembly reassembly on page 7 6 Loosen the lock nuts of the motor 2 Establish conditions required and tighten the nuts 1 P 200 g 2 3 mm f Figure 6 2 Adjusting the document drive belt XZAC 4219 05 Service Manual 6 3 Adjusting the print bar where torsion bar present e MACHINE STATUS Printer switched off and without casing Printhead positioned co axially with the axis of the screw used to make the adjustment e CONDITIONS TO BE CHECKED Distance of 0 4 0 5 mm between print bar 2 and feeler roller 3 e PROCEDURE Disassemble the mechanical unit See the section Mechanical assy disassembly reassembly on page 7 6 Bring the print unit to the writing position then using the two screws 1 adjust the print bar 2 in contact with the feeler roller 3 positioning the head 4 in axis with the screw Lift the print unit and move the print bar
37. number 8 xxx xxx RS63 R564 So oS GH I RS65 Ro cS RS73 ges usi C s ssi BoR aff RS RS59 a RS79 0 rsi si fe orce Rs R594 RS95 HEE 037 038 Service Manual Figure 1 6 Motherboard layout printer version with serial number 8 xxx xxx and location of connectors XZAC4219 05 1 Parallel interface connector 2 Serial interface connector 3 Printhead connector 4 Printhead connector 5 Alignment device photosensors Console connector Carriage motor connector Open close cover sensor connector o Oo N O Paper motor connector Analogue signal connector of the card for MICR configuration XZAC4219 05 11 13 14 15 16 21 22 23 24 Services motor connector SBI signal connector of the card for MICR configuration Power unit connector Signal connector for cards for Horizontal Magnetic and MICR configurations Power and signals connector for Horizontal Magnetic and MIC
38. paper paths XZAC 4219 05 Service Manual 2 1 UNPACKING AND INSTALLING THE MACHINE Unpacking Check the contents of the packing This must contain 1 PR2 Plus printer in the requested configuration Mains cable Ribbon cartridge User manual Card for cleaning the magnetic head only for Horizontal Magnetic and MICR options wp WN Figure 2 1 Contents of the packaging WARNING preserve the original packagings and protective material inserted inside the printer 2 2 Service Manual XZAC4219 05 1 Remove the machine from the bag 2 Completely open the upper cover of the printer Figure 2 2 Opening the upper cover 3 Remove the protective material that has been inserted for transportation Extract the card 1 and remove the foam padding from the side 2 and the front 3 WARNING before using the printer remove the card and the foam padding provided for its protection Preserve these protections so that they are available if in the future transportation of the printer is necessary Figure 2 3 Removing the protections provided for transportation purposes XZAC4219 05 Service Manual 2 3 a 4 Release the two red plastic stop brackets inserted for transportation purposes 1 These brackets block the printing carriage and the upper mechanical assembly Figure 2 4 Removing transport blocking devices 5 Raise
39. pixel overlap for the FRONT SCAN and for the REAR SCAN are both less than 20 300 In the case that these values are higher repeat the calibration paying maximum attention to aligning the calibration sheet completely on the left After the calibration during the self test phase the printer indicates Scanner front rear present NOTE to print the calibration parameters without changing the current values just enter the procedure for printing the calibration values for photosensors the scanner values will be printed after those for the photosensors 4 28 Service Manual XZAC4219 05 SCANNER CALIB Ver 3 300 dpi monochrome speed cm sec is 2a 2 FRONT SCAN Present lt Scan distance 902 216 of inch Mechanical scan pixel overlap 11 300 of inch amp Head measured document left edae 140 300 of inch Head measured document right edge 2963 3500 of inch Form width 2823 300 of inch OK REAR SCAN Present lt Scan distance 745 216 of inch Mechanical scan pixel overlap 6 300 of inch FRONT Temp ref 29 Failure None lt Led Dac Peak QutyvS top MixPeak MixDutyS ton areen LSS 249 31 81 as red 1 55 249 31 158 14 blue 155 242 72 2357 td REAR Temp ref 29 Failure None lt g Led Dac Peak DutyS top MaxPeak MaxbDutyS too green 150 ZA 26 78 li red 150 248 Bs 169 16 blue 150 243 21 240 11 kk SCANNER CALIB Ver 3 600 dpi monochrome speed L cm sec l 6 5 FRONT Temp ref
40. plastic clips Disconnect the connector 1 from the carriage transport motor 5 Lift the upper mechanical assy using the specific levers See the section Lever for lifting the upper part of the mechanism on page 3 4 6 Back off the two rear side hinge pins 2 to disconnect the upper mechanical assy Figure 7 13 Disassembling the upper mechanical assy NOTE during reassembly make sure that the cables are passed through the related compartments and check adjustment of the roller gear See the section Adjusting the roller gears on page 6 9 XZAC 4219 05 Service Manual 7 11 Paper feed motor disassembly reassembly 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 Remove the mechanical assy as explained above See the section Mechanical assy disassembly reassembly on page 7 6 3 Loosen the two lock nuts 1 of the motor and remove the document drive belt 2 from the pulleys 4 Loosen the nuts 1 and extract the motor Figure 7 14 Disassembling the paper feed motor NOTE during reassembly adjust the document drive belt See the section Adjusting the document drive belt on page 6 3 7 12 Service Manual XZAC4219 05 Printhead drive motor disassembly reassembly 1 Remove the upper mechanical assy as explained above See the section Printhead disassembly reassembly on page 7 10 2 Loosen the lock
41. printer staples elastic bands or other small objects that could be sucked inside Accessories and forms e Check that the accessories fitted on the machine are original and in good condition e Check that the documents inserted in the printer comply with machine specifications and are in good condition as described in the section DOCUMENTS THAT CAN BE HANDLED BY THE BASIC MACHINE on page 1 3 Printer operating status e Check for any dirt or paper and ink on inside parts of the machine that may affect the performance of the various devices e Check for any internal damage due to insertion of documents with paper clips metal staples pins or sample holders e Check lubrication of all parts for which this is prescribed See the section LUBRICATION on page 6 1 Identifying the problem Examining all the information gathered from the Operator printer error signals analysis of documents on which the fault has been encountered repetition of the error when the machine is started etc trace and isolate the problem that has occurred on the machine and which must be eliminated In some cases the fault may be caused by more than one problem it is important therefore to separate the various problems and deal with these one by one XZAC 4219 05 Service Manual 5 13 Tracing the cause According to your experience and referring to information provided in this chapter follow a logical path to trace the fault from the mos
42. the inked ribbon Colour Black Pigmentation Carbon free Vita ribbon 10 million characters draft mode 40 contrast no ribbons year 1 9 Packaging Waterproof with protective box Figure A 1 Ribbon cartridge Ribbon cartridge in NYLON SNUG CART indelible Same as the BLACK NYLON SNUG CART but with indelible ink XZA4219 05 Service Manual A 1 FONT AND CHARACTER SET All character generators fonts and codepages available in the various emulations and versions are preloaded in the basic version including the DAECO Print speed and definition Mode CPS Copies Matrix V x H Definition V x H VHSD 560 1 1 24 x 4 3 1 1 80 H 1 180 V HSD 510 1 2 24 x 4 3 2 1 90 H 1 180 V Draft 370 1 4 24 x 5 4 3 1 120 H_ 1 180 V NLQ 185 1 5 24 x 18 6 1 240 H 1 180 V LQ 125 1 6 24 x 36 1 360 H 1 180 V BIM min 2000 dps 1 120 H 1 180 V BIM max 2000 dps 1 360 H 1 180 V Attributes Available fonts depending on the active emulation e Alphanumeric native roman sans serif courier e Optical reading OCR A OCRSB single row Barcodes Maximum packing of the barcode module depends on the dimensions of the needle of the printhead Modules from 0 25 mm and multiple integers are possible Types of barcodes supported e EAN 8 code 39 e EAN 13 2 of 5 interleaved e UPC A 2 of 5 industrial e UPC E Codabar Ch
43. the upper group using the lever provided 1 Figure 2 5 Lever for lifting upper mechanical assembly 6 Check that the printer has not been damaged during transport 2 4 Service Manual XZAC4219 05 7 Remove the two red plastic stop brackets inserted for transportation 1 These brackets block the printing carriage and the upper mechanical assembly WARNING when removing the red plastic bracket on the right be very careful not to damage the component indicated in the figure S gt oes SS sos a gt gt gt s s F oat AP SS F yy ee e SSS NOTE bear in mind that before shipping or transporting the printer you must always reinsert the blocking devices Refer to the section Reinserting the transportation blocking devices on page 2 9 XZAC4219 05 Service Manual 2 5 Installing the ribbon cartridge 8 Take the ribbon cartridge and unhook the ribbon guide 1 pushing it to the back as illustrated in the following figure Figure 2 7 Unhooking the ribbon guide 9 Move the printhead manually to the centre of the printer 10 Insert the cartridge into the driving mechanism fitting it laterally onto the two sides Figure 2 8 Fitting the ribbon cartridge 2 6 Service Manual XZAC4219 05 11 Insert the ribbon guide 2 from the front and then lift it so as to fasten it on the two flexible pins in th
44. vice versa To eliminate this defect you can optimise the alignment of bi directional printing through calibration Calibration must be performed for each of the following printing modes Very High Speed Draft High Speed Draft Draft Near Letter quality Letter quality To calibrate the alignments proceed as follows 1 2 10 11 12 XZACA219 05 Open the printer cover Power on the printer with the cover open keeping the three console keys pressed Wait for the acoustic signal that indicates access to the calibration and adjustment procedure then close the cover Press the STATION1 button Press the STATIONZ2 button Press the STATION1 and STATION2 keys simultaneously For all the printing modes the default values theoretically near to the correct ones will be saved Insert an A4 sheet in the front slot to check print alignment status Press the STATION1 and or STATIONZ2 keys to calibrate the alignments e By pressing the STATION1 key you can anticipate start of printing e By pressing the STATION2 key you can delay the start of printing Repeat points 7 and 8 until calibration has been completed Press the LOCAL button twice to save the alignment value permanently for the current mode and to move automatically to the next calibration Carry out the calibration for the printing modes required To terminate the calibration switch off the printer
45. x re Ly N EJECT BREAK EJECT LQ TYPE LQ2 DRAFT SPEED NORMAL MENU CONFIG STATION1 confirm STATION2 Skip Press Local to continue XZAC4219 05 6 Also in this case let s imagine that we do not want to change this parameter Therefore we press the STATION1 key again to pass to the next parameter READY ON O O O O O N K A D STATION C LOCAL STATION2 EJECT BREAK EJECT allows you to pass to the next parameter NOTE the STATION1 key is therefore the key that confirms the value of the parameter printed and 7 The setting for the third configuration parameter is printed 8 Proceed in the same way pressing the STATION1 key until the setting of the fifth parameter INTERFACE is printed that we want to change 9 This is the parameter value that for the purposes of our example we want to change Press the STATION2 key to pass to the next value available for the parameter 10 The new value for the parameter is printed For the connection interface 6 values are possible USB COM1 USB USB PAR PARALLEL DUAL PAR and SERIAL1 The values are displayed in a cyclical fashion therefore by continuing to press the STATIONZ2 key you can return to the first value again PAPER WIDTH FIRST LINE LQ TYPE LQ2 DRAFT SPEED NORMAL MENU CONFIG LI STATION1 confirm STATION2 Skin Press ocal to continue INTERFACE USB BUZZ
46. 0 2 00 1 14 MiCRreader 0 2 022 020 0040 1 15 SCANNER seca cpet 8 SRG oe REA ES bow ee eein ea 1 16 Scanner technical data 4 1 16 ALIPR2 POWER SUPPLY 1 17 CONSOLE ei eisai ahs Senos Bee Ba ee y Bone Ree Se 1 18 Chapter 2 INSTALLATION 2 1 GENERAL INFORMATION FOR INSTALLATION 2 1 Powersupply 0 0 0 0 000 eee ee 2 1 Environmental conditions 2 1 Locating the machine 2 02040 2 1 UNPACKING AND INSTALLING THE MACHINE 2 2 Unpacking 0 0 00 a 2 2 Installing the ribbon cartridge 0 2 6 Reinserting the transportation blocking devices 2 9 Installing the printer 2 0 2 02 0 00 002 0040 2 10 OFF LINE TEST wn chen eae eb a ee ee ee eee 2 10 Activating and deactivating the printtest 2 10 Disactivating the test 000 2 10 SYSTEM CONNECTION 0 0 00 0 RS 232C serial interface standard Parallel interface ieee 1284 2 20202 202022020202202022 USB Interlace sos sed 2s B ser Eth ae zs dee ee Se A FINAL TESTING WITH PRINTER CONNECTED TO SYSTEM ONLINE 0 02200048 OPERATOR INFORMATION 0 0 Chapter 3 OPERATING THE PRINTER OPERATING CONTROLS ON OFF switch 02 0 200200205 Console keysandLEDs
47. 219 05 Parameter Values possible Description TABLE 1 PC TABLE Selection of the table of the character generator TABLE 2 LQ DRAFT CHAR DEFINITION Selection of print definition OCR A OCR B 10 Selection of printing pitch expressed in number of CPI 12 characters per inch 15 17 1 17 1 COMPRESSED Defines the spacing selected with ESC gt 15 N Activates Y or disactivates N automatic execution of LF CR a carriage return CR whenever a line feed command Y is received STATION1 N Activates Y or disactivates N automatic execution of CR LF a line feed STATION1 whenever a carriage return Y CR command is received NEVER LF HEAP UP AFTER EJECT NORMAL ESC BEL 0 CHECK FAST N ZERO SLASHED Enables Y or disables N printing of the zero slash Y 80 Selection of the maximum length of the print line LINE LENGTH 90 expressed in number of characters at 10 cpi DIRECT INSERT MODE PR2 LIKE FORM LENGTH FRONT 12 Selection of the maximum form length expressed 11 in inches N Selects the type of bottom margin of the form BOF for the document managed BOF IBM PP LIKE N The value of the bottom margin will be 4 23 mm Y The value of the bottom margin will be 13 7 mm XZAC 4219 05 Service Manual 4 11 Parameter Values possible Description TOF IBM PP LIKE y Selects the type of top margin
