DataMetrics 4080B Guía de solución de problemas

DataMetrics Corporation

1717 Diplomacy Row

Orlando, Fl 32809

This manual is intended to function as an example ONLY and does not represent all configurations and options for this product.

4080B THERMAL PRINTER

OPERATION AND

MAINTENANCE INSTRUCTIONS

DataMetrics Corporation

1717 Diplomacy Row

Orlando, Fl 32809

Phone: (407) 251-4577

FAX: (407) 251-4588

[email protected]

Data Rights Provisions

THE INFORMATION CONTAINED IN THIS MANUAL IS SUPPLIED WITH LIMITED

RIGHTS ONLY. DATA SHALL NOT, WITHOUT THE WRITTEN PERMISSION OF THE

CONTRACTOR, BE EITHER (A) USED, RELEASED, OR DISCLOSED IN WHOLE OR IN

PART OUTSIDE THE GOVERNMENT, (B) USED IN WHOLE OR IN PART BY THE

GOVERNMENT FOR MANUFACTURE OR, IN THE CASE OF COMPUTER SOFTWARE

DOCUMENTATION, FOR PREPARING THE SAME OR SIMILAR COMPUTER

SOFTWARE, OR (C) USED BY A PARTY OTHER THAN THE GOVERNMENT, EXCEPT

FOR: (1) EMERGENCY REPAIR OR OVERHAUL WORK ONLY, BY OR FOR THE

GOVERNMENT, WHERE THE ITEM OR PROCESS CONCERNED IS NOT OTHERWISE

REASONABLY AVAILABLE TO ENABLE TIMELY PERFORMANCE OF THE WORK,

PROVIDED THAT THE RELEASE OR DISCLOSURE HEREOF OUTSIDE THE

GOVERNMENT SHALL BE MADE SUBJECT TO A PROHIBITION AGAINST FURTHER

USE, RELEASE OR DISCLOSURE; OR (2) RELEASE TO A FOREIGN GOVERNMENT, AS

THE INTEREST OF THE UNITED STATES MAY REQUIRE, ONLY FOR INFORMATION

OR EVALUATION WITHIN SUCH GOVERNMENT OR THE CONDITIONS OF (1) ABOVE.

THIS STATEMENT SHALL BE INCLUDED ON ANY REPRODUCTION HEREOF.

OPERATION AND MAINTENANCE

DataMetrics Corporation i

RECORD OF CHANGES

Date Revision Description of Change

040325 – INITIAL RELEASE

OPERATION AND MAINTENANCE

DataMetrics Corporation ii

TABLE OF CONTENTS

Chapter Page

1. INTRODUCTION......................................................................................................... 1

1.1. Contents of Manual........................................................................................... 1

1.2. General Description........................................................................................... 1

1.2.1. Door Assembly.................................................................................... 1

1.2.2. Control Panel....................................................................................... 1

1.3. Equipment Characteristics, Specifications, and Capabilities............................ 1

1.4. Equipment Supplied.......................................................................................... 1

1.5. Equipment Required but not Supplied.............................................................. 1

2. PREPARATION FOR USE AND INSTALLATION INSTRUCTIONS .................... 5

2.1. General .............................................................................................................. 5

2.2. Unpacking and Handling................................................................................... 5

2.3. Inspection.......................................................................................................... 5

2.4. Installation Requirements.................................................................................. 8

2.4.1. Removal of Printer .............................................................................. 8

2.4.2. Installation of Printer........................................................................... 8

2.5. Cabling Data...................................................................................................... 10

3. GENERAL THEORY OF OPERATION ..................................................................... 12

3.1. Introduction....................................................................................................... 12

3.2. Overall Functional Description......................................................................... 12

3.3. Printer Functional Sections ............................................................................... 13

3.3.1. Power Supply Section ......................................................................... 13

3.3.2. Control Section.................................................................................... 13

3.3.3. Print Section........................................................................................ 13

4. OPERATING INSTRUCTIONS .................................................................................. 14

4.1. Introduction....................................................................................................... 14

4.2. Operational Switch-Lights, Indicators, and Switches....................................... 14

4.2.1. Operator Controlled Switch-Lights..................................................... 14

4.2.2. Indicators............................................................................................. 14

4.2.3. Nonoperator-Controlled Switch.......................................................... 14

4.3. Preoperating Procedures.................................................................................... 14

4.3.1. Paper Loading ..................................................................................... 14

4.3.2. Paper Removal .................................................................................... 16

4.3.3. Power and Data Cable Connections.................................................... 19

4.3.4. Field Power Distribution Unit............................................................. 19

4.4. Operating Procedures........................................................................................ 20

4.4.1. Power Turn On.................................................................................... 20

4.4.2. Annunciator Panel Functional Checks................................................ 21

4.4.3. Self Tests............................................................................................. 21

4.4.4. Normal Operation................................................................................ 25

4.4.5. Power Turn Off ................................................................................... 25

OPERATION AND MAINTENANCE

DataMetrics Corporation iii

TABLE OF CONTENTS (Continued)