48. ALIBRATION on page 4 1 e Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner or Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 XXX XXX Photosensor test failed See the section CALIBRATING THE PHOTOSENSORS on page 4 18 for an indication of the defective photosensor Magnetic reset Replace the horizontal magnetic or MICR interface card See the section Horizontal magnetic MICR disassembly reassembly on page 7 28 5 2 Service Manual XZAC4219 05 Console LED Anomalies Possible solution ON Ready Station Local Station 2 e Replace the MICR board See the section Horizontal magnetic MICR disassembly reassembly on page 7 28 O X Time out SBI e Replace the MICR head See the section Horizontal magnetic MICR printhead assy disassembly reassembly on page 7 30 o x g g S eivicemotor See the section Faults with document handling on page 5 19 Paper jammed on insertion See the section PROCEDURE FOR O X photosensors CLEANING REPLACING THE or photosensors PHOTOSENSORS on page 6 2 dirty Assit Proceed with forced loading of the O X X gene firmware and of the character missing or generator corrupt g _ See the section Faults during writing 9 a i Gamage Motor o
49. BETEN FIELD STRIPE HANDLING HW CODE 4 1 Verify functioning of printhead PR2 Y VERTICAL L OLIVETTI STISINT DRAFT 10 16 6 1 240inch N 90 N NO WAIT amp 5 01 Ver O11 gsm 3604 STANDARD N Y 3 NORMAL Figure 2 13 Example of printing test for printer with PR2 Plus CS scanner NOTE the previous figure provides only an example of a printing test The software versions shown and the exact data printed varies according to the model used XZAC4219 05 Service Manual SYSTEM CONNECTION or NOTE the printer can be connected to the system using the serial interface the parallel interface the USB B port or a combination of these Using the configuration procedure it is also possible to activate the N Autoswitching function that is the automatic recognition and connection of the printer that becomes active first with the port Refer to the section Description of configuration parameters on page 4 6 RS 232C serial interface standard 1 Connect the serial cable to the connector on the back of the machine Figure 2 14 Connector for serial interface 2 From Set up program the following interface parameters SERIAL 1 BAUD RATE BIT CHAR PARITY STOP BIT DSR e DCD refer to section CONFIGURING THE OPERATION PARAMETERS on page 4 1 2 12 Service Manual XZAC4219 05 Parallel interface ieee 1284 The parallel interface requires a 36 wire Cent
50. DITIONS TO BE CHECKED Pressure roller in work position e PROCEDURE Rotate the cam so as to bring the pin of the bridge 4 on its maximum radius then check that with the pressure roller resting on the paper sliding surface there is play in the coupling of point A Between 0 5 mm and 1 mm CS Figure 6 12 Positioning the horizontal magnetic MICR pressure roller XZAC 4219 05 Service Manual 6 13 Positioning the assy on the horizontal magnetic MICR structure MACHINE STATUS Printer switched off and without casing CONDITIONS TO BE CHECKED Co planarity between the closing flap of the magnetic unit and the paper conveyor of the slot PROCEDURE Position the slots 1 in the half cut outs 2 present on the sides of the machine Draw up the lock screws slightly 3 Push up the structure of the magnetic unit until it is in contact both to the right and left against the paper conveyor Torque the lock screws to 8 Kgcm 6 14 Figure 6 13 Positioning the assy on the horizontal magnetic MICR structure Service Manual XZAC4219 05 Replacement and adjustment of belt for carriage movement e MACHINE STATUS Printer switched off and without casing e CONDITIONS TO BE CHECKED Idler pulley support slide pushed externally to the printer by tension spring e PROCEDURE Loosen the screw 1 Check the sliding freedom of the slide lf necessary replace the belt Tighten the
51. Disconnect the power cord J16 that connects the motherboard to the mains unit Figure 7 25 Power connector 4 Remove the magnetic options option 1 Figure 7 26 Removing the magnetic options board XZAC 4219 05 Service Manual 7 21 5 Back off the six lock screws 1 of the motherboard Figure 7 27 Fastening screws of motherboard 6 Back off the two fasteners 2 of the standard serial interface connector and back off the two screws 3 of the Centronics interface connector and extract the motherboard from the base plate of the printer Figure 7 28 Interface connector columns and screws NOTE when replacing the board update the firmware with the latest release configure the parameters see the section CONFIGURING THE OPERATION PARAMETERS on page 4 1 and calibrate the photosensors see the section CALIBRATING THE PHOTOSENSORS on page 4 18 7 22 Service Manual XZAC4219 05 Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 XXX XXX 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 Remove the mechanical assy See the section Mechanical assy disassembly reassembly on page 7 6 3 Disconnect the power cable J16 printers with serial number 8 xxx xxx or J15 printers with serial number 1 XXX XXX J16 J15 Printers with serial number 8 xxx xxx Pr
52. ER Y PAPER WIDTH FIRST LINE LQ TYPE LQ2 DRAFT SPEED NORMAL MENU CONFIG READY ON O O O Q O y aa a 7 STATION LOCAL STATION2 Ps Se A We EJECT BREAK EJECT SERIAL INTERFACE USB COM1 USB PARALLEL DUAL PAR BUZZER Y PAPER WIDTH FIRST LINE LQ TYPE LQ2 DRAFT SPEED NORMAL NOTE the STATION2 key is therefore the key that allows you to change the value associated with each parameter By pressing this key you pass to the next value available in succession 11 When you reach the value you want to set for the parameter press the STATION1 key to confirm the value and pass to the next parameter 12 The next parameter is printed 13 Proceed in the same way pressing the STATION1 key for all the parameters in the menu until the option SAVE PARAMETERS is printed XZAC4219 05 Service Manual READY ON t O O O O Q ie STATION LOCAL STATION2 Pi Si Ne EJECT BREAK EJECT RSI EMULATION OLIVETTI SERIAL1 INTERFACE USB COM1 USB PARALLEL DUAL PAR BUZZER Y PAPER WIDTH FIRST LINE LQ TYPE LQ2 SAVE PARAMETERS Y PNS SELECTIONS N BIM MODE MONO PRINT MODE STANDARD SPECIAL FORMS N 4 3 14 15 16 To save the new values you have configured for the parameters press the STATIONZ2 key to pass from the value NO to the value Y The value Y is printed to confirm that the new configuration va
53. Magnetic reset section Horizontal magnetic MICR disassembly reassembly on page 7 28 e Perform calibration of the scanner See the section Calibrating the scanner on page 4 28 e Replace the CIS See the O X X APE scanner sections CIS assy upper error l scanner disassembly reassembly on page 7 33 and CIS assy lower scanner disassembly reassembly on page 7 34 Memory e Press any key on the console to Maintenance display the next anomaly when On the display if necessary present appears Proceed with initialisation of the the message printer WARNING Maintenance data o o X xX X Impossible to recover valid maintenance data from the dedicated Flash EPROM area The maintenance data will be reinitialised with the value 0 See the section Faults with a x i i i Senice malor document handling on page 5 19 Bie See the section PROCEDURE o X x photosensors FOR CLEANING REPLACING THE PHOTOSENSORS on page 6 or photosensors 2 dirty XZAC4219 05 Service Manual 5 5 Console LED Anomalies Possible solution ON Ready Station Local Station 2 e Perform calibration of the scanner See the section Calibrating the scanner on o X x _ FPGA scanner page 4 28 error e Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner HW Setup On e Press any key
54. R configuration cards USB port connector to host Connector for optional rear photosensors Connector for cover open closed sensor Power supply for optional fan Service Manual 1 9 etti Motherboard machines with serial number 1 xxx xxx one serial interface A B Fall EIB E RS16 Goa E 5 i li Misio ee FIFI ALJ lesz les J LY lo 4 wes Bl Ds11 DS15 DS16 Ee o PIERI s ws BIBI aL D523 HL 526 1 ine l D520 ia D524 D525 0827 ri re us4 rsa Sesi f FF D533 os36 1 D529 osai _ D534 D535 D537 25 ii E 7 mJ U Tom RS28 RS29 RS30 nat w mM fe aa e USB lt a rg g 3 g moc j Gs mss se Sgp RSA2_RSA3 RSAGRSAS RS46 RS47 DS eo 5 g i 30 E RS65 eis usia 30 ap oo Hi RS76 Qs2 a RS80 RS81 Fl B B i ni RS90 RS91 6 w R593 SOA nso RSE is Ka a One A a fl rs307 g Po O Bj amp i uses flrs T 7 a Fa I nago sn ise rs103 ma 3 2i OO ah o use of Sees go ite EJE ah 6 H t g De i TENO T Di us31 a R5 Re us30 9 8 Figure 1 7 Motherboard layout printer versions with serial number 1 xxx xxx one serial
55. See X X X X FOr i DOCUMENTS THAT CAN BE HANDLED BY THE BASIC p MACHINE on page 1 3 X Xx Xx X Document ruined Use another document X X X Closing levers open Lower the lever for closure 1 Carry out the calibration procedure See the section CALIBRATING THE PHOTOSENSORS on page 4 Front 18 a aaa 2 Clean and if necessary replace the fault photosensor See PROCEDURE FOR CLEANING REPLACING THE PHOTOSENSORS on page 6 2 1 Adjust the sensor position See the section Adjusting Paper Photosensor on page 6 8 Paper 2 Carry out the calibration procedure See p CALIBRATING THE PHOTOSENSORS on page 4 X photosensor 18 faul aus 3 Clean and if necessary replace the fault photosensor See PROCEDURE FOR CLEANING REPLACING THE PHOTOSENSORS on page 6 2 Replace the services motor See the section Services X Service motor fault i h motor disassembly reassembly on page 7 14 Paper feed Replace the paper feed motor See Paper feed motor X X motor fault disassembly reassembly on page 7 12 xX Adusiment oi nerde See Adjusting the roller gears on page 6 9 roller incorrect See Adjusting the print bar where torsion bar present X PANDA HOT AHUSIEN on page 6 4 or Adjusting the print bar where torsion bar correctly s absent on page 6 5 Adjust the printing band See Adjusting the print bar parallelism and leaf spring load on the basic machine on x Band noranjusi
56. See INTERFACE PARALLEL parameters PAR PORT MODE XZAC 4219 05 Service Manual 4 9 IBM Menu parameters Parameter Values possible Description P P II EMULATION Selection of IBM emulation X24 N If emulation X24 is set the AGM function is disabled AGM y If emulation X24 is set the AGM function is enabled PASSBOOK N Indicates whether the printer is enabled or not to y handle passbooks VERTICAL Linked to the PASSBOOK Y item selects the type of binding of the passbook horizontal or vertical If BINDING horizontal binding is selected during printing on the HORIZONTAL passbook the head will exit the passbook close to the binding so as to improve feeding L Selecting R Right SW compatibility with the PR50 SIDE with Right alignment is obtained Selecting L Left R SW compatibility with the PR50 with Left alignment is obtained PC CHAR SET Selection of the character generator ISO DK N If the character generator selected has been PC DK 210 GR 220 E 437 INT 850 LATIN 1 851 GREEK 852 LATIN 2 855 CYRILLIC PC CHAR SET 857 LATIN 5 858 LATIN EURO 860 P 862 IL 863 CANADIAN FRENCH 864 ARABIC 865 NORDIC 866 CYRILLIC 1250 PC WIN Latin2 252 PC WIN Latin1 OLI UNIX ISO 8859 1 ISO 8859 2 ISO 8859 5 ISO SET ISO 8859 6 If the character generator selected has been ISO ISO 8859 7 ISO 8859 8 ISO 8859 9 ISO 8859 15 4 10 Service Manual XZAC4
57. Service Manual 1 13 MAGNETIC OPTION CARDS Horizontal Magnetic and MICR interface cards for managing the optional magnetic units can be connected to the motherboard e Horizontal magnetic unit interface card code XYAB3124 to connect to the special connectors on the motherboard e MICR unit interface card code XYAB1564 to connect to the special connectors on the motherboard Horizontal magnetic unit This device can read write horizontal magnetic stripes It consists of a mobile magnetic printhead that operates across the insertion slot with a specific controlled movement mechanism It operates across the entire insertion slot of the printer and does not involve any particular constraints as regards positioning of the passbook inserted The operation on the stripe is carried out exerting controlled pressure on the passbook to guarantee uniform distance between the printhead and the magnetic support R W reference standards DIN ISO 32744 IBM 3604 ANSI alignment autoborder error rate lt 1 10000 after three automatic retries The following figure provides an illustration of the interface card that is connected to the special connectors on the motherboard O O 4 5 3 Figure 1 9 Layout of optional Horizontal Magnetic interface card indicating the locations of the connectors 1 Connector for power and motor signals from 4 Connector for photosensor for resetting transport the mot
58. TANDARD has been configured Parameter Values possible Description END SENTINEL C Sets the closing code F STANDARD DISPLACEMENT 10 Sets the position of the magnetic stripe 20 N DUPLICATE Sets or not duplication of the field Y N DOUBLE FIELD Sets or not control on the two fields recorded Y 3 RETRY Sets read retries 1 Permits fast or normal management of the magnetic stripe In the case of normal management each time NORMAL the magnetic stripe is read or written passbook width is measured in order to establish the precise position of the stripe STRIPE HANDLING In fast management the width of the passbook is measured once only with the procedure described in FAST the specific chapter and no measurements are made during reading or writing of the stripe thus increasing speed of management of the stripe 4 16 Service Manual XZAC 4219 05 If the ANSI or DIN ISO STANDARD has been configured Parameter Values possible Description STANDARD DISPLACEMENT 10 Sets the position of the magnetic stripe 20 N DUPLICATE Sets or not duplication of the field Y N DOUBLE FIELD Sets or not control on the two fields recorded Y 3 RETRY Sets read retries 1 Permits fast or normal management of the magnetic stripe In the case of normal management each time NORMAL the magnetic stripe is read or written passbook wid
59. a 1 MB Flash EPROM on which the management FW character generators and characters sets are held and can be replaced on line A second Flash EPROM optional with the same capacity able to contain complex character sets or high volumes of macros and logos can be installed on the motherboard The machine firmware comprises the following emulations e Olivetti environment STD 12 14 controlled protocol with native PR2 E environment and PR40 and PR2845 emulation Industry standard emulation IBM Proprinter II and Proprinter X24 e IBM environment Emulation protocol 9068 with coverage of the 4722 model Industry standard emulation IBM Proprinter Il and Proprinter X24 e Wincor Nixdorf environment Emulation protocol SNI 4915 with coverage of models 4905 Industry standard emulation EPSON LQ 2550 Character sets System level compatibility for each character set extends the environments listed below ENVIRONMENT CHARACTER SET PC DOS CP SET CODE PAGE WINDOWS 2 X 3 0 OS 2 UNIX ISO 8859 X WINDOWS 3 1 CP SET OLIVETTI STD 15 Each emulation present on the machine includes one or ore character sets The character sets present in each emulation are listed in the table below EMULATION CHARACTER SET OLIVETTI CP SET STD 15 Olivetti ISO IBM CP SET ISO Mode and character fonts The characteristics of the various print modes are listed below 10 cpi 12 cpi 15 cpi H S D High S
60. able indicates the meaning of the keys when they are pressed with the upper cover of the printer raised or during the first phases of powering on the printer Keys pressed Cover Function ON STATION2 Closed If the Station 2 key is pressed when the printer is switched on a printing test is printed reporting the printer configuration ON STATION1 STATION2 Closed If pressed simultaneously with switching on the printer the Configuration menu is displayed ON STATION1 Open Activates the procedure for removing paper jams Refer to PAPER JAM on page 3 11 ON LOCAL STATION1 Open Printer set up for firmware to be updated in forced online mode on Flash EPROM ON ON LOCAL LOCAL STATION1 STATION2 Open Open Access to the following procedures Calibration of the photosensors Calibration of the photosensors Setting of LH margin Measurement of document or passbook length Calibration of print alignments Printing of the calibration of the photosensors Prints the calibration values of the scanner Prints the Jitter verification data Cover open signal disabled Lever for lifting the upper part of the mechanism The lever used to raise the upper part of the mechanism positioned on the left hand side of the machine makes it possible to lift the mechanism and to access the paper path inside the machine with the possibility of r
61. alibration proceed as follows NOTE if this type of management is to function correctly the same passbooks as measured must be used To carry out this calibration proceed as follows 1 Open the printer cover 2 Power on the printer with the cover open keeping the three READY ON console keys pressed O O O O O 3 Wait for the acoustic signal that indicates access to the STATION LOCAL STATION2 calibration and adjustment procedure then close the cover ee rn BREAK oo EJECT 4 Press the LOCAL button and wait for the end of the machine READY ON reset procedure O O f 3 O 5 Press again the LOCAL key and wait until the end of the STATION1 4 LocaL sTATION2 reset procedure for the printer ee BREAK m 6 Insert an A4 sheet in the front slot and press STATION1 The READY ON sheet will be introduced and ejected automatically O O O O O 7 If necessary repeat point 6 STATION Loca STATION2 8 Press the LOCAL button to permanently save the value of EJECT BREAK EJECT the form width measured and to move automatically to the next calibration 4 24 Service Manual XZAC4219 05 MICR Calibration To calibrate the MICR proceed as described below 1 Open the printer cover 2 Power on the printer with the cover open keeping the three READY ON console keys pressed O O O y O O 3 Wait until the acoustic signal
62. aracter attributes e normal e boldface e subscripts e superscripts e italics e double width e double height e double height and width e horizontal and vertical zoom A 2 Service Manual XZA4219 05 CERTIFICATIONS AND APPROVALS Certifications and approvals 230V power supply unit version Safety CE Marking compliance with standards EN 60950 Electromagnetic Compatibility EN 55022 EN 55024 CE Marking compliance with standards EN 61000 3 2 harmonics EN 61000 3 3 flicker Environmental Compatibility Recycling Directive WEEE 2002 96 CE Hazardous substances directive ROHS 2002 95 CE Certifications and approvals 115V power supply unit version Safety International Marks compliance with standards C TUV NRTL US Electromagnetic Compatibility FCC Marking Class A Environment specifications Reference standards Temperature 15 35 C Operating Humidity 35 85 non condensing Temperature 10 60 C Stand by Humidity 10 90 non condensing XZA4219 05 Service Manual A 3 FIRMWARE AND CHARACTER GENERATORS Machine firmware In addition to that separate from the generator and from the set characters the management firmware of the printer is controlled independently in load operations in order to facilitate immediate access for modifications to the characters area The basic memory of the printer is
63. assembling the motherboard printers with serial number 8 xxx xxx and 1 xxX Xxx e Replace the MICR board See the section Horizontal magnetic MICR disassembly reassembly on page 7 28 O X Time out SBI e Replace the MICR head See the section Horizontal magnetic MICR printhead assy disassembly reassembly on page 7 30 SW Setup On e Press any key on the console the display if when appropriate to display the present appears next anomaly the message e Check if the default values WARNING forced by the printer are the Setup correct ones by printing the Software configuration data See the Inconsistency in section Activating and printer deactivating the print test on O O X configuration page 2 10 data e Proceed with initialisation of the programming printer values saved in the dedicated Flash EPROM area The printer forces the default values for the firmware release Pilalecies Proceed with forced loading of the O X X generator firmware and of the character missing or generator corrupt 5 4 Service Manual XZAC4219 05 Console LED Anomalies Possible solution ON Ready Station Local Station 2 See the section CALIBRATING o _ x g _ Photosensor test THE PHOTOSENSORS on page 4 failed 18 for an indication of the defective photosensor Replace the horizontal magnetic or MICR interface card See the O X X
64. ation parameters currently programmed for the printer Visually checking the writing allows also an evaluation of the printing quality An example of the information returned by the test is provided on the next page The contents of the test depend on the FW release installed on the printer Disactivating the test To de activate the test switch off the printer 2 10 Service Manual XZAC4219 05 BOOT REL 2 20 VER O06 FW REL 5 10E VER 002 FPGA VER SC 128 CG VER 068 lt a Scanner available Scanner front rear present Needles test 111111111122222 OE 1234567890123 4567890123 DY CONFIG DRAFT SPEED NORMAL LQ TYPE NLQL PAPER WIDTH FIRST LINE BUZZER Y OS OCR ron Be LATION OLIVETTI Parameter configuration PLUG amp PLAY Y 9 SCAN F BRIGHT 0 SCAN R BRIGHT 0O PAP EDGE DETEC N SPECIAL FORMS N E OES SLANDA Parameters for emulations used ien a OL IVETE EMULATION P P II PASSBOOK Y PASSBOOK BINDING VERTICAL BINDING SIDE L SIDE CHAR SET PC CHAR SET PC CHAR SET 437 CINT OLI CHAR SET PC TABLE TABLE 2 ere DEFINITION CHA AFT CHAR DEFINITION DR F i ESSE COMPRESSED 17 1 VERTICAL RESOL LF CR N LF CR SRE KERT y SYRGfikon LF HEAP UP NEYER ESC BEL O CHECK NORMAL STATUS REQUEST ZERO SLASH N LINE LENGTH 80 FORM LENGTH tie OPTION HOR MSRW BOF IBM PP LIKE Y wee Rel TOF IBM PP LIKE Y STANDARDE a DISPLACEMENT N DUPLICATE Magnetic options available
65. bbon cartridge e Extraction of a jammed document from the machine using the mechanism lift lever Stress the importance of correct internal ventilation and that the various ventilation slots of the printer must not be blocked by forms or documents Remind the operator that correct use of the machine guarantees optimal functioning in time If faults occur contact technical support immediately 2 14 Service Manual XZAC4219 05 Chapter 3 OPERATING THE PRINTER This chapter examines all the commands for operating the printer operations for inserting the forms or documents to be printed and some maintenance procedures that can be carried out without the use of instruments or tools OPERATING CONTROLS The machine has the following operating controls 1 On off switch 2 Console with three keys and five LED 3 Lever for lifting the upper part of the mechanism Figure 3 1 Operating controls ON OFF switch The on off switch of the machine is of the two position type The switch is operated by a mechanism that runs cross the machine in a lengthwise direction XZAC 4219 05 Sercice Manual 3 1 Console keys and LEDs The console of the machine includes five LEDs and three keys C A A N READY ON READY ON O O O O O O O Q O O STATION1 LOCAL C STATION2 STATION C LOCAL C STATION2 EJECT BREAK EJECT EJECT BREAK EJECT PR2 plus PR2 plus NS
66. ce and type of PARITY ODD parity control even or odd By default parity control is disabled none EVEN 1 STOP BIT Number of stop bits N DSR T Data Set Ready managed or not NO DCD Data Carrier Detector managed or not YES If the INTERFACE parameter has been configured as PARALLEL Parameter Values possible Description PAR EMULATION sinus This parameter is used to set the emulation type of the IBM parallel port Thi ter is used to set th ti dof PAR PORT MODE is parameter is used to set the operation mode for BIDIRECT the parallel port 4 8 Service Manual XZAC4219 05 If the INTERFACE parameter has been configured as COM1 USB Parameter Values possible Description RS1 EMULATION BAUD RATE BIT CHAR PARITY See INTERFACE SERIAL1 parameters STOP BIT DSR DCD USB EMULATION See INTERFACE USB parameters PLUG amp PLAY If the INTERFACE parameter has been configured as USB PAR Parameter Values possible Description USB EMULATION See INTERFACE USB parameters PLUG amp PLAY PAR EMULATION See INTERFACE PARALLEL parameters PAR PORT MODE If the INTERFACE parameter has been configured as DUAL PAR Parameter Values possible Description RS1 EMULATION BAUD RATE BIT CHAR PARITY See INTERFACE SERIAL1 parameters STOP BIT DSR DCD PAR EMULATION
67. contact Technical Support Mail box Banking Printers Olivetti com XZA4219 05 Service Manual A 7 A 8 Page left intentionally blank Service Manual XZA4219 05 UPDATE STATUS DATE UPDATE PAGES PAGES CODE 04 2007 15 EDITION 142 XZAC4219 05 2007 2 9 EDITION 154 XZAC4219 10 2007 3 EDITION 160 XZAC4219 03 01 2008 4 EDITION 176 XZAC4219 04 08 2008 5 EDITION 172 XZAC4218 05
68. cted has been IBM ISO SET ISO 8859 6 CHAR SET gt ISO ISO 8859 7 j ISO 8859 8 ISO 8859 9 ISO 8859 15 LQ DRAFT CHAR DEFINITION Selection of print definition OCR A OCR B 5 10 12 CPI Selection of printing pitch 15 16 6 17 1 17 1 COMPRESSED Defines the spacing selected with ESC gt 16 6 1 240 inch VERTICAL RESOL Selection of vertical resolution 1 216 inch N Activate Y or disactivate N automatic execution of a LF CR carriage return CR every time a line feed command Y STATION1 is received 90 Selection of the maximum width of the print line LINE LENGTH mee 94 expressed in number of characters at 10 cpi N REPLY SYNCHRON Management of the DSR in transmission Y NO WAIT This parameter determines the timing of the status WAT reply to an ESC j command Selecting NO WAIT STATUS REQUEST the reply will be provided as soon as possible and in parallel with printing or paper movements Selecting WAIT the status reply will be provided at the end of printing OPTION HOR MSRW This is a warning message related to the Horizontal Magnetic option Refer to section If the horizontal magnetic option is present on page 4 16 SAVE PARAMETERS NO YES Saves Y or cancels N the values configured in this area of the programming menu 4 14 Service Manual XZAC4219 05 If the SIDE gt R parameter has been selected Parameter Values possible Description STD
69. ction Horizontal magnetic MICR printhead assy disassembly reassembly on page 7 30 Inconsistency in printer configuration data programming values saved in the dedicated Flash EPROM area The printer forces the default values for the firmware release WARNING l e Press any key on the console when appropriate to display Setup Software No timeout the next anomaly l e Check if the default values forced by the printer are the correct ones by printing the configuration data See the section Activating and deactivating the print test on page 2 10 e Proceed with initialisation of the printer Inconsistency of calibration values photosensors alignments etc All the calibration values are initialised with their default values e Press any key on the console to display the next anomaly when necessary WARNING No timeout e Perform all the printer calibrations See the section Setup Hardware PROGRAMMING AND CALIBRATION on page 4 1 e Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner or Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 XXX XXX Memory Maintenance data area corrupted WARNING No timeout Impossible to recover valid maintenance data from the dedicated Mainten Data Flash EPROM area The maintenance data will be reinitialised with the value 0 ERROR Character generator missing or corrupt No timeout Proceed with forced l
70. d printers with scanner on page 7 21 or Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 XXX xxx on page 7 23 Line problems on the interface Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner on page 7 21 or Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 XXX xxx on page 7 23 Incorrect set up Check the settings of the operation parameters See the section CONFIGURING THE OPERATION PARAMETERS on page 4 1 5 16 Service Manual XZAC 4219 05 Faults during writing of the document Fault ElaP s E sglos les 5 cfisfias S 7 HR OOO BH nH stiles lsSaolg S Possible cause Solution oS joc s LE loS los cS S SSP Boe ko ls S so S lees sg on Om e w on on SIF SSiZGSElOE SS EQ EGS EZlo2S loc EZER es ejes ge esigs Ee JESI ES ES EERS X xX Ribbon cartridge Insert a ribbon cartridge See Installing missing the ribbon cartridge on page 2 6 l Replace the ribbon cartridge See X a REPLACING THE RIBBON p CARTRIDGE on page 3 8 Ribbon cartridge not Check how the ribbon cartridge is X X X inserted correctly installed iregular movement Check the carriage See Replacement X X g and adjustment of belt for carriage of the carriage
71. e 1 12 Power unit connectors XZAC4219 05 Service Manual 1 17 CONSOLE The PR2 Plus console comprises 3 keys 5 LEDs and a display For the meanings of the LEDs and keys refer to the section Console keys and LEDs on page 3 2 A magnetic switch Dry reed signals to the motherboard when the upper cover of the printer is opened a A O Ea O O O STATION 1 C LOCAL Guronz EJECT BREAK EJECT PR2 plus i Pi oD H p HAARA E DLS5 IOF KS1 a READY O ON O O STATION 1 O O sanon 2 k EJECT BREAK PR2 plus EJECT A ARBEI AE BB Figure 1 13 Console Flat cable connector of the console for connection to the motherboard 1 18 2 Connector for alphanumerical display Service Manual XZAC4219 05 Chapter 2 INSTALLATION GENERAL INFORMATION FOR INSTALLATION For optimum printer operation and to avoid servicing for causes that do not depend on the product comply with the information provided below Power supply Check that the electrical outlet to which the printer is connected has a ground connection and is suitably scaled to provide the power required by the machine An outlet without a ground connection may cause malfunctions and generate safety problems Do not connect the printer to power supply lines shared with appliances that may cause electrical disturbances and e
72. e front slot 5 The machine will print the meaning of the keys in this environment on one line STATION1 confirm STATION2 Skip Press Local to continue 6 Press the LOCAL key to enter the Configuration menu READY ON O O O O O NX oe N e STATION4 LOCAL STATION2 A J EJECT BREAK EJECT 7 The currently active menu is printed CONFIG or IBM or OLIVETTI for which you can change its parameters By default the first menu activated is the Configuration menu CONFIG MENU CONFIG STATION1 confirm STATION2 Skip Press Local to continue NOTE every time you press the STATION2 key you pass to the next menu in succession in this case IBM then OLIVETTI XZAC 4219 05 Service Manual 4 1 8 To pass to the next menu press the STATION2 key The new menu is printed and you can change the parameters related to the IBM emulation 9 Pressing the STATIONZ2 key again you can pass to the third menu 10 The new menu is printed and you can change the parameters related to the OLIVETTI emulation READY ON O O O O O 1 pd Ka WY WY Meat hy Va Ne Va STATION1 LOCAL STATION2 A N A A EJECT BREAK EJECT MENU CONFIG IBM STATION1 confirm STATION2 Skip Press Local to continue MENU CONFIG IBM OLIVETTI STATION1 confirm STATION2 Skip Press Local to continue 11 These menus operate in a cyclical