Chapter Page

5. PREVENTIVE MAINTENANCE AND TESTING..................................................... 27

5.1. Introduction....................................................................................................... 27

5.2. Preventive Maintenance.................................................................................... 27

5.2.1. Materials.............................................................................................. 27

5.2.2. Inspection............................................................................................ 27

5.2.3. First Level Cleaning............................................................................ 29

5.2.4. Printhead Cleaning.............................................................................. 30

5.3. Testing............................................................................................................... 31

5.3.1. First Level Testing .............................................................................. 31

5.3.2. Test Setup............................................................................................ 31

5.3.3. Testing................................................................................................. 31

5.3.4. Second Level Testing.......................................................................... 32

5.3.5. Test Setup............................................................................................ 32

5.3.6. Testing................................................................................................. 32

6. CORRECTIVE MAINTENANCE ............................................................................... 34

6.1. General .............................................................................................................. 34

6.2. Troubleshooting ................................................................................................ 34

6.2.1. Second Level Fault Isolation............................................................... 34

6.3. Corrective Maintenance Repair......................................................................... 34

6.3.1. Operator Remove and Replace Procedures......................................... 46

6.4. Second Level Removal and Replacement......................................................... 48

6.5. Printhead Assembly (A3) Replacement............................................................ 48

6.5.1. Printhead Assembly Removal............................................................. 48

6.5.2. Printhead Assembly Installation.......................................................... 50

6.6. Printhead Cable Assembly (W4) Replacement................................................. 50

6.6.1. Printhead Cable Assembly Removal................................................... 50

6.6.2. Printhead Cable Assembly Installation ............................................... 50

6.7. Motor Assembly (B1) Replacement.................................................................. 51

6.7.1. Motor Assembly Removal .................................................................. 51

6.7.2. Motor Assembly Installation............................................................... 51

6.8. Control Panel Assembly Replacement.............................................................. 53

6.8.1. Control Panel Assembly Removal ...................................................... 53

6.8.2. Control Panel Assembly Installation................................................... 53

6.9. Controller Circuit Card Assembly (CCA) Replacement................................... 55

6.9.1. Controller CCA Removal.................................................................... 55

6.9.2. Controller CCA Installation................................................................ 55

6.10. Power Supply Circuit Card Assembly (CCA) Replacement............................. 57

6.10.1. Power Supply CCA Removal.............................................................. 57

6.10.2. Power Supply CCA Installation.......................................................... 58

6.11. Data Cable Assembly Replacement.................................................................. 58

6.11.1. Data Cable Assembly Removal........................................................... 58

6.11.2. Data Cable Assembly Installation....................................................... 60

6.12. DC Power Cable Assembly Replacement......................................................... 60

6.12.1. DC Power Cable Assembly Removal ................................................. 60

6.12.2. DC Power Cable Assembly Installation.............................................. 62

6.13. 24 Vdc Cable Assembly Replacement.............................................................. 62

6.13.1. 24 Vdc Cable Assembly Removal ...................................................... 62

6.13.2. 24 Vdc Cable Assembly Installation .....................................................

OPERATION AND MAINTENANCE

DataMetrics Corporation iv

OPERATION AND MAINTENANCE

DataMetrics Corporation v

TABLE OF CONTENTS (Continued)

Chapter Page

6.14. NiCad Battery Assembly Replacement............................................................. 64

6.14.1. NiCad Battery Assembly Removal..................................................... 64

6.14.2. NiCad Battery Assembly Installation.................................................. 65

6.15. Circuit Breaker Cable Assembly Replacement................................................. 65

6.15.1. Circuit Breaker Cable Assembly Removal ......................................... 65

6.15.2. Circuit Breaker Cable Assembly Installation...................................... 65

6.16. Battery Cable Assembly Replacement.............................................................. 66

6.16.1. Battery Cable Assembly Removal ...................................................... 66

6.16.2. Battery Cable Assembly Installation................................................... 66

6.17. FPDU Assembly Replacement.......................................................................... 66

6.17.1. FPDU Assembly Removal .................................................................. 66

6.17.2. FPDU Assembly Installation............................................................... 67

6.18. Performance Verification.................................................................................. 67

7. PROGRAMMING/INTERFACE REQUIREMENTS ................................................. 68

7.1. Introduction....................................................................................................... 68

7.2. Programming Requirements.............................................................................. 68

7.2.1. Host-Provided Printer Control Codes ................................................. 68

7.2.2. Printer-Provided Control Codes.......................................................... 70

7.3. Interface Requirements ..................................................................................... 70

7.3.1. RS-232C Interface Electrical Characteristics...................................... 70

8. PREPARATION FOR RESHIPMENT ........................................................................ 73

8.1. General .............................................................................................................. 73

8.2. Preparation for Reshipment............................................................................... 73

OPERATION AND MAINTENANCE

DataMetrics Corporation vi

LIST OF ILLUSTRATIONS

Figure Page

1-1 DmC 4080B Printer....................................................................................................... 2