73. e insertion slot taking care to remove any scraps of ribbon or paper that may be deposited on parts and also any foreign objects LUBRICATION Although operations for restoring the lubrication and grease levels are not normally required during the life time of the printer it is nevertheless the responsibility of the field technician during every service intervention to check them When it is necessary to replace mechanical parts that were originally greased proceed applying a same level of grease The only points that may require restoration of lubrication with oil are e Print carriage sliding shaft e Carriage felt Figure 6 1 Position of points to lubricate XZAC 4219 05 Service Manual 6 1 PROCEDURE FOR CLEANING REPLACING THE PHOTOSENSORS Use a jet of compressed air from a spray can to blow accurately through the paper insertion slot to remove any dust from the photosensor units for document presence alignment After opening the upper structure blow into the optical fibre zones pointing the jet of air inside the paper passage area to remove any dust that may be present in the optical fibre nozzles 6 2 Service Manual XZAC4219 05 MECHANICAL ADJUSTMENTS To simplify consultation each adjustment is divided into Machine status Describes the status of the printer required to make the adjustment Conditions to be checked Indicates the points values and tolerances to be complied with for correct functioning of
74. e open slots 3 of the cartridge 1 on the back of the print roller a click is heard Figure 2 9 Attaching the ribbon guide 12 Turn the knob 1 of the cartridge in an anticlockwise directionuntil the ribbon is taut and then remove the tab 2 Figure 2 10 Ribbon tightening and tab removal XZAC4219 05 Service Manual 2 7 13 Using the specific lever completely lower the internal upper unit containing the printhead and ribbon cartridge Figure 2 11 Lever for lowering the upper mechanical assembly 14 Close the cover of the printer 2 8 Service Manual XZAC4219 05 Reinserting the transportation blocking devices 1 If present remove the ribbon cartridge Refer to section REPLACING THE RIBBON CARTRIDGE on page 3 8 2 Actioning the lever lower fully the upper part of the printer Refer to the previous figure 3 Remount the two red plastic stop brackets for transportation Figure 2 12 Reassembling the blocking devices for transportation 4 Put back into position the two foam paddings and the card Refer to the Figure 2 3 5 Close again the upper cover of the printer XZAC4219 05 Service Manual 2 9 Installing the printer WARNING make sure that the voltage indicated on the data plate matches that of the local power supply 1 Position the machine where it is to be used checking compliance with the
75. e printed Check that the left hand margin is set to the measurement required Press the STATION1 and or STATION2 keys to calibrate the left printing margin e Pressing the STATION1 key you can decrease the left margin e Pressing the STATION2 key you can increase it READY ON O O y O O S STATION LOCAL STATION eo NG JN EJECT BREAK EJECT READY ON O O O 7 O O A ma ga STATION1 LOCAL STATION2 J k r C EJECT BREAK EJECT READY O K ay O O Sa WE rg N STATION L LOCAL STATION2 e S J EJECT BREAK EJECT READY lant Q ON O k2 P s E l STATION 4 C LOCAL STATION2 EJECT BREAK EJECT Repeat steps 6 and 7 in a cyclic fashion until you obtain a correct margin Press the LOCAL key to save permanently the left margin Service Manual 4 23 Measuring document length It is necessary to measure the width of the form to permit faster management of the magnetic stripe of the passbooks Selecting via set up the STRIPE HANDLING FAST item see page 4 17 the value read with the form measurement procedure will be used to determine the position of the magnetic stripe and for positioning of the stripe above the magnetic head without having to make several measurements of passbook width This considerably reduces passbook management time To carry out this c
76. eassembly do not fix the photosensor support until the feeder unit is fixed as the feeder unit has two reference pins for the photosensor support During the reassembly phase you must adjust the front pressure rollers See the section Adjusting the front pressure rollers on page 6 10 At the end of these operations carry out calibration of the photosensors See the section CALIBRATING THE PHOTOSENSORS on page 4 18 XZAC 4219 05 Service Manual 7 17 Disassembling reassembling the print bar printers with torsion bar 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 From the front lift the entire mechanical assy from the base plate and rotate it partially so as to access the connectors of the motherboard See the section Lever for lifting the upper part of the mechanism on page 3 4 3 Disconnect all the cables except for those of the printhead 4 Back off the two lock nuts 1 of the platen and slide it out from above X E s Og 7A Aa Ta lll SSS we o SN fp Ulin Yi Ua 7 Figure 7 22 Disassembling the print bar NOTE after the reassembly phase carry out adjustment of the print bar See the section Adjusting the print bar where torsion bar present on page 6 4 7 18 Service Manual XZAC4219 05 Disassembling reassembling the print bar printers without torsi
77. ecovering a jammed document without having to switch off the printer Refer to section REPLACING THE RIBBON CARTRIDGE on page 3 8 1 To access the lever lift the cover of the machine rotating this to its stop position 3 4 Figure 3 3 Opening the cover Service Manual XZAC4219 05 2 Bringing the lever to its end of stroke position lifts the upper part of the mechanism permitting access to the document feed zone Figure 3 4 Lever for lifting the upper part of the mechanism OPERATING PROCEDURE FOR INSERTING THE DOCUMENTS TO BE PRINTED Inserting the document with automatic alignment The resting surface of the casing facilitates introduction of documents in the machine 1 With the printer on place the document at the center of the front slot and insert it in the feed slot 2 Release the document as soon as the automatic alignment system is activated Figure 3 5 Automatic introduction of the document XZAC4219 05 Sercice Manual 3 5 Inserting the passbook Before inserting a passbook fold this along the back until it remains completely opened in a horizontal position and check for any creased or torn pages in order to avoid poor quality printing and wrinkling of the pages during introduction The passbook must be placed open on the supporting surface with the magnetic stripe facing down Figure 3 6 Manual introduction of the passbook Inserting a document
78. ed page 6 6 or Adjusting parallelism of print bar without torsion bar on page 6 7 X Roller gears not Adjust the gears See Adjusting the roller gears on adjusted page 6 9 XZAC4219 05 Service Manual 5 19 Fault ba eal lt v amp 3 Y e 3 3 Q A n L amp Possible cause Solution os 7 CoD PT ha ox s gt 5 ee T yo X EQG ES ES o s 5S0 5 Seo jasle es oo 3 x ou Slissl sE ss ft lfplseleg KFS Re IRF Sikes Front pressure rollers or ee P Adjust the pressers of the front rollers See Adjusting the X X X not adjusted gt front pressure rollers on page 6 10 correctly X Rear roller motor not Replace the motor See Disassembling reassembling working pressure roller unit on page 7 20 5 20 Service Manual XZAC4219 05 Chapter 6 MAINTENANCE This chapter examines the cleaning and lubrication operations and a number of mechanical adjustments necessary for correct operation of the printer CLEANING For correct functioning of the printer it is suggested to clean parts of the machine periodically and after each servicing Cleaning the case Switch off the printer disconnect it from the power outlet and clean the case with a damp cloth do not use corrosive substances such as solvents alcohol benzene or products with abrasive components Cleaning the paper paths Clean all paper paths including the paper feed rollers of th
79. ee Adjusting Paper Photosensor on X X X not adjusted correctly page 6 8 X xX Print bar not adjusted See Adjusting the roller gears on page 6 correctly Wrong configuration Reprogram the parameters of the printer X X See Modifying configuration parameters parameters on page 4 2 Document driving See Adjusting the document drive belt X belt not correctly oats adjusted pay X Band not adjusted Adjust the printing band See Adjusting the roller gears on page 6 9 xX Roller gears not Adjust the gears See Adjusting the roller adjusted gears on page 6 9 Front pressure rollers Adjust the pressers of the front rollers X not adjusted Adjusting the front pressure rollers on correctly page 6 10 Adjust the belt for carriage movement See Carriage belt not i X X Replacement and adjustment of belt for calibrated i carriage movement on page 6 15 Replace the motor See Disassembling Rear roller motor not i Xx Xx reassembling pressure roller unit on working page 7 20 5 18 Service Manual XZAC4219 05 Faults with document handling Fault z v 3 v 38 3 A v amp Possible cause Solution os V eS S E l amp 5 SVT ES Es IES So S S50 5 es 8s s8 ise EVss iss jos gi jege igs RFS RFRVIR SES Doc mentnot ace Check the dimensions and the type of the document
80. eft hand end of stroke motor side e PROCEDURE Loosening the lock screws move the motor 2 until the conditions required are obtained and then tighten the screws 60g Figure 6 10 Adjusting the horizontal magnetic micr drive belt tension XZAC 4219 05 Service Manual 6 11 Adjusting the horizontal magnetic MICR closing flap e MACHINE STATUS Printer switched off and without casing Read write carriage in reset position end of stroke motor side and screw 1 which joins the semi tie rods loosened e CONDITIONS TO BE CHECKED Co planarity between the closing flap and the front surface of the structure e PROCEDURE Position the flap 2 in contact with the slot 3 operating in the compartment between the fork and toothing of the semi tie rods 4 then tighten the screw 1 Adjustment area Figure 6 11 Adjusting the horizontal magnetic MICR closing flap 6 12 Service Manual XZAC4219 05 Positioning the horizontal magnetic MICR pressure roller e MACHINE STATUS Printer switched off and without casing Pin of the bridge 4 on its minimum radius With regard to the above position the pressure roller 1 inside the conveyor 2 with a recess of 0 5 1 mm and then phase the cam 3 so as to bring the pin of the bridge 4 on its minimum radius With its screw 5 fasten the bridge on the shaft check that the recess of the pressure roller is across the entire paper path e CON
81. embly on page 7 4 2 On both sides back off the lock screws 1 of the tabs that fasten the front rubber pads so that these can be removed from their housing Figure 7 6 Disassembling the mechanical assy 3 From the front lift the entire mechanism from the base plate and rotate it partially so as to access the connectors of the motherboard 4 Disconnect all the connection cables of the mechanism to the motherboard except for the motherboard power supply unit connection cable Printers with serial number 8 xxx xxx Printers with serial number 1 xxx xxx Figure 7 7 Disconnecting the cables 5 Loosen the lock screws 2 of the tabs that fasten the rear rubber pads so that these can be removed from their housing 6 Back off the screw 3 that fastens the ground cables 7 Lift the mechanical assy and separate it from the base plate 7 6 Service Manual XZAC4219 05 i lt E7 Olope OR Figure 7 8 Removing the mechanical assembly unit XZAC4219 05 Service Manual 7 7 Printhead flat cable disassembly reassembly 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 Removing the ribbon cartridge from the printer See the section REPLACING THE RIBBON CARTRIDGE on page 3
82. ep from 10 default 0 SCAN F_BRIGHT From 60 to 60 with step from 10 default 0 SCAN R_BRIGHT N PAP EDGE DETEC Y 4 6 Service Manual XZAC4219 05 Parameter Values possible Description N STD MODE SPECIAL FORMS EJE MODE FULL MODE PASSPORT STANDARD PRINT MODE HI QUALITY HI SPEED MONO BIM MODE BIDIR PNS SELECTION N By selecting Y you can access the PNS y selection menu N PNS ZEROBOF Y N PNS TOF EXT Y N PNS KEY EJECT Y NEVER IBM EMUL PNS KEY INSERT OLI EMUL ALL EMUL SAVE PARAMETERS N Saves Y or cancels N the values configured in this y area of the programming menu If the INTERFACE parameter has been configured as USB Parameter Values possible Description OLIVETTI This parameter is used to set the type of emulation USB EMULATION used for the USB port IBM Y PLUG amp PLAY This parameter is used to set the plug and play option N XZAC4219 05 Service Manual 4 7 If the INTERFACE parameter has been configured as SERIAL1 Parameter Values possible Description OLIVETTI RS1 EMULATION Default emulation of the port IBM 9600 4800 2400 BAUD RATE Data transmission reception speed 1200 19200 38400 7 BIT CHAR Data format at 7 or 8 bits 8 NONE This parameter is used to set the presen
83. er PLEASE INSERT MICR CALIBRATION CHEQUE MICR ADJ SE 12 To calibrate the MICR head insert the MICR CALIBRATION CHEQUE board into the front slot of the printer 13 The MICR head performs 5 transactions and at the end saves the calibration reached consistent with the value given on the MICR CALIBRATION CHEQUE board 14 The printer ejects the MICR CALIBRATION CHEQUE board XZAC 4219 05 Service Manual 4 25 15 Insert an A4 sheet and the printer will print the correct values see example on side MICR ADJ APK 57 47 52 51 47 MICR ADJ PRG 26 28 26 25 27 MICR ADJ VAL 26 MICR ADJ RES OK lt 16 Always check the value MICR ADJ RES OK This value is of great importance it certifies that the MICR head is working correctly 17 Proceed to check the JITTER Checking the JITTER 1 At the end of the procedure for calibrating the MICR READY ON all the LEDs on the printer will be illuminated B STATION LOCAL _ STATION2 i he a i EJECT BREAK EJECT 2 Insert the JITTER board code XYAB4581 being careful to keep the magnetic band of the board in a horizontal position oriented downwards and aligned completely to the left 3 The printer performs a magnetic transaction 4 Re insert the JITTER board with the magnetic band in a horizontal position oriented downwards and aligned with the centre The printer performs a magnetic transaction For t
84. ernet LAN Card needs to be reconfigured only if you want to change the default configuration DHCP first AutolP second for example assigning a static IP address to the board 8 Enable the Ethernet LAN Card from the programming menu see the section CONFIGURING THE OPERATION PARAMETERS on page 4 1 or using the Toolbox application 8 2 Service Manual XZAC4219 05 9 When the printer configuration is complete activate the printing test see the section Activating and deactivating the print test on page 2 10 in the CONFIG section the following string should appear INTERFACE ETHERNET How to print Ethernet LAN card properties 1 Power on the printer with STATION1 and LOCAL keys READY ON pressed together O O O O O No y A f SIATIONI C LOCAL STATION2 EJECT BREAK EJECT 2 Atthe end of the phase for resetting the mechanics check READY ON that the ON and Ready LEDs are illuminated O O STATION1 D LOCAL D C STATION2 J N AN EJECT BREAK EJECT 3 Insert a sheet in A4 format into the front slot 4 A line of text is printed which indicates the functions of the STATION1 STATION2 and LOCAL keys for the printer in the current configuration STATION1 confirm STATION2 Skip Press Local to continue 5 Press STATION1 key and the printer will print the Ethernet LAN Card settings insert a new A4 document if needed Ethernet MAC Address Fw C
85. f the document on page 5 17 Sostituire l alimentatore See the PTC power unit section Fan power supply unit O O O O not working disassembly reassembly on page 7 26 Replace the motherboard See the NTC section Disassembling reassembling motherboard the motherboard printers with O O O O breakdown scanner or Disassembling Anomaly on reassembling the motherboard motherboard printers with serial number 8 XXX XXX and 1 XXX XXX O O O O Start of auto diagnostic cycle on powering on End of auto diagnostic cycle on powering on O LED ON LED OFF X LED FLASHING Number X indicates the number of flashes XZAC4219 05 Service Manual 5 3 Printer anomalies with serial number 1 xxx xxx Console LED Anomalies Possible solution ON Ready Station Local Station 2 p See the section Faults at power on ower unit on page 5 15 Replace the motherboard See the section Disassembling CRC Error in reassembling the motherboard 1xO xX xX xX xX BOOT sector of printers with scanner or flash Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 xxxX Xxx xO xX X xX X Firmware Proceed with forced loading of the not present firmware Replace the motherboard See the section Disassembling reassembling the motherboard 5x O xX xX X X External SRAM printers ae ae or Test failed Di isassembling re
86. fashion therefore when the STATION2 key is pressed again you return to the initial menu CONFIG 12 Therefore select the menu for which you want to change parameters and proceed to configure them as described in the next section Modifying configuration parameters similar way NOTE the procedure below illustrates the steps to follow to change the configuration parameters In this example the procedure is described for modifying the fifth parameter INTERFACE in the Configuration menu CONFIG To change the configuration of the other parameters proceed in a 1 Enter the Configuration menu following the procedure described in the previous section The currently active menu is printed 2 Press the STATION1 key 3 The setting for the first configuration parameter is printed 4 Let s imagine that we do not want to change this parameter Therefore we press the STATION1 key again to pass to the next parameter 5 The setting for the second configuration parameter is printed 4 2 Service Manual MENU CONFIG STATION1 confirm STATION2 Skip Press Local to continue READY ON O O O O O i r x A STATION LOCAL STATION2 7 S pei ye EJECT BREAK EJECT DRAFT SPEED NORMAL MENU CONFIG STATION1 confirm STATION2 Skip Press Local to continue O O Fal gt J o lt O O Q a S a STATION1 LOCAL STATION2
87. ff the four lock screws 2 of the roller assy 1 Remove the roller assy 1 lifting this as indicated in the figure and taking care not to mislay the transmission shaft 3 Figure 7 42 Disassembling the roller assy upper scanner 5 Remove the clamps 4 and recover the clips 5 Figure 7 43 Clamps fastening roller unit XZAC 4219 05 Service Manual 7 31 6 Remove the rollers 6 from the support 7 Figure 7 44 Removing the rollers 7 Remove the snap ring 8 and related gear 9 8 Remove the drive belt 10 Figure 7 45 Removing the transmission belt 9 Remove the snap ring 11 the cam 12 and the spring 13 10 Slide out and remove the shaft 14 Figure 7 46 Removing the scanner shaft 7 32 Service Manual XZAC4219 05 CIS assy upper scanner disassembly reassembly 1 2 Remove the casing See the section Casing disassembly reassembly on page 7 4 Remove the upper mechanical assy See the section Upper mechanical assy disassembly reassembly on page 7 11 Remove the roller assy See the section Roller assy upper scanner disassembly reassembly on page 7 31 Remove the two snap rings 1 Remove the CIS assy 2 lifting it and taking care not to mislay the spring 3 Figure 7 47 Removing the CIS unit 6 Disconnect t
88. gure 7 39 Fastening screws for horizontal magnetic unit printers with serial number 1 xxx xxx NOTE during reassembly adjust positioning of the assy on the structure See the section Positioning the assy on the horizontal magnetic MICR structure on page 6 14 Horizontal magnetic MICR motor disassembly reassembly 1 Remove the horizontal magnetic MICR assy See the section Horizontal magnetic MICR disassembly reassembly on page 7 28 2 Loosen the two nuts 1 and remove the motor with related protection shield Figure 7 40 Horizontal Magnetic motor lock nuts XZAC 4219 05 Service Manual 7 29 Horizontal magnetic MICR printhead assy disassembly reassembly 1 Remove the horizontal magnetic MICR assy See the section Horizontal magnetic MICR disassembly reassembly on page 7 28 Loosen the screw 1 and free the signals cable Loosen the screws 2 and extract the MICR printhead 3 7 30 Figure 7 41 Horizontal magnetic MICR printhead assy Service Manual XZAC4219 05 Roller assy upper scanner disassembly reassembly 1 Remove the casing See the section Casing disassembly reassembly on page 7 4 2 Remove the upper mechanical assy See the section Upper mechanical assy disassembly reassembly on page 7 11 3 Back o
89. he cable 4 from the CIS 2 taking great care not to damage the connectors use a slotted screwdriver as indicated in the figure Figure 7 48 Disconnecting the CIS cable XZAC4219 05 Service Manual 7 33 NOTE for reassembly reverse the procedure paying particular attention to correct fitting of the spring 3 See the Figure 7 47 Clean the glass of the CIS with a soft cloth After completing the re assembly procedure carry out mechanical adjustment and calibration of the scanner see the section Calibrating the scanner on page 4 28 CIS assy lower scanner disassembly reassembly 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 Remove the upper mechanical assy See the section Upper mechanical assy disassembly reassembly on page 7 11 3 Remove the roller guard 1 removing the related M3 lock screws 2 and release the cable 3 from the cable clips 4 7 34 Figure 7 49 Disassembling the CIS assy lower scanner Service Manual XZAC4219 05 the connectors use a slotted screwdriver 4 Disconnect the cable 5 from the connector on the CIS proceeding very carefully in order to avoid damaging
90. he path inside the machine Jamming may be caused by Paper path obstructed scraps of paper for example Paper fed crosswise Weight or format outside permitted limits Paper in bad conditions creased misshapen or in poor condition Paper with metal staples or paper clips this condition may seriously damage the machine Multicopy forms with incorrectly glued sheets Continuous form not correctly tightened on the tractor feeder Possible areas of jamming A area initial feed area from front feeder B area internal area of the printer C area rear area towards the documents outfeed Figure 3 14 Possible areas where the paper could get jammed If a paper jam occurs in any area switch off the printer and remove the paper following the illustrated procedure below XZAC 4219 05 Sercice Manual 3 11 To remove a document that has jammed from inside the printer proceed as follows 1 Switch off the printer 2 Open the cover and switch on the printer with STATION 1 EJECT pressed 3 Wait for the acoustic signal 4 Actioning the lever raise the upper part of the mechanical assembly Refer to section Lever for lifting the upper part of the mechanism on page 3 4 Figure 3 15 Removing paper jams 5 Pressing STATION EJECT or STATION2 EJECT the paper will be moved forward and back so that it is possible to remove the scraps of paper that have jammed 6 Switch off the machine and close the c
91. he third time insert the JITTER board with the magnetic band in a horizontal position oriented downwards and aligned completely to the right 7 The printer performs a magnetic transaction 8 Insert an A4 sheet 9 The calibration values are printed Magnetic Test Refer to the figure on the following page 10 Check that the result of the tests is OK for all the measurements 11 Switch off the printer NOTE if only the Horizontal Magnetic option is present during the calibration phase the printer requests only testing of the JITTER 4 26 Service Manual XZAC4219 05 oliv gt MAGNETIC TEST lt LEFT INSERTION Type Jitter Value Jitter in Reference in Test Result MINTMUM 4 80 3 lt 20 OK F MAX TMUM 6 55 H lt 20 OK Speed Jitter Value Jitter in Reference in Test Result MEDIUM 250 0 60 lt 2 oK lt q Max Time Found us Reference us Speed mm s Test Result 264 75 lt 437 340 OK 407 98 lt 649 226 CK a MIDDLE INSERTION Type Jitter Value Jitter in Reference in Test Result MINIMUM 6 11 lt 20 OK a MAX IMUM 6 55 lt 20 OK Speed Jitter Value Jitter in Reference in Test Result MEDIUM 250 0 60 lt 2 OK Max Time Found us Reference us Speed mm s Test Result 264 75 lt 437 340 OK 4 405 81 lt 649 226 OK RIGHT INSERTION Type Jitter Value Jitter in Reference in Test Resul
92. herboard motor of magnetic head 2 Connector for signals from the motherboard 5 Connector for magnetic head transport motor 3 Connector for magnetic head 1 14 Service Manual XZAC4219 05 MICR reader The MICR Magnetic Ink Character Reader reader technology allows CNC7 E13B characters printed on cheques to be read The reader located inside printer operates crosswise to the direction of movement of the paper It comprises a read head able to operate also on passbook magnetic stripes fitted on a specific mechanism that guarantees correct traverse during work phases The read range is equal to the size of the slot A position restriction on the right hand side of the feeder is accepted If present this restriction must be highlighted by a graphic sign on the top lip of the slot The interpretation SW must be able to recognize the font of the check being read automatically objective CHARACTERISTICS FONT CODING ISO 1004 1992 part one Panie teeeaeee one E 13B ISO 1004 1992 part two Spacing CMC7 E13B 8 cpi Reader position Lower side of the paper path The following figure provides an illustration of the interface card that is connected to the special connectors on the motherboard 7 1 16 E 4 6 C3 O E reat T aa Py Lo O a f eae ee eea 1
93. hip Ver Printer Name Interface Card x 00 20 4A AF 212 71 706 50 TCP IP Settings IP Address 7169 254 151 003 Gateway IP Add 000 000 000 000 Subnet mask 7255 255 000 000 SLOT Informations SLOT Id Cs Type Option 1 Cs vers e O Cs VIMO ver O PLD ver O Fw ver e Date 25 11 09 Lot n 000001 Baud Rate Slot 115200 Parity Slot None Data Bit Slot 8 Bit Stop Slot 1 Handshake Slot Xon Xoff Figure 8 4 Ethernet LAN Card settings XZAC4219 05 Service Manual 8 3 NOTE the Ethernet LAN Card ships with a default IP address of 0 0 0 0 which automatically enables DHCP and AutolP within the unit AutolP address range is from 169 254 1 0 to 169 254 254 255 and works in small networks when a DHCP server isn t active WARNING if the printer PR2 Plus do not show in configuration tool the printer might need a firmware update contact your Olivetti dealer for the last firmware release 8 4 Service Manual XZAC4219 05 APPENDIX A ACCESSORIES This section describes the accessories available for the PR2 plus printer Ribbon cartridge in black NYLON SNUG CART The ribbon cartridge provided for the product is of disposable type It is designed in way that allows the operator following the indications given both in the manual and on the container of the new ribbon to carry out the operations required for its replacement without coming into contact with
94. iagram indicating the procedure to follow to change Exiting from the Configuration menu To exit from the Configuration menu switch off the printer Switch on the printer again to eject the sheet XZAC4219 05 Service Manual the parameter values Description of configuration parameters In this section the configuration parameters present in the programming menu are listed with the various values that can be set and their meanings Values set by default are indicated in bold and highlighted with an asterisk Configuration mode menu MENU CONFIG parameters Parameter Values possible Description NORMAL Normal printing speed 370 cps DRAFT SPEED HIGH High printing speed 510 cps VERY HIGH Very high printing speed 560 cps LQ2 Letter Quality 125 cps LQ TYPE NL Q1 Near Letter Quality type 1 185 cps NL Q2 Near Letter Quality type 1 185 cps FIRST LINE The width of the document is measured on the first line printed PAPER WIDTH l PROGRAMMABLE The position used for measuring the width of the document can be programmed NO Switches the buzzer on BUZZER YES Switches the buzzer off System connection interface Depending on the USB interface selected the related parameters indicated in the tables below can be configured See page 4 7 SERIAL1 See page 4 8 INTERFACE PARALLEL See page 4 8 COM1 USB See page 4 9 USB PAR See page 4 9 DUAL PAR See page 4 9 From 60 to 60 with st
95. inter configuration procedure Wait Waiting message during printer operatione Download active Firmaware download operation in course Download MICR MICR module firmware update Selftest This message is visualized during the printer selftest Scanner error Scanner error SCANNER 300 dpi SCANNER 600 dpi Scanner configuration 5 12 Service Manual XZAC4219 05 MACHINE DIAGNOSTICS A technique for carrying out the operation is described below that may guide the less expert service engineer The operator who has detected a malfunction is able to provide information about operating status and the error signals output by the printer when the fault occurred Repetition of the fault where possible may make it easier to trace the problem For diagnostic purposes it is important to check whether the fault is repetitive or occasional Operating condition analysis Working environment e Certain problems may be caused by the environment if this is too cold hot or damp e The machine must not be positioned close to air conditioning system outlets or exposed to the rays of the sun e Check that the internal ventilation slots are not obstructed especially if the printer is installed in a cabinet e Certain forms documents or office accessories placed close to the machine may reduce internal ventilation with consequent overheating e Avoid leaving on the cover or in the vicinity of the