2-1 Printer Packaging .......................................................................................................... 6

2-2 Printer Inspection .......................................................................................................... 7

3-1 Printer Overall Functional Operation, Block Diagram ................................................. 12

4-1 Controls and Indicators ................................................................................................. 15

4-2 Paper Loading (Side View, Door Open)....................................................................... 17

4-3 Paper Unloading............................................................................................................ 18

4-4 Power, Data, and Ground Strap Connections................................................................ 19

4-5 Field Power Distribution Unit (FPDU)......................................................................... 20

4-6 40-Column Self-Test Printout....................................................................................... 23

4-7 80-Column Test Printout............................................................................................... 24

5-1 Printer Cleaning............................................................................................................. 30

6-1 Fault Isolation................................................................................................................ 36

6-2 RS-232 Data Cabling .................................................................................................... 44

6-3 Circuit Breaker Cable Assembly Replacement............................................................. 45

6-4 Field Power Distribution Unit (FPDU)......................................................................... 46

6-5 Printhead and Cable Assembly Replacement................................................................ 49

6-6 Motor Assembly Replacement...................................................................................... 52

6-7 Control Panel Assembly Replacement.......................................................................... 54

6-8 Controller CCA Replacement ....................................................................................... 56

6-9 Data Cable Assembly Replacement.............................................................................. 59

6-10 DC Power Cable Assembly Replacement..................................................................... 61

6-11 24 Vdc Cable Assembly Replacement.......................................................................... 63

6-12 NiCad Battery Assembly Replacement......................................................................... 64

7-1 Interconnection Diagram............................................................................................... 69

7-2 RS-232C Interface Diagram.......................................................................................... 71

7-3 RS-232C Driver/Receiver Interface.............................................................................. 71

7-4 RS-232C ASCII Sequence............................................................................................ 72

8-1 Packaging Printer for Reshipment................................................................................. 74

OPERATION AND MAINTENANCE

DataMetrics Corporation vii

LIST OF TABLES

Table Page

1-1 Equipment Characteristics, Specifications, and Capabilities........................................ 3

1-2 Equipment Supplied...................................................................................................... 4

1-3 Equipment Required but not Supplied.......................................................................... 4

2-1 Input Power Receptacle J1 Pin Assignments................................................................ 8

2-2 Data Input Receptacle J2 Pin Assignments................................................................... 9

2-3 Baud Rate Switch Selection.......................................................................................... 9

2-4 ASCII 64-Symbol Printing Subset................................................................................ 11

4-1 Control and Indicator Functions.................................................................................... 16

4-2 8-Bit Status Byte Format............................................................................................... 25

4-3 LED Fault Indicators..................................................................................................... 26

5-1 Preventive Maintenance Materials................................................................................ 28

5-2 First Level Test Equipment........................................................................................... 31

6-1 Corrective Maintenance Equipment and Materials....................................................... 35

6-2 Fault Isolation................................................................................................................ 37

7-1 RS-232C Serial Interface .............................................................................................. 72

OPERATION AND MAINTENANCE

DataMetrics Corporation viii

SAFETY SUMMARY

INTRODUCTION

Only qualified personnel will be permitted to perform maintenance tasks associated with the printer.

All personnel should be instructed in the safety precautions identified in station safety manuals.

Knowledge and training in handling equipment and materials and adherence to safety regulations will

prevent injury to personnel and possible damage to equipment. Untrained personnel must not operate

electronic equipment. This safety summary describes precautions to be followed to avoid hazards

involved in the operation and maintenance of the printer.

GENERAL PRECAUTIONS

Maintenance personnel are expected to use good shop practice at all times when handling

components, tools, and equipment. Although equipment is constructed to withstand normal handling

and usage, proper care can reduce failures and potential safety hazards. Because good shop practice is

assumed to be understood, procedures do not always provide cautionary notes concerning the

following:

a. Equipment, tools, or procedures cannot be altered or modified without proper written

authorization.

b. Electronic or delicate mechanical assemblies must not be dropped or subjected to

abnormal abuse (dropped units must be retested).

c. Cable assemblies must not be pulled, twisted, or subjected to undue physical stress.

d. Work areas and materials must be kept clean and orderly.

e. Protective equipment for components and materials must remain installed until it is

necessary to remove them during equipment maintenance.

f. Tools must be used only in the manner intended.

g. Tools should not be allowed to become so dirty or worn that usefulness is impaired.

h. Personnel should notify their immediate supervisor if unsure of any instructions or if equip-

ment functions in an abnormal manner.

Should situations arise that are not covered in the general or specified safety precautions, the com-

manding officer or other authority will issue orders as deemed necessary to cover the situation.

TOOLING

Common workshop tools specified in procedural steps are those considered best to accomplish the

task. However, personal preference may be taken into consideration. For example, if a ratchet is

called for and personnel accomplishing the task prefer a speeder handle, then this tool may be used in

place of the ratchet. Where special tools or fixtures are required and supplied, deviations are not

permitted.

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