96. interface and location of connectors 1 10 Service Manual XZAC4219 05 1 Parallel interface connector 2 Serial interface connector 3 Printhead connector 4 Printhead connector 5 Alignment device photosensors 6 Console connector 7 Carriage motor connector 8 Open close cover sensor connector 9 Paper motor connector XZAC4219 05 10 11 12 13 14 15 16 21 25 Analogue signal connector of the card for MICR configuration Services motor connector Carriage reset photosensor connector SBI signal connector of the card for MICR configuration Power unit connector Signal connector for cards for Horizontal Magnetic and MICR configurations Power and signals connector for Horizontal Magnetic and MICR configuration cards USB port connector to host Expansion board connector for optional Ethernet LAN Card Service Manual 1 11 etti Motherboard printer version with two serial interfaces 26 16 RS35 RS37 ee On us RS92 a SB ie RS93 RS94 RS95 o S S fA RS99 rs100 RS101 RS102 oS e soo 0 80 20 20 20 20 RS80 RS81 Fi 0 RS96 o rsio3 g ap g 1 s22 Is l f rs307 f rs305 f rs305 a f rs208 R3 R4 us30 es pe us BIE ps2 o M L E s HIE aa
97. inters with serial number 1 xxx xxx Figure 7 29 Power connector 4 Remove magnetic options option 1 Printers with serial number 8 xxx xxx Printers with serial number 1 xxx xxx Figure 7 30 Removing the magnetic options board XZAC 4219 05 Service Manual 7 23 5 Back off the lock screws 1 of the motherboard 1 Printers with serial number 8 xxx xxx Printers with serial number 1 xxx xxx Figure 7 31 Fastening screws of motherboard 6 Disconnect the cable of the standard serial interface 1 Printers with serial number 8 xxx xxx Printers with serial number 1 xxx xxx Figure 7 32 Cable of the standard serial interface NOTE if present disconnect the cable of the optional serial interface 7 24 Service Manual XZAC4219 05 7 Back off the two screws 1 of the Centronics interface connector and extract the motherboard from the baseplate of the printer N Figure 7 33 Parallel interface connection screws NOTE when replacing the board update the firmware with the latest release configure the parameters see the section CONFIGURING THE OPERATION PARAMETERS on page 4 1 and calibrate the photosensors see the section CALIBRATING THE PHOTOSENSORS on page 4 18 WARNING when reassembling the motherboard tighten the screws of the earth connections for both the board and the power unit ensuring a perfect grounding XZAC
98. ith debug option Local No timeout Cover open COVER OPEN pai OnLine a LOAD PAPER No timeout Waiting for paper status OnLine ssh PAPAER Ejected No timeout Signal that the paper is ejected OnLine he a PAPER Insertion No timeout Signal that the paper is aligned OnLine a PAPER PRESENT No timeout Signal that the paper is inserted OnLine Printing Data 2 seconds Signal that is processing data OnLine f Magnetic READ No timeout Magnetic operation read OnLine f Magnetic WRITE No timeout Magnetic operation write Online No timeout Magnetic operation erase Magnetic ERASE 5 10 Service Manual XZAC4219 05 MESSAGE TIME OUT DESCRIPTION OnLine P RFID READ No timeout RFID operatione read OnLine RFID WRITE No timeout RFID operatione write OnLine RFID ERASE No timeout RFID operatione erase OnLine P MICR READ No timeout MICR operation read OnLine MARKER READ No timeout Marker operation OnLine T fae No timeout Scan processing image Scanning image OnLine n Paper JAM No timeout Paper jam status XZAC4219 05 Service Manual 5 11 Service messages MESSAGGIO TIME OUT DESCRIPTION BOURRAGE ERROR Paper jam error DEBUG HARDWARE Hardware debug PHOTO ERROR Photo alignement error BOURRAGE Printer jam Press Local ST1 KEY ST2 to EXIT SET UP These messages are visualized during the pr
99. librate the TOF e Pressing the STATION1 key you can decrease the TOF e Pressing the STATION2 key you can increase it Repeat steps 6 and 7 in a cyclic fashion until you obtain a correct margin Press the LOCAL key to save permanently the left margin Service Manual READY O O ON N Led WS Y ra STATION LOCAL STATION2 EJECT BREAK EJECT READY ON O O O O nO a STATION LOCAL STATION2 EJECT BREAK EJECT READY ON O O O O O N ie gt o STATION LOCAL STATION2 EJECT BREAK EJECT HHHHHHHHHHHH ON STATION a k EJECT O O OO LocaL STATION2 J BREAK EJECT READY O O STATION1 A a Se EJECT ON O O O N a LOCAL STATION2 a ka BREAK EJECT XZAC4219 05 Calibrating the left margin This calibration makes it possible to set the distance between the left hand edge of the document and the first character printed To carry out this calibration proceed as follows 1 2 XZAC4219 05 Open the printer cover Power on the printer with the cover open keeping the three console keys pressed Wait for the acoustic signal that indicates access to the calibration and adjustment procedure then close the cover Press the LOCAL button and wait until the end of the machine reset procedure Press the STATION2 button Insert an A4 sheet and wait for the page to b
100. lues are saved Press the STATION1 key to save the new configuration READY ON O Cy CC oy ie KA ee VU S p ee e Y STATION LOCAL STATION2 2 NX A K EJECT BREAK EJECT SAVE PARAMETERS NO Y PNS SELECTIONS N BIM MODE MONO PRINT MODE STANDARD SPECIAL FORMS N READY ON O O O O O gt a gt a STATION LOCAL STATION2 EJECT BREAK EJECT PARAMETERS NO is printed NOTE if you do not want to save the new configuration press the STATION1 key when the value SAVE Procedure to save the value of a single parameter The procedure illustrated above allows you to scroll through all the parameters of the menu selected changing the values of the parameters as required The procedure described below on the other hand allows you to change the value of a single parameter exiting immediately from the menu at the end without having to scroll through all the other parameters NOTE in this case also let s imagine that we only want to change the value of the INTERFACE parameter in the Configuration menu CONFIG Proceeding as indicated in the previous section print the setting of the fifth parameter INTERFACE that is to be changed This is the parameter that in our example we want to change Press the STATIONZ2 key to pass to the next value for the parameter The new value for the parameter is printed For the connection interface 6 values a
101. movement on page 6 15 X X X X Closing levers open Lower the lever for closure X xX Printhead fault Replace the printhead See Printhead disassembly reassembly on page 7 10 1 Carry out the calibration procedure See CALIBRATING THE PHOTOSENSORS on page 4 18 Paper photosensor 2 Clean and if necessary replace the X X X fault defective photosensor See PROCEDURE FOR CLEANING REPLACING THE PHOTOSENSORS on page 6 2 Replace the flat cable See the section X X X X Prinhedaiat Gable Printhead flat cable disassembly fault A reassembly on page 7 8 Replace the transport motor See X X Transport motor fault Services motor disassembly reassembly on page 7 14 Replace the motherboard See Disassembling reassembling the motherboard printers with scanner on X X Motherboard fault page 7 21 or Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 Xxx xxx on page 7 23 Adjustment of needle See Adjusting the roller gears on page 6 Xx X X X roller incorrect 9 XZAC4219 05 Service Manual 5 17 Fault Elat s E szigsisgs s ESIR S E ES 7 HH HOH oS jv n 3 sities i e a0 8 S Possible cause Solution oS los zS LE loS los G G S S BVoel kof S ss EIJE SJEFS O om S kas Os O SS SO SI TEISSE amp 7 2 DL Nw V amp 2 25 esl eszjesleszjes Ee JESE IES ELERO Paper photosensor S
102. n Disassembling DYNAMIC RAM reassembling the motherboard printers with scanner on page 7 21 Adjustment scanner area corrupted or not valid Perform the scanner calibration Make SCANNER No timeout e Press any key on the console to display the next anomaly Calibration when necessary e Perform calibration of the scanner See the section Calibrating the scanner on page 4 28 XZAC4219 05 Service Manual 5 9 Status messages running MESSAGE TIME OUT DESCRIPTION WARNING A HEAD HOT No timeout Hot temperature on Print Haed WARNING PWS HOT No timeout Hot temperature on Power Supply WARNING HEAD PWS HOT No timeout Hot temperature on Print Haed amp Power Supply WARNING MB HOT No timeout Hot temperature on Mother Board WARNING i MB HEAD HOT No timeout Hot temperature on Mother Board amp Print Haed WARNING MB PWS HOT No timeout Hot temperature on Mother Board amp Power Supply WARNING MB PWS HEAD HOT No timeout Hot temperature on Mother Board amp Power Supply amp Print Haed WARNING P PWS COLD No timeout Low temperature on Power Supply means error on hw circuit WARNING PIS MB COLD No timeout Low temperature on Mother Board means error on hw circuit OnLine No timeout On line status OnLine DEBUG No timeout On line with debug option Local No timeout Local status Local DEGBUG No timeout Local status w
103. n the printhead eA kee D2 eS I Figure 7 11 Removing the printhead of the carriage To disassemble the components of the printhead 1 Unscrew the two front screws 2 and unmount the probe roller 2 Unscrew the two side screws 3 and unmount the ribbon protection flap 3 Unscrew the rear screw 4 disconnect the connector 5 and remove the paper photosensor NOTE to insert the flat cables into the printhead connectors free them from the cable guiding block then block them again after insertion During the phase for reassembling the components of the printhead carry out the adjustments Adjusting Paper Photosensor on page 6 8 Adjusting the print bar where torsion bar present on page 6 4 and Adjusting the print bar where torsion bar absent on page 6 5 7 10 Service Manual XZAC4219 05 Upper mechanical assy disassembly reassembly 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 From the front lift the entire mechanical assy from the base plate and rotate it partially so as to access the connectors of the motherboard See the section Mechanical assy disassembly reassembly on page 7 6 3 Disconnect the connection cables of the printhead of the carriage reset photosensor and of the upper scanner CIS if present from the motherboard Free the cable of the carriage reset photosensor from the
104. ness 0 2 to 0 5 mm e Type of binding permitted thread seam e Joining radius of outer corners 3 to 14 mm XZAC 4219 05 Service Manual 1 3 LOCATION OF MAIN COMPONENTS The following figure illustrates the main external components of the printer Figure 1 2 Location of main external components 1 Cover 6 USB interface connector 2 Display 7 Parallel interface connector 3 Console 8 Standard serial interface connector 4 Rear slot 9 Front slot 5 Mains connector cable 10 ON OFF switch The following figure illustrates the main internal components of the printer j G View without casing Figure 1 3 Position of main internal components 1 Printhead 5 Motherboard 2 Carriage transport motor 6 Power supply unit 3 Upper part of mechanical assembly 7 Services motor 4 Magnetic options board 1 4 Service Manual XZAC4219 05 GENERAL BLOCK DIAGRAM The schema represented in the following figure illustrates the most complete version of the printer with all the options and including the scanner For other versions of the motherboard used for the PR2 Plus printer only the connectors will be indicated In the following schema are indicated also the connectors for connecting the peripherals and the motherboard a aaa 2 1 e O O O Ed EJ Or J2 r eL WOT yy FR J UEI yp pamm HAN aml O in oll
105. ng the front pressure rollers e MACHINE STATUS Printer switched off and without casing Services cam with minimum lift zone facing towards the feeler roller e CONDITIONS TO BE CHECKED Check play between the pressure roller 7 and the services cam 6 e PROCEDURE Insert a 0 5 mm thick probe 1 between the pressure 7 and drive 8 rollers Operating on the shaft 2 position the three levers 3 in contact with the springs Insert the tool 4 on the central lever The pressure roller bridge 5 must be free to move into position without interference when in contact with the minimum radius of the cam 6 Torque the screw of the pressure roller bridge to 20 Kgcm holding the roller in contact with the minimum radius of the cam e Remove the probe and without changing phasing check for slight play between the roller and cam without loading the springs When the probe is inserted again there must be no play Figure 6 9 Adjusting the front pressure rollers 6 10 Service Manual XZAC 4219 05 Adjusting the horizontal magnetic MICR drive belt tension e MACHINE STATUS Printer switched off and without casing Read write carriage in reset position end of stroke motor side e CONDITIONS TO BE CHECKED Cogged belt 1 tensioned so as to obtain a deflection of 5 mm with a load of 60 g applied at the center of the stroke of the carriage Make the recording with the carriage in the reset position l
106. nical parts from the console see the section CALIBRATING THE PHOTOSENSORS on page 4 18 e If the power supply unit is replaced check that the mains voltage of the spare part matches the value indicated on the electrical data plate of the printer e On completion of the operation carry out a test to check the printer for any malfunctions XZAC 4219 05 Service Manual 7 1 BASIC MACHINE DISASSEMBLY REASSEMBLY PROCEDURES Console disassembly reassembly 1 Open the top cover of the machine Back off the two lock screws 1 and remove the cover of the flat cable Disconnect the flat cable 2 from the console Back off the four lock screws 3 and remove the console from the cover Back off the four lock screws 4 to separate the console 5 from the support vPwhn Figure 7 1 Disassembling the console 7 2 Service Manual XZAC4219 05 Top cover disassembly reassembly 1 Open the top cover of the machine 2 Disconnect the flat cable of the console as explained in the previous paragraph 3 Release the pins of the cover 1 from the guides 4 Using a tool for example a screwdriver exert pressure on the hinges 2 and extract the cover
107. nt paper present ae a a Scns Photosens 2 front paper present eae XXX 1 minimum value 2 3500 Photosens 1 front paper align wo x Lox 11 2 maximum value lt 1500 Photosens 2 front paper align 2xxx i box Oxxx 23 Photosens 3 front paper align j AXXx i Oxxx box 4 6 3 B A 2 3000 Photosens 4 front paper align POX OXXX Dx 5 3 Rear paper present photosens Reo l E 2XXX 25 AF gt B E Paper edge printhead photo Lox a ee 2XXX 18 3 Figure 4 3 Voltages and currents measured on photosensors 10 If the calibration operations complete with a positive outcome the printer returns automatically to its initial state allowing another calibration or adjustment procedure to be selected XZAC4219 05 Service Manual 4 19 If calibration fails the faulty photosensor will be indicated by the configurations of the LEDs Pressing one the console button highlights any other faulty photosensors Breakdown of photosensor n 1 Front paper alignment READY ON O O O e J ae a gt a STATION LOCAL STATION2 m s of ja EJECT BREAK EJECT Breakdown of photosensor n 3 Front paper alignment READY ON O O e O STATION LOCAL staton pes A J N EJECT BREAK EJECT Breakdown of photosensor n 2 Front paper alignment READY ON O O J STATION 4 LOCAL STATION2 EJECT BREAK EJECT Breakdown of photosensor n 4 Front paper alignment READY
108. ntrol SW controlled e Light intensity SW controlled e Image acquisition white black 16 shades of gray 256 shades of gray RGB colore or IR factory alternative legacy mode 200 dpi PR2 E compatible e CIS physical width 216 mm e Scanning width 210 mm max e Number of pixels 4960 e Scanning speed 10 inch s grayscale single side 8 inch s grayscale double side 3 3 inch s color single side double side requires two passes e Horizontal scanner position aligned with the left hand side of the slot e Scanning format W 65 to 210 mm H 70 to 297 mm e Type of documents handled constant thickness e Double scanner operativity concurrent grayscale or subsequent e Available memory 8 MB or above e Transmission superimposed on scanning e Type of interface used USB e Control of threshold value for black white managed with specific command e Image format output BIT stream 1 16 Service Manual XZAC4219 05 ALIPR2 POWER SUPPLY On the power unit controller board a fuse is provided to protect the printer from mains peaks and high charges Figure 1 11 Power supply unit Connector pin out and fuse ratings The signals on the power unit connectors are given in the following 14 External Power Supply ROUT 1 VAC 12 V 2 GND FZV 3 VAC t5V F1 GND Fuse 250V 3 15A GND GND 35 V 35 V 1 Motherboard Power Supply OANDARWDNDH Figur
109. oading of the firmware and of the character Characters Gen generator 5 8 Service Manual XZAC4219 05 MESSAGE TIME OUT DESCRIPTION Horizontal magnetic or MICR module error on reset sequence ERROR No timeout Replace the horizontal magnetic or MICR interface card See the Magnetic Reset section Horizontal magnetic MICR disassembly reassembly on page 7 28 ERROR Noiimeo t Motor carriage reset error Motor Carriage See the section Faults with document handling on page 5 19 Error on programming FPGA scanner e Perform calibration of the scanner See the section Scanner error No timeout Calibrating the scanner on page 4 28 FPGA LOAD e Replace the motherboard See the section Disassembling reassembling the motherboard printers with scanner on page 7 21 Analog Front End seria comunication error e Perform calibration of the scanner See the section Scanner error No timeout Calibrating the scanner on page 4 28 AFE TALK e Replace the CIS See the sections CIS assy upper scanner disassembly reassembly on page 7 33 and CIS assy lower scanner disassembly reassembly on page 7 34 Static RAM error scanner Scanner error No timeout Replace the motherboard See the section Disassembling STATIC RAM reassembling the motherboard printers with scanner on page 7 21 Dynamic RAM error scanner Scanner error No timeout Replace the motherboard See the sectio
110. of the page TOF for the document managed N The value of the top margin will be between 4 23 mm defined through calibration for documents N and 7 4 mm for passbooks Y The value of the top margin will be 4 3 mm for documents and 7 4 for passbooks i Selecting Y permits access to the selection menu of PNS SELECTION Y the PNS in the IBM environment j If enabled on reception of a Form Feed ejection is PNS oega y performed regardless of the form length selected N PNS 4501 Selects spacing of 1 5 Y SAVE PARAMETERS Saves Y or cancels N the values configured in this area of the programming menu OLIVETTI menu parameters Parameter Values possible Description PR2 PR2E EMULATION PR40 Selection of OLIVETTI emulation PNS2845 N If PR40 emulation is selected selecting Y the LINE BUFFER PR40 LIKE length of the receiving buffer is set as PR40 1 Kb Y or 8 Kb N If PR40 emulation is selected selecting Y TOF TOP MARGIN PR40 LIKE is managed by a fixed mechanical head PR 40 y Selecting N TOF can be adjusted N ee PASSBOOK If PR2 PR2E emulation is selected indicates if the y printer is enabled or not for handling passbooks VERTICAL Depends on the PASSBOOK Y item Selects the type of binding of the passbook horizontal or vertical BINDING If horizontal binding is selected during printing on the HORIZONTAL passbook the head will e
111. on bar 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 From the front lift the entire mechanical assy from the base plate and rotate it partially so as to access the connectors of the motherboard See the section Lever for lifting the upper part of the mechanism on page 3 4 3 Disconnect all the cables except for those of the printhead Back off the four lock nuts 1 of the platen and slide it out from above NOTE after the reassembly phase carry out adjustment of the print bar See the section Adjusting the print bar where torsion bar absent on page 6 5 XZAC 4219 05 Service Manual 7 19 Disassembling reassembling pressure roller unit 1 Raise the upper cover 2 Raise the print unit See the section Lever for lifting the upper part of the mechanism on page 3 4 3 Unscrew the four screws 1 4 Remove the pressure roller unit 2 extracting it downwards and being careful not to lose the component 3 Figure 7 24 Disassembling the pressure roller unit 7 20 Service Manual XZAC4219 05 Disassembling reassembling the motherboard printers with scanner 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 Remove the upper mechanical assy See the section Mechanical assy disassembly reassembly on page 7 6 3
112. on the console to the display if display the next anomaly when present appears necessary the message e Perform all the printer WARNING calibrations See the section Setup PROGRAMMING AND Hardware CALIBRATION on page 4 1 Inconsistency of e Replace the motherboard See O X O X X B calibration values the section Disassembling photosensors reassembling the motherboard alignments etc printers with scanner or All the calibration Disassembling reassembling values are the motherboard printers with initialised with serial number 8 xxx xxx and their default 1 XXX XXX values See the section Faults during O X X Carriage motor writing of the document on page 5 1 Replace the motherboard See the o X x _ X Scanner STATIC section Disassembling RAM error reassembling the motherboard printers with scanner Replace the motherboard See the cannar section Disassembling O X X X DYNAMIC RAM i error reassembling the motherboard printers with scanner Perform the e Press any key on the console to scanner display the next anomaly when calibration On necessary the display if e Perform calibration of the 0 X X X present the scanner See the section message Calibrating the scanner on appears Make page 4 28 SCANNER Calibration Replace the power unit See the PTC power unit section Power supply unit O O O O not working disassembly reassembly on page 7 26
113. operations On all models of the PR2 Plus to update the firmware release the Toolbox version 1 10_08 and higher must be installed NOTE before installing the Toolbox it is essential to remove any previous installation version from the Host For reasons of speed it is advisable to update the firmware release using the USB port XZA4219 05 Service Manual A 5 Proceed as indicated below 1 ui Pwhn Switch on the PR2 Plus holding down the Station 2 key in order to print the Self Test and check that the machine is set for USB data exchange see the section Configuration mode menu MENU CONFIG parameters on page 4 6 Interface parameter Otherwise set the machine Set Up parameter correctly Switch off the printer Switch the printer on again after checking that it is connected to the Host via the USB cable Start the Toolbox application and select the Resource Kit icon Select the printer FW icon PR2E PRZ Plus Toolbox 15 x Lege 001 A Qe tas p 0 f 4 i Setup stampante Macro e logo Memoria di manutenzione della stampante FW stampante za questo FW FW programma se vuoi s aggiornare il FW de a kA Q stampante A FW stampante FW MICR Cancel stato dispositivo connesso Figure A 2 Toolbox application display 6 Check that only the Firmware item has been selected in the File Format area 7 Select the Open key P Rel330EVer110 bin 2x Flash Version into
114. over before switching the printer on 3 12 Service Manual XZAC4219 05 Chapter 4 PROGRAMMING AND CALIBRATION CONFIGURING THE OPERATION PARAMETERS NOTE the set up environment is reserved for service engineers and programmers as certain parameters that can be selected are used to specialize the machine or the option installed and must not be modified Incorrect modification by the operator could cause malfunctioning of the printer The programming menu is composed of three main menus CONFIG IBM and OLIVETTI each menu having a series of related parameters NOTE for how to access these sub menus refer to the next section You can move from one sub menu to another by pressing the STATION2 key as described in the following To change the values associated with the parameters in the sub menus refer to the section Modifying configuration parameters on page 4 2 Set up activation To enter the programming set up menu follow the procedure below 1 Switch off the printer 2 Switch it on again holding down the STATION1 and STATIONZ2 keys of the console ON O O O N E BY ie STATION1 LOCAL STATION2 J A k EJECT BREAK EJECT 3 When the phase for resetting the printer mechanism READY ON completes check that the ON and Ready LEDs are O O O illuminated stationa LOCAL stamion2 a NX A EJECT BREAK EJECT Insert an A4 sheet in th
115. peed Draft 350 cps 314 cps 327 cps DRAFT 260 cps 260 cps 260 cps N L Q Near Letter Quality 130 cps 130 cps 130 cps L Q Letter Quality 86 cps 104 cps 131 cps A 4 Service Manual XZA4219 05 The reference standards for the printable optical characters are as follows Font Coding standard Dimensions std form Print specifications OCRA EUROBANKING ISO 1073 1 ISO 1831 OCR B EUROBANKING ISO 1073 2 ISO 1831 Relationship between writing styles and emulation environment Emulations Writing styles Selection HSD DRAFT NLQ1 NLQ2 LQ2 OCRA OCRB FROM SET UP PR50 PR2845 DRAFT NLQ1 FROM LINE HSD DRAFT NLQ1 NLQ2 LQ2 OCRA OCRB FROM SET UP PR50 PR40 DRAFT NLQ1 OCRA OCRB FROM LINE HSD DRAFT NLQ1 NLQ2 LQ2 OCRA OCRB FROM SET UP PR2E HSD DRAFT NLQ1 NLQ2 LQ2 OCRA OCRB ITALICO DRAFT ITALICO NLQ1 ITALICO FROM LINE NLQ2 ITALICO LQ2 HSD DRAFT NLQ1 NLQ2 LQ2 FROM SET UP IBM PP II X24 DRAFT NLQ1 FROM LINE THE APPLICATION TOOLBOX Using the Toolbox application version 1 10_08 and later you can obtain from the printer a series of data relating to its use This data relates both to the life of the printer non resettable data and the life of any parts replaced following technical interventions resettable data NOTE the Toolbox application is available on request Contact Technical Support Mail box Banking Printers Olivetti com Firmware loading
116. provals 230V power supply unit version A 3 Certifications and approvals 115V power supply unit version A 3 Environment specifications oaa a A 3 FIRMWARE AND CHARACTER GENERATORS A 4 Machine firmware aaa aa 000 0020 eee A 4 Character sets naaa aaa ee A 4 Mode and character fonts aaa a A 4 THE APPLICATION TOOLBOX 22224488 aaa A 5 Firmware loading operations o oo aaa aaa A 5 Forced loading of firmware o aaa aaa A 7 Index ix Page left intentionally blank x Index Chapter 1 OVERVIEW INTRODUCTION The PR2 plus is a mid range specialized printer for the banking environment able to handle documents both multi copy and not and passbooks for deposit withdrawal transactions This highly versatile printer can also be used for Public Administration front office transactions or in Post Offices The PR2 plus SC model of the printer integrates a colour scanner with a front back 600 dpi resolution The printer can be configured with the following optional components e Horizontal Magnetic unit for reading writing horizontal magnetic stripes e MICR Magnetic Ink Character Reader unit for reading CMC7 E13B characters printed on cheques e Console with optional LCD display shown in the following figure The PR2 Plus printer is available with or without an LCD display The table below indicates the different configurations in which the PR2 Plus printer is available
117. r 8 Installing the Printer Options provides the procedures for installing additional features of the printer Appendix provides information regarding obtaining spare parts and the software installed on the printer An illustrated procedure also describes how to update the printer firmware PRE REQUISITES The approach to the topics covered in this manual requires knowledge of similar products TECHNICAL SUPPORT CONTACTS Email address Banking Printers Olivetti com WEB Site www Olinet biz REFERENCES Spare parts catalogue cod XZAC3455 DISTRIBUTION General FIFTH EDITION November 2010 XZAC 4219 05 Service Manual lll Page left intentionally blank Service Manual XZAC4219 05 INDEX Chapter 1 OVERVIEW 1 1 INTRODUCTION oaoa 2 000000 02000 1 1 TECHNICAL SPECIFICATIONS 1 2 DOCUMENTS THAT CAN BE HANDLED BY THE BASIC MACHINE 1 3 LOCATION OF MAIN COMPONENTS 1 4 GENERAL BLOCK DIAGRAM 1 5 MOTHERBOARD 0 0 2000000020005 1 6 Motherboard scanner version cod XYAB3468 and XYAB3871 1 6 Motherboard machines with serial number 8 xxx xxx 1 8 Motherboard machines with serial number 1 xxx xxx one serial Interface aee ge bo a aa Nee ee ea te SE 1 10 Motherboard printer version with two serial interfaces 1 12 MAGNETIC OPTION CARDS 1 14 Horizontal magnetic unit 2
118. re possible USB COM1 USB USB PAR PARALLEL DUAL PAR and SERIAL1 When you reach the value for the parameter desired press the LOCAL key to confirm the new value and exit from the INTERFACE USB BUZZER Y PAPER WIDTH FIRST LINE LQ TYPE LQ2 DRAFT SPEED NORMAL MENU CONFIG READY ON STATION1 EJECT O O O VY N A e LOCAL STATION2 BREAK EJECT SERIAL1 INTERFACE USB COM1 USB PARALLEL DUAL PAR BUZZER Y PAPER WIDTH FIRST LINE LQ TYPE LQ2 DRAFT SPEED NORMAL SAVE PARAMETERS Y INTERFACE menu 4 4 Service Manual BUZZER PAPER WIDTH LQ TYPE USB COM1 USB PARALLEL Y FIRST LINE LQ2 XZAC4219 05 5 Press the STATION1 key to save the new configuration 6 IThe value for the parameter changed is saved and at the same time the procedure exits from the CONFIG menu READY ON y O O O O O STATION LOCAL 5 STATION2 A N aa EJECT BREAK EJECT MENU CONFIG SAVE PARAMETERS Y INTERFACE USB COM1 USB PARALLEL BUZZER Y PAPER WIDTH FIRST LINE The following diagram summarises graphically the procedure for changing the values of the configuration parameters PARAMETER 1 612 Value 1 gt eE Value 2 gt 61 lt lt i Value a D Y gt e _ Value2 gt SAVE PARAMETERS Figure 4 1 D
119. ronics connector for the connection 1 Connect the parallel cable to the connector located at the rear of the printer Figure 2 15 Connector for parallel interface 2 From Set up program the following interface parameters PARALLEL STROBE ACTIVE refer to section CONFIGURING THE OPERATION PARAMETERS on page 4 1 USB Interface 1 Connect the USB cable to the connector located at the rear of the printer Figure 2 16 Connector for USB interface 2 From Set up program the following interface parameters USB refer to section CONFIGURING THE OPERATION PARAMETERS on page 4 1 XZAC 4219 05 Service Manual 2 13 FINAL TESTING WITH PRINTER CONNECTED TO SYSTEM ONLINE After verifying that the configuration parameters are correct connect the printer to the system and activate the test for all the functions present in the printer configuration OPERATOR INFORMATION At the end of installation the field engineer must provide the Operator with various information in order to use the machine and to replace the cartridge and to eliminate paper jams without any problems For this purpose a practical demonstration of the following operations is recommended e Use of the console interpretation of the error messages and where possible unblocking of the machine Refer to section OPERATING CONTROLS on page 3 1 e Explain the method of insertion of the paper e Replacement of the ri
120. screw Figure 6 14 Replacement and adjustment of belt for carriage movement XZAC 4219 05 Service Manual 6 15 6 16 Page left intentionally blank Service Manual XZAC4219 05 Chapter 7 DISASSEMBLY REASSEMBLY OF PARTS In this chapter are described the procedures for disassembling reassembling the main components of the printer Each removal operation is described as follows e Reference to any previous removal operations so as to reverse the disassembly procedure e Phases of the operation described in sequence e Notes indicate any references to adjustments to be made after reassembly warnings or prescriptions to be complied with PRELIMINARY WARNINGS e Formaximum safety before carrying out any part disassembly operation switch off the printer and disconnect it from the mains e Perform all the operations in a clean free area e Follow the procedure carefully do not remove parts that must not be disassembled e After replacing parts check that these have not become misshapen during assembly if necessary restore initial conditions e Part reassembly operations must be carried out reversing the disassembly procedure e Make sure that all the connectors are correctly inserted After the operation relubricate where indicated e If the motherboard is replaced update the firmware to the latest release see the section CONFIGURING THE OPERATION PARAMETERS on page 4 1 and calibrate electro mecha
121. screw 1 of the idler pulley support slide and release the carriage movement belt from the motor pinion 3 Unhook the flat cable of the printhead loosening the screw 2 Back off the three special lock screws 3 and extract the printhead movement motor from its housing taking care not to damage the ribbon feed gears Figure 7 15 Removing the motor for printhead movement NOTE during reassembly correctly reposition the ground clip 4 and adjust the carriage drive belt See the section Replacement and adjustment of belt for carriage movement on page 6 15 XZAC 4219 05 Service Manual 7 13 Services motor disassembly reassembly 1 2 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 From the front lift the entire mechanical assy from the base plate and rotate it partially so as to access the connectors of the motherboard See the section Mechanical assy disassembly reassembly on page 7 6 Disconnect the cable that connects the services motor J26 to the motherboard Back off the two screws 1 that fasten of the motor to the left hand side structure and remove it from the machine no IH yy pmm Sul mom ae H fii flonofl tlie Sn oes Hl T myd ols rt ica 4 1 ae imn Or i f IgE oRsgoF IH eo_oosaq iM 1 pae Pias
122. sure roller unit Disassembling reassembling the motherboard printers with scanner Disassembling reassembling the motherboard printers with serial number 8 xxx xxx and 1 XXX XXX Fan power supply unit disassembly reassembly Power supply unit disassembly reassembly MACHINE OPTIONS DISASSEMBLY REASSEMBLY Horizontal magnetic MICR disassembly reassembly Horizontal magnetic MICR motor disassembly reassembly Horizontal magnetic MICR printhead assy disassembly reassembly Roller assy upper scanner disassembly reassembly CIS assy upper scanner disassembly reassembly CIS assy lower scanner disassembly reassembly Chapter 8 INSTALLING THE OPTIONS INSTALLING THE ETHERNET LAN CARD Installation kit contents 0 0040 Installation procedure 2 How to print Ethernet LAN card properties 7 1 7 2 Appendix A A 1 ACCESSORIES 0 0 0000 a A 1 Ribbon cartridge in black NYLON SNUG CART A 1 Ribbon cartridge in NYLON SNUG CART indelible A 1 FONT AND CHARACTER SET A 2 Print speed and definition aaa a A 2 Attributes oeno aaa Rw ek a wee e A 2 BalcOdess eee a a a aa Banh A ea pa E ae a ee A 2 Character attributes o a aaa a A 2 CERTIFICATIONS AND APPROVALS Certifications and ap
123. t MINIMUM 5 24 lt 20 OK MAXIMUM 6 55 lt 20 OK lt Speed Jitter Value Jitter in Reference in Test Result MEDIUM 250 0 60 l 23 OK lt _ Max Time Found us Reference us Speed mm s Test Result 264 75 lt 437 340 OK 4 409 07 lt 649 226 OK Figure 4 5 Printing calibration values when verifying Jitter Magnetic test XZAC4219 05 Service Manual 4 27 Calibrating the scanner 1 Open the printer cover 2 Power on the printer with the cover open keeping the three console keys pressed 3 Wait until the acoustic signal that indicates that the calibration and adjustment procedure has begun 4 Close the printer cover 5 Press the STATION2 key and wait until there is a complete READY ON mechanical reset of the printer O O O O O 6 Press the STATION2 key again STATION lt LOCAL _ STATION2 EJECT BREAK EJECT 7 Insert the scanner calibration sheet code XYAB3976 with the opaque face turned upwards and aligned completely to the left 8 Wait for calibration of the CIS on the scanner front back 9 Wait for calibration of the front back left TOF margin 10 Introduce an A4 sheet for printing the calibration parameters See the figure on the following page For the calibration parameters printed check e The presence of the FRONT SCAN and the REAR SCAN e That there are no failures Failure None e that the values of the parameter Mechanical scan
124. t likely cause to the most remote possibility until you have identified the faulty part Eliminating the fault Carry out the repair so that the machine can perform all its functions Testing the machine Once the machine has been repaired carry out a general cleaning and complete test of the machine possibly with the Operator present to check that the problem has been eliminated and that no other faults have occurred 5 14 Service Manual XZAC4219 05 FAULT CLASSIFICATION To simplify the tracing of faults these have been divided into e Faults at power on e Faults during writing of the document e Faults with document handling The most frequent faults encountered and possible remedies are listed for each assy The classifications provided cannot cover all the faults that may occur if the fault is not amongst those classified it may be useful to refer to the description of a similar fault Faults at power on Fault The machine does not switch on The machine does not connect with the system The self test indicates a fault on the Motherboard The self text indicates an error in the mechanics Possible cause Solution x lt Mains voltage absent incorrect Check the presence and specifications of the voltage supply gt x lt Mains cable damaged Replace the power cable Mains cable only partially inserted Check the connection of the power cable Fuse blown Replace the fuse
125. th is measured in order to establish the precise position of the stripe STRIPE HANDLING In fast management the width of the passbook is measured once only with the procedure described in FAST the specific chapter and no measurements are made during reading or writing of the stripe thus increasing speed of management of the stripe XZAC4219 05 Service Manual 4 17 CALIBRATING THE PHOTOSENSORS Machine photosensors are calibrated at the factory Changes in the electrical characteristics of the photosensors or the use of particular paper may require further calibration at the customer site Machine photosensors that must be calibrated are e Paper present photosensors Consist of two LEDs and two photo receivers and are the first to detect insertion of the document in the front slot The light beam is transmitted by optical fibers e Front paper alignment photosensors Housed in the same mechanical unit as the paper present photosensors indicated in this manual as front photosensors assy The front paper alignment photosensors check alignment of the document before this moves close to the printhead They consist of four LEDs and the same number of photo receivers all coupled by optical fibers e Autoborder photosensor Is fitted on the printhead and detects the presence of the paper in order to measure the position of the first print column This photosensor also permits if selected from set up control of printing interrupt
126. that indicates that the calibration sTationi LOCAL D C STATION2 and adjustment procedure has begun EJECT REK EET Close the printer cover 4 Press the STATION2 key and wait until there is a complete READY ON mechanical reset of the printer O O O O ii ra STATION LOCAL STATION2 ae N A wa EJECT BREAK EJECT 5 Press the LOCAL key READY ON O O O O aea Z y STATION LOCAL STATION2 EJECT BREAK EJECT 6 Insert an A4 sheet The printer prints the operation notes for this calibration procedure ST 1 COnA RM ST 2 SKIP PRESS OCAL T CONT I NUE 7 Press the LOCAL key to proceed MIC we IBRATION ADJUSTMENT adj val 32 ss 8 Check the MICR calibration value written on the MICR CALIBRATION CHEQUE coded with spare parts code 474245A This value is written at the bottom halfway down the document example 95 ERIAL M1027 W 13820 E13B MICR CALIBRATION DOCUME ALIBRATION DATE ON UMEN Di aaa CLEARWAVE ELECTRONICS uae U S A 716 283 7335 ANADIAN PAYMENTS ASSOCIATION CANADA 416 431 6347 STANDARDS AND SPECIFICATIONS TOLL FREE 1 888 751 8977 FOR MICR ENCODED DOCUMENTS y USA PATENT 2082353 ALIBRATED VALUE DS h CON PATENT 5488293 Figure 4 4 MICR CALIBRATION CHEQUE code 474245A 9 Press the STATION 2 key until you find the corresponding value written on the MICR calibration cheque 10 Press the STATION key to confirm 11 The A4 sheet is ejected from the print
127. tots RoR ononotononototota OCOO0CCO Cy a 200 OGOOGO O00 O00 ererer Si Figure 7 36 Fastening screws for power unit 6 Extract the power supply unit NOTE during reassembly pay particular attention to correct repositioning of the ground cables If the unit is replaced check that the power voltage is correct XZAC4219 05 Service Manual 7 27 MACHINE OPTIONS DISASSEMBLY REASSEMBLY Horizontal magnetic MICR disassembly reassembly 1 Disassembling the casing See the section Casing disassembly reassembly on page 7 4 2 From the front lift the entire mechanical assy from the baseplate and rotate it partially so as to access the connectors on the horizontal magnetic board 1 Printers with serial number 8 xxx xxx Printers with serial numbers 1 xxx xxx Figure 7 37 Disconnecting cables 3 Detach the connectors of the cables connected to the horizontal magnetic board 4 Back off the two lock screws that fasten the assy to the structure of the machine and disassemble the option Figure 7 38 Fastening screws for horizontal magnetic unit printers with serial number 8 xxx xxx 7 28 Service Manual XZAC4219 05 Fi
128. tra Base 7 14 Figure 7 16 Disassembling the services motor Service Manual XZAC4219 05 Feeder photosensors disassembly reassembly 1 Remove the mechanical assy See the section Mechanical assy disassembly reassembly on page 7 6 2 Remove the upper mechanical assy See the section Printhead disassembly reassembly on page 7 10 3 Remove the roller guard removing the related M3 lock screws 1 Printers with torsion bar Printers without torsion bar Figure 7 17 Disassembling the roller cover 4 Release the two springs 2 and slide out the document stop combs from their guides after straightening the two tabs that prevent sliding out of the paper 3 Printers with torsion bar Printers without torsion bar Figure 7 18 Removing the document stop comb XZAC 4219 05 Service Manual 7 15 5 Release the bush 4 of the shaft and remove the bracket 5 of the alignment pressure rollers then remove the entire assy 6 4 5 Figure 7 19 Removing the roller pressure unit 6 Back off the six lock screws 7 of the conveyor 8 lt lt 8 7 Figure 7 20 Feeder unit screws 7 16 Service Manual XZAC4219 05 7 Back off the two lock screws 9 of the photosensor support 10 and remove it Printers without torsion bar Printers with torsion bar Figure 7 21 Removing the photosensor support NOTE during r
129. xcessive variations in voltage fans and air conditioners large photocopiers lift and goods lift motors radio TV transmitters and signal generators high frequency safety devices etc Normal office machines calculators typewriters small photocopiers terminals and PC may be connected on the same line provided that they do not cause too many disturbances Environmental conditions The environmental conditions in which the product may remain for an indefinite time are those indicated by AB quality objectives normal conditioned office environment environmental temperature 15 35 OC relative humidity 15 85 HU Variations in environmental conditions such as to cause condensation must be avoided both during storage and functioning Dust dirt and smoke may cause excess wear of moving parts short circuits in the presence of high humidity and read write errors during the various operations High temperatures and low levels of humidity may cause problems due to static electricity Locating the machine e The printer must be installed on a flat firm vibration free surface e Do not install the printer close to ventilation systems sources of heat or points exposed directly to the rays of the sun e Do not obstruct the ventilation slots of the printer e If the machine is fitted inside a cabinet check good ventilation to avoid dangerous overheating e Install the machine in a position that does not prevent removal of documents along the
130. xit from the passbook close to the binding in order to improve feeding of the passbook 4 12 Service Manual XZAC4219 05 Parameter Values possible Description If the printer is enabled for handling handbooks L selecting L Left the SW is set up to be compatible with the PR50 with left alignment SIDE Selecting R Right the SW is set up to be compatible R with the PR50 with right alignment In this case refer to the table on page 4 15 for the specific parameters to configure OLIVETTI CHAR SET Selects the character generator IBM PC PC IBM CHAR SET If the character generator selected has been IBM PC ISO ST15INT ST15ITA ST15P ST15USSR ST15SDC ST15E ST15E2 ST15S SF ST15CH ST31 ST15TR If the character generator selected has been OE CHa AET ST15USA OLIVETTI ST15YU ST15ARABIC ST15CND ST15CIBC ST15 DK N ST15L ST15F ST15UK ST150 ST15GR DK N If the character generator selected has been IBM DK CHAR SET gt PC 210 GR 220 E 437 INT 850 LATIN 1 851 GREEk 852 LATIN 2 855 CYRILLIC PC CHAR SET 857 LATIN 5 858 LATIN EURO 860 P 862 IL 863 CANADIAN FRENCH 864 ARABIC 865 NORDIC 866 CYRILLIC 1250 PC WIN Latin2 252 PC WIN Latin1 XZAC4219 05 Service Manual 4 13 Parameter Values possible Description OLI UNIX ISO 8859 1 ISO 8859 2 llega If the character generator sele

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